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Easthampstead Park
Off Peacock Lane
Wokingham
Berkshire RG40 3DF
Thunderbird 2 is a new £77m, 1m2 distribution warehouse for Primark so named because of its shape is reminiscent of Thunderbirds 2. The 70 acre site was developed by London Metric with site construction carried out by Sir Robert McAlpine, earthworks by Willowbrook with soil stabilisation carried out by Combined Soil Stabilisation. The site is located at Islip near Kettering. The area is known to have sulfate bearing soils. This required an initial and ongoing sulfate testing programme plus a comprehensive design mix to ensure the correct hydraulic binders were used for each material type. Every 500m3 of material was sampled for sulfate testing with every 3rd sulfate sample being a bulk sample from the same location and material type taken form the mix design. Accelerated swell tests were also undertaken on the cohesive materials.
As worked progressed, it became apparent that the granular material intended for the capping replacement layer was depleting at an unsustainable rate and that there would be insufficient .volume to complete the building. Further trial pits and design mixes were undertaken to determine the suitability of Class 2 cohesive materials to create a Class 9E stabilised capping replacement with a specified strength of 15% CBR. Following completion of the mix design and full assessment some slightly elevated sulfate levels were recorded. Only minimum heave was recorded but in order to minimise risk a lime GGBS capping replacement was used as the best treatment to achieve a Class 9E from Class 2 materials. Timescales were an issue as the handover for the areas at 15% CBR was just 7 days. As GGBS is a slower setting mixture, Combined Soil Stabilisation worked the materials to the lower moisture limits in order to meet the timescales required.
Over the ten week contract, Combined Soil Stabilisation lime modified 62,000m3 of fill materials to 5% CBR, 12,000m3 of lime and GGBS fill materials to 5% CBR , 40,000m2 lime and cement stabilised Class 1 material as capping replace to 15% CBR and 39,000m2 lime and GGBS stabilised Class 2 material as capping replacement to 15% CBR.
The use of stabilisation saved over 50,000 tonnes of primary aggregates from being imported to the site which would have called for over 5,000 wagon movements.
Client:
London Metric/Primark
Main contractor:
Sir Robert McAlpine
Earthworks contractor:
Willowbrook
Soil Stabilisation contractor:
Combined Soil Stabilisation
Project direction:
10 weeks
Volume stabilised:
74,000m3 of modified fill and 79,000m2 of stabilised soil
Soil type:
Various cohesive and granular soil types
Blend:
Various mixes dependent upon application