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In 2007-8, the existing building on the site was demolished in preparation for redevelopment. However due to the economic climate, construction was delayed and it was not until October 2010 that the project was revived. Oxford Properties is now co-developing the property in partnership with British Land, and in July 2011 they announced Laing O’Rourke as the Main Contractor for the works.

The new tower will feature a tapered glass façade on one side which will reveal the steel bracings, along with a ladder frame that is aimed to accentuate the vertical appearance of the tower. The base will feature a 30 metre high atrium which will be open to the public, and extend the adjacent plaza.

The structural steelwork sub-contract was awarded by Laing O’Rourke to Watson Steel Ltd. Freyssinet were selected in early 2012 to supply 162No. Tetron Disc Bearings (Pot type) which will support the floor beams on the outer columns. Freyssinet’s in-house design team worked in close liaison with Watson Steel to produce bespoke bearing designs to suit the very limited dimensional requirements with high horizontal forces. Fixing arrangements have also been tailored to comply with the restricted requirements.

Production of the bearings at Freyssinet’s factory in Telford is phased to meet the installation programme and construction is scheduled for completion in 2014.

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The Forth Road Bridge is located in Scotland, connecting Fife and the north east of Scotland with capital city Edinburgh and the south. When the bridge was opened in 1964, it was the fourth longest in the world, and the longest outside the United States, with a main span of 1006 meters between the two towers. In total, the structure is over 2.5km long.

Maintenance to the Forth Road Bridge is ongoing and a large capital programme to strengthen the bridge is also continuing. In 2009 the Forth Estuary Transport Authority (FETA) embarked on a competitive tender process for the Viaduct Bridge Bearing Replacement project, estimated to total £15 million.

The contract is the biggest single contract awarded since the bridge opened. It has involved the replacement of all the mechanical bridge bearings on the Forth Road Bridge’s north and south approach viaducts, which sit at either end of the bridge on each shore, connecting the A90 and M90 with the main body of the suspension bridge. The steel bearings support the bridge deck and enable it to move as required by changes in temperature. The contract also required an extensive overview of the concrete pier condition in conjunction with concrete repair works and the installation of an impressed current CP system.

Freyssinet was chosen to design, supply and install the bridge bearings, and complete associated concrete repair and cathodic protection works on the structure, having demonstrated a successful track record with this type of work.

40No. permanent mechanical bearings were specially designed to BS 5400, and manufactured in Freyssinet Ltd’s factory in Telford in quality controlled conditions that exceed the requirements of BS EN ISO 9001.

Freyssinet also designed and supplied 35No. temporary support bearings and over 100No. hydraulic jacks to meet the requirements of the temporary support and restraint works. In addition Freyssibar, Freyssinet’s own high-tensile pre-stressing bars, was supplied and stressed to assemble and fix the longitudinal restraint frames onto the structure.

Freyssinet were responsible for all the hydraulic jacking and monitoring of the bridge deck to allow removal of the existing bridge bearings. The bridge bearing replacement work by Freyssinet considered also the careful coordination of hydrodemolition works, steel cutting and drilling, and heavy lifting and positioning techniques to all allow the careful and safe positioning of each bearing into an extremely restricted access gap.

The impressed current CP system utilised three anode systems; titanium mesh, titanium ribbon and discreet mixed metal oxide anodes. In addition, galvanic anodes were installed into repairs outside the impressed current zones.

Over 14,000m of titanium ribbon anode strip was installed into the concrete faces of the pier head cross beams and legs to form part of the CP system. Freyssinet introduced an innovative technique that utilised a special chase cut into the concrete using a remote operated wall saw. This cut up to 60m per day without exposing operatives to excessive hand arm vibration or concrete dust.

Corrosion Control Services (CCSL), a sister company of Freyssinet, were involved in the procurement of specialist materials and supplied the necessary specialist site supervision / technical commissioning as required by the contract

The Forth Road Bridge is a category ‘A’ listed structure and consent had to be granted for the works to be carried out. Selection of all repair materials and methods of placement were carefully considered in technical trials prior to the start of the works in order to meet the requirements of the consent.

Freyssinet’s Northern Area Manager, Paul Wood, says “Works have progressed well, and are projected to successfully complete in August 2012, on time and within budget.”

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The services offered include identification of the bridge bearings, condition assessments, and advising on the practicalities of refurbishment, and/or bearing replacement. As part of the service, a comprehensive report is available, which would be photographically illustrated, and available in an electronic format as necessary. This allows the client to integrate our report into their own tender documentation and reports as required.

Freyssinet are the leading bearing manufacturer and experts in the fields of bridge bearing replacement, you can be assured that your new bridge bearings and bridge bearing replacement works will be of the highest quality. Freyssinet offer the full range of bearing manufacture and bearing replacements, both elastomeric and mechanical, from their UK factory. The designs are to BS 5400, and the quality control of bearing manufacture and bearing replacement exceeds the requirements of BS EN ISO 9001.

The team of leading designers at Freyssinet are able include suitable modifications into original designs of bearing manufacture, so that later bearing replacement operations can be made easier.

The replacement of bridge bearings and other operations, such as bridge expansion joint replacement, require extremely specialised jacking and propping solutions to facilitate the work. Freyssinet can offer a wide range of appropriate techniques, no matter how demanding or challenging the situation is. Freyssinet are able to supply vertical jacks to prop up structures, and also horizontal jacks, to facilitate movement of structures.

1000 tonne capacity, hydraulic jacks are available from Freyssinet with locking collars and swivel heads. To complement these, Freyssinet can use their manufacturing expertise to add to the jack heads, elastomer and PTFE sliding surfaces. These surfaces give the jack heads the ability to accommodate a limited amount of horizontal, and vertical, structural movement.

For both permanent and temporary situations, Freyssinet also supply flat jacks up to a 1000 tonne capacity, which are able to be used in gaps of 50mm or even less. For temporary solutions, where removal of the jack will be required, the inflation would be with hydraulic oil. If the bearing is to be used in a permanent situation, such as structural lifting or bearing pre-loading, a cementitious grout may be used. Alternatively, at a later date, the grout can be transfused under load if the situation requires.

Control over the entire jacking operation, can be monitored either manually or electronically, offering extremely high levels of control. The jacks can be grouped together into complex circuits, where they can be operated either in groups, or individually as required.

If the client has specified a more conventional propping system for a temporary situation, Freyssinet’s in-house designers are well placed to accommodate this, offering big advantages in terms of cost, speed and access. Propping also eliminates the need for excavation and temporary foundations.

Whether you require experts for bearing testing, or a bearing manufacturer for a bridge bearing replacement project, Freyssinet’s are the ones you should turn to.

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Expert bearing testing service
As the UK’s leading bridge bearing designer and manufacturer, Freyssinet is perfectly positioned to offer an expert bearing inspection and testing service to assess the condition of existing bearings and advise on rehabilitation. Highly qualified and experienced engineers provide on-site bearing inspections throughout the UK and Ireland and their expert bearing testing service includes the following components:
• Inspection and comment on bearing condition
• Bearing identification (including competitor’s products)
• Bearing design information and drawings from archives (where they exist)
• Advice on the practical aspects of refurbishment
• Selection of equivalent replacement bearings where necessary
• Development/budget-pricing for replacement and refurbishment proposals
• A complete photo-illustrated report
• Documents available in electronic formats for inclusion in client’s own reports/tenders

Foremost UK bearing manufacturer
As the foremost UK bearing manufacturer, Freyssinet offers a comprehensive selection of mechanical and elastomeric replacement bearings – all designed and manufactured in their UK factory to BS 5400 and exceeding the requirements of BS EN ISO 9001. Furthermore, their highly-skilled bearing design team also produce custom bearing designs to make future replacement operations easier.

Bearing testing
Freyssinet’s testing facility offers two main test presses, namely 2000 tonne and 300 tonne. Both presses are regularly calibrated to National standards by the National Physical Laboratory.
Two calibrated horizontal strand test beds are also available, namely 1300 tonne and 500 tonne. Together with other testing equipment, the following tests can be undertaken:
• Mechanical and elastomeric bridge bearings up to 2000 tonne
• Multi strand anchorages up to 1300 tonne (BS 4447)
• Anchorage efficiency testing to BS 4447
• Force transfer testing to BS 1881
• Concrete cube crushing (100 tonne)
• Jack calibrations including stressing jacks and pot rams
One-stop bearing replacement package
A bearing replacement operation requires careful consideration of the bearing pressures, effective load transfer mechanisms, balanced gradual lifting, super-structure stability and the speed of replacement. This can require the participation of a number of different engineering specialists.

However, Freyssinet offers a complete, cost-effective one-stop package for bearing replacement – as a principal contractor or as a subcontractor. Their high quality service encompasses:
• Proven expertise in bearing design and as a bridge bearing manufacturer
• Supply and operation of jacking systems
• Expertise in specialty construction chemicals e.g. grouts and epoxies
• Hydro-demolition by an in-house team
• Innovative alternatives to conventional propping for significant time and cost benefits

Quality
Freyssinet are ISO 9001 accredited, with a long track record of quality management. When bearing replacement is undertaken, Freyssinet guarantee that the dismantling, repair, re-painting, bearing installation and re-assembly are all carried out to the same rigorously high standards insisted upon in all aspects of their business. The Highways Agency and many Local Authorities are amongst regular clients – who all trust in the proven expertise of Freyssinet for a cost-effective, durable bearing manufacture, testing and installation.

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To download the new brochure please click below

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22-23 February 2012
UK Concrete Show, Ricoh Arena, Coventry
Freyssinet Limited will be exhibiting at Stand M13 of Europe’s best specialist concrete show, which brings the industry together, under one roof, to see and hear about all that’s new in concrete.

Freyssinet offers a full range of concrete repair, concrete structure repair and maintenance techniques providing clients with a “one stop” contracting service for all their repair requirements. Freyssinet assures clients of impartial advice with regard to repair material selection from the widest range of sources. The types of structure successfully repaired include bridges, buildings, car parks, and industrial structures. Freyssinet is a member of the Concrete Repair Association, Corrosion Prevention Association, Institute of Corrosion and Sprayed Concrete Association.
Freyssinet is recognised by the British Standards Institute to ISO 9001:2008, OHSAS 18001:2007 and ISO 14001:2004. We have a large in-house design department, and directly employ a highly trained, well motivated, experienced, and safety conscious workforce.

Assessment
Accurate identification of the type, severity and extent of problems affecting a structure are crucial in determining the underlying causes, and in developing effective and economic repair solutions. Freyssinet offers a comprehensive range of testing and reporting to allow clients to identify an appropriate repair strategy.

Concrete Replacement
Where concrete is in poor condition, or strengthening is required, replacement is often the only viable option. Freyssinet offer removal both by conventional breaking and hydrodemolition, with subsequent replacement using high performance repair concretes and mortars.

Concrete Repair
A wide range of techniques are available for repairing spalled, cracked, damaged, and honeycombed concrete including: modified mortars for patch and thin bond repairs; pressure and vacuum injection using epoxy, polyester, and cementitious grouts; and sprayed concrete.

Coatings
Freyssinet offer a full range of coatings.

Complementary services
Freyssinet undertake concrete repair as part of a wider range of complementary services that includes: cathodic protection and chloride removal, strengthening, parapet replacement, deck refurbishment, bearing replacement, jacking and sliding, plate bonding and carbon fibre bonding, retrofit steelwork installation, slab joint replacement, and external post-tensioning.

The UK Concrete Show is aimed at all concrete industry professionals, with over 100 exhibitors and 30 seminars the show is the biggest it’s ever been, totalling 6000m2 of all that’s best in concrete products, tools, systems and technology.
To reserve your place and for further information please click here

27-28 March 2012
Bridges 2012: Home & Away, The Midland Hotel, Manchester
Freyssinet origins are as a specialist in bridge construction and the manufacture of bridge bearings and our knowledge and expertise in this area remain unparalleled. Years of experience in the design, construction, testing and monitoring of structural systems have equipped Freyssinet Limited with exceptional insight and resources in the field of repair and strengthening. Our extensive track record of bridge work, including concrete bridge repair, illustrates our capabilities to complete projects both large and small, and always to the highest standard. Traditionally our main area of work has been on highway structures, but Freyssinet have also been actively involved in the rail sector both as specialist civil engineers and structural enhancement professionals.

Services available include:
• Complete refurbishment as main contractor
• Bridge Jacking and Bearing Replacement
• Concrete Repair
• Concrete Coatings
• Cathodic Protection
• Strengthening / Retrofitting
• Post tension tendon regrouting
• Cable stay maintenance, replacement or repair
• Expansion Joint Replacement / Repair

Now in its 20th year, “Bridges” remains the leading event for highway authority bridge engineers and their private sector partners, and continues to act as the definitive forum for all issues relating to bridge management and maintenance, policy, strategy and funding.
To reserve your place and for further information please click here

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Concrete Bridge and Concrete Building Repair in Scotland
Freyssinet is a specialist bearing manufacturer producing standard and customised bearing design for concrete bridge repairs. If required, prior to bearing replacement, inspection and testing is carried out by our experts in Scotland. Freyssinet’s expert services include every other aspect of a high quality concrete bridge repair.

The range of techniques available for concrete bridge and concrete building repairs in Scotland includes:
• Modified mortars for patch and thin-bond repairs
• Pressure and vacuum injection using epoxy, polyester and cementitious grout
• Sprayed concrete – both wet- and dry-sprayed concrete structural repairs
• Expert hydrodemolition concrete removal

Hand- and machine-applied concrete repair mortar is appropriate for structural and non-structural concrete repairs. Hand application is suitable for small-scale concrete repairs and sprayed concrete is used on large-scale structural concrete refurbishment.

Strengthening
Freyssinet offers a range of highly effective strengthening techniques for structural concrete refurbishment in Scotland to prolong the life-span of existing structures or allow a change of use. These high-grade concrete structure repairs include:
• Column strengthening,
• Bridge deck strengthening
• Raising allowable floor slab loads
• Strengthening around new openings

External post-tensioning
This method is especially suitable for concrete bridge strengthening and Freyssinet offer an expert in-house design and installation service of supplemental post-tensioning to existing structures. Additional tendons can be fitted within the structure or externally depending on the size of the bridge. External post-tensioning is also a highly effective concrete structure repair technique for upgrading circular storage tanks in Scotland and the rest of the UK.

Plate bonding
Plate bonding is carried out by Freyssinet to provide an excellent strengthening method for under-strength beams and floor slabs.

Freyssibar high-strength bars
Freyssibars are versatile, high-strength bars used to introduce pre-stress into existing areas which are subject to bursting force or high stress concentrations. For example, concrete structure repair to bridge deck diaphragms, anchorage regions and column heads. In addition, Freyssibars provide a significant increase in load-carrying capacity and are a suitable alternative to plate bonding.

FRP Composites
Freyssinet also offers TFC®, a carbon-fibre product developed by the Freyssinet Group. TFC® has numerous strengthening applications for concrete structural repairs in Scotland. For example, beam strengthening, column-wrapping, reinforcement around new openings and floor slab strengthening.

Freyssinet One-stop Design and Build Service
Strengthening techniques required for concrete bridge and concrete building repairs demand careful consideration of the existing and desired loading regimes to assess what strengthening methods are viable and to facilitate a technically appropriate, cost-effective design. Freyssinet has a highly-qualified and experienced team available to offer clients a comprehensive design and build service for concrete repairs in Scotland.

Innovative Techniques
Innovative Cathodic Protection (CP), Chloride Migration and Re-alkalisation are modern techniques which have been used with success in hundreds of structures worldwide. Furthermore, electro-chemical methods have been approved by the Highways Agency for use in concrete corrosion prevention in Scotland and the rest of the UK. Chloride Migration is available as a technique for structural concrete refurbishment in Scotland, providing an excellent concrete corrosion prevention treatment. Re-alkalisation is the newest method for carbonated concrete structures in Scotland and worldwide.

Freyssinet Limited is a forward-thinking and highly experienced company, offering technically sound and cost-effective concrete repair and structural concrete refurbishment techniques in Scotland and the UK.

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During 2011 Freyssinet has sustained their success in this area, completing a number of bridge bearing replacement contracts throughout the UK.

Freyssinet Ltd were appointed by Jackson Civil Engineering to design, manufacture and install two new mechanical bridge bearings on the A14 Orwell Bridge in Ipswich, as part of the Highways Agency Area 6 Framework. Jacking and monitoring of the deck was also included within Freyssinet’s scope of works.
Overseen by Contracts Manager, Gavin Thomas, the bridge bearing replacement works were carried out during a 52hour closure of the North Deck, carrying the Eastbound A14, over the weekend of 11th-14th February 2011.
Prior to the possession, 3no jacking systems coupled with a computerised monitoring system were installed and commissioned to enable a controlled lift of the deck. The main lifting jacks were positioned on the pier top acting to the underside of the deck with a maximum uplift capacity of 3500Tonnes.
Due to the reduced capacity of the bridge box at the jacking point, a further 2 sets of jacks were installed within the bridge box to effectively brace the box and resist the forces induced via the main lifting jacks. The sets of internal jacks used were Vertical Strut Jacks with a maximum capacity of 2240Te and Diagonal Strut Jacks with a maximum capacity of 1400Te.
Once the deck had been jacked to the required height, the existing bridge bearings were removed and replaced with new. Each bearing weighed approximately 3Tonnes and had a vertical capacity of 1600Tonnes at SLS.

In March Freyssinet Ltd commenced work in Peterborough, completing bridge bearing replacement and concrete repairs for Osborne Ltd on the A1260 dual carriageway. The road, also known as the “Nene Parkway”, serves as major trunk road from the southern end to the northern end of Peterborough, circumventing the city centre. The purpose of the works was to both prolong the life of the bridge structures and enable them to continue to cope with increasing levels of traffic. The works were considered essential by Peterborough City Council; if the bridges had deteriorated further the stability and integrity of the structures would have been compromised.
A total of 7 bridge structures were included in this contract which involved the complete replacement of 12no pier crossheads on each of 4 bridges at two interchanges on the A1260 trunk road at Peterborough, and also associated concrete repair works. Concrete repairs were also carried out on 3 other nearby structures concurrent to the main works.
Each bridge was a 4 span simply supported structure, with the deck being constructed from 28 inverted ‘T‘ beams, supported at each end on 28 elastomeric pads. The elastomeric pads were due for routine replacement and Peterborough City Council decided to re-design the pier crosshead and change the support at each span end from 28no elastomeric pads to 12no elastomeric pads and 1no mechanical shear key.
This re-design would enable any future jacking of the deck to be carried out from the pier top removing the need for extensive steel temporary works.
Bespoke steel trestles were erected on either side of the pier to be strengthened. The trestles incorporated 8no 250Tonne pot jacks with mechanical bearings on top of them to enable the deck to move and rotate during the works.
The top 1.5m of the pier was removed using hydro-demolition and re-cast to the new design.
New elastomeric pads were installed on the newly formed plinths. Once the new concrete pier head had achieved the required strength, the deck was de-jacked onto its new supports and the temporary works were relocated to the next pier so that the process could be repeated.

Freyssinet Ltd was appointed by Birse Civils Ltd in April to carry out the scheduled replacement of roller bearings to 3no overbridges on the M27 motorway near Southampton.
Bespoke temporary works were designed and installed by Freyssinet Ltd. The bridge deck was then jacked to release the load from the existing bearings, the existing roller bearings were then replaced with new mechanical bearings, which were again designed and manufactured by Freyssinet Ltd’s own in-house team.
The main criteria for these works was to minimise the time period for traffic management on the M27, therefore in order to expedite the replacement process, the existing upper and lower casting plates were reused removing the curing process of new concrete & grout from the installation process. A new Highways Agency approved protective coating system was installed on these plates.
As the existing upper and lower cast in plates were found not be horizontal or parallel to each other, compound taper plates were manufactured to create horizontal and parallel bearing surfaces; these plates were installed to very tight tolerances to enable the accurate installation of the new mechanical bearings.

In June Freyssinet were selected by Southampton City Council to carry out bridge bearing replacement and concrete repairs on Itchen Bridge as part of a routine maintenance contract.
Freyssinet Ltd acted as Main Contractor and the scope of works consisted of jacking and bearing replacement, protective coating, concrete repairs and all associated works, including temporary works and traffic management.
Bespoke temporary works were designed and manufactured by Freyssinet Ltd incorporating high capacity hydraulic jacks. These were installed to support the deck during the works at the suspended span half joints and piers.
A total of 22no mechanical bearings were replaced; 12no mechanical bearings at the free end of the suspended spans, 2no at the East Abutment and 8no at prioritised piers. All of the bridge bearings were designed and manufactured by Freyssinet Ltd’s own in-house team.
The existing bearings were removed using high pressure water jetting and the new mechanical bearings were then cast into the structure prior to de-jacking the deck onto its new supports.
Whilst these critical path works were ongoing, other ‘off-line’ works such as re-wiring the internal boxes and the installation of new expansion joints were undertaken. A total of 6no expansion joints were replaced on the bridge deck during one weekend closure of the deck.
Maintenance was also carried out on all other bearings within the structure, including the application of new protective coating system.
Re-profiling works were completed on the East and West revetments to the abutments, installation of high security access doors were installed through the abutment cheek walls into the abutment chambers and the internal box lighting systems were completely rewired. Concrete repair works were also carried out as necessary by Freyssinet Ltd’s specialist operatives.

Each of these contacts was completed on programme and within budget, to the satisfaction of the contractors and the clients.
Repairs and strengthening work, and bridge bearing replacement contracts in particular continue to represent a significant proportion of Freyssinet Ltd’s turnover, demonstrating their capabilities to continuously execute this type of work to a high standard.

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