When we had our initial meetings we discussed the design of the rebar that had to match the variable shapes with the Pier Columns and Peir Heads. The design involved multiple bends in each bar and variable degrees. The construction of the main support Piers involved using moulds that would be continuously used and due to the height of these Piers they had to be correct before being lifted as they couldn’t be taken back down as some of the Pier elements weighed over 50 tonnes that required special lifting equipment. We had a plan to test of the of the bars on our CNC machinery to make sure we could get the accuracy based on the bends that the client was trying to achieve. The first issue that we noticed was the customer was using measurements to achieve the bending angles which was not the correct way to achieve the accuracy as this method is open to interpretation of where the mark is to bend. In some cases when using 32mm or 40mm bar there could be a variance of over 100mm in the finished bending angles at the end of the bar which of course is not accurate enough.
We had a plan to test of the of the bars on our CNC machinery to make sure we could get the accuracy based on the bends that the client was trying to achieve. The first issue that we noticed was the customer was using measurements to achieve the bending angles which was not the correct way to achieve the accuracy as this method is open to interpretation of where the mark is to bend. In some cases when using 32mm or 40mm bar there could be a variance of over 100mm in the finished bending angles at the end of the bar which of course is not accurate enough.
With collaboration with the design team we set about testing various bar designs on our machinery using both measurements to achieve the correct bending angles and a test using degrees and critical measurements which naturally we could have the best results using degrees and critical measurements.
Once we tested each bar using the new designs we were able to record this information on our CNC machinery. We tested the bars over and over and the results all came out the same and the accuracy was within +/-2mm of the required dimensions which is less than the allowance in BS8666 standards.
As the design of the Piers were repeating we were able to save the design within our machinery and repeat the accuracy over and over again. We were able to work ahead of the project and batch up certain types of bars that we knew that would be needed in future Piers which allowed us to mass produce difficult shapes in batches then feed them to site on each call-off.
At the point that we have engaged with Merseylink JV we knew that they were falling behind on the project but soon after we commenced supply we managed to provide them with enough steel in advance to catch the programme up. As it is publicly noted that the project finished well ahead of schedule and we finished our supply well ahead of the schedule timeframe.
As the design of the Piers were repeating we were able to save the design within our machinery and repeat the accuracy over and over again. We were able to work ahead of the project and batch up certain types of bars that we knew that would be needed in future Piers which allowed us to mass produce difficult shapes in batches then feed them to site on each call-off.
At the point that we have engaged with Merseylink JV we knew that they were falling behind on the project but soon after we commenced supply we managed to provide them with enough steel in advance to catch the programme up. As it is publicly noted that the project finished well ahead of schedule and we finished our supply well ahead of the schedule timeframe.
Our commercial team had made contact with Capital Reinforcing to discuss the supply of the Steel Reinforcement on the Mersey Gateway Project main bridge. We had some difficulty in getting the special shape code 99 rebar made to the correct dimensions on the support piers of the main bridge. After several meetings with Capital Reinforcing they gave us a solution to change the way the design had been presented and made some sample loads for us prior to being given the contract. We had received the test loads from them and with the change in design they were able to supply one of the most difficult sections on the project on the main support piers on the bridge. We were very happy with the supply and had no complaints to give them as the quality and delivery of the steel was produced to an excellent standard. We would certainly like to work with Capital Reinforcing on any future projects we have in the UK.
Tania Belver
Engineer
Merseylink CCJV
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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.
