Pod-Trak was engaged as the Civils and Rail Systems sub-contractor to support the Horley Underpass Deck Replacement – a key infrastructure renewal beneath the four-track main line serving Gatwick Airport.
The works involved the replacement of one section of the subway underpass on the Up Slow line, located directly beneath the rail corridor. The project was delivered within a 58-hour blockade on the Slow lines, with Fast lines remaining operational for 28 hours of the possession.
Our multi-disciplinary team worked collaboratively with the Principal Contractor to deliver the scheme safely, efficiently, and without disruption to the Gatwick Express and other passenger services.
The project required precise coordination to ensure rail operations at Gatwick were unaffected throughout the Christmas blockade. Pod-Trak collaborated closely with the Principal Contractor to optimise the construction sequence, guaranteeing that all access windows were fully utilised and possession times maximised.
Our team also worked with designers to resolve interface challenges between the new precast concrete slab and the Delkor rail support system, ensuring design compliance and achieving smooth transitions along the deck.
Through integrated planning and cross-disciplinary support, Pod-Trak deployed skilled civil, rail, SMT, and ETE protection teams at short notice to maintain programme delivery. All heavy plant, RRVs, and operators were supplied internally, giving full control of logistics, quality, and safety performance.
Pod-Trak delivered a fully coordinated underpass renewal by integrating civil and track teams from the outset, ensuring seamless interfaces and efficient delivery. Our experienced team developed a robust, hour-by-hour programme that met all QSRA requirements. Flexible resource management — supported by Pod-Trak’s in-house plant and RRV fleet — allowed the team to respond dynamically to changing site demands, while a collaborative procurement strategy with the Principal Contractor secured critical materials within short lead times. A design-led approach to risk reduction ensured compliance at all key interface points, and proactive safety engagement resulted in zero accidents or incidents throughout the works. Despite tight budgetary constraints, the project was delivered successfully, with our team providing regular live cost updates to support the client’s financial authority process — demonstrating disciplined planning, transparency, and strong commercial stewardship.
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