Gallows Corner Flyover, Romford
Project Overview
Gallows Corner interchange is a key connection in East London’s road network, linking the A127, A12 and A118. Built in the 1970s, the flyover had deteriorated and was subject to speed and weight restrictions to enable its continued use.
Transport for London approved a project to replace the flyover which, once completed, will remove these restrictions and improve journey times, reliability and safety.
Briggs Amasco Ltd was appointed to deliver the bridge surfacing package across the newly constructed deck of the flyover. The project required an asphalt solution that was lighter than traditional tarmacadam yet capable of delivering long-term durability, while working within strict structural loading limitations.
Challenges
Having experienced delays since work began on the flyover in 2025, the project has been under public scrutiny. Completing the remaining surfacing work within the projected timescale and budget was crucial.
The structural loading of the flyover, along with kerb heights, posed limitations. Conventional asphalt surfacing systems, typically around 160mm thick, would have exceeded the structural loading limits and failed to accommodate kerb height. A lightweight, high-performance asphalt alternative was needed.
Working within in a live environment, alongside busy London traffic and using hot-melt asphalt, also presented significant health and safety challenges. Tradespersons and processes would need meticulous management to keep the site safe and standards high.
Solution
The IKO Permatrack bridge surfacing system was chosen for its adaptability; the system could be installed at the required thickness and reduce structural weight by over 70%. This lighter structural load resulted in a saving on overall materials. A single-layer, 45mm-thick surface accommodated kerb heights, while providing the durability and strength required.
Installation of the IKO Permatrack system required a high level of specialist workmanship and strict quality control. Traditional hot-applied mastic asphalt techniques were employed, including careful monitoring of material temperature, placement and finishing to achieve a fully-bonded, uniform surface across the bridge deck.
Care was taken to achieve a consistent surface thickness and ensure the uniform application of pre-coated anti-skid chippings while the asphalt remained in a hot state. Particular attention was paid to detailing around kerbs, gullies, movement zones, bridge interfaces and the continuity of waterproofing and surfacing systems across phased work areas.
Installing the system at a reduced thickness (45mm compared to the standard 160mm) resulted in an overall carbon saving. An Embodied Carbon Life Cycle Assessment (LCA), undertaken by IKO in accordance with PAS 2080 accreditation for manufacture and supply, calculated a whole-life embodied carbon value of 14,025.55 kgs/CO2 for the project. Gallows Corner has since won an Innovation in Carbon Reduction Award at the 2026 New Civil Engineer Awards.
Solution Continued
Careful planning and project management enabled the work to be delivered in phases, aligning with the wider flyover construction programme and traffic management requirements.
Close coordination between Briggs Amasco, Costain, IKO and associated trades ensured that material deliveries, surfacing operations and interface works were completed safely and efficiently within restricted working conditions.
Due to the live infrastructure environment and the specialist nature of the surfacing works, health and safety was key. Strict monitoring focused on hot-applied asphalt operations, vehicle and plant movements within restricted areas, the management of multiple contractors and trades and safe material handling and surfacing operations. Such detailed planning and coordination meant works were completed safely while maintaining high installation standards across every phase of the project.
By combining specialist mastic asphalt expertise with the IKO Permatrack Bridge Surfacing system, Briggs Amasco delivered a lightweight, durable solution that met the project’s structural and safety requirements.
Project name and location:
Gallows Corner Flyover, Romford
Main IKO system:
IKO Permatrack bridge surfacing system
Area:
1,500m2
Project sector:
IKO Guarantee:
10 Year Materials Guarantee
Main Contractor:
Installing Contractor: