In conjunction with J. Murphy & Sons we developed a unique precast solution for over 2 kilometres of bespoke culvert to reach completion dates for the Port.

This project was all about speed and efficiency – the original cast in-situ design involved shuttering and pouring concrete onsite and given the complex nature of the culvert it meant that only 12 metres could be cast in one day.

By switching to precast and using offsite mass production, the installation times were increased to 120 metres per day saving weeks off the programme.

This innovative approach allowed the units to be cast using bridge beam mass production technology. The units were highly complex with falls for drainage built into the base of the elements and very high tolerances were required due to the extreme volumes of traffic and loading.

Impressively each 12 metre long unit had a manhole unit built in for access which were engineered and manufactured to a tolerance of 1 mm.

Using a precast solution avoided delays due to weather on this very exposed site and was 10 times faster than conventional construction.