The main was constructed in two phases: the southern leg in 1988 to 1991, and the northern leg in 1991 to 1993. A tunnel was also built between
Coppermills Water Treatment Works and Stoke Newington at the same time, although this was not connected to the rest of the ring until the later extension phase. The project was geographically split into stages, separately contracted and constructed largely simultaneously. Different contractors' work resulted in minor variations in tunnel details. The tunnels were constructed using
tunnel boring machines, with interlocking wedgelock linings. The southern leg of the project refurbished and reused the existing Southern Tunnel Main, completed in 1974 between Ashford Common and Merton, but otherwise the project consisted of brand new tunnels. Eleven new pumping stations were constructed as part of the project, to extract water from the tunnel and send it to the water distribution network. These were positioned to deliver water to the areas of London with the greatest demand, which often meant they had to be constructed in locations where space was at a premium. In three locations — Barrow Hill, Holland Park Avenue, and Park Lane — the pumping stations were constructed entirely underground. Once the ring main was completed, it was envisaged that four existing water treatment works at Barn Elms, Stoke Newington, Surbiton, and Hornsey would be decommissioned, although Hornsey ultimately remained open.
Geology The main lies mostly within
London Clay with sections within the overlying alluvium and underlying
Lambeth Group and
Thanet Sand. The predominance of the London Clay lengths is by design, as being easily excavated, largely impermeable and somewhat self-supporting for short periods it is a near-ideal tunnelling material. Where the design required entry into the Lambeth Group and Thanet Sand, tunnelling was considerably more difficult. In particular, the Thanet Sand requires a high boring torque, is highly abrasive and, most challengingly, sufficiently permeable to contain a water table continuous with the underlying Chalk and measured at pressures up to . An unexpected entry into the Thanet Sand while excavating near
Tooting Bec Common led to the flooding of the tunnel and the temporary abandonment of a tunnel boring machine. A further problem with Thanet Sand was the presence of
glauconite, which oxidises on contact with air. The resulting de-oxygenated air resulted in two fatalities during the excavation of a pump-out shaft. ==Extension==