Laing O’Rourke benefits from BRE’s large scale structural testing

Overview

Laing O’Rourke is known for pioneering modern methods of construction and innovation. This is central to its commitment to delivering certainty for its clients. Decarbonisation is a priority for organisations across the construction sector, and one example for Laing O’Rourke is the decarbonisation of its modular bridge elements, largely manufactured at its Centre of Excellence for Modern Construction (CEMC) in Nottinghamshire.

About

Formed in 2001 when R O’Rourke & Son and John Laing plc were brought together, Laing O’Rourke is the UK’s largest privately owned engineering and construction company, delivering state-of-the-art infrastructure and buildings projects for clients in the UK, Middle East and Australia. In the UK, its unique operating model is based on digital design and advanced manufacturing technologies, with projects delivered via its integrated supply chain of specialist in-house businesses.

Laing O’Rourke manufactures a wide range of components for projects at its UK factories in the East and West Midlands; CEMC is Europe’s most advanced facility for manufactured concrete products.

Background

Laing O’Rourke has a comprehensive decarbonisation strategy that encompasses both on-site construction and off-site manufacturing. A significant number of elements for Laing O’Rourke’s unique modular bridges are manufactured at the CEMC, making it an ideal starting point for benchmarking and exploring decarbonisation opportunities. While all structural elements require thorough assessment to accurately evaluate alternative decarbonisation options, the shell abutment was selected as the first element for assessment.

Large scale structural testing provides evidence on the behaviour of structures, systems, and products under different conditions, and requires expert technicians working in dedicated facilities. Laing O’Rourke worked with BRE to develop a dedicated testing facility that would adequately simulate the loads on structural elements, incorporating complex simulation of the hydrostatic pressure required.

Solutions

BRE conducts specialist testing into the real-world performance of structures, systems, and products, helping to optimise designs for resilience and robustness. BRE’s dedicated structures laboratory hosts a wide range of tests, from model-scale to large-scale load tests, tailored to specific project requirements. Laing O’Rourke was keen to work closely with BRE to develop a testing environment that would provide accurate and detailed test results.

Following a detailed project discussion, covering Laing O’Rourke’s challenges, project goals, and specific requirements, testing took place in mid-2024. Once complete, BRE analysed the results and supplied Laing O’Rourke with a comprehensive report, providing details of the test procedure and test results. This data is informing lower carbon infrastructure solutions, particularly the use of low-carbon shells across the UK’s highways infrastructure. This marks a significant step toward advancing sustainable construction practices within the industry.

Laing O’Rourke’s research and development team was particularly impressed with BRE’s testing facilities, their technicians’ knowledge on how to create experimental setups, and the overall promptness in communication throughout the testing process.

Benefits

With initial testing having provided an accurate representation of how the first set of low carbon elements will perform in real-world conditions, Laing O’Rourke is planning additional testing of other elements with BRE. Further testing will contribute to the development of Laing O'Rourke's lower carbon solutions for sustainable construction, supporting its commitment to decarbonising the industry and achievement of its ambitious science-based carbon reduction targets.