Carver Engineering has been bridging the gap with innovative steel fabrication since 1993. Our expertise is evident in the railway footbridge installations we’ve played an integral role in. Combining a team of highly experienced steel fabricators, reliable contract hire cranage, and just-in-time deliveries of modular fabricated segments results in smoother, more efficient railway footbridge installations with minimal disruption.
In this article, we’ll revisit some of the ways Carver Engineering’s steel fabrication services have reduced assembly and installation time at railway sites, working closely with external teams to supercharge productivity and complete timely installations that reduce the need for rail closures.
5 Times Carver Streamlined Railway Footbridge Installation with Innovative Steel Fabrication
-
Brent Cross West Station
Our extensive work at Brent Cross station took place over three years as part of the Brent Cross Cricklewood regeneration program. With approximately 1,300 tonnes of bespoke steel fabrications required to complete the project, minimising travel disruption was a key priority of this major, large scale project.
That’s where Carver Engineering came in.
We knew that the key to reducing assembly and installation periods on the site was essential to provide time for other trades to install cladding, glazing and secondary steelwork prior to site installation.
Fabricating as much of the project as we could in advance made for a far smoother, more efficient install. We devised a methodical install plan utilising just-in-time deliveries to ensure the site installation team were never left waiting on the next segment. We fabricated and trial assembled a bespoke ‘Y’ column and ‘feature canopies’ at our 24/7 dedicated facility in South Yorkshire.
Precision detailed design of the flat steel plate folded to form stair treads also ensured that welding time was kept to a minimum, further speeding up production to get structures on site even quicker.
-
Felixstowe Bridleway
The Felixstowe Bridleway railway footbridge consisted of 22 ramp sections, including one span, four stairs, and two stair/landings. We were contracted to complete steel fabrication work for this project as part of the East Anglian upgrades framework.
Usually, a project of this scale and complexity would require special movement orders or the sourcing of high capacity cranes. However, by fabricating the components for the ramp in our state-of-the-art-facility, this wasn’t necessary.
Instead, each 20 tonne component was transported to the site using just-in-time deliveries, lifted onto support trestles and then fully assembled onsite. Crucially, we had four 24-hour time periods for the site installation, meaning efficiency was key.
This streamlined both the cost and time to install. However, contract hire cranes were still crucial, with a 60-500-tonne cranes used for the installation.
-
Tottenham Hale Station
2019 saw the grand opening of the footbridge installation at Tottenham Hale Station. This was part of an upgrade under the WAML (West Anglia Main Line) scheme, which aimed to introduce a third track between Stratford, Tottenham Hale and Angel Road to increase the service to a regular 4 trains per hour – a much needed capacity infrastructure improvement to meet the demand of 17 million passengers per annum (2018).
Alongside just-in-time deliveries, Carver improved efficiencies through innovative engineering and design. We organised the contract hire of 130-750-tonne cranes to install each bespoke modular section.
Thanks to our trial assembly services, the bolted connections were pre-assembled in our dedicated workshop, meaning that each section only had to be lifted into position and bolted before the next section could be craned in.
Every detail had been designed to speed up production and get items on site quicker, without compromising on the quality and high standards Carver is known for. This includes the flat steel plate folded to form stair treads, which was specifically designed to reduce welding time.
-
Harrow on the Hill Station
The Harrow on the Hill project is one of three stations we worked on as part of the LUL (London Underground Limited) scheme. This ambitious project saw the installation of four lift shafts, three lobbies and three footbridges.
We played a crucial role from the early stages, assisting lead designers through Early Contractor Involvement (ECI) with the preparation of detailed fabrication drawings. Coordinated with BAM Nuttall, we simplified connection design and buildability for efficient fabrication and site installation. Our subcontracted works included site installation, protective coatings, movement order logistics, and cranage, with 200-450-tonne cranes used. The installation was carried out during limited night-time possession hours to minimise disruption.
The innovative design allowed for trial erection during fabrication in our workshop, reducing on-site issues and the need for modifications during installation.
This resulted in a smoother site install as we had a clear understanding of the erection sequence and any potential challenges, allowing for better planning and coordination onsite. Each section was then delivered modularly using just-in-time deliveries to minimise the impact on railway infrastructure.
The install also utilised folded plate items which were sub-contracted out to our trusted suppliers and reduced the need for welding multiple plates in corner areas.
-
Seven Kings Station
In 2019, Carver Engineering supported the successful completion of the installation of a new railway footbridge at Seven Kings Station as part of the LOCROS East Scheme upgrades. This project exemplified the company’s innovative steel fabrication techniques and meticulous planning.
A key strategy was the use of just-in-time deliveries, ensuring components arrived precisely when needed. This approach minimised on-site storage, reducing potential damage and inconvenience. Carver Engineering also utilised contract hire craneage, optimising both time and resources.
The project’s scale demanded a methodical installation plan, eliminating downtime for the installation team. This was facilitated by the timely delivery of each segment, ensuring a continuous workflow.
Carver Engineering’s design featured sub-20-tonne components, which were transported and lifted onto support trestles for full on-site assembly. This modular approach significantly streamlined the installation process. Each section, pre-assembled and trial bolted in the workshop, required only lifting into position and final bolting on-site. This efficient process allowed the subsequent section to be craned in promptly.
Through these innovative techniques and meticulous planning, Carver Engineering effectively streamlined the installation of the Seven Kings Station footbridge, demonstrating our capability to handle large-scale projects with precision and efficiency.
What makes these railway footbridge installations stand out?
These railway footbridge installations stand out due to the diverse range of crane types sourced and contracted by the team at Carver, each with different lifting capacities tailored to specific project needs.
The use of modular sections maximised productivity during possessions, significantly reducing rail closures and disruptions for maximum productivity during possessions and minimised rail closures/disruptions.
Who installed the railway footbridge steel fabrications at these sites?
Carver Engineering led the installations of the railway footbridge steel fabrications at these sites. In some instances, subcontractors were involved, but always with a Carver representative on-site to ensure quality and consistency.
What equipment was used during the installations?
The installations employed a variety of equipment, including:
- Contract hire cranes with lifting capacities ranging from 60 to 750 tonnes.
- Fabricated support trestles for on-site assembly of modular components.
- Precision-engineered tools for trial assembling and bolting connections in Carver’s 24/7 workshop facility.
Partner with Carver Engineering for Railway Footbridge Fabrications
Choosing Carver Engineering means partnering with a company that combines innovative steel fabrication with meticulous planning and execution. Our track record, evidenced by the projects at Brent Cross West, Felixstowe Bridleway, Tottenham Hale, Harrow on the Hill, and Seven Kings, showcases our ability to streamline installations and minimise disruptions. Contact us today to learn how we can support your next railway footbridge project – or check out more of our recent projects here!