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Joseph Gallagher Ltd

Tees Valley Pipeline

Deep shafts and tunnel construction providing critical water transfer infrastructure within the Tees Valley network.

By: Joseph Gallagher Ltd

Published: August 12, 2026

Aerial view of the Tees Valley construction site, showing shaft construction and site operations delivered by Joseph Gallagher Ltd for the water infrastructure scheme

Project Overview

Joseph Gallagher Ltd delivered a complex shaft and tunnelling scheme in the Tees Valley to facilitate new water infrastructure. The works comprised an 8.0 m internal diameter, 33 m deep reception shaft and a 7.5 m internal diameter, 45 m deep launch shaft, both constructed using underpinning techniques selected to suit the local sandstone geology.

An 1800 mm precast concrete tunnel was installed between the shafts to accommodate twin DN700 pipelines rising to the shaft collars. Additional works included replacement of existing pipework, application of protective coatings, installation of new ductile iron pipes, joint protection, tunnel grouting, PCC slab construction, mass‑fill operations and final backfilling.

TBM being lowered into the launch shaft at the Tees Valley site, as part of the Joseph Gallagher Ltd water infrastructure works

Delivery and Technical Approach

Drawing on its extensive experience in deep shafts and tunnelling, Joseph Gallagher Ltd developed a robust construction methodology to manage challenging ground conditions and artesian water pressures encountered during the works. Pipeline protection included Macropoxy P300 coating to existing pipelines and ES1212 coating to new ductile iron pipework, with all connections completed to specification.

Grouting between the tunnel lining and pipework ensured long‑term stability and protection against water ingress. Vertical pipe installations at both shafts were completed and successfully tested prior to handover.

Challenges, Innovation and Added Value

Artesian groundwater conditions required design updates during construction, while load restrictions, constrained access and adverse weather demanded careful planning and flexible sequencing. In response, Joseph Gallagher Ltd developed a fibre‑reinforced concrete mix for the base plug to reduce shrinkage risk, demonstrating a proactive and value‑driven engineering approach, although the mix was ultimately not required on site.

The team also worked closely with designers to refine the West Shaft base plug design and agree a safe tunnel breakthrough sequence. Despite the challenges, the project was completed safely, to specification and in close coordination with the main contractor.

Joseph Gallagher Ltd as part of the Tees Valley water infrastructure project

Completed segmentally lined tunnel forming part of the Tees Valley water infrastructure scheme, with permanent pipeline and service installations in place.

For More Information, contact us at https://www.josephgallagher.co.uk/

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