Key metrics
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bridge constructed off-site
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total social value generated
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CO₂e carbon reduction achieved
Overview
When National Highways needed to replace the ageing A533 Expressway Bridge, the challenge went beyond engineering a new structure.
As a vital route connecting communities across Cheshire, the bridge helps people access work, education, public transport and essential services. Any prolonged disruption risked affecting thousands of journeys and placing additional pressure on the local economy.
Working in partnership with Sir Robert McAlpine, we delivered the £27 million bridge replacement scheme using a design and construction approach focused on customer outcomes as well as engineering excellence. By constructing the new 67-metre bridge off site and moving it into position during planned weekend closures, we reduced the amount of time road users were affected while maintaining safe operation of the busy M56 motorway and nearby rail infrastructure.
The result was a safer, modern crossing with improved walking and cycling provision, significant carbon savings and a delivery approach that put road users, local communities and stakeholders at the centre of every decision.
At a glance
- Delivered a £27 million bridge replacement scheme for National Highways on a key route linking communities across Cheshire.
- Built the 67-metre replacement bridge off site and installed it during planned weekend closures to reduce disruption to road users.
- Maintained access and journey reliability while working above the M56 and close to the West Coast Main Line.
- Worked closely with residents, community groups, MPs and road users to provide clear communication throughout delivery.
- Achieved international industry-wide recognition for sustainability, construction excellence and project delivery.
Replacing critical infrastructure without disconnecting communities
The A533 Expressway Bridge is a key transport link between Runcorn and Northwich. As the existing structure approached the end of its operational life, National Highways needed a full replacement that would provide a safer, more resilient crossing for road users, pedestrians and cyclists.
The challenge was not simply to construct a new bridge. The team had to maintain safe operation of the busy M56 motorway below while working within tight site constraints and in close proximity to the West Coast Main Line. At the same time, disruption to local communities, businesses and daily journeys needed to be kept to an absolute minimum.
National Highways required a solution that balanced safety, programme certainty, sustainability and customer experience. Success would be measured not only by the quality of the finished bridge, but by how effectively the project protected journeys and connectivity throughout construction.
Designing delivery around customer impact
Working as the Amey and Sir Robert McAlpine joint venture, we developed a delivery strategy that reduced the amount of construction activity taking place above live traffic and shortened the time that road users would experience disruption.
Rather than relying on traditional bridge construction methods, the new structure was built off-site and transported into position using a self-propelled modular transporter. This approach enabled the majority of construction activity to take place away from the operational network before the bridge was installed during planned weekend closures.
Key elements of the delivery approach included:
- Early integration of design, construction and specialist transport expertise helped optimise both the bridge design and the installation methodology.
- Demolition, highway realignment and resurfacing activities were planned around two weekend closures, minimising disruption to road users and local communities.
- Ongoing engagement with residents, road users, MPs and community stakeholders ensured people were informed and able to plan ahead for unavoidable disruptions.
- A single integrated delivery team brought together designers, contractors and specialist suppliers, improving coordination and supporting efficient decision-making throughout the project.
This approach ensured engineering decisions were closely aligned with customer outcomes, allowing the team to protect journeys while delivering a complex bridge replacement safely and efficiently.
Faster delivery with less disruption
The completed bridge provides a modern crossing that supports safer and more reliable journeys between communities across Cheshire while enhancing facilities for pedestrians and cyclists.
Key outcomes included:
- Off-site construction reduced time working over live infrastructure, helping minimise disruption to motorway users and the local community.
- The programme was completed three months faster, reducing the period during which road users were affected by major works.
- Weekend installation and demolition reduced network disruption, with major activities completed during planned closures rather than extended restrictions.
- Recycling and reuse initiatives reduced environmental impact, including the reuse of 4,982m³ of materials and almost complete reuse or recycling of demolition materials.
- Integrated project delivery helped achieve award-winning outcomes, with recognition for sustainability, constructability and major project delivery.
Beyond the engineering achievement, the scheme demonstrated how a customer-focused delivery model can transform a complex infrastructure project.
The project reduced carbon emissions by more than 1,000 tonnes CO₂e, generated significant social value and created a model for how future infrastructure renewals can balance operational performance with customer experience.
Together, these outcomes demonstrate how innovative delivery, close collaboration and careful planning can renew critical infrastructure while keeping people, communities and the wider transport network moving.
Testimonial
“The ambitious innovative approach of off-site manufacturing and transportation of the whole 1200t bridge deck to site, despite the challenging route constraints, set the benchmark higher in the industry for what can be achieved with effective integration of all parties, especially the specialist supply chain, and working in the spirit of a true enterprise partnership ethos.”