Project Overview
Brent Cross West Station, a fundamental part of the Brent Cross Cricklewood Regeneration Program, required approximately 1,300 tonnes of bespoke steel fabrications for overbridges, canopies and concourse buildings.
Due to the size of this task, the project was completed over a three-year construction period. This required meeting tight deadlines and installation during possession working hours to ensure minimal disruption.
Our Approach
Carver embarked on the project in collaboration with VolkerFitzpatrick, WSP, and Network Rail to deliver a modular approach. We recognised that off-site pre-assembly and painting would be key to significantly shorten installation periods.
This ensured the trial assembly was within tolerance to how it would sit in its final position on site. To maintain the look of the original bridge, we used fake studs during the fabrication process.
Following comprehensive consultation and planning, we first designed detailed fabrication drawings, following which trial erections of the key structural elements ensured build accuracy and reduced on-site installation time. We fabricated and trial assembled a bespoke ‘Y’ column and ‘feature canopies’ at our 24/7 dedicated facility in South Yorkshire.
The use of just-in-time logistics minimised disruption during possession hours, allowing for efficient coordination across multiple stakeholders and contractors involved in the project. We ensured longevity of the many sub-contracted works by applying advanced protective coatings.
Execution and Installation
The scope included two overbridges, canopies, driver accommodations, and concourse buildings.
Fabricated components were transported and installed during scheduled rail possessions, which required a comprehensive delivery schedule to ensure efficient craneage and movement order management with minimal disruption.
This was essential to provide time for other trades to install cladding, glazing and secondary steelwork prior to site installation. 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 faster.
The outcome
Our just-in-time approach to this project ensured efficient completion of this project in December 2023, with the station being opened by London’s Mayor, Sadiq Khan.
The station was a fundamental part of the Brent Cross Cricklewood Regeneration Program, which has provided a gateway to north London’s new park town. The project demonstrated Carver’s capability to execute large-scale, high-value railway infrastructure efficiently alongside collaborating with key parties. It also highlighted our ability to innovate and deliver quality solutions whilst adhering to strict timelines and minimising site disruption.
“I would like to extend our sincere gratitude for the exceptional work, support, and effort you & your team have consistently provided during the construction of the Pump Room steel & cladding works. Your dedication and professionalism have made a significant impact on the delivery end.”
“Carver, you did a fantastic job for us at Barmouth, the one team approach certainly paid off for this very complex install.”
“A superb fabrication company that are highly reliable and deliver work to the highest standard.
We look forward to many more successful projects with Carver.”
“I cannot recommend Carver Engineering highly enough, the whole team from start to finish were exceptional.”
“The team at Carver offered great advice and their fabrication team produce work of the very highest quality. They delivered the work on-time and on-budget.”
