Bletchley Flyover – Y4 Bridge Beams

Who is the client?

East West Rail Alliance is a partnership of leading UK rail and civil engineering organisations. They are responsible for delivering the East West Rail project, a transformative infrastructure scheme to reconnect Cambridge and Oxford and enhance regional connectivity.

Project Overview

ABM Precast Solutions was selected to supply critical precast components for the Bletchley Flyover reconstruction, a key element of the East West Rail route. Our role focused on delivering high-quality Y4 Bridge Beams, associated prestressed beams, and innovative formwork systems for rapid installation over the West Coast Mainline. This project required precision scheduling and the ability to deliver all components ready for installation during a single weekend blockade, minimising disruption to rail services.

✅ Units Supplied by ABM Precast Solutions
✅ 103 Prestressed Y4 Bridge Beams and YE4 Bridge Beams

Designed and manufactured for high load-bearing capacity and durability
Delivered to site and staged for immediate installation adjacent to the tracks
Y4 Bridge Beams are ideal for long-span railway bridges, providing both strength and efficiency

✅ 45 Precast Cill Beams

Each weighing up to 28 tonnes
Engineered for stability and ease of placement

✅ ABM’s Unique Diaphragm Formwork Systems (DFS)

Pre-fitted to the Y4 Bridge Beams and other prestressed beams
Provided permanent vertical formwork for the diaphragm
Eliminated the need for temporary works at height, significantly improving safety and installation speed

The Client’s Challenge

The existing Bletchley Flyover, built in 1959, was redundant and needed replacement to support the new rail link

The project had to be completed within a single weekend blockade to avoid disruption to the busy West Coast Mainline

Delays or overruns would have caused major disruption to rail services, increased costs, and impacted the overall East West Rail programme

Our Solution

Early, detailed coordination with the East West Rail Alliance and project engineers to ensure seamless delivery

Parallel production of all Y4 Bridge Beams, YE4 Bridge Beams, and cill units to meet tight deadlines
All components delivered and staged ahead of installation, ready for rapid deployment
DFS system supplied pre-fitted to the Y4 Bridge Beams, streamlining on-site works and enhancing safety

The Results

All 101 prestressed beams and 41 cill beams were installed successfully within the planned weekend window

No delays to the West Coast Mainline, thanks to the reliability and efficiency of the Y4 Bridge Beams and associated solutions

Improved safety and efficiency on site, with minimal on-site casting required due to the DFS
Positive feedback from the client for ABM’s reliability, technical expertise, and the value added by the Y4 Bridge Beam solution

Key Takeaways

Early engagement and strong collaboration are vital for complex, time-critical rail projects
ABM Precast Solutions’ technical expertise with Y4 Bridge Beams and innovative formwork systems delivers real value to major UK infrastructure schemes

This project demonstrates the effectiveness of Y4 Bridge Beams for railway bridge construction, offering both structural integrity and installation efficiency