A19 Testo's Junction Improvement Scheme

Cleveland Bridge install 143m-long flyover ahead of schedule, with minimal traffic disruption.

  • Year: 2020
  • Location: A19, England
  • Client: Costain
Download Case Study

Requirement

To improve traffic flow and reduce congestion, Highways England needed to raise the A19 carriageway onto a flyover above the existing roundabout. New slip roads would be built to connect the raised A19 to the A184 via the Testo’s roundabout, allowing traffic on the A19 to flow freely. The scheme aims to support economic growth and provide a safer, more serviceable and better
integrated road network. Raising the A19 carriageway required the construction of a 143m-long steel bridge to span the existing roundabout.

143m-long

Flyover

1,393-tonne

Weathering grade steel

99%

UK sourced steel

Solution

Smart infrastructure solutions company Costain appointed Cleveland Bridge to fabricate, deliver and construct the steel work of the triple-span flyover, which was designed by Jacobs. As a highways bridge specialist, Cleveland Bridge has vast experience of fabricating and installing major road bridges in the most challenging locations and offered all the skill sets and large scale manufacturing capabilities required for this project. The bridge was constructed from weathering steel, which requires no painting or protective treatment throughout its life – minimising the cost of lifetime maintenance. More than 99% of the steel used to construct the bridge was sourced from the UK.

Challenges

The major challenge of this project was safely installing the triple-span, 143m-long bridge in the centre of a busy roundabout. The central sections of the bridge, crossing the centre of the roundabout, were installed during weekdays over the two-week installation period. The sections of bridge that spanned the carriageway were installed during weekend road closures, on the first and final weekends of the installation window. However, on the first weekend, poor weather and high winds prevented any work from being completed on the Saturday, so the entire planned installation had to be completed in a single day on Sunday.

Challenges

The site was criss-crossed with numerous water and gas pipes, electricity cables and BT services, which significantly reduced the available working area. The use of a 1,000-tonne mobile crane enabled all lifting to be accomplished from two locations in the centre of the roundabout, meaning the crane only had to be moved once during the installation programme.

Outcome

Despite weather-related delays and Covid-19 restrictions, the bridge structure was completed on time and to budget. During the final weekend road closure, installation work was even completed ahead of schedule, enabling the road to reopen early. Cleveland Bridge used its value-engineering expertise to reduce the extent of temporary works required on site. The original erection methodology stipulated eight sets of ten support trestles, but Cleveland Bridge was able to reduce this to just two sets of ten trestles – significantly reducing the time, cost and work associated with installing temporary support structures. By adopting a collaborative approach, Cleveland Bridge, Costain and other subcontractors on site were able to deal swiftly with any issues that arose, ensuring minimal delay or disruption to the planned works.

Reaching the milestone of placing the steel bridge beams was exciting. It’s fantastic that people are now able to see this huge structure taking shape which, when ready, will reduce journey times for drivers and create safer and more free-flowing journeys. Putting the beams into place and completing this critical step of the scheme has been a huge collaborative effort from so many people.

Liam Quirk Highways England

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