One North Quay | London, United Kingdom

Building Division Partnership with Proven Engineering Support

Kilnbridge Construction operates multiple specialized divisions, with an established track record in civil engineering projects using EFCO systems. For this complex commercial structure, the team leveraged a comprehensive suite of formwork systems, including High-Strength PLATE GIRDER®, E-BEAM®, SUPER STUD® support, structural beams, and custom-engineered SB-24 support brackets with cast-in coil anchor locations. This integrated approach, combining PLATE GIRDER® with strategically placed support, created a spanning solution that transferred loads directly through the structural columns, eliminating the need for backpropping through lower levels.

Spanning Technology Eliminates Multi-Level Back Propping

The beam configuration at One North Quay presented a significant formwork challenge due to the size and depth of the structural beams spanning multiple construction zones. Traditional back propping would have required supporting these massive construction loads through the slab underneath, which lacked sufficient capacity and would have required installation all the way down to the basement level, resulting in substantial material costs, labor hours, and schedule implications. EFCO’s spanning beam application changed this equation by transferring loads directly through the structural columns using support brackets.

Custom-Engineered Solutions for Variable Beam Depths

The project presented unique challenges with its variable-depth beam configuration and stepped soffit geometry. One of the most significant technical requirements involved forming beams that transition from 2.5m (8.2 ft) to 3.3m (10.8 ft) depth while maintaining alignment with round columns at centerline and offset positions.

This non-standard dimension required custom engineering to develop installation and removal sequences that worked within the project’s crane capacity and tight work spaces. EFCO’s engineering team created comprehensive methodology drawings showing detailed placement procedures for assembling the formwork at height, along with separate dismantling procedures for safe removal. Rather than hinging the soffit down as would be standard practice, crews positioned and struck the formwork in specific configurations—removing sections at height as L-shapes and straight pieces according to precisely engineered steps.

The custom SB-24 support brackets, with cast-in coil anchor locations, were integrated with the spanning deck system between beams. The engineering team conducted an on-site review of installation procedures with the field crews, ensuring that everyone understood the specialized assembly requirements before commencing concrete placement.

Comprehensive Field Support Accelerates Crew Learning Curve

Field service played a crucial role in One North Quay’s success, providing regular on-site assistance throughout the beam casting sequence across all nine beam and slab sections. The carpenters working on the project had never delivered a structural formwork spanning beam system before and needed to understand how the system maintained stability without the support of ground-based structures.

Through hands-on field support and explanation of the load transfer principles using the PLATE GIRDER® and support bracket systems, the crew quickly gained confidence in the system’s capabilities. After completing the first beam pour and observing how the engineered solution performed exactly as designed, the carpenters significantly accelerated their production rate.

The approximately eight-member crew, typically consisting of four carpenters handling striking operations and four focused on assembly, developed an efficient workflow that maintained consistent progress throughout the structural beam casting phase. This demonstrated how combining proven formwork technology engineered to internationally recognized standards with attentive field support transforms complex engineering solutions into practical construction methods that crews can implement confidently and efficiently.