THE UK LEADER IN REINFORCED CONCRETE BASEMENT, SUB- AND SUPERSTRUCTURE FRAME CONSTRUCTION.
About us
COMPANY INFORMATION

The Expanded Group provides a total capability in the early construction phases of major projects, providing an end-to-end solution or a bespoke choice of services, backed by a central technical design and engineering resource.

OUR UNIQUE APPROACH – DESIGN, DIGITAL BUILD, MANUFACTURE AND CONSTRUCT

Boasting a directly employed workforce of almost 1,300 operatives and over 400 staff, we know we can deliver. Working as ‘one team’ we have the ability to design, manufacture and install precast components through our own manufacturing facility; we can supply plant, small tools, accommodation and tower cranes through our partner company Select Plant Hire, and provide stone and stone cladding services from Vetter UK.

Meet Our people

COMPANY INFORMATION

The Expanded Group provides a total capability in the early
construction phases of major projects, providing an end-to-end
solution or a bespoke choice of services, backed by a central
technical design and engineering resource.

Our services include:

  • Infrastructure
  • Groundworks
  • Substructures
  • Superstructures
  • Precast facades
  • Specialist engineering

This diverse capability streamlines the delivery process by enabling us to undertake works directly – reducing the time and cost implications associated with multiple handovers between different trades/packages.

OUR UNIQUE APPROACH – DESIGN, DIGITAL BUILD, MANUFACTURE AND CONSTRUCT

Boasting a directly employed workforce of almost 1,300 operatives and over 400 staff, we know we can deliver. Working as ‘one team’ we have the ability to design, manufacture and install precast components through our own manufacturing facility; we can supply plant, small tools, accommodation and tower cranes through our partner company Select Plant Hire, and provide stone and stone cladding services from Vetter UK.

We also offer a highly skilled temporary works department, materials technology centres in Manchester and London, geotechnical design, land surveying specialist teams, reinforcement detailing, in-house post-tensioning design and installation. We use the latest digital technologies to implement a state of the art digital build before any manufacture or construction commences to ensure absolute certainty during project delivery.

Meet Our people

Neil Henderson started his career as a civil engineer building roads and bridges across the UK. In 1995 he joined Expanded and focused on concrete structures with a particular interest in foundations and deep basements. As a Project Manager in the London area he was responsible for a number of complex top-down basements including the apartments at One Hyde Park, the Canary Wharf Crossrail station and the new stations at Nine Elms and Battersea on the Northern Line Extension to name but a few.

Whilst his speciality is in basements he has been responsible for the civils element on the ‘Millennium Dome’, the tower blocks on One Hyde Park, the new Ascot grandstand and more recently the tunnels, track and over-ground structures on the Northern Line Extension.

As a Fellow of the Institution of Civil Engineers he is engaged in developing and training graduate engineers and is focused on developing positive and motivated teams on each of his projects. He has earned the respect of the Clients he has worked with, for delivering projects on time whilst maintaining a strong focus on safety and quality.

In his current role as one of the Operation Leaders in Expanded, Neil is responsible for managing teams on a number of live projects and is also working on tenders for future work.

NEIL HENDERSON
Operations Leader

Appointed to lead Expanded’s concrete structures and geotechnical business, Peter has almost 20 years expertise, during which he has acquired an extremely broad skillset gained on a range of large scale projects such as Crossrail, London’s Leadenhall Building and most recently on Newfoundland, an iconic residential scheme on the Canary Wharf skyline.

As a qualified Civil Engineer, known for his ability to rise to complex challenges, he leads teams that focus on both learning, and delivering, efficient and innovative solutions. Known to empower and nurture talent, he fosters a culture on projects where a broad range of skills and competencies are shared, from steel frame, top-down construction, cofferdam construction and the delivery of Design for Manufacture and Assembly (DfMA) solutions in various sectors.

PETER LYONS
BUSINESS UNIT LEADER

Martin has worked in the construction industry for over 30 years, delivering projects within the residential, hotel/ leisure, commercial, rail/infrastructure, mixed-use/retail and government sectors. He started his career with Laing O’Rourke Civil Engineering in 1984 as a carpenter and soon progressed through the ranks to construction manager – a role he held for 16 years, working on many of the company’s most prestigious contracts throughout the UK.

In 2002, he was promoted to Operations and Labour Relations Director. During his career, Martin has gained a wealth of knowledge in smart build techniques, including slip form and jump form core construction, bulk earthworks, basement construction (including top-down), facade retention, high- rise structures, sub and superstructure works (post-tension and traditional reinforced) and precast concrete frames.

Strongly committed to staff training and development, he mentors up and coming staff and also leads the company’s Apprentice+ scheme.

MARTIN DURKAN
OPERATIONS AND LABOUR RELATIONS DIRECTOR

Andy is a commercial professional with over 20 years’experience in the industry. He has considerable expertise in reinforced concrete structures, gained through time spent working on site. Andy joined the business as a Quantity Surveyor and progressed to Commercial Manager and Regional Commercial Manager positions. In 2012 he transferred to the Australian business where he spent three years working on highly complex civil engineering projects before returning to the UK business in 2015 and his current role as Commercial Director for Expanded. Throughout his career, Andy has gained invaluable experience in cost control, change management and management accounts reporting.

ANDY CHANEY
COMMERCIAL DIRECTOR

Andy is an Operations Director with over 20 years’ experience in the construction industry, specifically relating to reinforced concrete frames. Andy began his career with the business starting with O’Rourke Civil Engineering in London in 1999 and has progressed through the business fulfilling a number of varied roles. Before taking up his current role he worked extensively on a range of projects including city centre retail and commercial offices, residential towers, industrial units and high-rise construction. His particular expertise in the delivery of projects, cost control and productivity management within the RC frame section of the industry informs his ability to provide buildability and cost advice to clients and design teams. In addition to the day-to-day commercial and contractual management of RC frame projects during construction, Andy works alongside both client and design teams from very early in the process – advising on the development of cost plans, assisting in design reviews, providing advice relating to construction issues and value engineering, and ensuring that clients are provided with accurate financial advice at the outset and throughout construction.

ANDY CROMPTON
OPERATIONS DIRECTOR

Kris joined the business in 1999, where he has gained 20 years’ experience, having been involved in a range of projects across the civil engineering, air and rail, commercial, residential and education sectors. He is thorough and committed and has worked on some of our most challenging and complex projects, particularly within tight city centre locations. Throughout this time, Kris has amassed a great deal of knowledge and experience in all stages of construction from preconstruction, delivery and post construction, delivering concrete sub and superstructure projects using in situ, precast and hybrid solutions. Kris is a proven operations manager with over 11 years’ experience in project management and operational management roles.

KRISTIAN WOOTTEN-GREEN
OPERATIONS LEADER

Neil joined the business in 1994 upon graduating from university and after a successful industrial placement with the company. He progressed from Site Engineer through the Engineering structure, spending a year seconded to our in house temporary works department, into project management and then into functional technical lead within the Infrastructure business, a role he held for eight years before returning to Expanded as operations manager in 2014, where he is currently responsible for delivering a £120m portfolio of contracts.

Neil brings to the role a wealth of specialist technical knowledge on deep basements and high-rise concrete frames, as well as problem-solving ability developed over 20 years within the construction industry. He is committed to progressing our engineering background and developing the 200 engineers within his function to become members of the Institution of Civil Engineers and also to identify and develop suitable undergraduates through the Laing O’Rourke scholarship scheme.

NEIL GARRETT
OPERATIONS LEADER

With over 30 years experience in the construction industry Mitchell has a wide range of experience through residential, hospitality, theme parks / resorts, healthcare, infrastructure and industrial. His experience in deploying and managing both directly employed and subcontracted resources coupled with high quality safe methods of construction leads to well organised motivated delivery.

Mitchell is experienced in leading pre-construction planning and services teams, cost planning and negotiating bids and final accounts. He has a wide range of experience in building methods and solutions that lead to improved safety, build programmes and costing.

Mitchell has a range of operational responsibilities across a number of projects in the UK including high rise residential, industrial, health care and highway infrastructure / bridge construction, utility infrastructure and earthworks together with business development and bidding roles.

MITCH PRETIOUS
OPERATIONS LEADER

Barry leads the estimating teams across our Geotechnical, Structures, Vetter UK and Facades businesses, drawing on 16 years of varied international construction, estimating and cost planning experience. He joined the business in 2007 as an Estimating Leader on the £120m Salford and Wigan BSF programme in Manchester – the first of its kind in the UK, before becoming a member of the CIOB.

Barry spent five years working as a Senior Estimator in our Canadian team, where he established and led the estimating function for the pursuit of major projects in a range of sectors, including education and stadia.

Upon his return to the UK in 2014, he joined Expanded as Estimating Leader, where he has been a key member of the team in securing high profile, complex and challenging projects across the UK.

BARRY LEWIN
ESTIMATING LEADER
ST. JAMES, EDINBURGH.
Our work
RESIDENTIAL
RESIDENTIAL
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RETAIL
RETAIL
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COMMERCIAL
COMMERCIAL
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HIGH RISE
HIGH RISE
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EDUCATION
EDUCATION
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HEALTHCARE
HEALTHCARE
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INFRASTRUCTURE & MSCPs
INFRASTRUCTURE & MSCPs
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BASEMENTS
BASEMENTS
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SPORTS AND LEISURE
SPORTS AND LEISURE
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CLADDING
CLADDING
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CLADDING
SPORTS AND LEISURE
BASEMENTS
INFRASTRUCTURE & MSCPs
HEALTHCARE
EDUCATION
HIGH RISE
COMMERCIAL
RETAIL
RESIDENTIAL
190 STRAND
Client:
St Edward Homes Ltd
Main Contractor:
St Edward Homes Ltd
Architect:
Grid
Structural Engineer:
Robert Bird Group
Sector:
Residential
Value:
£27m

We designed and constructed the sub and superstructure for this luxury residential development in central London. Our works included the construction of a secant wall around and through an existing three-level basement. Innovative temporary works allowed demolition of the existing basement, allowing construction of a new four-level basement. The new basement build utilised precast concrete solutions to construct six lift and stair cores, whilst also saving 30 weeks’ work. The superstructure frames range in height from five to eight-storeys and were constructed using precast solutions, creating the 206 apartments. A two level basement and a seven-storey superstructure was also constructed on a neighbouring island.

X1 MEDIA CITY
Client:
Knight Knox / X1 Developments Ltd
Main Contractor:
Vermont Construction Limited
Architect:
Falconer Chester Hall
Structural Engineer:
WSP
Sector:
Residential
Value:
£7m

We delivered the first phase of the new luxury residential development at Salford Quays. Phase One of the development delivered 275 apartments. We completed pile cap excavation with concrete basement and superstructure construction, including a 27-storey slipformed core and post-tensioned upper floors. Our works included bulk excavation and piling mat works, excavation and formation of the reinforced concrete works including; pile caps, ground beams, concrete bases, ramps basement sumps and lift pits, basement shear walls and columns and construction of the ground floor slab, podium slab, ground and upper floor shear walls and columns, post tensioned floor slabs, precast concrete staircases and insitu concrete floor slab.

ONE HYDE PARK
Client:
Candy & Candy
Main Contractor:
Laing O’Rourke
Architect:
Rogers Stirk Harbour
Structural Engineer:
Arup
Sector:
Residential
Value:
£25m

One Hyde Park consists of 85 luxurious apartments ranging in size from 1,000 square feet to over 27,000 square feet and is set in the heart of Knightsbridge. The four pavilions display white precast columns and spandrel beams which form the external structural frame. The core frame consists of a reinforced concrete structural steel composite solution with post tensioned reinforced concrete slabs. For cladding and glazing to fit the double height external precast had to be installed to within 4mm’s. The basement of the structure was constructed top down at the same time as the superstructure.

ONE ELEPHANT ROAD
Client:
Delancy / APG
Main Contractor:
Laing O’Rourke
Architect:
Structural Engineer:
Waterman Group
Sector:
Residential
Value:
£28m

Tribeca Square (Elephant 1) was completed by Laing O’Rourke in 2017 and is a mixed-use development comprising of 24, 19 and 16 storey towers with two basement levels which offer parking space and accommodate plant rooms. Self-delivery ensured that the construction, design and off-site manufacturing teams adopted full efficiency with the utilisation of precast elements and pre-fabricated bathroom pods and smartwall. Our DfMA approach allowed for a 32% reduction in programme duration and a 29% labour saving. The use of Digital Engineering helped us to create a multidimensional model that helped visualise the project showing which components were needed and where.

HINKLEY WORKERS CAMPUS
Client:
EDF NNB
Main Contractor:
Laing O’Rourke
Architect:
Laing O’Rourke + Caledonian Modular Ltd
Structural Engineer:
Laing O’Rourke + Caledonian Modular Ltd
Sector:
Residential
Value:
£12m

Using the latest offsite construction practices under an NEC contract, Expanded supported Laing O’Rourke in delivering modular accommodation blocks across two locations, one in Bridgwater and another closer to the Hinkley project, all in less than 14 months on site. A 30% programme saving compared to traditional methods was secured using our efficient DfMA approach. Due to one campus being located close to a housing estate, minimising disruption was essential. Residents highlighted that noise generated by piling works was a concern, so we used a smaller piling rig to reduce it. Monthly meetings with residents and stakeholders were continued throughout the works to establish close ties with the community.

CLARGES
Client:
British Land
Main Contractor:
Laing O’Rourke
Architect:
Squire and Partners
Structural Engineer:
Waterman’s
Sector:
Residential
Value:
£20m

Expanded delivered top-down construction of a three-storey basement across the footprint of the site, followed by four individual superstructures. These comprised ten and five-storey residential reinforced concrete structures, made up of precast columns, twin-wall cores and lattice plank with in-situ concrete topping floors; seven and four storey steel structures, both with a solid precast concrete core and MEGAPLANK floors which only required in-situ stitch reinforcement. The basement two slab was constructed just below the ground floor slab, tied to the ground floor slab and then lowered into position via hydraulic strand jacks following completion of the basement excavation.

TWO FIFTY ONE, SOUTHWARK
Client:
Oakmayne Properties / ECA Developments
Main Contractor:
Laing O’Rourke
Architect:
Allies and Morrison
Structural Engineer:
Waterman Group
Sector:
Residential
Value:
£120m

Two Fifty One comprises a 41-storey residential tower – 70% of which was constructed off site using DfMA. A 33% reduction of the frame assembly programme was secured using DfMA rather than in situ methods for the residential tower. In addition, the DfMA approach provided increased certainty of time and labour costs, increased productivity, reduced onsite activities and an opportunity to ‘design out’ significant health and safety risks. This unrivalled certainty was made possible through early client engagement and the close links between our planners, designers and in- house manufacturing facilities. The project met the Passive Home Standards and Code for Sustainable Homes Level 3.

RIVERLIGHT
Client:
Berkeley Group
Main Contractor:
St James Group
Architect:
Rogers Stirk Harbour + Partners
Structural Engineer:
Ramboll UK
Sector:
Residential
Value:
£65m

We were appointed to construct a new two-level basement box, which comprises a car park and health suite, connects all six high rise blocks, filling the entire site footprint. We constructed the six reinforced concrete frames delivering 800+ apartments(including two penthouse levels). All six high rise blocks have PCC edge beams and twin wall to cores and central shear walls provided by Explore Manufacturing along with PCO stairs/landings provided by Bison. In addition to this each high rise has extensive architectural steel with coloured steel balconies to all even levels and double height vertical and diagonal bracing.

NEWFOUNDLAND
Client:
Canary Wharf Group
Main Contractor:
Canary Wharf Contractors
Architect:
Horden Cherry Lee
Structural Engineer:
WSP
Sector:
Residential
Value:
£35m

We delivered the substructure, frame and core for this 60-storey residential tower in Canary Wharf. The structural frame solution consists of an exoskeleton steel structure with node floors every four floors. The jumpform structural core is a combination of precast and post-tensioned / in situ concrete floors. A bespoke dual jumpform system was designed and built in collaboration with PERI, reducing the floor cycle from 5.5 to 4.4 days. Expanded engineers designed a bespoke piece of temporary works to enable the use of the lift shaft for passenger hoists, which enabled the lift contractors to undertake works while the hoist was used on the levels above

SOUTHBANK PLACE
Client:
Canary Wharf Group
Main Contractor:
Canary Wharf Group plc and Qatari Diar
Architect:
Allies and Morrison
Structural Engineer:
WSP
Sector:
Residential
Value:
£115m

We delivered the piling, tower cranes, substructure and superstructure works as part of the redevelopment of the 27-storey Shell Centre tower. Our works included construction of a three-level concrete basement substructure for one third of the site footprint, a two-level basement for the remainder of the site footprint and construction of eight new buildings ranging between 11 and 37 storeys. Overall 120,000m3 of concrete was required and 237,600m2 floor area were constructed using a combination of insitu, precast, post-tensioning, metal decking and slipform cores. Five buildings are separated from their foundations by acoustic bearings to avoid vibration from underground lines.

250 CITY ROAD
Client:
Berkeley Group
Main Contractor:
Berkeley Homes
Architect:
Foster+Partners
Structural Engineer:
Ramboll UK
Sector:
Residential
Value:
£46m

We completed the piling, sub and superstructure for this mixed-use development in Islington, London. Substructure works included the demolition of the existing basement and construction of an insitu reinforced concrete single and double-storey basement. Superstructure works included construction of a 42-storey tower and five eight-storey blocks. The tower was constructed using a jumpform core, while the remaining eight-storey blocks comprise a precast solution. Using our inhouse expertise, we could convert the original core designs to the five eight-storey blocks into twinwall (over 10,000m2); insitu slabs generally converted to lattice slabs (66,000m2 floor area); and Stairmaster stairs converted to precast.

MERANO RESIDENCE
Client:
Berkeley Homes
Main Contractor:
Berkeley Homes
Architect:
Rogers Stirk Harbour + Partners
Structural Engineer:
Ramboll
Sector:
Residential
Value:
£10m

Expanded constructed the reinforced concrete frame for this high-end residential and commercial property, comprising of 28-storeys with a 3-level basement. Top down construction was used to construct the basement using permanent and temporary plunge columns, along with a secant wall and bearing piles. The superstructure was constructed using lattice and twin wall. The basements were formed using traditional in-situ concrete methods. Expanded successfully dealt with the logistical challenges and space constraints within this site, situated just South of the River Thames and worked closely with the sister business Select Plant Hire in management of the tower cranes on site.

SOUTH QUAY PLAZA
Client:
Berkeley Group
Main Contractor:
Berkeley South East London
Architect:
Foster + Partners
Structural Engineer:
WSP
Sector:
Basements
Value:
£54m

We formed the two-levels of basement via top-down sequence to allow the core construction to begin for the 68-storey building. An optimised jumpform system formed the main core, with post-tensioned slabs and high-strength columns. One of 30 pours in total, the final 1,200m3 pour for the 3m deep raft slab was a significant milestone for the project. The pour was completed with only two mobile concrete pumps, peaking at 180m3 /hour. Precast, double-storey columns form the perimeter vertical elements, with twinwall dividing the core into separate lift shafts. Precast stairs and landings have been installed through the jumpform system.

ONE BLACKFRIARS PHASE 2
Client:
Berkeley Group
Main Contractor:
St George PLC
Architect:
Simpson Haugh & Partners Architects
Structural Engineer:
WSP
Sector:
Basements
Value:
£25m

We completed the piling,substructure and construction of a complex three storey basement. The substructure is enclosed by a 300m-long secant wall constructed of 400 piles, the basement is founded on 140 bearing piles. Construction of level B3 involved installing a 3m deep raft foundation using a single concrete pour of 3,300m3. Precast panels were then used to form passenger/vehicle lift cores up to ground level to access the hotel. Infill floor areas were completed using reinforced concrete slabs. The concrete raft pour was delivered a week ahead of schedule. The pour took only 24 hours to complete with two teams working in shifts.

WOOD WHARF BASEMENT
Client:
Canary Wharf Group
Main Contractor:
Canary Wharf Contractors Ltd
Architect:
Allies and Morrison
Structural Engineer:
AKTII
Sector:
Basements
Value:
£30m

We are constructing this 57-storey tower (A1) and double-level basement and site-wide basement raft slabs shared by A1 and two other buildings (A2 and A3) for Canary Wharf Contractors Ltd. Our scope includes temporary works propping to the combi-wall, pile trimming, pile caps and raft slab construction. It also includes drainage, retaining walls and substructure construction to B2 level, ground floor slab to building A1 and superstructure floor slab and core construction from basement to roof. Precast stairs installation and tower cranes bases construction for buildings A1, A2 and A3 also form part of the scope.

NINE ELMS SQUARE
Client:
R&F Properties
Main Contractor:
Expanded Ltd
Architect:
KPF
Structural Engineer:
AKT II
Sector:
Basements
Value:
£7m

Expanded delivered an enabling works package for R&F Properties in Vauxhall, London. The ten-acre site will offer over 1,800 new homes as part of a residential led mixed-use scheme comprising a total of 12 buildings, including a trio of slender towers rising to 54 storeys. Expanded delivered these works nine weeks early. Key success factors included identifying programme opportunities (such as driving workforce productivity through forming good relationships with the team), and holding milestone celebrations and daily activity briefings with supervisors to ensure productivity and progress was encouraged and maintained.

CLARGES
Client:
British Land
Main Contractor:
Laing O’Rourke
Architect:
Jacobs
Structural Engineer:
Waterman’s
Sector:
Basements
Value:
£20m

Expanded delivered top-down construction of a three-storey basement across the footprint of the site, followed by four individual superstructures. These comprised ten and five-storey residential reinforced concrete structures, made up of precast columns, twin-wall cores and lattice plank with in-situ concrete topping floors; seven and four storey steel structures, both with a solid precast concrete core and MEGAPLANK floors which only required in-situ stitch reinforcement. The basement two slab was constructed just below the ground floor slab, tied to the ground floor slab and then lowered into position via hydraulic strand jacks following completion of the basement excavation.

ONE HYDE PARK
Client:
Candy & Candy
Main Contractor:
Laing O’Rourke
Architect:
Rogers Stirk Harbour
Structural Engineer:
Arup
Sector:
Basements
Value:
£25m

One Hyde Park consists of 85 luxurious apartments ranging in size from 1,000 square feet to over 27,000 square feet and is set in the heart of Knightsbridge. The four pavilions display white precast columns and spandrel beams which from the external structural frame. The core frame consists of a reinforced concrete structural steel composite solution with post tensioned reinforced concrete slabs. For cladding and glazing to fit the double height external precast had to be installed to within 4mm’s. The basement of the structure was constructed top down at the same time as the superstructure.

THE ATRIUM
Client:
Crest Nicholson Regeneration
Main Contractor:
Laing O’Rourke
Architect:
DLG Architects
Structural Engineer:
Thomasons
Sector:
Basements
Value:
£18m

Situated on a seven-acre site, this mixed-use scheme has transformed Camberley town centre into a vibrant, highly accessible location. The development comprises 218 residential units (55 of which are affordable and provide key worker accommodation), together with restaurants, cafés and bars, 17 retail units, a nine-screen multiplex cinema, bowling, a health and fitness club and a 300-space multi-storey car park. We also provided a further 383 car parking spaces. Expanded successfully delivered the structural elements for this mixed-use retail complex – with commercial, leisure, private and social housing, as well as extensive highway and public realm works.

SOUTHBANK PLACE
Client:
Qatari Diar
Main Contractor:
Canary Wharf Contractors
Architect:
Squire and Partners
Structural Engineer:
WSP
Sector:
Basements
Value:
£125m

Re-development of Shell Centre adjacent, to London eye. Construction of three-storey basements and eight towers ranging in height between 10 and 40 storeys. Four of the towers were fully acoustically isolated. The structures are made up of a combination of in-situ reinforced concrete, post tension, reinforced concrete DfMA elements and structural steel. The high-rise concrete cores were slipformed with lower-rise being constructed with off-site manufactured twinwall. Expanded works included the supply and install of cladding for 30-storey residential structure, featuring the first pre-stressed concrete cladding panels to be manufactured in the UK.

ONE HYDE PARK
Client:
Candy & Candy
Main Contractor:
Laing O’Rourke
Architect:
Rogers Stirk Harbour
Structural Engineer:
Arup
Sector:
Cladding
Value:
£25m

One Hyde Park consists of 85 luxurious apartments ranging in size from 1,000 square feet to over 27,000 square feet and is set in the heart of Knightsbridge. The four pavilions display white precast columns and spandrel beams which from the external structural frame. The core frame consists of a reinforced concrete structural steel composite solution with post tensioned reinforced concrete slabs. For cladding and glazing to fit the double height external precast had to be installed to within 4mm’s. The basement of the structure was constructed top down at the same time as the superstructure.

MERANO RESIDENCE
Client:
Berkeley Homes
Main Contractor:
Berkeley Homes
Architect:
Rogers Stirk Harbour + Partners
Structural Engineer:
Ramboll
Sector:
Cladding
Value:
£10m

Expanded constructed the reinforced concrete frame for this high-end residential and commercial property, comprising of 28-storeys with a 3-level basement. Top down construction was used to construct the basement using permanent and temporary plunge columns, along with a secant wall and bearing piles. The superstructure was constructed using lattice and twin wall. The basements were formed using traditional in-situ concrete methods. Expanded successfully dealt with the logistical challenges and space constraints within this site, situated just South of the River Thames and worked closely with the sister business Select Plant Hire in management of the tower cranes on site.

BRIGHTON 3Ts
Client:
NHS
Main Contractor:
Laing O’Rourke
Architect:
BDP
Structural Engineer:
WSP
Sector:
Cladding
Value:
£45m

Expanded have constructed the first new development at Brighton 3T’s (Teaching, Trauma and Tertiary Care Centre). The project has utilised a significant amount of manufactured concrete components from the sister business Explore Manufacturing. Using a team that understand DfMA delivery, they have constructed the two-storey basement and thirteen floors over three wings in over a year. Expanded have also installed 1600 pre-cast concrete cladding components. The Expanded team worked closely with the wider Laing O’Rourke business and sister companies to ensure that the live hospital continues to function throughout the construction work and with minimal disruption to the patients.

ST JAMES QUARTER
Client:
Nuveen Real Estate
Main Contractor:
Laing O’Rourke
Architect:
BDP, Allan Murray Architects, Jestico & Whiles
Structural Engineer:
Arup
Sector:
Cladding
Value:
£120m

A 1.7millionft2 mixed-use development in the centre of Edinburgh, replacing the existing St James Centre with 850,000ft2 of retail, leisure and hotel facilities and 152 new homes. Our Engineering Excellence Group have provided technical advice to de-risk delivery of this major project. Our input introduced a DfMA approach to deliver the extensive subterranean car park and feature stone clad facades, delivering over 4,000 components. The extensive basement was engineered to remove intrusive props through rock anchoring and a progressive excavation sequence. We have also utilised 4D modelling to plan and validate the complex underpinning works to the John Lewis store.

HEATHROW TERMINAL 2
Client:
BAA / Heathrow
Main Contractor:
HETCo
Architect:
Luis Vidal, Pascall+Watson, Foster and Partners and Grimshaw Architects.
Structural Engineer:
Arup
Sector:
Infrastructure & MSCP’s
Value:
£45m

Expanded constructed the 90,000m3 reinforced concrete raft slab to support the Terminal steel frame. The raft slab construction required extensive de-watering for the duration of the works. Meticulous waterproofing installation was required to avoid water ingress which could affect the baggage-handling plant at one of the busiest airports in the world. Works also included construction of the new cooling station which was clad in black and white reinforced concrete precast panels.

TWO FIFTY ONE, SOUTHWARK
Client:
Oakmayne Properties / ECA Developments
Main Contractor:
Laing O’Rourke
Architect:
Allies and Morrison
Structural Engineer:
Waterman Group
Sector:
Cladding
Value:
£12m

Two Fifty One comprises a 41-storey residential tower – 70% of which was constructed off site using DfMA. A 33% reduction of the frame assembly programme was secured using DfMA rather than in situ methods for the residential tower. In addition, the DfMA approach provided increased certainty of time and labour costs, increased productivity, reduced onsite activities and an opportunity to ‘design out’ significant health and safety risks. This unrivalled certainty was made possible through early client engagement and the close links between our planners, designers and in- house manufacturing facilities. The project met the Passive Home Standards and Code for Sustainable Homes Level 3.

CLARGES
Client:
British Land
Main Contractor:
Laing O’Rourke
Architect:
Squire and Partners
Structural Engineer:
Waterman’s
Sector:
Cladding
Value:
£20m

Expanded delivered top-down construction of a three-storey basement across the footprint of the site, followed by four individual superstructures. These comprised ten and five-storey residential reinforced concrete structures, made up of precast columns, twin-wall cores and lattice plank with in-situ concrete topping floors; seven and four storey steel structures, both with a solid precast concrete core and MEGAPLANK floors which only required in-situ stitch reinforcement. The basement two slab was constructed just below the ground floor slab, tied to the ground floor slab and then lowered into position via hydraulic strand jacks following completion of the basement excavation.

SOUTHBANK PLACE
Client:
Qatari Diar
Main Contractor:
Canary Wharf Contractors
Architect:
Squire and Partners
Structural Engineer:
WSP
Sector:
Cladding
Value:
£125m

Re-development of Shell Centre adjacent, to London eye. Construction of three-storey basements and eight towers ranging in height between 10 and 40 storeys. Four of the towers were fully acoustically isolated. The structures are made up of a combination of in-situ reinforced concrete, post tension, reinforced concrete DfMA elements and structural steel. The high-rise concrete cores were slipformed with lower-rise being constructed with off-site manufactured twinwall. Expanded works included the supply and install of cladding for 30-storey residential structure, featuring the first pre-stressed concrete cladding panels to be manufactured in the UK.

WOOD WHARF H1-H4 CLADDING
Client:
Canary Wharf Contractors Ltd
Main Contractor:
Canary Wharf Contractors Ltd
Architect:
Patel Taylor
Structural Engineer:
Explore Manufacturing
Sector:
Cladding
Value:
£2.5m

Expanded are supplying and installing precast façade elements for this new development in Canary Wharf

WOOD WHARF D1/D2 CLADDING
Client:
Canary Wharf Contractors Ltd
Main Contractor:
Canary Wharf Contractors Ltd
Architect:
Herzog & de Meuron
Structural Engineer:
Explore Manufacturing
Sector:
Cladding
Value:
£4.5m

Expanded are supplying and installing precast façade elements for this new development in Canary Wharf

THE EITIHAD STADIUM
Client:
Manchester City Football Club
Main Contractor:
Laing O’Rourke
Architect:
Populous
Structural Engineer:
Buro Happold
Sector:
Sport & Leisure
Value:
£5m

Expanded was contracted to increase stadium capacity from 48,000 to 55,000 and increase the range of facilities for visitors. We engaged with MCFC to develop a logistics strategy that limited disturbance to the stadium operation, using 3D modelling to analyse risk and disruption. The construction of the upper tier required new columns to run through the existing structure and concourse areas. The location of these columns was balanced against the size of plant required to sink the foundation piles. We worked closely with the client and design team, using the same columns to provide temporary support for the existing roof.

HOUGH END LEISURE CENTRE
Client:
Machester City Council
Main Contractor:
Laing O’Rourke
Architect:
AHR
Structural Engineer:
BDP
Sector:
Sport & Leisure
Value:
£2m

Hough End Leisure Centre was part of a major programme of investment undertaken by Manchester City Council that created three new leisure centres – all built by Expanded. Among other facilities, the building includes a 25m six-lane swimming pool, a 17m learner pool, a gym with 90 stations and two squash courts. The first floor ‒ above a brick-clad ground level ‒ was conceived as a lightweight metal and glass ‘pod’ with bronze-toned rainscreen cladding. To highlight any concerns between information sources, the swimming pool pipes and joints for concrete pours that have water bar embedded into them were digitally modelled.

LEVENHULME LEISURE CENTRE
Client:
Machester City Council
Main Contractor:
Laing O’Rourke
Architect:
AHR
Structural Engineer:
BDP
Sector:
Sport & Leisure
Value:
£3m

Working in a collaborative partnership to Manchester City Council, we developed a set of standardised components to be used on this project and any future leisure centres in the area. This improved efficiency across initial investment and operational costs. The leisure centre includes a 25m main pool. A 12-person sauna and steam rooms is easily accessible from the adjacent changing rooms. First-floor facilities include a 264m2 health and fitness suite, equipped with 60 stations, and an adjoining 100m2 space that can host community meetings and serve as a dance studio for 30 people.

THE FACTORY
Client:
Manchester City Council
Main Contractor:
Laing O’Rourke
Architect:
BDP
Structural Engineer:
Buro Happold
Sector:
Sport & Leisure
Value:
£10m

Expanded is a construction partner for two-stage design-and-build project for a 16,000m2 performing arts venue in Manchester city centre. The building will serve as a permanent home for Manchester International Festival, with a combined capacity of up to 6,500. The Factory is a challenging construction project, most notably in the complexity of the structural proposals, the constrained site, interface with heritage structures, and the exacting performance requirements. Having reviewed the early and emerging design reports, we carried out in-depth option appraisals to determine how we would construct The Factory, identifying opportunities to improve programme or reduce cost.

MANCHESTER INSTITUTE FOR HEALTH AND PERFORMANCE
Client:
Manchester City Council
Main Contractor:
Manchester City Council
Architect:
AHR
Structural Engineer:
BDP
Sector:
Sport & Leisure
Value:
£4m

MIHP’s state-of-the-art health, performance and research facilities include a range of cutting-edge technology and facilities. The concrete-framed health/office block is clad in off-white concrete panels, with glazing which includes ceramic-backed glass spandrels and glazed-in anodised infill panels. The steel-framed performance analysis hall has half-round aluminium cladding above an engineering brick plinth. We used DfMA for the concrete frame and external off- white concrete panels. This reduced activities and labour on site, and thereby noise and disturbance to neighbours whilst providing a high quality off site manufactured structure/elements. This method of construction is more sustainable as it reduces waste, and has less CO2 emissions from deliveries.

SOHO PLACE (1 OXFORD STREET)
Client:
Derwent Lonon
Main Contractor:
Laing O’Rourke
Architect:
AHMM
Structural Engineer:
Arup
Sector:
Sport & Leisure
Value:
£30m

Situated directly above Tottenham Court Road station, the Soho Place development presents numerous technical challenges due to its central location, stringent acoustic requirements and glass-clad beacon design. When complete, the 285,000ft2 mixed-use, two-building scheme will comprise 209,000ft2 of offices, 36,000ft2 of retail space, a 40,000ft2 theatre and a new public realm. The unique design is configured as a tiered stack of volumes, which not only work around the rail infrastructure beneath, but also relate to the scale of the internal five- storey 350-seat theatre.

PENWHAPPLE RESERVOIR
Client:
Scottish Water
Main Contractor:
Expanded Ltd
Architect:
Jacobs
Structural Engineer:
Jacobs
Sector:
Infrastructure & MSCPs
Value:
£1.9m

Penwhapple Reservoir is located approximately 8km West of Girvan, South Ayrshire. The project was the first of its kind for Scottish Water, using a DfMA solution for construction of a new spillway, measuring 100 metres in length with a 3-metre base and 2.5-metre height. This was formed using pre-cast concrete base units with twinwall. Expanded oversaw pipework diversions, construction of a new vehicle access bridge, re-routing of existing services and temporary works including existing dam retention and slope formation. Expanded also oversaw the rock anchoring works, carried out by others.

LOCH ARKLETT RESERVOIR
Client:
Scottish Water
Main Contractor:
Laing O’Rourke
Architect:
Jacobs
Structural Engineer:
Jacobs
Sector:
Infrastructure & MSCPs
Value:
£4.4m

Laing O’Rourke designed and installed 64 rock anchors from dam crest through the body of the structure to an underlying rock formation with the depths varying from 25m to 52m. Replacement of a one span, over-flow Bridge and repairs to abutments were made. Repairs were also carried out on downstream masonry facing blocks between valve houses. This process of drilling into the Dam structure is the biggest that has been attempted in the UK, with the Anchor stressing the biggest in Europe. The work is being completed by Laing O’Rourke sub-contractor BAM Richie.

CANARY WHARF STATION BOX
Client:
Canary Wharf Group
Main Contractor:
Canary Wharf Contractors Ltd
Architect:
Foster + Partners
Structural Engineer:
Arup
Sector:
Infrastructure & MSCPs
Value:
£120m

Expanded Structures and Expanded Geotechnical combined on the innovative delivery of a station box measuring 250 metres by 30 metres wide, in a water-filled dock, 10 metres deep. The completed project was then incorporated into a six-storey development with retail, restaurants and a community facility beneath a rooftop garden. Expanded Piling used a range of techniques to ensure for a safe and efficient station box construction. The cofferdam was built with noise and vibration levels at a minimum, reducing any potential disruption to nearby workers and residents. Expanded Piling received an award from Ground Engineering in 2014, for technical design and delivery on this project.

HEATHROW TERMINAL 2
Client:
BAA / Heathrow
Main Contractor:
HETCo
Architect:
Luis Vidal, Pascall+Watson, Foster and Partners and Grimshaw Architects.
Structural Engineer:
Arup
Sector:
Infrastructure & MSCPs
Value:
£45m

Expanded constructed the 90,000m3 reinforced concrete raft slab to support the Terminal steel frame. The raft slab construction required extensive de-watering for the duration of the works. Meticulous waterproofing installation was required to avoid water ingress which could affect the baggage-handling plant at one of the busiest airports in the world. Works also included construction of the new cooling station which was clad in black and white reinforced concrete precast panels.

DALBEATTIE
Client:
Scottish Water 2
Main Contractor:
Expanded
Architect:
N/A
Structural Engineer:
Jacob’s
Sector:
Infrastructure & MSCPs
Value:
£4.5m

Dalbeattie was a failing sewage treatment works that required immediate remedial action throughout the site. Our scope included the provision of two new bio-filters, refurbishment of two PSTs and two HSTs, new sludge pump station and recirculation station, new outlet and new inlet works. In terms of innovation, the new bio-filter tanks make use of precast concrete wall panels. Square distribution chambers were also changed to precast concrete manhole rings for speed of construction, to reduce working time for men in excavations and to benefit from the quality of offsite manufactured products.

HEATHROW TERMINAL 2 MSCP EAST
Client:
BAA / Heathrow
Main Contractor:
Laing O’Rourke
Architect:
Luis Vidal, Pascall+Watson, Foster and Partners and Grimshaw Architects.
Structural Engineer:
Buro Happold
Sector:
Infrastructure & MSCPs
Value:
£20m

The MSCP East Project forms part of the Eastern Campus development programme at Heathrow Airport, including construction of a new multi storey car park providing 1,380 spaces. Access to the car park is via new road infrastructure and reinforced concrete ramps spanning over a new Terminal 3 approach road. As part of the MSCP East project the car park ties into the new Terminal 2A building via a covered court and link bridges at both high and low level.

CRAIGNURE
Client:
Scottish Water
Main Contractor:
Expanded
Architect:
N/A
Structural Engineer:
Jacob’s
Sector:
Infrastructure & MSCPs
Value:
£4m

The Craignure project on the Isle of Mull for the client, Scottish Water. Work involved the construction of a new service reservoir, the upgrade of service pumps, and a new tanker delivery pump station. Additionally, there was work to upsize the raw water main to increase the output from the Tobermory Water Treatment.

BOAT OF GARTEN
Client:
Scottish Water Solutions 2
Main Contractor:
Expanded
Architect:
N/A
Structural Engineer:
Jacob’s
Sector:
Infrastructure & MSCPs
Value:
£3m

Expanded constructed a combined sewer overflow, a control building, an intermediate pumping station and four septic tanks. Additionally, Expanded upgraded the main town sewer, relieving flooding issues within the town and reducing contamination risk. Temporary works included a sheet piled cofferdam, a thrust wall, piling mats, excavation support, sewer diversion and a de-watering system. DfMA was used to construct the main structures, including a permanent shutter to save time and cost, and precast concrete with mechanical equipment pre- installed. As the project was in the Cairngorm National Park, additional environmental protection was required to ensure no environmental damage occurred during construction.

HS2 ENABLING WORKS
Client:
Laing O’Rourke / Murphy JV
Main Contractor:
LM JV
Architect:
Structural Engineer:
WSP / Ramboll I
Sector:
Infrastructure & MSCPs
Value:
£13m

Expanded are working under the Laing O’Rouke / Murphy joint venture to deliver the enabling works within the BIS Triangle. These works will allow for the re-direction of traffic within this area through the creation of four new bridges, which cross the M42, A453 and A446.

MANCHESTER AIRPORT TRANSFORMATION
Client:
Manchester Airport PLC
Main Contractor:
Laing O’Rourke
Architect:
Pascall+Watson
Structural Engineer:
BuroHappold
Sector:
Infrastructure & MSCPs
Value:
£50m

Laing O’Rourke was the Principal Contractor for the design and build of Package 01 of the Manchester Airport Transformation Programme. Our scope of works included a new extension to the existing Terminal 2, piers, outbound baggage hall and a new 3,700-space multi-storey car park, with phased handover of facilities between 2019 and 2021. The programme includes expansion of Terminal 2 by 140% through extension and space reconfiguration, as well as provision of new grade and multi-storey car parks and surrounding infrastructure. In conjunction with Explore Manufacturing, Expanded also successfully built a new car park for T2, predominantly of DfMA construction.

FARNHAM ROAD HOSPITAL
Client:
NHS
Main Contractor:
Laing O’Rourke
Architect:
PM Devereux
Structural Engineer:
WSP
Sector:
Healthcare
Value:
£12m

Completed in 2015, Farnham Road Hospital has a gross floor area of 6,350m2 and comprises 60-bedrooms for mental health care and is linked to an existing heritage building. Expanded were able to offer the Client the latest technology and products, such as the fully serviced internal partitioning system SmartWall, pre-cast concrete columns and lattice slabs. We delivered this project with our other integrated delivery businesses within the Laing O’Rourke group. A federated BIM model was adopted to co-ordinate the architectural design, services integration and structural strategy.

GUY’S AND ST. THOMAS’ HOSPITAL
Client:
NHS & King’s Health Partners
Main Contractor:
Laing O’Rourke
Architect:
Rogers Stirk Harbour + Partners, Stantec, Anshen & Allen
Structural Engineer:
Arup
Sector:
Healthcare
Value:
£20m

Guy’s Hospital is one of the new cancer treatment centres, built as part Government’s Cancer Reform Strategy to deliver an integrated cancer centre for patients across southeast London and beyond, combining first-class clinical care with ground-breaking research. The building’s footprint stretches over 27,000m2 over 14-storeys tall. The design achieves BREEAM Excellent status. Driving efficiency, we adopted lean manufacturing techniques. The centre’s superstructure is predominantly precast and was manufactured in our industry-leading facilities at Explore Manufacturing. Modular risers and plantrooms have also been designed by our in-house specialist; CHt to allow the efficient offsite preassembly and simple installation of M&E components.

CLATTERBRIDGE CANCER CENTRE
Client:
NHS
Main Contractor:
Laing O’Rourke
Architect:
BDP
Structural Engineer:
AECOM
Sector:
Healthcare
Value:
£12m

Expanded delivered the structural frame for the Clatterbridge Cancer Centre which is formed of 11-storeys and covers 28,000m2 of area, allowing for 110 beds. The building was extended to 11 storeys after tender stage, and we worked with the design team to re-engineer this. Our Digital Engineering capabilities allowed us to represent this visually to the full range of stakeholders. Use of DfMA techniques contributed to alleviating what was already a complex logistics scheme, given the small storage space provided on site. 70% of the workforce on the project comprised of local employment. In addition, 50 apprenticeships were provided during construction.

DUMFRIES & GALLOWAY ROYAL INFIRMARY
Client:
NHS Dumfries and Galloway
Main Contractor:
Laing O’Rourke
Architect:
Ryder Architecture
Structural Engineer:
WSP
Sector:
Healthcare
Value:
£30m

Expanded completed the reinforced concrete structural and facade works for the 63000m2 hospital. Many of our construction solutions were a development from previous hospital projects – for example, we could increase repetition within the envelope design without compromising the aesthetic, with Explore Manufacturing able to produce 1,005 composite facade panels using just 27 typologies. Digital Engineering, innovation and offsite manufacturing helped to deliver this new hospital five months quicker than could be achieved with traditional methods.

WEST CUMBERLAND HOSITAL
Client:
North Cumbria University Hospitals NHS Trust
Main Contractor:
Laing O’Rourke
Architect:
Gilling Dod A
Structural Engineer:
ECOM
Sector:
Healthcare
Value:
£15m

As design-and-build contractor for this acute hospital, we delivered 19,500m2 of new-build wards and completed the refurbishment of 21,300m2 of existing wards. Our DfMA approach provided greater control over quality and allowed works to remain on programme despite some challenging weather conditions. A key constraint was the need to redevelop the hospital within the footprint of the existing buildings and clearing areas of the existing site to make way for new buildings while keeping other parts of the hospital running. Our DfMA approach provided greater control over quality and allowed works to remain on programme despite some challenging weather conditions. A key constraint was the need to redevelop the hospital within the footprint of the existing buildings and clearing areas of the existing site to make way for new buildings while keeping other parts of the hospital running.

GRANGE UNIVERSITY HOSPITAL
Client:
Anuerin Bevan Local Health Board
Main Contractor:
Laing O’Rourke
Architect:
BDP
Structural Engineer:
WSP
Sector:
Healthcare
Value:
£40m

The 55,000m2 new build hospital will provide specialist care treatment for over 600,000 people in south east Wales and includes a 24-hour acute assessment unit and emergency department. A 23% programme saving was secured by using DfMA components. Prefabricated and precast elements included manholes, concrete columns, twinwall, lattice planks, hollowcore slabs, delta beams and facade panels. Early engagement allowed us to integrate DfMA and lessons learnt into the design to secure logistical and programme benefits – this included moving the energy centre to another part of the site and constructing the permanent site access roads to enable more efficient logistics.

BRIGHTON 3Ts
Client:
NHS
Main Contractor:
Laing O’Rourke
Architect:
BDP
Structural Engineer:
WSP
Sector:
Healthcare
Value:
£45m

Expanded have constructed the first new development at Brighton 3T’s (Teaching, Trauma and Tertiary Care Centre). The project has utilised a significant amount of manufactured concrete components from the sister business Explore Manufacturing. Using a team that understand DfMA delivery, they have constructed the two-storey basement and thirteen floors over three wings in over a year. Expanded have also installed 1600 pre-cast concrete cladding components. The Expanded team worked closely with the wider Laing O’Rourke business and sister companies to ensure that the live hospital continues to function throughout the construction work and with minimal disruption to the patients.

IMPERIAL WEST BLOCK F
Client:
Voreda
Main Contractor:
Laing O’Rourke
Architect:
PLP
Structural Engineer:
WSP
Sector:
Education
Value:
£20m

The 215,000m2 residential tower, Block F, is the next milestone piece in Imperial College’s major new west London educational campus. It will provide 34-storeys of 192 new apartments in a mix of sizes, including 59 affordable units. Technical challenges were overcome through interactive planning and DfMA solutions for offsite manufacture.DfMA and BIM have been applied extensively; prefabricated welded reinforcement has improved safety, reduced manual handling and guaranteed cover. Strong engineering expertise, early strategy and careful sequencing have unlocked further benefits to the project, including using jumpform to build a concrete core, enabling concurrent installation of risers.

GRAPHENE ENGINEERING INNOVATION CENTRE 2
Client:
The University of Manchester
Main Contractor:
Laing O’Rourke
Architect:
Rafael Vinoly
Structural Engineer:
Ramboll
Sector:
Education
Value:
£7m

Expanded delivered the structure works for GEIC, a £60m capital investment to strengthen the UK’s position in advanced materials research and development, allowing collaborative university and industry programmes in graphene and 2D materials. GEIC will complement The University of Manchester’s (UoM’s) National Graphene Institute (NGI), which opened in 2015. GEIC is a three-storey 8,400m2 building located on UoM’s North Campus. This state-of-the-art technical facility features two continuous floorplates of modular labs to maximise flexibility of the highly technical, specialised research space. The project involves the construction of laboratories, ancillary offices and conference facilities.

HENRY ROYCE INSTITUTE
Client:
The University of Manchester
Main Contractor:
Laing O’Rourke
Architect:
NBBJ
Structural Engineer:
Rambol
Sector:
Education
Value:
70m

The Henry Royce Institute is a new research facility for University of Manchester, and part of the government’s Northern Powerhouse scheme. Our delivery began with collaboration from RIBA Stage 2 design onwards. We used real-time field data to log progress and manage the quality of components manufactured in-house. We also built a 3D model to maintain accuracy, identify clashes and enable tasks like swept path analysis to be undertaken. During the frame construction, Expanded installed 340 precast columns, 932 lattice planks, 580 twinwall panels and 111 other components, produced at Explore Industrial Park, our in-house precast manufacturer.

YORKSHIRE PRIORITY SCHOOLS
Client:
Education Funding Agency
Main Contractor:
Laing O’Rourke
Architect:
Atkins
Structural Engineer:
Atkins
Sector:
Education
Value:
£20m

Simultaneous delivery of seven secondary schools across the county, which were identified to be in urgent need of renewal. The logistical planning and extensive use of concrete DfMA components enabled new facilities to be delivered as quickly as possible. The time, space and logistics constraints experienced at each site, as well as the challenge of delivering multiple projects across the county with one team, suited a DfMA approach. Construction of the concrete frames was almost exclusively a lifting operation often with over 100 units installed each day; element weights varied between 1.5 tonnes and 19 tonnes.

BLAVATNIK SCHOOL OF GOVERNMENT
Client:
Oxford University Estates Directorate
Main Contractor:
Oxford University Estates Directorate
Architect:
Herzog de Meuron
Structural Engineer:
Pell Frishmann
Sector:
Education
Value:
£7m

Working with our parent company Laing O’Rourke, we delivered the piling, two-level substructure and six-storey superstructure for this new building at the University of Oxford. The scheme design of a series of shifted discs and pure geometric circles is developed from the parameters of the site and plot boundaries. Architectural finishes were specified with no obvious joints and surface mounting of services. While concrete for structures like the curved staircases are poured in situ,the shuttering was crafted off site in a controlled environment. Laser- controlled technology was used for the high specification formwork to create smooth curves and edges, atrium walls and staircases.

OXFORD BIOCHEMISTRY PHASE 2
Client:
Oxford University
Main Contractor:
Laing O’Rourke
Architect:
Hawkins\Brown
Structural Engineer:
Pell Frischmann
Sector:
Education
Value:
£7m

Expanded are working with Laing O’Rourke on the second phase of the Oxford Biochemistry building for the University of Oxford. Expanded Geotechnical piled the two-storey basement and Expanded Structures have formed the in-situ basement, constructing the lining walls whilst proceeding with excavation. The project has under taken the Digital Build. The Digital Build meant that Expanded could construct the 360-tonne raft slab with 0.005% of waste reinforcement left at the end of its construction. In conjunction with Explore Manufacturing, Expanded have installed the double-storey pre-cast concrete columns and lattice slabs across six floors, reducing the overall programme of works.

MANCHESTER UNIVERSITY ENGINEERING CAMPUS
Client:
University of Manchester
Main Contractor:
Balfour Beatty
Architect:
Mecanoo Arup Group Education £33m
Structural Engineer:
Arup Group
Sector:
Education
Value:
£33m

We were responsible for the construction of a piled contiguous wall, substructure and superstructure for a 44m high learning facility for the University of Manchester. This is part of a ten-year plan to create a world- class campus. Our package included; construction of a contiguous piled wall and capping beam, followed by reinforced concrete pad foundations, below ground drainage, a 6m deep basement structure and 10,000m2 of reinforced concrete podium slab. The superstructure works included four 44m high jumpformed cores and 33,000m2 superstructure slabs and over 900nr columns with exposed surfaces throughout. The programme included 37,000m3 of concrete, 5,000tn of rebar serviced by four tower cranes and two crawler cranes.

BELLATRIX (BIOMEDICAL RESEARCH FACILITY)
Client:
A Leading University
Main Contractor:
Laing O’Rourke
Architect:
Sheppard Robson
Structural Engineer:
AECOM
Sector:
Education
Value:
£10m

A new six-storey research facility completed in 2019 will centralise biomedical research located on the current campus of a leading University. Working within the parent company frame work of Laing O’Rourke, Expanded managed the design and construction of the structure and played a large part in manufacturing 80% of the structure off site. The extensive use of Digital Engineering and input from the Laing O’Rourke Engineering Excellence Group meant that the project could provide better cost certainty. Direct delivery enabled the project to pull forward activities if an earlier task is completed ahead of plan. This led to a 25-week programme saving.

OXFORD BEECROFT BUILDING
Client:
Oxford University Estates Directorate
Main Contractor:
Laing O’Rourke
Architect:
Hawkins Brown
Structural Engineer:
Peter Brett
Sector:
Education
Value:
£10m

Expanded constructed 6,800m2 of floor space and the deepest basement in Oxford as part of this project; this deceptively spacious building is as deep as it is tall. It links to the existing Clarendon Laboratory three levels above ground; below, a five-level 16m-deep basement laboratory space has been excavated. Being close to a busy road, the basement labs required a very high degree of environmental controls. Several ‘quiet labs’ were constructed as ‘room within room’, to provide vibration and acoustic isolation. Engineering-led, innovative approach to delivery was supported by our DfMA solution, which reduces onsite traffic and resourcing, with logistical and safety benefits.

250 CITY ROAD
Client:
Berkeley Group
Main Contractor:
Berkeley Homes
Architect:
Bennetts Associates
Structural Engineer:
Ramboll UK
Sector:
High-Rise
Value:
£46m

We completed the piling, sub and superstructure for this mixed-use development in Islington, London. Substructure works included the demolition of the existing basement and construction of an insitu reinforced concrete single and double-storey basement. Superstructure works included construction of a 42-storey tower and five eight-storey blocks. The tower was constructed using a jumpform core, while the remaining eight-storey blocks comprise a precast solution. Using our in- house expertise, we could convert the original core designs to the five eight-storey blocks into twinwall (over 10,000m2); insitu slabs generally converted to lattice slabs (66,000m2 floor area); and Stairmaster stairs converted to precast.

SOUTHBANK PLACE
Client:
Qatari Diar
Main Contractor:
Canary Wharf Contractors
Architect:
Squire and Partners
Structural Engineer:
WSP
Sector:
High-Rise
Value:
£125m

Re-development of Shell Centre adjacent, to London eye. Construction of three-storey basements and eight towers ranging in height between 10 and 40 storeys. Four of the towers were fully acoustically isolated. The structures are made up of a combination of in-situ reinforced concrete, post tension, reinforced concrete DfMA elements and structural steel. The high-rise concrete cores were slipformed with lower-rise being constructed with off-site manufactured twinwall. Expanded works included the supply and install of cladding for 30-storey residential structure, featuring the first pre-stressed concrete cladding panels to be manufactured in the UK.

TWO FIFTY ONE, SOUTHWARK
Client:
Oakmayne Properties / ECA Developments
Main Contractor:
Laing O’Rourke
Architect:
Allies and Morrison
Structural Engineer:
Waterman Group
Sector:
High-Rise
Value:
£12m

Two Fifty One comprises a 41-storey residential tower – 70% of which was constructed off site using DfMA. A 33% reduction of the frame assembly programme was secured using DfMA rather than in situ methods for the residential tower. In addition, the DfMA approach provided increased certainty of time and labour costs, increased productivity, reduced onsite activities and an opportunity to ‘design out’ significant health and safety risks. This unrivalled certainty was made possible through early client engagement and the close links between our planners, designers and in- house manufacturing facilities. The project met the Passive Home Standards and Code for Sustainable Homes Level 3.

NEWFOUNDLAND
Client:
Canary Wharf Group
Main Contractor:
Canary Wharf Contractors
Architect:
Horden Cherry Lee
Structural Engineer:
WSP
Sector:
High-Rise
Value:
£35m

We delivered the substructure, frame and core for this 60-storey residential tower in Canary Wharf. The structural frame solution consists of an exoskeleton steel structure with node floors every four floors. The jumpform structural core is a combination of precast and post-tensioned / in situ concrete floors. A bespoke dual jumpform system was designed and built in collaboration with PERI, reducing the floor cycle from 5.5 to 4.4 days. Expanded engineers designed a bespoke piece of temporary works to enable the use of the lift shaft for passenger hoists, which enabled the lift contractors to undertake works while the hoist was used on the levels above.

THE LEADENHALL BUILDING
Client:
British Land
Main Contractor:
Laing O’Rourke
Architect:
Rogers Stirk Harbour + Partners
Structural Engineer:
Arup
Sector:
High-Rise
Value:
£20m

A unique, angular steel and glass spire, rising 224m high with spectacular views over London. The building’s tapering profile reflects the planning requirement to respect the view of St Paul’s Cathedral. Expanded were the UK’s first contractor to use precast concrete floor modules in a high-rise building. These are assembled off site at our own Explore Manufacturing facility. The planks are delivered to site in modular units and craned into position to construct the building’s floor plates. This is a major break from traditional construction and avoids the risks to health and safety, and noise and disruption normally associated with working at height and concrete works.

SOUTH QUAY PLAZA
Client:
Berkeley Group
Main Contractor:
Berkeley South East London
Architect:
Foster + Partners
Structural Engineer:
WSP
Sector:
High-Rise
Value:
£54m

We formed the two-levels of basement via top-down sequence to allow the core construction to begin for the 68-storey building. An optimised jumpform system formed the main core, with post-tensioned slabs and high-strength columns. One of 30 pours in total, the final 1,200m3 pour for the 3m deep raft slab was a significant milestone for the project. The pour was completed with only two mobile concrete pumps, peaking at 180m3 /hour. Precast, double-storey columns form the perimeter vertical elements, with twinwall dividing the core into separate lift shafts. Precast stairs and landings have been installed through the jumpform system.

WOOD WHARF BLOCK A1/ ONE PARK DRIVE
Client:
Canary Wharf Group
Main Contractor:
Canary Wharf Contractors Ltd
Architect:
Herzog de Meuron
Structural Engineer:
AKTII
Sector:
High-Rise
Value:
£30m

We are constructing this 57-storey tower (A1) and double-level basement and site-wide basement raft slabs shared by A1 and two other buildings (A2 and A3) for Canary Wharf Contractors Ltd. Our scope includes temporary works propping to the combi-wall, pile trimming, pile caps and raft slab construction. It also includes drainage, retaining walls and substructure construction to B2 level, ground floor slab to building A1 and superstructure floor slab and core construction from basement to roof. Precast stairs installation and tower cranes bases construction for buildings A1, A2 and A3 also form part of the scope.

ONE BISHOPSGATE PLAZA
Client:
Stanhope Plc
Main Contractor:
Lend Lease
Architect:
MSMR Architects
Structural Engineer:
WSP
Sector:
High-Rise
Value:
£27m

We delivered the substructure and superstructure for this 42-storey tower in the City of London. The tower comprises a central core surrounded by a 1050m2 floor plate which tiered inwards as the structure rose in height. The floor slabs took on a complex geometric form with the presence of three column-free sharp angled corners. Pre-fabricated reinforcement mesh was integrated into the design of the post tensioning, supplemented by double-height precast concrete columns. The central core was constructed using a jumpform system with GRP shuttering used within the cells for forming doorways – minimising the requirement for striking or re-use of timber.

55-65 NORTH WHARF ROAD
Client:
Derwent London
Main Contractor:
Laing O’Rourke
Architect:
Fletcher Priest Architects
Structural Engineer:
Arup
Sector:
Commercial
Value:
£21m

The Brunel Building is a Paddington landmark, designed with an external steel diagrid structure, enabling flexible, column-free office floors. The building accommodates 240,000ft2 of offices fronting the Grand Union Canal, opposite Paddington station, and providing a new public waterside. Additionally, 100 apartments have been built, divided from the commercial building by a full-length concrete core. Expanded constructed the concrete finish jump-form cores, along with the special diagrid feet and two storey basements. A BIM-enabled collaborative design-management process enabled certainty for all parties. There was an element of architectural pre-cast concrete which clad the face of a core. The project was Highly Commended by The Concrete Society in 2018.

NO. 2 ST. PETER’S SQUARE
Client:
Mosley Street Ventures
Main Contractor:
Laing O’Rourke
Architect:
SimpsonHaugh and Partners
Structural Engineer:
BuroHappold Engineering, Arup
Sector:
Commercial
Value:
£8m

No. 2 St Peter’s Square was a single-stage design-and-build contract which provided 15,000m2 of BREEAM Excellent, Grade A office accommodation over 12 floors, basement parking for 70 vehicles and 500m2 of retail space. Expanded re-engineered the two-storey basement to de-risk its construction and provide early access for materials storage. Additionally, there was a requirement to install long span cellular beams, which weighed up to 30t. Because of restriction by the operational Metro Line, Expanded instead utilised in-house Temporary Works Department to design a method of placing a 250t crane within the building footprint, through back propping the lower floors.

LD7 DATA CENTRE
Client:
Equinix
Main Contractor:
Laing O’Rourke
Architect:
Arup
Structural Engineer:
Arup
Sector:
Commercial
Value:
£5m

Expanded worked alongside Equinox during the PCSA for one of their newest data centre projects, LD7, provided the opportunity to use the experience from delivering the LD4, 5 and 6 data centre projects and raise the bar even further. This enabled us to plan the strategy for LD7, mitigating potential risk way before construction started on-site. In-house delivery on the major packages has allowed us to achieve an accelerated programme. Each installation has been digitally engineered to design out risk before we start on site. We have increased our DfMA offer and maximised our digital engineering to enhance construction and assist future FM.

SCOTTISH POWER HQ
Client:
Helical Bar PLC
Main Contractor:
Laing O’Rourke
Architect:
Page/Park
Structural Engineer:
Arup
Sector:
Commercial
Value:
£15m

Laing O’Rourke constructed this 13-storey block to provide 220,000ft2 of prime Grade A commercial office space in Glasgow city centre. Although the building was originally planned as an in situ post-tensioned concrete frame, we could influence the outcome such that almost all the superstructure is of manufactured – mostly precast concrete – components. Our methodology involved double-height columns with beams, hollowcore planks and a structural topping. Cores are a combination of in situ reinforced concrete and twinwall, while the facade includes polished precast concrete panels and glazed curtain walling. In terms of piling and groundworks, the top-down basement used plunge columns, eliminating the need for baseplates and holding- down bolts.

BBC PLOT A
Client:
Stanhope PLC
Main Contractor:
MACE
Architect:
Alford Hall Monaghan Morris Architect
Structural Engineer:
Arup
Sector:
Commercial
Value:
£20m

Expanded constructed the substructure and concrete frame for a 10-storey block that provides 300,000 sq. ft. of office space, housing cinema rooms, retail units, and a private members’ club. The Plot A works were adjacent to the existing BBC Worldwide building, which remained in use – therefore strict noise and working hour controls were in place. Expanded constructed the core using a jump form system, with the Reckli form liner used to produce the bespoke timber board mark effect. Our scope of work also included sheet piling, jumpform cores, post-tensioned slabs, precast columns. Expanded were Highly Commended by The Concrete Society in 2018 for this project.

GOOGLE PRECAST
Client:
Google
Main Contractor:
Lendlease
Architect:
Heatherwick Studio / BIG
Structural Engineer:
Explore Manufacturing
Sector:
Commercial
Value:
£10m

Expanded are working with Lendlease to supply some key architectural pre-cast concrete to the new Google London Headquarters in Kings Cross. Consisting of eleven storeys and located on the slender patch of land between Kings Cross Railway and Pancras Square, the building will eventually accommodate 1 million square feet and up to 7,000 Google employees. Sister business Explore Manufacturing are producing the bespoke slab and stair elements at their facilitiy in Worksop, near Sheffield.

JAGUAR LAND ROVER – TRIANGLE BUILDING
Client:
Jaguar Land Rover
Main Contractor:
Laing O’Rourke
Architect:
Bennetts Associates
Structural Engineer:
Burohappold
Sector:
Commercial
Value:
£35m

A two-stage BREEAM Excellent design-and-build project for a new- build high-quality office and design facility across 67,000m2. The design incorporated a steel frame with integrated precast concrete basement walls and exposed concrete floor slabs and timber Glulam roof beams. Expanded was engaged from the outset as part of Laing O’Rourke’s tender team for the delivery of piling, plunge columns, substructure, drainage, in situ and precast concrete (walls, floors and stairs). Similarly, Expanded Piling was engaged at an early stage for piling, including plunge piling. The team could offer a single-phase option, which significantly reduced the overall programme period and cost to the client.

JAGUAR LAND ROVER – NOISE VIBRATION & HARSHNESS (NVH)
Client:
Jaguar Land Rover
Main Contractor:
Laing O’Rourke
Architect:
Ridge and Partners
Structural Engineer:
Ridge and Partners
Sector:
Commercial
Value:
£10m

Expanded supported Laing O’Rourke as the main contractor on a two-stage design-and-build project for a 21,000m2 noise, vibration and harshness specialist automotive testing facility, part of JLR’s vision to create one of the world’s foremost automotive product, engineering and design sites. Expanded (piling and structures) and Explore Manufacturing (components) worked alongside the EnEx.G to develop an optimal solution for the acoustically isolated test cells that will put JLR’s vehicles through rigorous, state-of-the-art tests before they can hit the road. The solution developed for the 25 test cells to meet acoustic and vibration criteria comprises seismic mass block foundations, structural steel, and up to 8m-high twinwall components.

21-32 NEW OXFORD STREET
Client:
Brockton Capital
Main Contractor:
Laing O’Rourke
Architect:
AHMM
Structural Engineer:
Arup
Sector:
Retail
Value:
£14m

The Post Building comprises 44,000m2 of mixed-use development over 12 floors, including mezzanines. The scheme design required retention and incorporation into the design of the existing basement and three floors of existing structure over approximately a third of the building footprint. The Post-Building comprised of a structural refurbishment to the existing composite deck structure and construction of a 9-storey pre-cast concrete residential block. The structural refurbishment consisted of a composite metal deck system that was tied into sections of existing retained structure to tailor the new building layout to the required footprint. The Residential block consisted of pre-cast lattice planks, columns and twinwall which were manufactured at Explore Manufacturing.

WATFORD CHARTER PLACE
Client:
WRP Management Limited for Intu Properties PLC
Main Contractor:
Laing O’Rourke
Architect:
Leslie Jones Architects
Structural Engineer:
Waterman Group
Sector:
Retail
Value:
£12m

Expanded, as part of Laing O’Rourke as Principal Contractor, were invited to replace the original contractor to deliver the shopping centre’s new 400,000ft2 extension, after the successful completion of the Nottingham Victoria Centre’s refurbishment. We also worked closely with the demolition contractor, Keltbray, to ensure that all temporary works were integrated effectively with the permanent works, thereby ensuring a smooth, cohesive delivery. We used innovative construction methods, including precast concrete components and modular services distribution, which reduced site labour levels as well as minimise noise pollution, dust and nuisance.

WESTGATE OXFORD
Client:
Westgate Oxford Alliance
Main Contractor:
Laing O’Rourke
Architect:
BDP, Chapman Taylor
Structural Engineer:
Waterman Group
Sector:
Retail
Value:
£28m

Expanded completed the design and construction of the shell and core of a three-storey retail centre, two-storey basement car park and a new residential apartment block, all to a BREEAM Excellent standard. Our in-house delivery team’s wealth of recent retail experience was a key factor in our appointment. For the new John Lewis store, we applied a DfMA philosophy and used offsite manufacturing for the precast concrete frame and facade, which features masonry panels. We exceeded the client requirement to save 25,777t of CO2 of embodied carbon during construction by over 35% through intelligent design and procurement. More than 99.98% of all construction waste was successfully diverted from landfill.

EDINBURGH ST JAMES
Client:
Nuveen Real Estate
Main Contractor:
Laing O’Rourke
Architect:
BDP, Allan Murray Architects, Jestico & Whiles
Structural Engineer:
Arup
Sector:
Retail
Value:
£120m

A 1.7millionft2 mixed-use development in the centre of Edinburgh, replacing the existing St James Centre with 850,000ft2 of retail, leisure and hotel facilities and 152 new homes. Our Engineering Excellence Group have provided technical advice to de-risk delivery of this major project. Our input introduced a DfMA approach to deliver the extensive subterranean car park and feature stone clad facades, delivering over 4,000 components. The extensive basement was engineered to remove intrusive props through rock anchoring and a progressive excavation sequence. We have also utilised 4D modelling to plan and validate the complex underpinning works to the John Lewis store.

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100 MOUNT STREET. NORTH SYDNEY. AUSTRALIA
name
100 MOUNT STREET. NORTH SYDNEY. AUSTRALIA
description
Project: 100 MOUNT STREET. NORTH SYDNEY. AUSTRALIA
Work type: BUILDINGS
Value: $200 MILLION

St. Brandon’s Church, Brancepeth
name
St. Brandon’s Church, Brancepeth
description
Project: St. Brandon’s Church, Brancepeth
Work type: Restoration & Conversation
Value: 574