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Precast Production

Colne Valley Viaduct precast factory completes 1,000 segments

By Richard High, 15 July, 2024
A group of people orange PPE standing in front of a precast concrete bridge pier Workers outside HS2's Colne Valley Precast Factory celebrate production of the 1,000 segment.

The Align JV’s precast factory has successfully completed the casting of 1,000 concrete segments for the construction of the Colne Valley Viaduct, a significant milestone in this major infrastructure project.

The first segment was cast in January 2022. A total of 1,022 segments are required to complete the viaduct deck, with 22 cast in situ on-site—two on each V-Pier—and the remaining 1,000 produced in the Viaduct Precast Factory. The final segment was cast recently, marking the completion of this crucial phase.

Each segment, weighing between 60 and 140 tonnes, was formed using a match-casting technique to ensure a perfect fit when the deck is assembled. This technique is essential for accommodating the gentle curve of the viaduct as it spans the Colne Valley. The process involved casting each segment to fit precisely with its neighbours, ensuring structural integrity and seamless assembly.

In addition to the casting achievements, the team set records for segment production. In April, they delivered 15 complete segments in a single week, with five segments from each of the factory's three casting cells. By the end of May, this was increased to 18 segments per week, demonstrating significant efficiency and productivity improvements.

The Colne Valley Precast Factory's main yard. All photographs: HS2.
Workers inside the factory check and fasten the concrete segment's rebar.
Inside the Colne Valley Viaduct's Precast Factory.
HS2's Colne Valley Viaduct crosses the Grand Union Canal.
Pre-cast concrete segments at the South Portal site.
The Colne Valley Viaduct factory from the air, Feb 2022.
Workers checking the first segment of the Colne Valley Viaduct landscape, Feb 2022.

Outside the factory, teams working in various weather conditions constructed 1,000 rebar cages, each tailored to fit the segment moulds before casting. This meticulous work ensured that each segment met the high-quality standards required for the viaduct's construction.

The success of the Viaduct Precast Factory was a collaborative effort involving multiple teams and supply chain partners, including Tarmac, SENDIN, VGC Group, and Danny Sullivan Group. Contributions from the Surface Plant, Quality, and Survey teams were also pivotal in achieving this milestone.

In a statement, the company said: “This accomplishment highlights the expertise and dedication of everyone involved in the project, setting a strong foundation for the completion of the Colne Valley Viaduct and the broader HS2 project.”

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