The six-lane Mersey Gateway Crossing toll bridge crosses the Mersey River and Manchester Shipping Canal.

As of the end of 2019, journey numbers for the Mersey Gateway stood at 6.1 million. The crossing, which opened in October 2017, has three traffic lanes in each direction and is approximately 1.5 km east upstream of the Silver Jubilee Bridge. The Astmoor Approach Viaduct, led by main contractor Mersey Link CJV, forms a vital part of the 2 km crossing.

The contractor approached RMD Kwikform to provide a solution to support the 115-tonne pre-cast concrete beams for the Astmoor Approach Viaduct. However, due to the tight timescales on-site where the main contractor needed to build a 40-metre span each week, RMD Kwikform only had seven days from initial contact to produce the design and commence delivery of equipment to site.

“We supplied a Megashor and Rapidshor propping system to support the pre-cast beams situated at each 40-metre span,” explains Ian Fryer, Engineering Director at RMD Kwikform.

“As this is an exposed riverside site, and the viaduct reaches heights of 25 metres, it was vital that we provided a solution that made the most out of the permanent works in order to withstand high wind loads. In the end, it was a combination of RMD Kwikform’s systems that provided the optimum arrangement.

“On the outside of the composite assembly, the pre-cast beams are landed directly onto Megashor supports which subsequently also support the bulk of the deck construction. The Megashor is laterally supported in one axis by Megashor yokes that clamp around the piers. Between the piers, Rapidshor falsework supports the Megashor yokes and the cast in-situ crosshead, and also provides a boarded access from which the pre-assembled Megashor falsework could be safely erected and attached.”

Ian Fryer continues: “Earlier in the project, RMD Kwikform provided customised steel-faced climbing formwork for the multitude of multi-lift piers. The finish on these piers is exemplary and we were pleased that when Mersey Link CJV needed a solution on the viaduct deck, we were approached once again to provide a solution. Of course, short timescales are often part and parcel of the industry and this project is testimony to our engineering, service, and delivery teams nationwide. We’re very pleased to have been involved in this project.”

In total, the Megashor and Rapidshor towers support over 6,500 tonnes of bridge. Due to the sheer scale of the project, and the volume of equipment required on such short notice, we called on our national branch network to supply materials and equipment. Equipment was sourced from London, Glasgow and all over the UK and delivered to site on time, with no delay to the programme.