ECI on new and bespoke contracts via USL TEKSERV.
With more complex and substantial machining demands for projects, Ekspan now operate a state-of-the-art Hurco DCX3226i CNC machine, an essential addition to their in-house manufacturing facilities.
USL Ekspan is the UK's largest quality bearing supplier and installer to meet demands both in the UK and worldwide.
USL Ekspan install an extensive range of mechanical and elastomeric expansion joints and seal joints to CD358 standards.
Bridge jacking and temporary works are an essential part of most bearing replacement and refurbishment operations, ensuring works are carried out safely and efficiently without affecting the integrity of the structure.
The importance of carrying out bearing and expansion joint inspections by proficient and competent engineers who understand their functionality can often be key to maximising a structure’s lifespan and avoiding major, unexpected, emergency repair costs.
USL Ekspan have carried out a number of projects for swing bridges and foot bridges. From design, fabrication of all structural components, to trial erection and final installation. Details of these type of bridge installations can be supplied on request.
The Northern Hub, operated by Northern Hub Alliance and Network Rail, was a programme of planned work schemes for major improvements and upgrades to the rail infrastructure in the north of England. The Northern Hub project would provide improved and increased rail travel/services and connectivity, and in turn stimulate economic growth.
Skanska BAM Nuttall JV, one of the alliance partners, were awarded a number of key structures, including the Ordsall Chord - the installation of a new 300m-long twin-track rail link crossing the River Irwell. The Ordsall Chord will provide a direct connection between Manchester Piccadilly, Manchester Oxford Road and Manchester Victoria stations for the first time ever.
USL Ekspan’s Workscope
USL Ekspan were contracted by Skanska BAM Nuttall JV to supply and install bridge bearings and expansion joints to numerous structures during the construction phase of the project.
In total USL Ekspan designed, manufactured and supplied a total of 152 mechanical and elastomeric bridge bearings all to the relevant EN1337 standard. The bearings range in vertical capacity from 380KN to 22,500KN ultimate limit state. Due to high horizontal forces exerted by moving rolling stock and the geometry of certain structures, bespoke mechanical bearings with 5755KN horizontal capacity were produced. The largest bearing supplied was a guide bearing on Trinity Way Structure (OCD6) measuring 1300 x 1200 x 380mm, weighing approximately 2,600kg.
Mechanical bearing installed
Elastomeric bearings installed
In addition to the bridge bearings, USL Ekspan supplied and installed 13, T-Mat expansion joints over an eighteen-month period. The expansion joints varied in length and size to suit specific structure geometry and movement range with the longest expansion being 12.5m and able to accommodate movement of +/- 130mm. This type of expansion joint was selected, not only to accommodate the movement range, but also as it features a flush finish at deck level, with no recesses, allowing ballast to be laid without obstructing the traditional expansion joint gap/recess.
T-Mat expansion joint installation works
Ekspan completed their works on The Ordsall Chord in August 2017, with the new rail viaduct opened in December 2017 on completion of all the external contractors’ associated works.
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