Construction and installation of major new railway bridge for at Stapleton Road railway station in Bristol, UK

Stapleton Road – Network Rail Structures

Project overview

Working for Vinci Taylor Woodrow, Carney Construction have completed the labour, management and temporary materials for the RC construction of a triple span viaduct in the city of Bristol. The scope was further increased during the delivery of Station platform works, plant, scaffolding and possession works.

Key info

  • Start date: February 2018
  • Project completion date: April 2019 (60 weeks)
  • Form of contract NEC: Option B
  • Total value: £3.2million+

Carney were first approached to deliver the RC concrete for the pile caps, abutments, piers and bridge deck. This was then increased during delivery to include the new platform, additional head and retaining walls.

The site was itself very restricted, being in between a live motorway to the North and live railway to the East with local high street to the South West. With 26 total different contractors to co-ordinate with and the logistical and interface issues associated Carney proved they could deliver safely on time and to the highest quality.


1. Safety & Environment

Safe access was foreseen as a major risk while constructing the piers and as such Carney Construction incorporated a bespoke access platform to the shutter in fabrication, by being engaged early Carney were able to incorporate safe methods of access into the temporary access systems allowing for construction and inspection activities to be carried out safely and efficiently.

By using modern robotic compaction plates and combining with linking beams Carney Construction were able to reduce Hand Arm Vibration while increasing output during compaction activities.

Working with Taylor Woodrow to ensure their client (Network Rail) was achieving the best possible finish product with varying constraints such a tight site, live rail line and motorway in proximity. Along with this remaining professional to passing public always. Carney Construction received zero complaints and our Safety Culture was recognised by senior Network Rail stakeholders.

2. Quality

For this scheme the structure is on the main road to a city town centres with shops and high footfall. It was thus important that the quality of finish was of the highest degree. Carney Construction recognised that and ensured all shuttering systems used were of the highest quality with special attention to different forms such as the bullnose piers being fabricated out of steel to reduce the risk of deflection and provide high finish tolerances.

Carney Construction know that working with instead of against the end client is the only way to successfully deliver a project. Where snags were raised through inspections or pre-inspections the team impressed through our attitude towards resolving these issues. “Always listening to the Network Rail and VINCI inspectors and taking ownership of these defects”.

The formwork also incorporated a hanging system for the bolt cluster to achieve the tight tolerances required in the specification, thus ensuring the successful landing of the bridge decks that were cast offline adjacent to the final position.

3. Productivity

With 26 separate contractors to work around and a confined site whereby the bridge decks occupied 1/3rd of the land available and deep underground drainage shafts on another 1/3rd It was crucially important Carney Construction sequenced the works and ensured only the plant and resource necessary for Just In Time delivery was available onsite at any given moment.

Carney Construction were able to meet and improve on the construction programme working with designers to reduce the number of pours were possible to save time for critical rail closures key dates.

Conclusion & Summary

  • Awarded Taylor Woodrow Vinci contractor of the project award
  • Temporary works designed to incorporating safe access, inspection platforms and bolt hanging systems for follow on trades.
  • Challenging shape and featured finish of the Bullnose, patterned featured piers – Bespoke shutters were designed to maximise pour rates and quality of the finish product.
  • All key dates met and bridge handed over default free
  • Zero lost time incidents reported on the project

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