Kenilworth Sewer Outfall

Approached by West Point Construction in 2020 to carry out specialist works required to construct a storm outfall for housing development, The Pavillions, being constructed by the Vistry Group. (  The 5.85ha site is located on the east side of the Warwick Road and will be utilised for 125 residential houses. Rorcon picked up the contract for the tunnelled connection into the live sewer formation with groundwater present at depths between 1.74m and 2.69m.

To meet the upmost standard of health and safety, Rorcon innovatively designed the project to remove the need for extra concrete breaking thus resulting in a reduction of hazards which ultimately contributed to the project having zero incidents or injuries! Something we take seriously on all of our projects.

The 9m deep, 4.5m diameter, segmentally lined shaft was constructed by the underpinning method. Knowing the rock was hard sandstone that contained angular to rounded line coarse gravel, Rorcon went against the ‘conventional’ hand mining methods Rorcon proposed an outline scheme using both mechanised mining and full steel square work to take the concept forward. The team used a combination of a Brokk 160 demolition robot (  and a mini digger to load the muck skip.

After the shaft was completed, the gang drove a 1.5x 1.5m square heading, 15m in length, which was excavated using a Brokk 70 with a Bob Cat MT55 Skid Steer Loader for muck removal. The heading was driven underneath Warwick Road and formed a connection into the existing sewer. The team then installed a 225mm diameter pipe which will serve as the new outfall for the development.

Want to know more Check out our feature in this article published in NATM magazine in October 2020 (page 33-41!):


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Kenilworth – The team sank an 8m underpinned caisson shaft (pictured) and drove a 1.5m X 1.5m heading to connect to an existing sewer.