HS2 Tackles Materials Shortfall By Opening A New On-Site Rebar Components Facility
The title of this post, is the same as that of this news item from High Speed Two.
These are the three bullet points.
- A new facility on HS2’s Copthall tunnel site addresses materials shortages by making rebar products on site
- A team of 14 will make 92,000 rebar couplers needed for the Copthall tunnel in Hillingdon
- The innovative solution has created jobs, saves time and money, reduces waste and cuts lorry movements
These three paragraphs outline what was done.
HS2 has set up a rebar threading facility to address materials shortages at its Copthall tunnel construction site in Hillingdon – creating jobs, cutting waste and reducing lorry movements. The new facility will make 92,000 rebar couplers, needed to construct the Copthall tunnel.
The Skanska Costain STRABAG joint venture (SCS JV) team constructing the tunnel were faced with delays due to a shortfall of available prefabricated fatigue rated rebar couplers, after suppliers had exited the market. To address this, the team has constructed a threading facility on site to produce the required quantities of the materials themselves.
As well as addressing supply shortfall, the threading facility has resulted in a significant financial saving on the project by reducing waste, costs and lorry movements, and overall creating a more efficient way of working.
This looks like the sort of solution that could be applied more often.
There’s also an excellent video.
I have definitely been impressed with the project management of High Speed Two.
Belgians To Start Building World’s First Artificial Energy Island Next Year (VIDEO)
The title of this post, is the same as that, of this article on offshoreWIND.biz.
This is the sub-heading.
Belgian offshore construction companies Jan De Nul and DEME, through their consortium TM EDISON, have won the tender for the construction of the Princess Elisabeth Island in their home country and the first artificial energy island in the world.
And this first paragraph outlines the project.
The artificial island, which will be built some 45 kilometres off the Belgian coast and will occupy an area of approximately five hectares above the waterline, will serve as the link between the offshore wind farms in the country’s second, 3.5 GW Princess Elisabeth offshore wind zone and its onshore high-voltage grid.
Initial plans don’t seem to be putting any wind turbines or solar panels on the island.
The most impressive part of the article is the video, which shows how the island will be constructed.
To some people of my age, the construction of the island will seem familiar, as the island will be built in a similar way to the Mulberry harbours of World War II.
A few years ago, I went inside some of the giant Pheonix caissons in The Netherlands, where they were initially used to plug the dykes after the North Sea Flood of 1953. They are now a museum of the floods called the Watersnoodmuseum.
Engineering is repeating itself.
Into The Realm Of The Rabbits
The completed Bank Station Upgrade opened today and I went and took these pictures of what is now a rabbit warren of a station.
Note.
- There are now three cross passages between the two Northern Line platforms.
- There are two lifts between Cannon Street and the Northern Line and one extends to the Docklands Light Railway.
- The Northern Line and Cannon Street are now connected by two sets of three very long escalators.
- I took a walk to Cannon Street, whilst taking this pictures and from leaving the new entrance to being on a train out of Cannon Street, took mt five minutes.
- After photographing the station, I walked to the bus stop for the 141 bus, which took me home. As there is now a new passage between the gate-line and the bus stop, it took just two minutes.
The new Cannon Street entrance is a practical, stylish and well designed and built addition to the Bank station complex.
I would let the same architects and builders loose on Camden Town, Holborn and Oxford Circus/Bond Street stations.
Is Old Street Roundabout A ‘Too Many Cooks’ Project?
The remodelling of Old Street station and the roundabout on top was the lead item on BBC London news this morning.
The project is certainly not going well and seems to be proceeding at a snail’s pace.
Progress On The 24th February 2023
I took these pictures a few days after I wrote the original post.
Compare these pictures with those in Old Street Station – 9th September 2022, which were the last ones I took.
Conclusion
I do wonder, if this project is suffering from too many politicians trying to manage the project at the top.
I suspect Hackney and Islington Councils, the City of London, the Greater London Authority, Transport for London and the Mayor of London are all having a say.
And I suspect other interested parties like Moorfields Hospital, the various bus companies, and many disgruntled passengers are all adding their four pennyworth.
What is needed is for someone with authority to take charge!
Unfortunately for the project, the guy with the authority; Sadiq Khan won’t be interested, as it’s a North London project.
But please someone, get a grip on this important project!
HS2 Smashes Carbon Target
The title of this post, is the same as that of this article on Rail Engineer.
This is a must-read article which explains how the various companies building High Speed Two are progressing in making all of the work sites diesel-free.
GeoPura is mentioned in the article and on this page on GeoPura’s case studies, which is entitled HS2 Reveals Successful Results Of Hydrogen Generator Trial, full details of the trial are given.
An HS2 construction site in London has held successful trials for two zero-emissions hydrogen fuel cell-based electricity generators – cutting carbon and improving air quality for workers and the local community.
The two GeoPura 250kVA hydrogen power units (HPUs) were trialled over the last year at HS2’s Victoria Road Crossover Box in Ealing, as a direct replacement for diesel generators to power machinery on the site.
There is also this video from High Speed Two.
Note.
- The use of electric cranes, diggers, dump trucks.
- The red trailer with lots of small cylinders, which is used to supply hydrogen.
- HS2 are also using HVO and flywheels to store energy.
- The video is narrated by HS2’s Air Quality Manager. If every project had one of these, it must surely speed decarbonisation.
We need more electric construction.
Is This The Television Program Of The Year?
I’m just watching The Mayfair Hotel Megabuild in BBC2.
It’s fascinating and a must watch, as builders and miners expand Claridge’s Hotel up and down!
- More rooms and a penthouse on top.
- A spa and two swimming pools in the basement.
- A large number of rooms are also being refurbished.
And all while the hotel is nearly fully occupied.
I suspect that a lot of the techniques shown in the documentary have been used on the construction of the Elizabeth Line and the execution of the Bank Station Upgrade.
Low Carbon Construction Of Sizewell C Nuclear Power Station
Sizewell C Nuclear Power Station is going to be built on the Suffolk Coast.
Wikipedia says this about the power station’s construction.
The project is expected to commence before 2024, with construction taking between nine and twelve years, depending on developments at the Hinkley Point C nuclear power station, which is also being developed by EDF Energy and which shares major similarities with the Sizewell plant.
It is a massive project and I believe the construction program will be designed to be as low-carbon as possible.
High Speed Two is following the low-carbon route and as an example, this news item on their web site, which is entitled HS2 Completes Largest Ever UK Pour Of Carbon-Reducing Concrete On Euston Station Site, makes all the right noises.
These three paragraphs explain in detail what has been done on the Euston station site.
The team constructing HS2’s new Euston station has undertaken the largest ever UK pour of Earth Friendly Concrete (EFC) – a material that reduces the amount of carbon embedded into the concrete, saving over 76 tonnes of CO2 overall. John F Hunt, working for HS2’s station Construction Partner, Mace Dragados joint venture, completed the 232 m3 concrete pour in early September.
The EFC product, supplied by Capital Concrete, has been used as a foundation slab that will support polymer silos used for future piling works at the north of the Euston station site. Whilst the foundation is temporary, it will be in use for two years, and historically would have been constructed with a more traditional cement-based concrete.
The use of the product on this scale is an important step forward in how new, innovative environmentally sustainable products can be used in construction. It also helps support HS2’s objective of net-zero construction by 2035, and achieve its goal of halving the amount of carbon in the construction of Britain’s new high speed rail line.
Note.
- Ten of these slabs would fill an Olympic swimming pool.
- I first wrote about Earth Friendly Concrete (EFC) in this post called Earth Friendly Concrete.
- EFC is an Australian invention and is based on a geopolymer binder that is made from the chemical activation of two recycled industrial wastes; flyash and slag.
- HS2’s objective of net-zero construction by 2035 is laudable.
- It does appear that this is a trial, but as the slab will be removed in two years, they will be able to examine in detail how it performed.
I hope the Sizewell C project team are following High Speed Two’s lead.
Rail Support For Sizewell C
The Sizewell site has a rail connection and it appears that this will be used to bring in construction materials for the project.
In the January 2023 Edition of Modern Railways, there is an article, which is entitled Rail Set To Support Sizewell C Construction.
It details how sidings will be built to support the construction, with up to four trains per day (tpd), but electrification is not mentioned.
This is surprising to me, as increasingly, big construction projects are being managed to emit as small an amount of carbon as possible. Sizewell C may be an isolated site, but in Sizewell B, it’s got one of the UK’s biggest independent carbon-free electricity generators a couple of hundred metres away.
The writer of the Modern Railways article, thinks an opportunity is being missed.
I feel the following should be done.
- Improve and electrify the East Suffolk Line between Ipswich and Saxmundham Junction.
- Electrify the Aldeburgh Branch Line and the sidings to support the construction or agree to use battery-electric or hydrogen zero-carbon locomotives.
Sizewell C could be a superb demonstration project for low-carbon construction!
Sizewell C Deliveries
Sizewell C will be a massive project and and will require a large number of deliveries, many of which will be heavy.
The roads in the area are congested, so I suspect rail is the preferred method for deliveries.
We already know from the Modern Railways article, that four tpd will shuttle material to a number of sidings close to the site. This is a good start.
Since Sizewell A opened, trains have regularly served the Sizewell site to bring in and take out nuclear material. These occasional trains go via Ipswich and in the last couple of years have generally been hauled by Class 88 electro-diesel locomotives.
It would be reasonable to assume that the Sizewell C sidings will be served in the same manner.
But the route between Westerfield Junction and Ipswich station is becoming increasingly busy with the following services.
- Greater Anglia’s London and Norwich services
- Greater Anglia’s Ipswich and Cambridge services
- Greater Anglia’s Ipswich and Felixstowe services
- Greater Anglia’s Ipswich and Lowestoft services
- Greater Anglia’s Ipswich and Peterborough services
- Freight services serving the Port of Felixstowe, which are expected to increase significantly in forthcoming years.
But the Modern Railways article says this about Saxmundham junction.
Saxmundham junction, where the branch meets the main line, will be relaid on a slightly revised alignment, retaining the existing layout but with full signalling giving three routes from the junction protecting signal on the Down East Suffolk line and two in the Down direction on the bidirectional Up East Suffolk line. Trap points will be installed on the branch to protect the main line, with the exit signal having routes to both running lines.
Does the comprehensive signalling mean that a freight train can enter or leave the Sizewell sidings to or from either the busy Ipswich or the quieter Lowestoft direction in a very safe manner?
I’m no expert on signalling, but I think it does.
- A train coming from the Lowestoft direction needing to enter the sidings would go past Saxmundham junction on the Up line. Once clear of the junction, it would stop and reverse into the branch.
- A train coming from the Ipswich direction needing to enter the sidings would approach in the wrong direction on the Up line and go straight into the branch.
- A train leaving the sidings in the Lowestoft direction would exit from the branch and take the Up line until it became single track. The train would then stop and reverse on to the Down line and take this all the way to Lowestoft.
- A train leaving the sidings in the Ipswich direction would exit from the branch and take the Up line all the way to Ipswich.
There would need to be ability to move the locomotive from one end to the other inside the Sizewell site or perhaps these trains could be run with a locomotive on both ends.
The advantage of being able to run freight trains between Sizewell and Lowestoft becomes obvious, when you look at this Google Map, which shows the Port of Lowestoft.
Note.
- The Inner Harbour of the Port of Lowestoft.
- The East Suffolk Line running East-West to the North of the Inner Harbour.
- Lowestoft station at the East side of the map.
I doubt it would be the most difficult or expensive of projects to build a small freight terminal on the North side of the Inner Harbour.
I suspect that the easiest way to bring the material needed to build the power station to Sizewell would be to do the following.
- Deliver it to the Port of Lowestoft by ship.
- Tranship to a suitable shuttle train for the journey to the Sizewell sidings.
- I estimate that the distance is only about 25 miles and a battery or hydrogen locomotive will surely be available in the UK in the next few years, that will be able to provide the motive power for the return journey.
In The TruckTrain, I wrote about a revolutionary freight concept, that could be ideal for the Sizewell freight shuttle.
In addition, there is no reason, why shuttle trains couldn’t come in from anywhere connected to the East Suffolk Line.
Zero-Carbon Construction
Sizewell C could be the first major construction site in the UK to use electricity rather than diesel simply because of its neighbour.
Conclusion
I shall be following the construction methods at Sizewell C, as I’m fairly sure they will break new ground in the decarbonisation of the Construction industry.
ZERRCI – Zero Emissions Repowering Of Railway Construction Infrastructure
This project was one of the winners in the First Of A Kind 2022 competition run by Innovate UK.
In this document, this is said about the project.
Project No: 10037562
Project title: ZERRCI – Zero Emissions Repowering Of Railway Construction Infrastructure
Lead organisation: EMINOX LIMITED
Project grant: £59,852
Public description: Eminox, HS2 and SCS Railways propose a solution for the delivery of a low emissions, greener
railway. Our solution covers the development of an electric motor and battery system, which can be
retrofitted into existing construction equipment, replacing the traditional diesel engine with a quieter,
cleaner, zero emissions drivetrain. These pieces of plant and equipment will be used as direct
replacements for diesel machines in the constructing and maintaining railway infrastructure.
Eminox is leading this project with its experience in providing cost effective retrofit emissions
solutions and together with HS2 and SCS JV will be involved in demonstrating the first repowered
construction equipment in a real-world rail infrastructure environment.
This proposed venture has been instigated by HS2 in line with their ambition as set out in their Net
Zero Carbon plan for diesel free construction sites by 2029. As the solution will extend the life
expectancy of the machine, it will contribute to HS2’s vision of net-zero by 2035.
This solution will offer a more cost-effective route to zero emissions construction compared to
purchasing similar new electric powered equipment by extending the life expectancy of existing
plant and machinery. With a target of 50% the price of purchasing new excavators it is expected to
incentivise the broader uptake of demand in electric plant and equipment at scale across the
industry supply chain.
Phase 1 of this project aims to deliver a proposal for a prototype zero-emissions excavator. By
performing a feasibility study on the conversion principals, we intend to extract a broad
understanding of the challenges associated with integration and develop an optimised battery and
motor system specification.
Phase 2 will involve the conversion, commissioning and delivery of a repowered excavator, and
subsequent in-service validation. By using this converted machine to conduct initial trials, it will be
proven that no machine functionality or safety features have been compromised during conversion,
and we will establish power storage requirements to provide adequate duty cycle performance.
This will result in a fully proven demonstrator with real-world validation enabling further
development of optimised battery solutions.
My Thoughts And Conclusion
Carbon-Neutral Concrete Prototype Wins €100k Architecture Prize For UK Scientists
The title of this post, is the same as that of this article on the Architect’s Journal.
Under a picture of two white-coated scientists with their protective boots on concrete samples, the story and their invention is outlined.
A pair of PhD students at Imperial College London have won a global architecture prize for devising a groundbreaking method of creating carbon-neutral concrete
Material scientists Sam Draper and Barney Shanks landed the €100,000 2022 Obel Award with their ‘simple way’ to capture carbon from industrial production processes and create an end product that can eliminate the CO₂ footprint of concrete.
The prototype technology, dubbed Seratech, takes industrial CO₂ emissions directly from flues and produces a carbon-negative cement replacement material (silica). According to the scientists, when this is used in combination with Portland cement, the carbon capture associated with producing the silica means the concrete products can be zero carbon.
One of the products, we will need in the world is concrete and if we can make it in a carbon-neutral manner, then that will surely reduce worldwide carbon emissions.
The Technology Explained
This page on the Seratech website is entitled Our Technology.
It gives this description of the technology.
Seratech has developed a process that consumes olivine and waste CO₂ from flue gases and produces two products which both have significant value in construction.
Silica is produced which can be used as a supplementary cementitious material (SCM) in concrete meaning the amount of Portland cement in the concrete can be reduced by up to 40%. As the silica comes from a process that captures CO₂ it is “carbon negative” and the concrete can become carbon neutral.
Magnesium carbonate is produced that can be used to make a range of zero carbon construction materials and consumer products, including alternatives to building blocks and plasterboard.
The aim is for humanity to be able to continue building robust cities and infrastructure, but without the climate cost of traditional cement mixes and with the Seratech technology this goal is achievable!
Note that olivine in Europe is generally mined in Norway.
Replacement Of Steel By Concrete
Could we also replace steel in some applications with concrete?
In UK Cleantech Consortium Awarded Funding For Energy Storage Technology Integrated With Floating Wind, I talked about some of ground-breaking methods used by a company called RCAM Technologies to create infrastructure using 3D printing of concrete.
If Imperial’s concrete, which is called Seratech can be 3D printed, I can see lots of applications for the technology.
So you could kill two sources of large carbon emissions with one technology.
Conclusion
I have said on this blog before, that we will have to keep or even build more gas-fired power stations, as they can be an efficient source of pure carbon dioxide, that will be needed as a feedstock to create an increasing number of agricultural and building products.
ITOCHU, Taisei Corporation And Mineral Carbonation International Announce Collaboration
This collaboration is reported in this article on Market Screener, which is entitled ITOCHU : Announces Collaboration With Taisei Corporation In Initiative With MCi Testing Uses Of Concrete From Calcium Carbonate With Mineral Carbonation.
This paragraph described MCi’s mineral carbonation technologies.
MCi is a company that has pursued fifteen years of research and development into mineral carbonation and possesses the technology to produce a range of low carbon embodied materials including calcium carbonate by carbonating minerals in slag and other by-products of the steelmaking process (mainly steelmaking slag), coal ash produced by thermal power plants, and other industrial waste materials containing magnesium or calcium (mine tailings: by-products from the collection of metals and ore).
It also appears that ITOCHU invested in MCi last year.
I have read the whole article and I suggest that this collaboration could grow into something very big.
The Anonymous Widower 