TBM Launch Ramp

Project Overview

As part of a £5bn development near Whitby, Anglo American is constructing a major polyhalite mine. The mineral will be extracted at Woodsmith and transported via a 37km tunnel to the Wilton International facility in Redcar, where it will be granulated and prepared for export.

STRABAG AG was appointed Principal Contractor for the tunnel construction, with Rainton Construction playing a key role in facilitating the 225m-long Tunnel Boring Machine (TBM) launch and rockface operations.

Our scope included constructing multiple concrete slabs, traditional drainage systems, manholes, catchpits, a TBM launch ramp, and laying over 10,000m² of macadam to various specifications. Surfacing was completed by our in-house team using materials supplied by Tynedale Roadstone.

Challenges

This complex civil engineering project involved the dual construction of a 400m-long TBM assembly and launch ramp. Key challenges included excavating pile caps, installing capping beams, and building a 100m TBM assembly ramp. The 300m launch ramp required precise MGF bracing and excavation through hard mudstone strata.

Rail tolerances were limited to just ±3mm and were adjusted every 2 metres using shims and Excalibur bolts to fine-tune alignment. Additional works included the temporary diversion of the Mill Race Watercourse, installation of a 400m culvert, cropping over 300m of 1m-diameter concrete piles, and multiple service diversions including mains water and electricity.

Our flexible workforce responded swiftly to design changes and short-notice variations, minimising impact on the critical path. Daily look-ahead meetings, regular client reviews, and a dedicated in-house Quantity Surveyor ensured the project remained on programme.

Safety and Sustainability

We adopted a collaborative, data-driven approach. The ‘MyZone’ proximity sensor system was introduced to manage the people/plant interface, significantly enhancing site safety.  All recyclable demolition materials were processed and reused within the earthworks.

Summary

Thanks to the dedication and expertise of our team, the project was delivered on time and within budget.

Rainton Construction was proud to receive both the ‘Subcontractor of the Year’ and ‘Project of the Year (£1m to £5m)’ awards at the CECA North East Awards 2021 in recognition of our work on this scheme.