Bearing replacement and temporary works – M23 London to Brighton Bearing Replacement Scheme

ECI benefits

• Supported client engagement with Network Rail (NR) agreements (BAPA & APA). Including early engagement with NR on possession planning for inspections and scaffold erection works.
• Engagement of supply chain partner, Systra, to provide the NR CEM role, with the CRE role filled in-house by the Freyssinet Project Manager.
• Early technical engagement with Permanent Works Designer (PWD). Developed and secured Approval in Principle for temporary works and scaffold.
• Planned the complex site logistics on the constrained site.
• Used specialist 3D scanners during rail line blockades to survey the structure, enabling accurate data capture where access was limited and supporting TWD and PD design development.

To deliver efficiently and provide best value, we maintained strong communication with the client and subcontractors through daily
monitoring, fortnightly lookaheads, and regular Clause 32 updates. Specialist works, possessions, blockades, night and weekend shifts were all planned in advance.

We designed and supplied our own temporary works and proprietary jacking equipment. Bearings were designed, manufactured, and supplied by Freyssinet Products Company (FPC), part of the Freyssinet Group. This integrated approach streamlined delivery and was critical given the complexity of the bearing designs. We then self-delivered the core works on site using our specialist operations team, reducing interfaces and ensuring aligned expertise throughout to achieve a high-quality product.

Safe rail access was identified as the key project risk. Early planning and liaison with Network Rail ensured scaffold access was safely erected and dismantled within tight possession windows. From ECI, we engaged specialists (Systra and Railman of Kent) for NR coordination and compliance. Robust possession planning secured all safety-critical personnel, documentation, and approvals in advance.

Collaboration

A fully collaborative approach streamlined scaffold design and approvals, considering signal sighting and gauge clearance. This delivered a bespoke solution tailored to site constraints, ensuring safe access for all.

To minimise disruption and maintain safe conditions for road users on the scheme, we developed a comprehensive People, Vehicles, and Plant Movement Plan during the ECI phase. In implementation, this reduced vehicle movements to site, improving safety and reducing congestion. Staff transport was consolidated, materials were delivered from an off-site warehouse before being transferred to the site, optimising logistics despite limited laydown space. These measures delivered a safer work environment, reduced disruption for customers, and supported NH’s commitment to efficient, high-quality delivery.

Waste was managed under a Site Waste Management Plan with segregated skips. Hazardous materials were WAC-tested and removed by licensed contractors. Dry mixed recycling and food waste bins were introduced and monitored, achieving 100% compliance and zero hazardous incidents.

Carbon reduction measures included a hydrogen/solar welfare unit, solar CCTV towers, car sharing, mileage tracking, reuse of temporary works steel, and recycling of old bearings. Supplier deliveries were consolidated to cut transport emissions and support circular economy principles. Result: 7.75 tCOe (8.1%) reduction against project targets.

Benefits and outcomes

Long term asset improvement: By leveraging our specialist expertise and self-delivery in both bearing design and installation, as well as the temporary works required for replacement, we provided a robust, long-term solution at a location intersecting another stakeholder’s asset, thus minimising future site returns and reducing disruption to road users, delivering safety, reliability, and value for the client.

Programme acceleration: Early access to railway possession enabled scaffold removal in October, supported by extended shifts, additional resources and plant, cutting the project duration and customer disruption by eight weeks.

Value for money: Our proposal to accelerate works and reduce the programme by eight weeks was proven to be cost-saving to NH against the target cost value.

Defect-free handover: Through a robust quality management system and with proactive collaboration with NH to recognise, action, and close defects. The scheme was completed to specification with no outstanding defects at handover.

Safety performance: Delivered with zero accidents or incidents, totalling 26,399 accident-free man-hours.

Client recognition: The scheme was well received by NH and Jacobs. Freyssinet has since been invited to support similar bridge-over-railway works, reflecting confidence in its delivery capability.

Customer benefits: As well as reducing TM disruption by eight weeks, we also took part in the 2025 Dignity Bag campaign, donating two boxes to the worthy cause.