FP McCann managed and delivered Phase 1, which is part of an ongoing project to rehabilitate the entire rail network's culvert structures.
The rail network's culverts are basic but essential components of that infrastructure. They carry waterways under the live rail infrastructure and prevent damage from flooding and erosion. The works involved the open cut replacement of 3no. culverts on the Bleach Green to Larne Line and 1no. on the Coleraine to Ballymoney Line as well as the relining of a further 6no. culverts with UV cured in place glass reinforced plastic (GRP) liners on the Belfast to Portadown Line, Ballymoney to Coleraine Line and the Bleach Green to Larne Line.
The open cut replacement works involved the entire replacement of 4no. culverts with precast concrete spigot and socket pipes and bespoke designed segmental precast concrete headwalls manufactured and supplied by FP McCann's Precast Factory in Knockloughrim. Rock armour and scour protection was supplied from a combination of FP McCann's quarries, namely Loughside Quarry in Larne and Bradley's Quarry in Kilrea and installed at both the inlet and outlet of each of the four culverts replaced in accordance with the specification and construction drawing.
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Two of the culverts were replaced in conjunction within a single 56-hour Line Blockade with the remaining two installed in subsequent 56-hour blockades in concurrently with other planned significant and strategic rail infrastructure works.
The remaining six culverts within this contract were relined with UV cured-in-place pipe (CIPP) liners to ensure their serviceability for a further 120 years. The resin-soaked liners (prior to curing) are sensitive to temperature and must be kept refrigerated until installation. This and the significant logistical challenges in accessing the culvert locations while ensuring the unimpeded operation of the rail network were challenges overcome in the delivery of this project. This was achieved through a combination of night and day shifts utilising several varying safe systems of works, plant and equipment. In conjunction with the relining, existing brick headwalls and brick scour protection aprons on the Belfast to Portadown culverts were repaired and repointed. New precast concrete headwalls supplied by FP McCann's Precast facility in Knockloughrim and scour protection from FP McCann's Bradley's Quarry in Kilrea were installed at the Ballymoney to Coleraine line culvert in accordance with the specification and construction drawings.
