Water works being carried out alongside the Gallows Corner project were at "risk" of overrunning before the roundabout even closed, it can be revealed.
Transport for London (TfL) meeting minutes obtained via a Freedom of Information (FOI) request reveal that TfL was aware of the possibility of delays to Gallows Corner works long before this was communicated to the public.
Dozens of documents, covering meetings between February and November 2025, paint a picture of delays gradually being realised as completion of the major project is pushed back by months.
As a meeting on June 5 outlines, the replacement of the Gallows Corner flyover was intended to finish in early September - and at this stage the scheme was on track for this completion date.
However, there was already a "risk that Essex and Suffolk Water (ESW) works may overrun due to the large excavation on the A127 eastbound".
The minutes said: "Despite this, TfL maintains that it is preferable to coordinate both projects concurrently to avoid two separate periods of disruption.
"Communication between TfL and ESW remains positive and frequent."
At this point in time, it had not been communicated to the public that ESW were also undertaking works at Gallows Corner - it only became clear the company was replacing water pipes underneath the junction in July.
The first mention of ESW at the TfL meetings was on March 12, when it was discussed that initial works had started under the flyover to "expose the water main for ESW".
Fast forward to July 9 and ESW were joining the weekly meetings, with drilling to install the new water mains anticipated to run between July 11 and August 15.
By the end of the month, TfL was aware of a "programme delay", as works began "slipping to end of September".
The "poor ground conditions" said to be the reason behind the Gallows Corner delays were first brought up at a meeting on August 6, with the issue escalated to senior management at ESW after its discovery.
After this, more issues became apparent.
At a meeting the following week, it was revealed that "ESW's original drilling process for the water main diversion has failed".
The meeting notes do not explain further whether this was related to the ground conditions.
In response, TfL still did not anticipate a delay to reopening the flyover and roundabout, but instead discussed ESW "returning post-opening to complete works".
ESW was also given conditions by TfL, including that their site compound must be removed by the flyover is opened.
During the final two meetings of August, ESW provided an update on site issues relating to "ground movement and foundation instability", adding that "ground heave has occurred in several areas".
Ground heave, which is often triggered by increased water in the soil, is where the ground swells upwards - and can result in roads cracking, foundations becoming unstable or underground pipes bending or breaking.
By the beginning of September, ESW confirmed that it would "not return later" to complete its works following the renewal of the flyover.
However, the water firm's works at the eastern end of the flyover (along A127) were described as "driving the overall programme", and as such, TfL asked for clarification on their plans and next steps.
A "broken structure" was also discussed although it is not clear exactly what this refers to.
The meeting notes from September 10 said: "The design solution for the broken structure remains a critical factor influencing the programme.
"Ground movement caused by ESW works has impacted the foundations at the east end.
"TfL's engineering team is currently developing a solution, including assessing how remedial works will interact with the existing water main".
By the end of September, TfL was pressing ESW "to vacate the roundabout and flyover as quickly as possible", while businesses and emergency services were being advised to plan on a "worst-case scenario basis".
It was also mentioned that ESW needed to "assess the risks of construction foundations adjacent to a live water main".
Into October and November, nothing further was discussed relating to these risks and there was "no confirmed date" for ESW's departure from the roundabout.
Between October 14 and November 12 the target date for reopening Gallows Corner was pushed back from December 20 to spring 2026 - but the documents do not explain the jump in the delay.
TfL and ESW have been contacted for comment.
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