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Regent Street Flyover
The Regent Street Flyover refurbishment was a £1.5m infrastructure project delivered under significant contract constraints within Leeds City Centre. Cairnhill provided the complete structural steelwork solution, successfully fabricating, surface-coating, and installing large-scale plate girders to meet demanding timescales.
Originally constructed in the 1960s, the Regent Street Flyover is a critical piece of infrastructure within Leeds City Centre, carrying approximately 70,000 vehicles per day via the A64(M), and A61. Constructed from reinforced concrete, the structure had suffered deterioration due to poor original construction, making refurbishment essential to ensure its continued safety and performance.
Cairnhill was awarded the £1.5m structural steelwork package by Balfour Beatty, with a limited timeframe to complete fabrication, surface treatment, and installation to align with the main contract programme. Maintaining momentum on the overall construction schedule was a key priority for the client.
Cairnhill’s scope of works included the manufacture of six pairs of large, fabricated plate girders. Twin plate girders measuring 46m and 31m in length were fabricated and subsequently bolted together on site to form longitudinal sub-assemblies exceeding 76m in length, and weighing over 100 tonnes each.
All fabrication was completed in Cairnhill’s facilities in Coatbridge and Renfrew, with surface treatment carried out using inhouse painting facilities. The completed assemblies were transported to site using specialist abnormal load transport due to their size and weightage.
Installation was undertaken by Cairnhill’s inhouse steel erection team and completed over five overnight shifts. Using Baldwin’s 1200-tonne mobile crane, all six girder pairs were installed safely and efficiently within tightly controlled possession periods. The total steel installed during Phase Two amounted to approximately 380 tonnes, all delivered within the timescales originally set by the main contractor.
The project presented significant challenges, with traditional construction methods unable to mee the required installation dates. In response, Cairnhill invested in new welding equipment and enhanced fabrication processes, enabling increase productivity whilst maintaining high quality standards. This proactive approach proved critical to the successful delivery of the works.
Following completion of the project, Cairnhill’s ConstructionOnline certification was upgraded from Silver to Gold status, reflecting the company’s performance and commitment.
Balfour Beatty formally acknowledged Cairnhill’s contribution, stating;
“Thank you for all your help this year with the structural steelwork fabrication, painting, and installation here at Regent Street Flyover. Cairnhill Structures have been instrumental in ensuring the ongoing success of this project and your hard work has not gone unnoticed.”
– Dan Barnes, Balfour Beatty