The Challenge:
The project presented multiple complex challenges, primarily the need to construct three T-junctions on existing live carriageways while maintaining traffic flow. The works also required designing and building a new bridge crossing over a brook, installing strategic surface water and foul drainage networks, and managing substantial earthworks. A particularly demanding aspect emerged when the client sold land parcels to other developers during the project, necessitating significant redesign of the site’s profile and drainage systems mid-programme.
Scope of Works
We implemented a carefully phased approach, dividing the works into three main phases (across five sections) to manage complexity and maintain progress. For the Section 278 highway works, we coordinated closely with local authorities to minimise disruption to road users while constructing the new junctions. The brook crossing presented a special engineering challenge, for which we proposed an innovative precast portal frame structure that significantly reduced on-site construction time to just five days.
When faced with the substantial redesign requirements due to land sales, we developed a comprehensive materials management plan to maintain the client’s objective of keeping all excavated materials on site. This approach required careful remodelling of the earthworks and redesign of drainage systems to accommodate the changed site profile, demonstrating our flexibility and problem-solving capabilities.
Location:
148 weeks (13th May 2019 - 21st March 2022)
Project Value:
£9,220,739
Duration:
148 weeks (13th May 2019 - 21st March 2022)
Client:
Countryside Properties
Contract:
Infrastructure Conditions of Contract Design and Construct Version August 2011 with Amendments
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Rawreth Lane, Rayleigh
Comprehensive infrastructure scheme at Rawreth Lane delivering highways, drainage, and utilities for residential development.
Our Approach:
Our extensive delivery included:
Highways Infrastructure:
Construction of three T-junctions on existing live carriageways (S278 works)
Development of on-site highways (S38 works) linking the junctions
Design and construction of a new bridge crossing over a brook using precast portal frame
Installation of strategic footways and cycleways throughout the development
Implementation of street lighting and signage systems
Drainage Systems:
Installation of strategic surface water networks across the site
Excavation of new attenuation basins for sustainable drainage
Construction of foul water pumping station and pumping main
Redesign of drainage systems to accommodate changed earthworks profile
Utilities Infrastructure:
Excavation of combined service trenches and road crossings
Construction of four electricity substations to service the development
Installation of gas governor facilities
Provision of utility connections for the wider development
Earthworks:
Major cut and fill operations following site profile changes
Implementation of comprehensive materials management plan
Landscape re-profiling to accommodate on-site materials
Construction of haul roads for future development phases
Overcoming Challenges:
The project’s most significant challenge emerged when the client sold land parcels to other developers, requiring substantial redesign of the site’s profile. This created a major cut and fill exercise that threatened the client’s objective of keeping all materials on site. Our response was to develop a detailed materials management plan that guided the redesign of finished site levels, ensuring no materials needed to be removed from site despite the significant changes.
The brook crossing initially presented a programme risk due to the complexity of constructing a bridge structure in a sensitive watercourse environment. Our value engineering solution—using a precast portal frame structure—reduced the on-site construction programme from several weeks to just five days, minimising environmental impact and programme risk.
Throughout the project, we successfully managed 142 Employer’s Instructions, many relating to design changes and technical approvals from Essex County Council for Section 278/38 works and from Anglian Water for Section 104 drainage approvals. This required exceptional document control and technical coordination to maintain progress despite the evolving scope.
Key Achievements:
Despite the significant challenges of design changes and remodelled earthworks, we successfully delivered this complex infrastructure project while maintaining the client’s key objective of retaining all materials on site. The innovative precast solution for the brook crossing demonstrated our ability to introduce value engineering that benefited both programme and environmental considerations.
The completed infrastructure created the essential foundation for a major residential development, with high-quality roads, drainage systems, and utility provisions ready for the subsequent house building phases. Our flexible approach to the changing requirements proved invaluable in maintaining progress throughout the extended 148-week programme, ultimately delivering a successful outcome for this substantial development.