London Gateway

Case Study

The port which comprises of the quay, container terminal, rail terminal and logistics park has an enormous footprint. Banagher Precast Concrete in conjunction with Murphys developed a unique precast solution for over 2 kilometers culvert to allow construction to meet completion dates for the Port.

The project was all about speed The original cast insitu design would involve shuttering and pouring concrete onsite.  The complex nature of the culvert would mean that only 12 m could be cast in one day. By switching to precast and using offsite mass production, the installation times were increased to 120m per day saving weeks off the programme.

J.Murphys and Sons by working with Banagher Precast Concrete’s specialist team developed a design which enabled units to be cast in 12m long sections. This innovative approach allowed the units to be cast at our factory using bridge beam mass production technology. The units were highly complex with falls for drainage built into the base of the elements. Very high tolerances were required and achieved on a project which demanded the highest standards due to the extreme volumes of traffic and loading which the port infrastructure must be capable of withstanding. Each 12m long unit had a manhole unit built in for access which were engineered and manufactured to a tolerance of 1mm.

The Precast system also had the benefit of avoiding any delays due to weather on what is a very exposed site. This system enabled the site team to install up to 120m of culvert per day, 10 times faster than with conventional construction.

London Gateway provides 2,700 metres of quay, six deep-water berths with depth alongside of 17 metres, 24 giant quay cranes and an annual capacity of 3.5 million TEU. It will make London a hub for international trade once again.

As well as being on the doorstep of London and the South East, London Gateway is better placed to serve destinations much further afield, enabling shippers from across the UK to make substantial savings – by reducing delivery times, haulage costs, fuel consumption and carbon emissions.

Banagher Precast Concrete are proud to be associated with this project. With brand new state-of-the-art infrastructure and equipment, London Gateway will bring greater reliability to supply chains enabling the largest ships in the world to access the ever growing London market.