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EPS Infill to Railway Bridge, Cardiff

EPS Infill to Railway Bridge, Cardiff

Project: EPS Infill Contract. Supply EPS wrapped blocks for lightweight fill to replacement bridge.

Client: Kier International

Summary: The supply and installation of impermeable membrane to encapsulate expanded polystyrene lightweight fill.

• The installation of 6,500 EPS blocks to rail bridge abutments and embankments underneath a replacement bridge at Windsor Road, Cardiff.
• Supply and installation of Landflex 100ES impermeable liner system to cover the EPS blocks.
• Supply of plant movement of EPS blocks, membrane and Geotextile.

Challenges: The installation of 6,500 EPS blocks and Landflex Hydrocarbon resistant 100ES to support a replacement bridge spanning the main railway line from Cardiff to London. Our teams were presented with very limited access, working adjacent to a live railway line and the need to accomplish the work without compromising risk to themselves or the contractor. The installation was completed during winter months, with occasional severe weather conditions.
Butek Landline employed multiple teams, working on both sides of the railway, tailoring the EPS blocks and membrane around the bridge infrastructure, using fall arrest systems due to the work being carried out at heights of around 6 meters. Machine movements were restricted in the area.

Our Solution: Our Landflex 100ES material is a chemically resistant flexible membrane and the preferred choice for this project due to its superior chemical resistances, tensile strength and flexibility. Utilising prefabricated panels of Landflex 100ES membrane enabled work to progress quickly and efficiently, cutting and dressing the EPS blocks on site with hot wire cutters, the blocks were positioned using long reach tele-handlers.

Contract Period: The entire project (6,500 blocks @ 2400 x 1200 x 600mm high) was completed in just 5 weeks.

Results: Landflex 100ES is designed specifically for challenging environments, and provides an excellent protective cover for the EPS blocks, keeping them safe from the environment. Its flexibility allows for speedy installation using prefabricated panels and the wide welding window is ideal for twin wedge or hot air welding techniques.
The work was carried out during November / December and was completed on time and within budget despite the inclement weather and much to the delight of the main contractor.

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Encapsulated Polystyrene Infill, London

Encapsulated Polystyrene Blocks

Project: Encapsulated Polystyrene Infill Project, Supply & install EPS wrapped blocks to three road bridge arches in London.

Client: F M Conway


The encapsulation of Expanded Polystyrene blocks with a hydrocarbon resistant membrane inside a three arched road bridge.
• The installation of Landflex 100ES to the floor and walls of the arches to 1.2m below soffit.

• Installation of Landflex 100ES welded to the wall section to ensure total encapsulation of EPS blocks

• Total encapsulation of individual EPS blocks in our factory to enable completion of the final 1.2metres

Challenges: Working in restricted areas with limited space. The challenge was to provide a solution to the completion of the EPS installation without compromising risk to the contractor or installation teams.

Our Solution: Our Landflex 100ES material is a chemically resistant flexible membrane and the preferred choice for this project due to its chemical resistances, tensile strength and flexibility. It’s designed for longevity in challenging environments. The road bridge at Lisson Grove is expected to settle by 10mm, exerting pressure on the EPS installation. The combination of lightweight EPS blocks and the chemical resistance of our Landflex 100ES will ensure the integrity of the project for the future.
The installation comprised 296 individually wrapped EPS blocks, pre-wrapped off site in our Billericay factory; utilising a total of around 5,800m2 of material. Each block measured 2.4m x 1.22m x 600mm and the whole project was completed in 38 days (22 days manufacturing, 16 days on site).