- Sector:
- Utilities
- Client:
- United Utilities
- Main Contractor:
- Advance Plus
- Location:
- Kendal, Cumbria
Contact usTo hear about our experiences and how we can help you.
Project Overview
Joseph Gallagher Limited (JGL) was appointed to deliver a complex microtunnelling and shaft construction package as part of the redevelopment of Kendal Wastewater Treatment Works (WwTW). The project involved the installation of a new wastewater tunnel beneath challenging ground conditions, including limestone rock and glacial till, and beneath a fast‑flowing river environment. Our scope included the construction of two deep shafts and a 1.8m internal diameter microtunnel extending over 112m, followed by open‑cut works to connect the new infrastructure into the existing network. Due to fixed outfall constraints and the presence of the River Kent, the tunnel alignment and depth were tightly controlled, requiring exceptional accuracy throughout the drive. Despite the environmental and geological challenges, the project was delivered successfully, achieving pinpoint accuracy on the tunnel crossing and meeting the client’s technical and operational requirements.
Scope of Works
- Construction of a 5m diameter, 17m deep segmental reception shaft, including finishing works and cover slab
- Excavation of a 6.4m diameter, 14m deep drive shaft (secant piled by others)
- Installation of a 1.8m ID microtunnel over 112m, using a Herrenknecht AVN1800 MTBM
- Installation of a 900mm concrete carrier pipe within the tunnel, fully grouted
- Open‑cut excavation (circa 40m) to tie new works into existing assets
- Full provision of temporary works design, labour, plant and materials
Our Approach
JGL applied its extensive experience in trenchless technology and deep shaft construction to develop a robust delivery strategy tailored to the site constraints. Careful planning was undertaken to manage working space limitations, interface with the existing wastewater treatment works, and mitigate the risks associated with mixed ground conditions.
All temporary works were designed in‑house, ensuring full control over safety, programme and constructability. A clear organisational structure was implemented on site, supported by specialist operatives and dedicated tunnelling equipment from within the Joseph Gallagher Group.
By selecting the most appropriate tunnelling methodology and equipment early in the process, and by maintaining close coordination with the client and main contractor, JGL ensured the works progressed safely and efficiently through each stage of construction.
Key Challenges
Confined Working Areas
The project operated from two compact working compounds, requiring meticulous logistics planning to manage plant movements, materials storage and workforce access without disrupting surrounding operations.
Sensitive Location
The drive shaft was located in a field adjacent to residential properties, while the reception shaft was within a live wastewater treatment works. Strict controls were implemented to manage noise, access and site safety, ensuring minimal disturbance to neighbouring stakeholders.
Complex Ground Conditions
Tunnelling progressed from high‑strength limestone into glacial till consisting of sands, gravels and boulders. This transition demanded careful monitoring, precise machine control and flexible engineering solutions to maintain line and level accuracy throughout the drive.
Added Value
During construction, unexpected boulder sizes were encountered within the glacial till. JGL was able to add value by upsizing the tunnelling machine, selecting a more suitable unit from its in‑house fleet. This proactive approach reduced risk, improved productivity and ensured the continuous progress of the tunnel drive without programme disruption.
To hear about our experiences and how we can help you.
Explore related content
Tunnelling and Underground Works
Specialists in tunnelling and underground engineering, delivering safe, precise excavation, ground support, and subsurface infrastructure solutions.
Shaft Sinking
Experts in shaft sinking, delivering safe, precise vertical excavation, ground support, lining installation, and deep access infrastructure solutions.
Ground Improvement and Enabling Works
Specialists in ground improvement and enabling works, delivering safe site preparation, remediation, utilities, drainage and construction readiness.