Bridge Balustrade and Structural Steelwork Replacement

Client: Greencore

Duration: 8 Weeks

Location: Worksop

Year: 2026

Value: Undisclosed

Overview & Objectives

As principal contractor, Ambrey Baker managed the bridge balustrade and structural steelwork replacement works at Greencore’s facility in Worksop, Nottinghamshire.
The project involved removing the existing bridge balustrade and associated steelwork, preparing the retained structure for new connections, fabricating and installing replacement components, and reinstating the surrounding concrete and asphalt surfaces.
Ambrey Baker carried out the works within a live operational environment while maintaining Greencore’s day-to-day activities. Restricted access and the bridge’s limited load-bearing capacity also meant that conventional crane lifting was not an option, requiring an alternative approach to handling and installing the steelwork.
The project required careful planning and coordination, from initial structural load testing and controlled demolition through to steelwork fabrication, installation, drainage improvements and final reinstatement.

The key objectives were:

• To carry out structural load testing before commencing removal works.
• To safely remove the existing bridge balustrade and associated steelwork.
• To break out existing blockwork and 300mm-thick concrete to access the structural connections.
• To prepare retained structural steelwork for connection to the new components.
• To fabricate and install a new bridge balustrade and associated structural steelwork.
• To complete the required steel ties, fabrication and connection details.
• To develop a safe lifting and installation method suitable for the bridge’s load restrictions and limited working space.
• To maintain live site operations throughout the project.
• To install new drainage and reinstate the affected concrete and asphalt surfaces.

Scope of Work

Structural Assessment & Preparation

• Structural load testing before commencement of removal works.
• Assessment of the existing balustrade and its connections to the main structure.
• Planning and preparation for the removal and replacement of existing steelwork.
• Identification of structural elements to be retained and modified.
• Planning of lifting and installation activities around bridge load restrictions and ongoing site operations.

Structural Steelwork & Fabrication

• Preparation of retained steelwork to accommodate new structural connections.
• External fabrication works associated with the main structural connections.
• Fabrication of the replacement bridge balustrade.
• Internal fabrication of steel ties and associated connection details.
• Installation and integration of new steelwork with the existing structure.
• Use of a hoist-and-roll method to manoeuvre and position steelwork within the restricted working area.

Demolition & Removal Works

• Removal of the existing bridge balustrade.
• Breaking out of existing blockwork to expose structural connections.
• Controlled breaking and removal of 300mm-thick concrete.
• Removal of existing steelwork connecting the balustrade to the main external structure.
• Preparation and clearance of the affected areas for new steelwork installation.

Concrete, Drainage & Asphalt Reinstatement

• Backfilling of areas affected by the removal works.
• Installation of new concrete in accordance with the required finish design.
• Installation of new drainage to accommodate the revised surface design.
• Reinstatement of asphalt surfaces around the new structural components.
• Final finishing works around the replacement balustrade and steelwork.
• Site clearance and demobilisation following completion of the works.

Challenges & Solutions

Restricted Access, Bridge Load Capacity & Live Operations

Challenge: One of the main challenges was carrying out the structural steelwork replacement within the bridge’s load-bearing limitations and a restricted working area. These constraints ruled out the use of a crane for lifting and positioning the new steelwork.
The project was also undertaken within Greencore’s live operational facility, meaning daily activities had to continue while the construction works progressed. This required careful management of access, lifting operations and the movement of heavy steel components.
Solution: Ambrey Baker developed an alternative lifting and installation approach using a hoist-and-roll method. This allowed the team to manoeuvre and position the steelwork within the limited working space without relying on a crane.
The works were planned and sequenced around Greencore’s operational requirements, allowing the bridge refurbishment to progress while minimising disruption to ongoing site activities.

Removing Existing Steelwork Connected to the Main Structure

Challenge: Steel components surrounded by blockwork and concrete connected the existing bridge balustrade to the main external structure. Accessing these connections required the removal of substantial sections of existing material, including concrete measuring 300mm in thickness.
The removal works also needed to account for the retained steel structure, which would form part of the new installation.
Solution: Ambrey Baker carried out structural load testing before beginning the removal works and followed a planned demolition sequence.
The team removed the existing balustrade, blockwork, concrete and associated steel connections to expose the required areas. This provided access to the retained steelwork and allowed the team to prepare the structure for the new connections.

Integrating New Steelwork with the Existing Structure

Challenge: The replacement balustrade and structural steel components needed to connect to the existing bridge structure. The team prepared the retained steelwork to accommodate new connections and coordinated the fabrication details to suit the existing arrangement.
Solution: Ambrey Baker prepared the retained steelwork for the new structural connections and carried out the required fabrication works.
The scope included external steelwork fabrication, internal fabrication of ties and associated connection details, and installation of the new balustrade. These works allowed the replacement components to be integrated with the existing structure.

Outcomes

Ambrey Baker delivered the bridge balustrade and structural steelwork replacement project at Greencore’s Worksop facility, covering structural load testing, controlled demolition, steelwork preparation, fabrication, installation and civil engineering reinstatement. Despite the bridge’s load capacity restrictions, limited working space and the need to maintain live operations, the team completed the steelwork installation using an alternative hoist-and-roll method. The completed works included a newly fabricated bridge balustrade, integration of replacement steelwork with the retained structure, new drainage and reinstated concrete and asphalt finishes. The project demonstrates Ambrey Baker’s experience in delivering structural steelwork replacement and bridge refurbishment within live industrial environments. Through practical engineering solutions, coordinated fabrication and carefully planned construction activities, the team was able to overcome site constraints while accommodating Greencore’s ongoing operational requirements.