Melton Mowbray’s purpose build precast manufacturing facility played host to the Federation of Piling Specialists (FPS) Early Careers Group (ECG) last week. Held on 3rd December 2024, with attendance from Roger Bullivant, Bauer Equipment and Volker Ground Engineering.
FTB is an unincorporated joint venture comprising of: Freyssinet Limited, Freyssinet International & Compagnie, Tierra Armada SA and, Roger Bullivant Limited. FTB has been appointed by BBV (Balfour Beatty Vinci) to manufacture and deliver precast and pre-stressed bridge elements (beams and props) for the N1 & N2 sections of the HS2 Project. Over the lifetime of the JV, a total of 3600 bridge elements will be manufactured at the site in Melton Mowbray, and shipped to site to form 75 critical structures across HS2.
The site visit provided a thorough overview of the FTB joint venture, from inception of the JV, to getting the manufacturing facility out of the ground, through to sending the first precast pre-stressed concrete bridge beams out to site. Following a project overview delivered by FTB’s Grant Nicholson (Roger Bullivant) & Chris Cleary (Freyssinet Limited), attendees were shown around the active manufacturing facility.
The joint venture involved the construction of a 365m long steel framed production building, complete with the infrastructure for an on-site concrete batching plant. Tight programme timescales for product delivery meant that contingencies had to be put in place to manufacture the delivery of precast pre-stressed beams. This involved manufacturing beams in an existing Tierra Armada SA plant in Spain and shipping the sections across to facilitate on time delivery of the beams.
Following on from the first delivery of precast product, the manufacturing facility in Melton Mowbray became operational in April 2023, for accreditation following in May of the same year. The first batch of beams manufactured in Melton Mowbray left the plant in June 2023. To date, FTB has delivered product for the construction of 16 out of 76 structures thus far. In order to meet the project delivery dates for the remaining structures, on average 6 beams will be manufactured and cast per day.
The day was thoroughly enjoyed by all and although it was a sidestep from the typical ground engineering projects the ECG host, it was quite the learning experience, regardless of role or experience.