Client: Transport for London
Date: 2020-Ongoing
Transport for London (TfL) is Europe’s largest integrated transport authority. It keeps London moving by running the day-to-day operation of the capital's public transport network and managing London's main roads. As a delivery partner to TfL, we work closely together to co-create engineering solutions across its portfolio of assets.
Whether we’re designing upgrades to the signalling infrastructure on the Piccadilly line or carrying out feasibility studies, developing designs and delivering major road refurbishment projects, our objectives remain the same. At Costain, we’re committed to enabling safer and more efficient journeys, providing long-term value-for-money and positively contributing to the communities we work with.
We offer a range of services from across the project lifecycle, including:
- Needs analysis, feasibility studies and business cases
- Concept and detailed design
- Commercial and programme management
- Technology, engineering and construction services
- Stakeholder engagement, environmental services and social value consultancy.
Projects
Piccadilly line signalling infrastructure design
With its new fleet of rolling stock set to start entering into passenger service at the end of 2025, TfL came to us with a complex problem: it needed to upgrade the existing signalling system so that it would be compatible with the new 24TS trains, while also continuing to support the existing fleet in the meantime. We were commissioned to design critical upgrades to the civils infrastructure supporting approximately 200 existing signals, working closely with London Underground to do so. Find out about our solution here.
A40 strategic artery connecting east and west London
Phase One
This project transformed the safety and quality of customer journeys on a key section of the A40, which is used by 96,000 vehicles per day. We were appointed by TfL to replace the operationally critical roller shutter expansion joint on the A40 Westway flyover, between Wood Lane and Paddington station. The commission included the concept design, detailed design and construction phases, culminating in the replacement of the expansion joint. All of this took place over eight months, while the road remained open from Monday to Friday. Our A40 project team ensured these critical upgrades were completed in time for the Queen’s Jubilee celebrations in 2022 – five weeks ahead of schedule.
Phase Two
Having successfully delivered the first phase of the A40 upgrade, we are currently providing detailed design and construction services for the second phase of the improvements. The works are taking place between Wood Lane and Marylebone Flyover and include the replacement of seven cantilever expansion joints, and resurfacing and concrete repairs on a four-and-a-half-kilometre section of road. The project is expected to complete in summer 2025. Read about the commission here.
Gallow’s Corner Flyover
At Gallows Corner Flyover, we are creating the detailed design ahead of the refurbishment of this complex structure, which joins two main arteries from Essex into London, the A127 and the A12, via Gallows Corner roundabout. This contract award follows on from the successful completion of the concept design phase and the team will use innovative construction methods to minimise disruption from onsite working. We’re integrating opportunities for active travel and reducing requirements for carbon intensive materials.
Brent Cross Interchange
Costain is also producing the concept and detailed designs for planned renewals to Brent Cross Interchange, a major road junction which is used by more than 120,000 drivers each day. It connects two dual carriageways, the A406 and A41, and is made up of the A41 flyover and a gyratory above the A406, which also provides access to the M1 North and the A5. The concept design will develop TfL’s preferred option for renewing the structures which make up this vital road hub, with the detailed design setting out the best way of delivering these critical works.
Key outcomes
1. We delivered significant productivity improvements on the Piccadilly line upgrade:
- We identified and delivered cost savings of more than 25% against the original price.
- We delivered the programme 82 days ahead of schedule, representing a time saving of more than 15%.
2. The A40 Phase One was delivered five weeks early, in time for the Queen’s Jubilee, and under budget.
3. We deployed Production Thinking techniques to adapt the A40 Phase Two programme, so that the Notting Hill Carnival was not affected by construction. Techniques used on the project include:
- A coordinated, systematic approach to road closures working closely with other TfL projects.
- Advance completion of preparatory works.
- Use of 3D asset surveys and 3D scanning.
- Offsite fabrication of joints and trial of joint installation.
- Extensive joint gap monitoring for seasonal response variation and movement range of expansion joints.
4. At Gallows Corner, we identified 11% of carbon savings in the concept design, which is equivalent to 644 TCO2e. The concept design also provides a 35% carbon reduction when compared with demolishing the structure and rebuilding it.
Contact
Andy Clarke
Sector director
[email protected]