The buildings were designed to cover the access holes for plant and equipment required for tunnelling as well as the removal of earth and installation of concrete tunnel linings.
DAM’s contract also included the procurement of the acoustic cladding and acoustic doors which were secured through our established supply chain, this unique package has ensured the most cost effective design coordination between the critical parties with no integration issues and compliance with the employers’ requirements, which in turn ensured the noise reductions required for the local tenants.
As the 50te EOT crane was the fundamental element to the scheme we were able to take the KONE crane drawing and then develop a building around it whilst still maintain the tight site boundary’s and the position of the building and crane in relationship to the piled access hole.
The overall building height was set by the clear hook requirements as well as the minimum clearance above the crane thus minimising the impact to the surrounding area, rails were designed as single span to reduce the overall width and length of the building but still ensuring the most cost effective installation of the acoustic cladding. The column positions were also positioned to minimise the impact on the piles and capping beam to the access tunnel.
Erection has been phased to integrate the cladding installation as well as leaving the end bay of the roof open to allow the installation of the crane before infilling with purlins and then cladding.
This ‘one stop shop’ approach has allowed the contractor to procure the major elements of the structure on a shorter procurement period than traditionally achieved as all the necessary interfaces have already been put in place. The same principal applies on site during installation as all parties are fully engaged with each other the process flows from one stage to the next seamlessly.
The second phase of the Battersea redevelopment providing 39,500m2 retail & events space on the lower floors with 58,000m2 of offices above and crowned by 248 flats on the site of the old Power Station.
Client: Keltbray Group Ltd Contract Value: £686,000
DAM Structures were contracted to supply and install nine temporary façade retention towers and two frames to allow work to start on the dismantling and rebuilding of the Grade II listed Annex A and Turbine Hall A to modern specifications.
Due to the temporary towers requiring fitting within the existing steelwork we undertook a detailed survey of the site prior to starting steelwork detailing and installation planning. This prior planning ensured that once on site the installation went ahead to programme.
A BIM model was provided to the client’s design team to permit the steel towers to be incorporated into the master site model allowing for a coordinated design approach.
Due to the age and previous designation of the building all our staff underwent asbestos training prior to starting work on site.
DAM structures were awarded the contract for the manufacturing, delivery and installation of the 1,100 tonnes of temporary propping.
Fabricated trusses that intersected the large circular hollow section (CHS) to allow for the future requirement for extensions to the propping, were provided. These trusses were fabricated out of universal beams (UB) and rolled steel angle (RSA) sections which were required to intersect the CHS props. To achieve this DAM had to create voids in the props to allow for the truss to pass through.
DAM worked closely with the site team to deliver the steelwork on a “just in time” basis and the installation was carried out over 24/7 site shifts so that site programme was achieved. The steelwork had to be delivered to a very tight deadline, so it was essential that the fabrication work and site installation works were completed on time.
DAM Structures was contracted to provide detailed design, fabrication, supply and installation of a temporary tie system to restrain the existing ‘secant wall’ during the excavation of new foundations and basement works for the new multi-storey structure.
The restraint was provided via 3 large (1220 mm diameter) tubular sections which acted in tension. These members were up to 66 metres in length and cantilevered over the wharf water and connected to a capping beam on the wharf wall.
Conventional methods for installation were not possible due to the weight of the members and proximity to the wharf, crane size also needed to be restricted due to the load pressures applied from
the crane on the adjacent wharf wall and the Jubilee Tube line tunnels beneath the site.
DAM developed a bespoke installation method that comprised of much smaller cranes and water based pontoons providing access to all spliced connections and capping beam connections. A bespoke sleeve was also designed by our in-house designer, which was inserted into the capping beam to allow for tensioning of the Macalloy bars after installation giving the client programme time savings and ensuring the tensioning bars tied in with the rebar installation.
Canary Wharf one of the largest Crossrail stations built in the North Dock water area of West India Quay.
Client: Laing O’Rourke Contract Value: £473,000
Our contract comprised of the fabrication & installation of ship protection fenders and a ‘U’ Tube for underwater cables at the new Canary Wharf Station.
The fenders comprised of a steel gridded support system fixed to cast in sockets on the wharf wall, on which timber buffers were attached to stop the ships damaging the wall and ultimately Canary Wharf Station. To ensure the design worked within the site constraints special asymmetrical section profiles were manufactured from plate steel and a special blind bolt system was developed to ensure erection from the floating pontoons was possible. The fabrication was made even more complicated as the grid system and timber verticals needed to tie in with the vertical hand railing positions on the wharf above.
The requirement of getting cables underwater from the dock to the Station building was overcome by the provision of a 20m high x 10.3m wide ‘U’ Tube. The complexity of the design required the tube to:
Be spliced and faceted to achieve the required bend and to keep its shape when split in half along its length, allowing conduits and rebar to be laid in before re-sealing
Be part filled with concrete to allow the full profile to sink in the water, but not too much that the crane couldn’t lift it.
The 1200 diameter tube was designed with square stiffeners at 1500 centres ensuring that each half of the tube maintained its shape when cut along its length and also remained level and stable throughout the process from manufacture to site.
Transforming Nine Elms inner city riverside district into a shining example of world class urban redevelopment for Central London.
Client: Ballymore Group Contract Value: £1,100,000
DAM Structures were tasked with providing and installing a 500 tonne vierendeel truss bridge, which spans between the two new residential towers in Embassy Gardens, London at levels 8 to 12.
The original scheme required on-site welded connections but we identified a value engineering alternative, which allowed for the supply of cruciform beams and site bolted connections. This alternative created a significant cost saving and hazard minimisation for the client due to the amount of work which could be carried out at DAM’s fabrication shop prior to delivery.
Prior to being delivered to site the steelwork was painted in a 2hr fire intumescent protective coating which allowed for minimal on-site touch up. To aid installation access a crash deck was installed to the base of the bridge, this also allowed us to install purpose built tracks to allow MEWPS to be used and also ensured the safety of our personnel.
The only surface station on the Central Line, Custom House Station is located one stop from Canary Wharf.
Client: Laing O’Rourke Contract Value: £1,100,000
Whilst the main station structures were formed out of concrete there was a requirement for steel structures and bridges, which was awarded to DAM Structures due to our expertise in steel fabrication.
The steelwork received a multiple coat paint system which utilised thermal sprayed aluminium before protective coatings including fire protection were applied. All protective coatings were to a high architectural decorative finish.
The DLR Bridge was installed over a 28 hour weekend possession window where overhead high voltage lines added to the complexity of the installation requiring detailed logistical planning and strict safety vigilance.
A new Southern ticket hall with an entrance at street level at Victoria Underground Station.
Client: Taylor Woodrow BAM Nutall JV Contract Value: £520,000
DAM Structures were contracted to fabricate, install and connect new structural steelwork to existing structure at Victoria Station to facilitate the new southern ticket hall upgrade, providing the ground floor support structure & ticket hall entrance structure.
To ensure connections were integrated correctly the existing steelwork was surveyed & new steelwork was detailed to exacting specifications. The existing steelwork was either drilled or site welded to allow for the connection of the new steelwork. Once the structure was complete shear studs were drawn arced to the top flange to allow the new concrete slab to key to the steelwork.
The site was situated between two main London arterial roads which made for very tight site, so deliveries were required on a ‘just in time’ delivery system. All deliveries were required to conform to Crossrail’s strict safety requirements which included FORS registration.