Case Study: London Bridge Station

Client: Costain

8 Weeks on Programme Saved

60% improved overall site efficiency

London Bridge Station

Midland Steel provided an Offsite Modular Rebar solution for the London Bridge Redevelopment which delivered a modern, spacious and fully accessible train station fit for the 21st century. Network Rail described this project as “the most ambitious station redevelopment in a generation”. Costain Group PLC contracted this redevelopment with Midland Steel responsible for the design and prefabrication of all reinforcing steel elements.

Midland Steel’s involvement consisted of developing detail and design of steel reinforcement to allow prefabrication of 24 individual hour-shaped columns and crossheads. The resulting design included 451 bars of which none had the same angle shape or dimension. This was made possible through 3D modelling of the prefabrication solutions, with efficiency and safety at the core of the innovations.

The client required the provision of prefabricated structures which had to be placed in extremely tight time frames and within deadlines coordinated by Network Rail. Our provisions provided all requirements, the reinforcing steel columns were dropped in from the trailer to the final destination and fixed within 45 minutes. Each column weighed approximately 10 tonnes so this task was a key outcome that was only made possible with our prefabricated solutions. The cross heads were installed from trailer to destination within 2 hours. These weighed approximately 20 tonnes each and had to be placed with a tolerance of +/- 5 mm. Our solutions drastically reduced the program time which was needed to meet the client’s requirements.


  • Eliminates approximately 60% of onsite time for installing steel reinforcement
  • Approximately £250,000 to £300,000 was saved just on one project, equivalent to approximately 40% of steel by weight
  • Delivers specialised solutions and configurations for main contractors, developers and structural engineers through Midland Steel’s Rebar BIM process.
  • Midland Steel is able to provide a collaborate data management tool – all information in one platform
  • Produces highly detailed as-built Building Information Models: provides the ability to visualise a constructible model of a project and identify problems immediately, allowing them to be solved at that point rather than later onsite.

The distinguishing factor was our experience with the 3D modelling of this project. The model was used in collaboration with the main contractor, Costain and the structural engineer, Hyder WSP providing full transparent information on the design, detail, prefabrication, delivery and construction of the 24 elements provided for the columns, crossheads and pile caps. A seamless process was achieved with no errors onsite allowing program time to be reduced. The entire project was achieved on budget with a substantial cost saving for the client on prelims.

The achievement of fabricating these products to such precise tolerance indicated the value of the 3D model. The project consisted of no welding as everything was stainless steel wire tied. Transport from Mountmellick to London provided a major challenge which was overcome with diligent planning and verification. The logistic tolerances of less than 20mm on some bridge structures on the journey were successfully managed which was a massive achievement. These low loaders were transporting a massive structure on the verge of the limit in transporting something of this size and over such a distance. And, as always, our health and safety policies were at the core of all practices taken.


By effectively using BIM, Midland Steel has proven to reduce formwork labour cost by 20%, efficiency on rebar fixing on-site by 60% and costs overall by 25%. Tony explains: “In the past, you can have a fixer foreman who spends 85% of their time inside an office; reading the drawings and relaying that information – they are just directing 15% of their time into actual physical labour. Now by using 3D model information from Tekla, they are able to move around the site with an iPad and read the elements they are about to fix, therefore becoming significantly more productive. The progression of using Tekla 3D imagery, scheduling internally, fabricating internally, and dropping prefab rebar elements on the site has improved the overall efficiency on-site by approximately 50-60%.

Modelling and visualizing the concrete using Midland Steel’s Rebar BIM Process enables accurate assessments of the area of formwork required. Having this knowledge allows for the precise ordering of materials, as well as the exact planning of where formwork can be reused and scheduled – this is value engineering deriving from having the accurate quantities and dimensions of the concrete model. In addition, the 3D model reduces the likelihood of unforeseen errors onsite, preventing the requirement for additional labour to rectify mistakes.

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See what some of our customers have to say about about our quality services.

“We knew from the outset to meet our Client’s requirements, we would require innovative thinking in lieu of traditional building methods. Midland Steel’s FasterFix Modular Rebar proved to be the right choice for this fast-track project. They completed all the 3D detailing and approval, off site fabrication, a user-friendly call-off system for JIT delivery for Circa 26,000t of prefabricated rebar. Their backup service, accessibility and knowledge were outstanding throughout along with their continuous drive to improve and push boundaries. Their passion for what they do breaks the mould”

Eddie Egan, Contracts Manager, BAM (Intel Project)

‘’On the project 8th Lock, Midland Steel have designed and installed all in-situ concrete reinforcement on the project. With their FasterFix solution it has allowed us to achieve and help to beat a challenging programme since the start. With the FasterFix solution, it makes podium slabs that would usually lead to large number of operatives and reinforcement on site a simple and smooth process. Large slabs can be completed in days rather than weeks

Brendan McCormack, Senior Project Manager, ballymore ( 8th Lock Dublin)

“When we used Midland Steel to produce some prefabricated reinforcement cages, they provided us with invaluable advice on some of the practicality challenges we were faced with. They turned our order around in record time to meet very tight programme constraints on site. We use them again without hesitation”

David Budden, Project Manager, Balfour Beatty (HS2)

Midland Steel were able to offer practical advice on how to detail, fabricate, and install the complex geometric shapes of the columns and crossheads at London Bridge Station.

Approaching each challenge with a collaborative “can do” approach, Midland Steel worked to develop a system that would meet both the technical and programme requirements with financial benefit to the client.

Ian Arden. Project Manager, Costain (London Bridge Station)

“Midland Steel have proven to us they are an all round reliable supplier for all our steel needs. Not only have they fabricated reinforcements to our designs and quality expectations but they give brilliant customer service. They provide a quick response to any questions we raise and have been an extremely patient supplier when we have requested any alterations to our designs.  ”

Here are some extra positives we have

  • Timely Response, quotes issued quickly
  • Feedback, any issues on designs you raise with us quickly and clearly communicate the issue
  • Logistics, delivered to dates you say
  • Logistics communication – clear delivery notes
  • Customer service, great response times

Technical – supply cut and bend specialist shape codes where others can not  .”

Emily Benson,Site Engineer, Balfour Beatty Vinci (HS2)

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