Highways Past Project

M4 Junction 13

Improvements

0 Project Value

0 Year Programme

0 Peak Workforce

Project Overview

BCL completed 10 bridges on this scheme with spans ranging from 40 metres to 70 metres.
Three of these completed using pre cast beams and omnia deck.

The major bridge was the M4 itself which had to be completed in possession work and road closures with live traffic and in some cases 24 hour working was essential to reach project milestones.

Pre cast beams were in excess of 30tonnes and varied in shape

Project Details

Client Costain

Principal Contractor Tier 1 Contractor

Project Value £38 Million

Sector Major Infrastructure

Location Chieveley, United Kingdom

Duration 2009 – 2010

£38M Total Project Value

50+ Peak Operatives On Site

24 Month Programme Duration

Our

Scope of Works

BCL delivered a comprehensive package of labour and supervision services across all major construction phases of the project.

Project Overview

BCL completed 10 bridges with spans ranging from 40 m to 70 m. Three bridges were delivered using pre-cast beams and Omnia deck systems, while the major structure was the M4 bridge, constructed under possession work with live traffic management. Certain works required 24-hour operations to meet critical programme milestones.

Bridge Substructure and Foundations

The substructure works provided the essential support for all bridges: Excavation and construction of pile caps and foundations Installation of reinforced concrete abutments and piers Integration of pre-cast elements where applicable Quality control of concrete placement and structural alignment These works ensured stability and longevity for each bridge span.

Superstructure and Pre-Cast Elements

The superstructure works included: Placement and installation of pre-cast beams in excess of 30 tonnes, with varying shapes Construction of Omnia deck systems for three bridges Concrete casting and finishing for cast-in-place sections Alignment, levelling, and quality inspection of all structural components These activities ensured structural integrity while accommodating complex design geometries.

M4 Bridge and Traffic Management Works

Special procedures were required for the M4 bridge due to live traffic: Works carried out under possession schedules with lane closures Use of temporary traffic management systems to ensure safety and minimise disruption 24-hour working during critical lifts and deck installations Coordination with highways authorities to maintain project milestones This approach allowed the major bridge to be delivered safely and efficiently within programme constraints.

Health and Safety Management

Due to the scale and nature of the works, safety was critical: Preparation and enforcement of site-specific RAMS Supervision of heavy lifting operations for pre-cast beams and deck elements Continuous monitoring of working at height, traffic interaction, and night works Daily toolbox talks, PPE enforcement, and safety audits to ensure compliance These measures mitigated risks associated with large-scale bridge construction and live traffic operations.

Labour Supply and Resource Management

The project required careful management of skilled personnel: Deployment of crane operators, steel fixers, concrete operatives, and supervisors Scheduling of labour to match traffic closures, night works, and critical lifts Coordination with subcontractors and specialist lifting teams Ensuring sufficient workforce for simultaneous operations across multiple bridges This strategy ensured the timely delivery of all bridges while maintaining safety and quality standards.

Project Gallery

Key stages and completed elements of this major infrastructure programme.

Foundation works in progress

Key Challenges & Solutions

Delivering major works within a complex infrastructure environment presented significant engineering and logistical challenges requiring innovative solutions from our teams.

Handling and Installation of Heavy Pre-Cast Beams

Challenge: Pre-cast beams for three bridges weighed over 30 tonnes each and varied in shape, requiring careful handling and precise placement. Any misalignment could compromise structural integrity and delay the programme. Solution: Detailed lifting plans and crane logistics were developed, with experienced crane operators and rigging teams executing lifts. Continuous supervision and alignment checks ensured beams were installed safely and accurately, maintaining programme continuity.

M4 Bridge Construction under Live Traffic

Challenge: The major bridge over the M4 had to be completed while live traffic was maintained, necessitating lane closures and coordination to avoid disruption. Certain operations required 24-hour working to meet milestones. Solution: A comprehensive traffic management and possession plan was implemented, including temporary lane closures, signage, and coordination with highway authorities. Critical lifts and deck placements were executed during off-peak hours and night shifts to ensure safety and minimise impact on traffic.

Programme Sensitivity Across Multiple Bridges

Challenge: The scheme involved 10 bridges with overlapping construction activities, requiring all works to align with the overall programme to avoid delays in structural completion and downstream works. Solution: A robust programme management strategy was adopted, including phased scheduling, daily progress monitoring, and proactive labour and resource allocation. This approach ensured all bridges were completed on time while maintaining quality and safety standards.

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