Widening a busy stretch of the M1

Clever design, sustainable construction and well-planned communications helped us deliver this civil engineering project under budget, five months early.

When the Highways Agency asked us to widen 24km of the M1, as well as bringing the scheme in under budget, we also completed this major civil engineering project five months ahead of schedule.

Extra lanes were needed on both sides, including drainage and signal gantries. So careful construction management was key - for traffic as well as local stakeholders.

Applying value engineering from day one, we delivered cost reductions of £20 million through clever design, material selection and lean construction techniques.

Alongside construction, we preserved and built new habitats, planting indigenous woodlands where possible for local wildlife.

All was delivered safely with minimal disruption, thanks to innovative traffic management and detailed coordination on site.

Project summary

    • Client: Highways Agency
    • Sector: Infrastructure
    • Value: £300m
    • Size: 24km stretch (3 to 4 lanes)
    • Region: Midlands
    • Services: McAlpine Design Group, Construction, Pre-Construction, Civil Engineering
Engineers working on raising and widening a bridge over the M1, part of the infrastructure improvements to accommodate the expanded motorway.

Design expertise

To reduce cost and programme, we reconfigured the carriageways to a compact motorway design (CMD).

A first for long stretches of motorway in the UK, this not only delivered a significant saving, it also minimised footprint. As a result it meant replacing only one of 46 bridges along the route.

Engineer showcasing sustainable techniques like gabions and soil nailing to reduce retaining wall costs

Construction expertise

  • The length (and cost) of retaining walls were minimised through cost-effective, sustainable construction techniques like gabions and soil nailing.

  • We analysed pavement design to develop cost-effective construction methods. Then we worked with the Environment Agency to develop a solution which meant we could recycle the removed pavement rather than disposing of it as hazardous waste.

  • Thanks to extensive testing and analysis we were able to keep 60% of the hard shoulder as part of the new inside lane, delivering a 16,000t reduction in CO2.

Environment

To help minimise the amount of materials sent to landfill, we reused  wherever possible.

  • Excavated footings and drainage pipes were all crushed and reused.
  • 100,000m3 of excavated ground was diverted from landfill and used to re-profile the site compound and local farmland.
  • 30,000m3 was used to create a motorway embankment for a local farmer.
Aerial view of the M1 motorway
Newly planted trees beside the M1 to restore and enhance local biodiversity, part of the project’s commitment to sustainability.

Preserving habitats

Our team worked with the client and Environment Agency to limit tree felling and preserve local species.

  • 150,000 trees and shrubs were planted along the route. 
  • Wildlife was preserved through reptile surveys, bat and bird boxes.
  • Project volunteers also worked with a nearby school to enhance the ecology of its small woodland, helping make the most of an under-used educational resource.
  1. DECORATIVE

    Considerate Constructor Scheme Awards

    Silver 

  2. DECORATIVE

    Green Apple Environment Awards

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