Faced with materials shortages at the HS2 Copthall tunnel construction, the Skanska Costain STRABAG joint venture (SCS JV) turned to Leviat for training, specialist equipment and ongoing support in order to create an on-site steel threading facility capable of producing the required 92,000 rebar couplers.

This innovative and efficient rebar facility removes the risk of delays, enables new jobs, reduces lorry movements, cuts waste and saves at least £22m.

A shortfall in the marketplace of available prefabricated fatigue-rated rebar couplers meant the construction of the HS2 tunnel in Hillingdon would face unnecessary project delays. SCS JV required a solution that would supply fatigue rated, and CARES certified mechanical reinforcement connections that met the requirements of the HS2 construction programme. With comprehensive and ongoing support from Leviat, this led to the creation of an on-site rebar threading facility for a project on this scale.

Following meetings with the SCS JV Senior Project Manager, Leviat recommended the optimum approach would be to manufacture the couplings on-site by placing Bartec/CXL threading equipment close to the tunnel operations. Leviat provided extensive ongoing advice and support on the site layout, procurement of roller tables, energy and ancillary equipment, and staff training.

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A critical element was expediting the CARES TA1-A&B certification (Certification Authority for Reinforcing Steels) for the threading site. Leviat’s information and guidance combined with technical know-how and frequent site visits ensured this certification was secured in a timely fashion.

With the factory production control regime established and approved, the production team could purchase stock rebar and then complete the processing operations on site, before taking it through the four-step threading process and delivering it to the Copthall tunnel construction area.

Ray Moloney, Senior Project Manager for SCS JV said: "In mid-2022 we started engaging with partners including Leviat and CARES to develop an on-site processing scheme and within 20 weeks, we were processing our first order."

"The solution has created new jobs, offered new training opportunities for engineers and means that we can remove the risk of any delays in construction due to supply shortages," added Ray Moloney.

Rob Helliwell, Business Development Manager, Structural Connections UK at Leviat said: "Transforming what was essentially a field into the onsite facility we see today has been an incredible undertaking but we are immensely proud to have played our part in the delivery of such an innovative and sustainable onsite solution. The professionalism and collaborative approach by Raymond Moloney BSc(Hons), MIEI and his team at Skanska Costain STRABAG Joint Venture with Leviat in the UK and Ireland has been exemplary throughout the process.

"We look forward to continuing to support the Copthall Tunnel and the other opportunities this undoubtedly creates for other HS2 (High Speed 2) Ltd projects and the wider construction industry."