S P E C I A L I S T S I N S T E E L FA B R I C AT I O N

‘We are extremely satisfied with the service provided by DAM Structures for the supply & installation of the temporary ties. The team delivering the works was very professional and worked to agreed standards, scope of work and programme ensuring that the work was carried out to the highest health & safety standards.’

Wood Wharf, Secant Wall Ties Barbara Czaika, Asst. Project Manager, Canary Wharf Contractors

‘All four members of your team worked in an extremely professional manner and without incident in what is an extremely constrained worksite. They integrated with the current team on site and worked collaboratively throughout ensuring at all times that they stuck to our Target Zero safety campaign.’

Crossrail Liverpool Street Station, Broadgate Access Deck Rohan Perin & Michael Richards, Laing O’Rourke Project Managers

The company's manufacturing capabilities as specialist steel fabricators of both temporary and permanent works range from plunge columns, plated beams/box sections, tower crane grillages, small and large diameter propping works, façade retention towers, portal framed structures through to mezzanine floors, heavy duty stairs and bridges.

Flexibility is one of our key strategies, enabling us to match expertise with requirements thus providing tailored solutions to client's needs.

Overview

DAM Structures Limited is a Yorkshire based innovative steel fabrication company offering a comprehensive design, manufacture and erection service for the construction industry.

With the combination of close personal involvement of the senior management team, flexibility and attention to inevitable changes in the work place, we have cultivated our reputation as a contender in today's European market.

Our focus is total client satisfaction, achieved through a partnering approach to ensure our contracts are completed on time, within budget and to an outstanding level of quality.

DAM Structures is located on a 23 acre site allowing for expansive storage of raw materials and finished goods, along with hardstanding for trial assemblies and where required, pre-assembling members off-site to facilitate on-site installation requirements.

With approximately 55 directly employed fully trained and experienced production staff, split over three shifts, ensuring our facility is capable of production 24 hours a day, equating to 2200 man hours a week.

We have vast experience in the design and fabrication of both temporary and permanent works including plunge columns, plated beams / box sections, tower crane grillages, small and large diameter propping works, façade retention towers, portal framed sheds through to mezzanine floors, heavy duty stairs and bridges.

Crane lifting capacity - The fabrication shop has multiple gantry and overhead cranes providing the shop with a maximum lifting capacity of 25T. In addition to the overhead cranes, we have side loaders and fork trucks of 16T, 25T and 35T lifting capacity which adds versatility to the on-site lifting capacity.

In-house profiling & drilling – We have a heavy duty Viper plasma cutting machine that can cut widths from 1.5m to 6.5m and virtually any cut length, up to 8 plasma or oxy-fuel cutting torches can be fitted for the highest production capability. The production information is imported directly into this machine by way of an NC file which is exported directly from the Tekla model.

Our Production Facility

A 50,000sqft workshop facility capable of processing 400 tonne of structural steelwork per week for distribution across the UK.

Cutting & drilling – The fabrication shop has a heavy duty FICEP Endeavour multi spindle beam saw and drill line capable of cutting sections up to 1155mm deep x 18m long and a smaller FICEP bandsaw, which again is capable of cutting large sections.

The Endeavour machine can drill both flanges and web at the same time, which greatly reduces working hours and operating costs. The machine also provides layout scribing/marking and center point marking to assist with the accuracy of fabrication.

Pipe cutting – Our HGG 3D pipe profiling machine can cut and bevel the edges of large diameter tubular hollow sections. This tube bevelling feature ensures an optimal weld preparation and ultimately yield savings on fabrication and welding costs. The HGG machine utilises CADCAM connections with our Tekla detailing system, enabling very simple downloading of drawings and NC data straight into the machine increasing project throughput times by up to 30%.

Onsite & Shop Welding

We work closely with our Independent Welding Engineer to ensure full compliance with the EXC3 & 4 requirements, but also have two trained experienced Responsible Weld Coordinators (RWC) in-house who monitor compliance for works up to EXC2.

Our company can provide MAG & Drawn Arc welding for shop fabrications and MMA welding for site welding. Our experienced welders work to weld procedures created in-house and tested and approved by Sandberg LLP.

We have experience in working with S275, S355, S460 and S890Q grades of material, ranging from 2mm thick plate up to 140mm thick plates. As per BS EN 1090 requirements all materials supplied come with a 3.1 material certification.

If material certificates are not readily available, due to using surplus stock for larger CHS sections, we send sample pieces of each item to an independent test house where the chemical composition, yield strength and charpy results are tested and recorded on an independent laboratory certificate which is then provided as part of the client documentation pack.

Our processes have been assessed and certified to Execution Class 4 (EXC4) for CE marking (to BS EN 1090-2), the highest of the execution classes.

We have the in-house capability to carry out both Magnetic Particle Inspection testing (MPI) and Ultrasonic Testing (UT) by our fully qualified experienced inspectors or, if specification requires 3rd party testing, this can be undertaken by our external partners, such as Sandberg LLP .

All works carried out both in our fabrication shop and on-site are delivered in-line with an approved inspection test plan (ITP), which is customised for each contract to meet client specification. Once a package of works is completed a document pack is issued. This pack will include, but is not limited to:

• Welder qualifications • WPQRs & WPS • Material certification • NDT reports • Fabrication inspection reports • Site handover sign off • Declaration of performance

Our People

Our people are our greatest asset – they set us apart from our competitors.

DAM Structures have developed an enviable reputation for the specialist expertise and quality of our people with their pride and passion for delivering great results whilst maintaining a "one team" attitude.

At every step of our employees’ careers we invest in them, ensuring we maximise individual potential, increase commercial effectiveness, reinforce the firm’s safety culture, and help them contribute positively to their greater communities.

We are dedicated to fostering an inclusive, collaborative culture where every voice is heard, where people at every level of the organisation, from apprentice to senior manager, can develop their expertise, make an impact, and build their careers.

We insist on respect, integrity and inclusion from ourselves and each other. We think that everyone has a critical part to play in fostering an inclusive culture at DAM - one that we firmly believe will deliver superior results for our clients.

Value Engineering

‘One of the most important & pivotal events whilst working with the company has been their involvement in value engineering proposals at Western Ticket Hall. A collaborative team effort in reducing a fifth level of propping has assisted with reducing costs and savings on the programme at the site. Most other companies would have been reluctant to assist with this if it resulted in a reduced value on the contract, and as such this is a credit to DAM Structures.’

Tottenham Court Road, Western Ticket Halll Christian Cerrada, Site Agent, BAM Ferrovial Kier JV

DAM Structures in-house engineers have over 25 years’ experience in the design of steel structures, so are able to take your design requirements from initial concept through to detailed connection design.

Our designs are based on the clients’ requirements taking into account the most cost effective use of material, modern fabrication methods and site erection requirements.

We have a track record of taking the Consultant Engineers scheme and developing it to ensure that the end result is the most cost effective solution for the client based on the requirements of the project. This means looking at the project as a whole to see where there are constraints or potential problems, including lead time for material, fabrication and welding requirements, site constraints such as programme, logistics and craneage and then developing a design which best solves these issues.

Value Engineering means light weight designs are not always the answer, sometimes it is more cost effective to have a heavier primary design which in turn saves on the fittings required for connections thus reducing the fabrication time and hence reducing cost and programme.

When engaged in the project from an early stage we will work with you to ensure the most cost effective design is achieved yet still maintaining the programme, if required our engineer can be based in the consultants offices thus ensuring the smooth flow of information whilst maintaining best practice design solutions.

We will review tender designs and advise on alternative solutions at time of tender in order to facilitate the main contractors’ best chance of securing the project whilst still maintaining a profit margin.

This is all supported by our in-house drawing office that using Tekla software are able to produce:

• 3D models • GA drawings • Fabrication drawings • Marking plans • Material buying and bolt lists • Electronic NC (manufacturing) data It also allows us to provide our customers with cost and production accuracy.

This is assisted by the system produced NC data which is electronically fed through to our shop floor machines, resulting in a precise finished product that is fabricated exactly to the 3D model specification and dimensions.

The Tekla software also allows us to produce BIM models to exchange information with consultants and other trades and build the project digitally prior to going to site.

DAM Structures are capable of delivering a collaborative managed 3D BIM solution to Level 2.

Embassy Gardens, Ponton Rd, London

The fabrication and installation of a 500 tonne vierendeel truss bridge to span between two new residential towers in Embassy Gardens at levels 8 to 12.

This complex structure originally required on-site welding connections but we identified a value engineering solution, which allowed for the supply of cruciform beams and site bolted connections. This alternative created a significant cost saving and hazard minimisation for the client due to the amount of work which could be carried out off-site at DAM’s fabrication shop prior to delivery.

To aid installation access and to ensure personnel safety a crash deck was installed to the base of the bridge, this also allowed us to install purpose built tracks to allow MEWPS to be used.

Project Experience Permanent Works

Riverside South, Canary Wharf

DAM Structures were tasked with providing and installing truss steelwork and pile sleeves to strengthen the existing foundation piles to act as a crash barrier to protect the nearby superstructures from impact by ship.

The piles required site drilling to allow for the sleeves to bolt to them, both these sleeves and the existing piles were drilled to accept a pre-fabricated truss.

Due to access restrictions and size of the piles some locations required site welding of the steelwork over three levels to the piles, when complete all the items were concreted into the foundations.

The piles were surveyed for positioning which allowed DAM Structures to fabricate the steelwork to size and reduce the need for additional site works and packing.

Custom House Station, London

DAM Structures were contracted to supply a new bridge over the DLR line, entrance staircase and bridge over Victoria Dock Road to the new Crossrail Station and steelwork to support the ETFE roof.

As the steelwork would be visible the clients’ specification required a high architectural decorative finish. The DLR steelwork received a 2-hour intumescent paint system made up of 4 coats including thermally sprayed aluminium and the VDR bridge received the same paint specification to a 1-hour fire rating.

Project Experience Permanent Works

The ETFE roof steelwork involved a substantial amount of site welding and although the paint did not need to be fire rated the structure was handed over in line with architectural specification.

The DLR Bridge was installed over a 28 hour weekend possession window where overhead high voltage lines added to the complexity of the installation requiring detailed logistical planning and strict safety vigilance. The ETFE roof steelwork was installed by crawler crane requiring a single lane closure on the Victoria Dock Road, this required meticulous planning to minimise disruption.

All the works were carried to Execution Class 3 to BS EN 1090 standard (CE Marking).

‘Performance during the design phase was exceptional – the willingness to develop the design with LOR was boundless and design changes were speedily and accurately implemented.’

Custom House Station, London James Redman, Engineering Lead, Laing

O’Rourke Infrastructure

Southern Ticket Hall, Victoria Station

DAM Structures were contracted to fabricate, install and connect new structural steelwork to existing structure at Victoria Station to facilitate the new southern ticket hall upgrade, providing the ground floor support structure & ticket hall entrance structure.

To ensure connections were integrated correctly the existing steelwork was surveyed & new steelwork was detailed to exacting specifications. The existing steelwork was either drilled or site welded to allow for the connection of the new steelwork. Once the structure was complete shear studs were site drawn arced to the top flange to allow the new concrete slab to key to the steelwork.

The site was situated between two main London arterial roads which made for very tight site, so deliveries were required on a ‘just in time’ delivery system. All deliveries were required to conform to Crossrail’s strict safety requirements which include FORS registration.

Project Experience Permanent Works

Canary Wharf Station – Fenders & ‘U’ Tube

This contract comprised of the fabrication & installation a ‘U’ Tube for underwater cables and ship protection fenders at the new Canary Wharf Station.

The fenders comprised of a steel gridded support system fixed to cast in sockets on the wharf wall, on which timber buffers were attached to stop the ships damaging the wall and ultimately Canary Wharf Station.

To ensure the design worked within the site constraints special asymmetrical section profiles were manufactured from plate steel and a special blind bolt system was developed to ensure erection from the floating pontoons was possible.

The requirement of getting cables underwater from the dock to the Station building was overcome by the provision of a 20m high x 10.3m wide ‘U’ Tube. The complexity of the design required the tube to:

• Be spliced and faceted to achieve the required bend

• Keep its shape when split in half along its length, allowing conduits and rebar to be laid in before reconnecting the top

• Be part filled with concrete to allow the full profile to sink in the water

Acoustic Sheds, Northern Line Extension, Kennington

The design, fabrication and installation of two acoustic sheds, at Kennington Park and Kennington Green, to cover the access holes for plant and equipment required for tunnelling as well as the removal of earth and installation of concrete tunnel linings as part of the London Underground redevelopment.

The overall building height was set by the clear hook requirements as well as the minimum clearance above the 50T EOT crane thus minimising the impact to the surrounding area, rails were designed as single span to reduce the overall width and length of the building but still ensuring the most cost effective installation of the acoustic cladding. The column positions were also positioned to minimise the impact on the piles and capping beam to the access tunnel.

Project Experience Temporary Works

Secant Wall Ties, Wood Wharf

DAM Structures was contracted to provide detailed design, fabrication, supply and installation of a temporary tie system to restrain the existing ‘secant wall’ during the excavation of new foundations and basement works for the new multi-storey structure.

The restraint was provided via 3 large (1220 mm diameter) tubular sections which acted in tension. These members were up to 66 metres in length and cantilevered over the wharf water and connected to a capping beam on the wharf wall.

Due to site constraints a bespoke installation method was devised which comprised of much smaller cranes and water based pontoons providing access to all spliced connections and capping beam connections.

A bespoke sleeve was also designed by our in-house designer, which was inserted into the capping beam to allow for tensioning of the Macalloy bars after installation giving the client programme time savings and ensuring the tensioning bars tied in with the rebar installation.

Project Experience Temporary Works

Design Museum, Parabola, Kensington

The fabrication and installation of temporary support steelwork to facilitate the refurbishment of the existing Commonwealth Institute into a new Design Museum, comprising of:

• ‘A’ frame structures to support existing floors during the demolition process.

• Needle beams, temporary RMD raking props and waler system to support the perimeter walls

• Column support gantries to reinforce the buildings two main columns, this included tie bar supports frames to hold the tie rods to secure the columns together, which support parabola shaped roof.

The majority of the steelwork was installed through pockets in the existing floors and walls and a telehandler was utilised throughout the contract due to access restrictions.

Western Ticket Hall, Tottenham Court Road Station

The fabrication, delivery and installation of 1,100 tonnes of temporary propping.

To allow for the identified future extension to the propping DAM were able to provide fabricated trusses that intersected the large circular hollow sections (CHS). These trusses were fabricated out of universal beams (UB) and rolled steel angle (RSA) sections, to allow them to intersect the CHP props DAM had to create voids in the props to allow for the truss to pass through.

DAM worked closely with the site team to deliver the steelwork on a “just in time” basis and the installation was carried out over 24/7 site shifts so that site programme was achieved.

Project Experience Labour Only

Farringdon Station, London

DAM Structures were awarded the contract to remove six levels of temporary propping works (1,500 tonnes) from the Farringdon Station project.

The bottom level was designed to be partially removed to allow for the Crossrail Tunnel Boring Machine (TBM) to pass through the shaft.

Once the TBM had passed through the shaft then the bottom level of propping had to be reinstated to allow for the removal of the supports between the bottom two levels.

The removal of the steelwork had to be carried out in conjunction with the installation of the new station works. This meant that some areas had to be removed after the concrete slabs had been installed above the propping. These items had to be cut into manageable pieces and skated to mole holes to allow for the removal from the shaft.

The steelwork removed from site was bought back by DAM Structures for recycling which provided the client with additional savings and also reducing environmental impact.

Accreditations

Our accreditations and professional association memberships demonstrate our commitment to continual improvement and guarantees we can deliver projects to the highest standard of safety, quality and industry best practice.

Why DAM Structures?

• ‘Health and Safety – Without Compromise’ is our primary focus

• Certified to Execution Class 4 for CE marking (BS EN 1090)

• Our team has the depth of experience to deliver technical and quality excellence

• 50,000sqft of fully equipped fabrication space allowing for the processing of up to 400T per week of structural steelwork

• 23-acre site allowing for expansive storage of raw materials and finished goods, along with hardstanding for trial assemblies and where required, pre-assembly off-site to facilitate on-site installation requirements

• Capability to carry out full design and build contracts through to connection only design

• Collaboration and innovation are core business values; highlighted by the delivery of some unique fabrications such as the Canary Wharf Station ‘U’ Tube and fenders.

• We understand the importance of deadlines and their impact on the successful delivery of a project

• Flexible enough to handle any changes to the initial design brief that may occur

• Potential temporary steel/propping buy back option, reducing your contracts carbon footprint

• A robust and established supply chain

DAM Structures Ltd Heron House, Lancaster Road, Carnaby Industrial Estate, BRIDLINGTON, YO15 3QY

Tel: 01377 271843 Fax: 01377 271575

www.damstructures.co.uk