Forming the Foundation of the UK’s Longest Railway Bridge

Colne Valley Viaduct | United Kingdom

Forming the Longest Bridge in the UK

Stretching for more than 3.4km (2 miles) across a series of lakes and waterways between Hillingdon and the M25, the Colne Valley Viaduct will be the longest railway bridge in the UK. The viaduct will carry the new high-speed rail line across a series of lakes and waterways on the northwest outskirts of London. The viaduct stands out not just for its scale but also for its integration of advanced engineering with stringent environmental stewardship. It represents a major engineering achievement within the broader HS2 project, a cornerstone of the UK’s future transportation strategy.

Longstanding Customer Trust in the EFCO Way

Kilnbridge Construction secured the contract for 58 piers for this massive project and selected EFCO as the formwork provider for 11 highly complex V-piers that support the bridge span. With a history of relying on EFCO’s engineering expertise, quality products, and comprehensive support, Kilnbridge knew EFCO was well-equipped to handle the demands of this project. Preparations began over a year before the project started, with EFCO engineers collaborating closely with Kilnbridge to design custom formwork systems tailored to the project’s requirements.

"To build one of the longest, most structurally complex bridges in the UK, you need an established and world-renowned formwork company with an excellent engineering team. EFCO delivers on both fronts, and our long-standing partnership with them has ensured a high-quality build." Michael Tiffoney, Kilnbridge Construction Ltd.

Precision Planning for Perfection

The planning phase included creating detailed drawings, followed by building a full-scale mockup of a V-pier using a combination of EFCO’s PLATE GIRDER ?, E-BEAM & SUPER STUD ? systems. This mockup was crucial for testing various aspects such as load capacities, connection points, tying systems, and concrete pour pressure. By using advanced 3D design technologies, the team could visualize and tweak the design in a virtual environment, which significantly enhanced the precision of the actual construction work.

Why Kilnbridge Chose EFCO

Kilnbridge Construction chose EFCO for the Colne Valley Viaduct project due to their long-standing trust in EFCO’s capabilities. Recognized for their engineering expertise, quality products, and supportive collaboration, EFCO was ideally suited for the demands of constructing one of the UK’s longest and most complex bridges. This was solidified by EFCO’s proactive approach to designing custom formwork systems for the project’s unique requirements. The detailed planning phase included the creation of innovative engineering drawings and a full-scale mockup of a V-pier, which was instrumental in testing structural integrity aspects and ensuring the precision of the construction work. This preparation demonstrated EFCO’s commitment to providing Super Service and reassured Kilnbridge of their capability to handle the significant engineering challenges of the project.

"When Kilnbridge secured the contract for the 58 piers to the UK’s longest railway viaduct, we knew the key to the project’s success lay in delivering the 11 highly complex and architecturally challenging V-Pier structures. We needed a partner to develop the solution alongside our delivery team. The stand-out choice was EFCO due to the long-standing relationship between the two businesses on complex projects."

"EFCO assembled a highly skilled design team to work with our team, and together, they developed a highly effective solution to the complex problem. The support provided by EFCO during the design, manufacture, and delivery of the works speaks volumes about the commitment of the EFCO team. Two years later, as we complete the last of these iconic structures, we can all look back together with a sense of pride and look to the future as the bonds between the two businesses have been strengthened." Graeme Stewart, Kilnbridge Construction Ltd.

EFCO is proud to announce that Kilnbridge Construction has been honored with the EFCO Safety Award for their work on the Colne Valley Viaduct. This recognition reflects the project's unwavering commitment to maintaining the highest safety standards, implementing innovative safety measures, and fostering a strong culture of safety among all team members.

Congratulations to everyone involved in this outstanding achievement!

EFCO EQUIPMENT

PLATE GIRDER ?, E-BEAM & SUPER STUD ?

KILNBRIDGE CONSTRUCTION LTD. TEAM

Graeme Stewart, Project Director

Michael Tiffoney, Project Manager

Pablo Porcel, Project Engineer

Rob Jones-Gerrard, Project Engineer

EFCO FORMWORK SPECIALISTS

Gary Dillon, Territory Manager

Colin Walker, Field Supervisor

Stuart De Freyne, Engineer

Jeremiah Curley, Engineer

Steven Halverson P.E., Engineer

Garrett Holm, Major Projects Consultant

Cliff Plymesser P.E., Major Projects Consultant

Andrew L. Pearson P.E., Product Engineering & Efficiency Manager