BUSES MEET CROSSRAIL WITH HUGE CONCRETE DECK SHORING SOLUTION
Kelly Formwork is constructing a huge concrete slab for main contractor Costain, using a range of formwork and shoring from RMD Kwikform. The slab is an integral part of a new-elevated bus deck at Crossrail’s Westbourne Park station, which is situated next to the Hammersmith & City line underground station.
The one metre deep, six metre high, 8,500m2 reinforced concrete deck is being constructed using a combination of lightweight Alshor Plus shoring, with steel Superslim and Alform aluminium beams from RMD Kwikform. In addition to formwork and shoring the site is also using Alshor safety platforms and advanced guardrails.
To meet the tight timescale of the project, the bus deck will be constructed in just 12 concrete pours, thanks to the use of over 2,500m2 of Alshor Plus shoring onsite. In addition to the slab, Kelly Formwork was also challenged with constructing a new Concrete Plant onsite. To support the 15 different structures incorporated into the plant, RMD Kwikform engineers produced over 50 drawings to model the solution.
In order to construct the structures, which included the Elevator Hopper, Skip Elevator, Lining Walls and Settling Ponds, the solution developed combined the use of steel Superslim Soldiers, aluminium Alform Beams and Minima Panel system formwork.
Commenting on the project, Mark McKenna, Project Manager for Kelly Formwork said: “In order to secure this high profile job, we had to prove our solution and the equipment we were putting forward could meet the very demanding specifications laid down by the client and Costain. So before we even got onto site, we worked with RMD Kwikform engineers to design a solution that was focused on safety, efficiency and productivity. This is why we opted to use lightweight Alshor Plus aluminium shoring, as it has a very high leg load capacity at 120kN and its quick release mechanism allowed us to strike, move, and re-erect legs very quickly.
As part of the overall design, and due to the strength of the Alshor Plus product, we were also able to design larger access routes through the project, allowing the erection teams to be more efficient.”
To support safe access to the top of the deck slab, Alshor Plus working platforms were designed into the overall solution, with advanced guardrails surrounding the working area to protect workers both on top and below the slab.
Speaking about the solutions for the project, RMD Kwikform sales representative Tom Day said, “Having worked with Kelly Formwork and Costain on numerous projects across the UK, both businesses were familiar with the capabilities of our equipment. For this project it was all about the design solution and how we were able to integrate safety features into every stage.
“A good example of this was the design of the Alshor Plus solution for the removal of the trough moulds. Here we were able to create a safe working level within the Alshor Plus shoring, to allow the site team to strike and remove the moulds safely.”
Once the bus deck is completed a brand new bus depot will be constructed, completing the multi-million pound infrastructure investment.