We had been through a rigorous tender process that involved in several submissions and many meetings about capacities and capabilities. We also had the Align JV Construction and Engineering teams at our works in Bromborough to discuss the various designs that were going to be supplied to the project.
We had made some samples of the special shape code 99 bars for the Align team to inspect on their visit to our works and again like previous projects we had pointed out some errors in design that meant the accuracy of the steel would not meet the tight tolerances they needed unless the made some modifications to the design. When we discussed the bends on Rebar we pointed out to the site team that the point of bending around a former, especially with manual machines could mean that the bend angle can turn out differently on each bend and not have the accuracy of bends with degrees established.
At Capital Reinforcing all the machinery we use have the capabilities of bending from angles and the machines calculate to the millimetre when the bars have to be bent and with consistent accuracy they can bend the bars to the same shape every time. Of course we naturally check our bars after being bent and no less than 100 random checks occur on each shift ensuring the highest quality standards are being maintained.
We had been tasked to supply several major sections of Align JV's and its sub-contractors for this section of HS2 that had been successfully supplied simultaneously.
We had started on the South Portal Project walls which contained over 1500 tonnes of Rebar would be designed to allow the TBM's to start their journey making the new Chiltern Tunnels. In addition to the standard cut and bent rebar we had also supplied thousands of TA1-A approved couplers due to the connection requirements of this project. We had a tight timeline to get this material delivered to site due to the imminent arrival of the two TBMs, Florence and Cecilia. We were able to supply all the materials in good time and the two TBM's arrived as planned and were set up ready for the journey under the Chiltern Hills.
The ventilation shafts on the Chiltern Tunnels were an important part of the project, this was a time sensitive part of the project that needed to be completed before both TBMs had reach each shaft. We started these in sequence and all shafts were being supplied together which meant that we had around 8 parts of the project overall being simultaneously supplied meaning that there was over 600 tonnes of steel per week at peak points of the project. This was also co-ordinated along with our other existing customers projects and included special shapes or many difficult shape code 99s right throughout the length of the project.
The ventilation shafts were particularly challenging due the shape of the shafts being circular which meant that there was a lot of heavy radius shapes and special shapes to be continuously supplied.
As per the South Portal Project, we had again supplied the steel for the North Portal to allow both TBMs to break through the walls in March 2024. Again due to the fast pace of the TBMs, we had to provide the cut and bent rebar along with TA1-A approved couplers just in time for the moment of breakthrough. We had provided the site team with a fast reliable service, ensuring that the North Portal walls were ready for the final breakthrough of Florence and Cecilia. All materials had been provided again without any issues and the walls were ready in good time for both TBMs breakthrough moments.
Our next section we had supplied with the temporary bridge segments containing over 1400 tonnes of Rebar which would help support the movement of materials to build the Colne Valley Viaduct bridge and support piers.
We had several parts of the Colne Valley viaduct although we did not supply the main bridge segments, we had supplied quite a lot of materials for the V Piers, stems and mock-up V Pier steel. We had also come up with a design to remove a lot of steel fixing in the pier stem by using special welded mesh sheets that were designed in conjunction with Align JV. The mesh sheets contained 10mm both across and down the length of the sheet welded at 100mm centres over a sheet size of 4.80m x 2.40m, we had supplied over 300 tonnes of these special mesh sheets to the project.
Hidden low into the landscape between Great Missenden and South Heath in Buckinghamshire, the North Portal will only be partially visible from a footbridge over the railway to the north.
Two perforated concrete hoods will cover the track, extending the tunnel into the open air. These ‘porous portals’ will avoid sudden changes in air pressure – and resulting noise – caused by trains entering and exiting the tunnels.
Capital Reinforcement have been supplying Align JV with rebar and couplers since 2021. The service they have provided to our project has been exceptional. They were very helpful in ensuring Align JV had a supply of rebar during Covid-19 and the Ukraine war. Their advice and support were very much appreciated during some very difficult times for the industry. Orders have been fulfilled to a high degree of accuracy. Replacement bars in the event of design error have been replaced promptly and without fuss. Certification, records of call-offs, delivery tickets, etc. have been provided as requested. We have undertaken two HS2 audits in the last two years and there have been zero NCRs reported. I would have no hesitation in recommending Capital for further works
John Feeney
Commercial Manager
Align JV
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Capital Reinforcing was founded in 2004 by the Managing Director and owner Dermot Owens. In establishing the Company, Dermot brought with him over 20 years’ experience in the steel reinforcement fixing Industry and over the years has built a management team and facilities to match his ambitions.