Waterloo Network Rail Interface Works

Pod-Trak were engaged by ISG (and then Designer Group) to manage the rail interface for all retail development works at Waterloo Station. The scope was to manage and complete any works that encroach within the rail environment- platforms, rail access areas and track works related to the multi-million pound retail development being managed by LCR.

In late 2019 – Pod-Trak were approached by ISG to look at works within the multi- million pound retail development at Waterloo station. ISG and Designer Group both have extensive experience in the retail development works but limited experience of the Network Rail environment.

Pod-Trak were engaged to manage and deliver all works that affected rail systems, access and affected track or platform environments- we were engaged to act as the rail PC in all elements affecting rail for the project. This included providing full rail compliant designs for scaffolding, hoarding, flue and chiller installation works- providing CRE cover for the entire project.

The projects had some complex works on platform 11 and 12 and 19 to install new flues to the full height of waterloo station (platform 11 and 12) and install new chillers for the underground retail
development on platform 19. Pod-Trak undertook the full rail design process and management for all works including temporary works, hoarding, scaffold and provided plant support for on-track works.

Our management team undertook to deal with Network Rail, possession management, interface with the station maintainers and Asset Protection (ASPRO). The project has significant challenges due to the vast number of stakeholders- a detailed design and access plan for all works was produced and Pod-Trak managed all the stakeholders.

Part of the access plans were detailed ped flow surveys to mitigate issues with pedestrian access and restrictions with Covid-19. Pod-Trak also arranged specialist crane deliveries of all the bespoke plant – installing chillers and flues and are due to carry out complex works on the station canopy glass roof to facilitate access for the flue install and large crane supply for the installation and removal of chillers.

TfL Signal Box Restorations

As part of TfL’s Station Works and Improvements Programme (SWIP) they identified two Grade ll Listed buildings at Ruislip and Chorleywood stations constructed in the late 1800s that needed to be restored to their former glory.

Pod-Trak undertook the full restoration of both Grade II listed buildings at Ruislip and Chorleywood stations. The scope included:
Stripping down existing lead-based paint.

  • Replace timber members with pattern-matched timber.
  • Full restoration of Welsh slate and lead roofing.
  • Replacement of cast iron guttering & downpipes.
  • Re-painting in original colour schemes.
  • Refurbishment with reclaimed items where possible.
  • Design, fabricate and install timber stairs to match the original specification.

Works were carried out during midweek night-time possessions. As the site was adjacent to residential areas it required constant and careful monitoring of light and noise emissions. Lead testing, safe removal, health-monitoring of staff and responsible disposal of the waste were carried out under strict control measures. On completion both buildings were shortlisted for Historic England awards in late 2017.

Codsall Drainage

A section of track northwest of Codsall Station in South Staffordshire had poor drainage and unable to cope with heavy persistent rain. As a result, the commuter services to and from Wolverhampton and Birmingham were becoming unreliable.

Pod-Trak was contracted to construct an access road, set up the compound and complete all drainage works. Once land access was agreed with the landowner, Pod-Trak made an opening in the hedge, installed a stock fence and a temporary access road & compound using the dura-base system from Terrafirma Roadways to minimise impact and damage to the land. Site setup included all welfare and offices.

The on track drainage consisted of 700m of 300mm diameter HDPE drainage pipe with 14 chambers. To support the existing flow from adjacent land two cascades were installed using the smart ditch channel lining system.

A 650mm diameter drainage UTX was also installed to move from one cess to another. As a result of the drainage works 150m of concrete troughing had to be removed and reinstalled to protect existing cables.

The off track drainage which was carried out during normal working hours consisted of 50m of 600mm diameter pipe and four precast header walls. All plant and material had to be delivered to the
land locked area using rail trailers during a possession. All existing local ditches were cleared out to allow for stone pitching.

The Project required careful planning due to short midweek possessions. Difficulties encountered on site included mud, stone and clinker through the dig along with excess water which needed to be
over pumped. During the UTX installation old buried rail was discovered which had to be burned out. Works were successfully delivered and the field was handed back to the landowner in excellent condition.

Centerparcs Fibre and Data Installation

The project was a design and build project to deliver a full data and telecommunications network throughout the park as part of a fibre and data installation.

Pod-Trak undertook the full design and build project with supply partners Belden on behalf of SSE. The main fibre network was a passive optical network (PON) supported by a stand-alone copper telephone network. The park was controlled by 2 Main Equipment rooms (MER) and 12 Secondary Equipment rooms (SER)- 82 roadside cabinets and a duct network of over 100km.

Originally a 450 acre forest- the park was formed and carved out of the existing Landscape to form a 470 lodge and 30 apartment facility. The park centrepiece is a state of the art central village with many amenities and attractions – supported by a network of forest activity centres. The new park forms a central part of the Irish Tourism offering for Europe and further afield and to date has been booked out to capacity.

Pod-Trak also installed over 180,000 m of fibre and copper to build the network. Each lodge had an individual FTTH (Fibre to the home feed) and specified lodges had separate copper feeds for back
up telephony systems. There was also a network of retro An Post telephone boxes installed throughout the park. The network was installed in 2 phases pre-Christmas 2018 and post-Christmas 2018, finishing off with the delivery of the central village equipment rooms and data installation.

In addition to this Pod-Trak undertook a full data installation of the Wastewater Treatment Plant- new UPS power supply and commission duties, CCTV and barrier installation works throughout the park. The MER and SER rooms were fitted out by Pod-Trak to support the park communications network as well. At project end- Pod-Trak have been awarded the MV Maintenance project to maintain the MV Power network supporting the park- so our involvement continues with the Centerparcs team!

West Anglia Main Line (WAML) Civils

As part of the overall WAML scheme the Pod-Trak Civils team undertook the delivery of the civils and groundworks required for the new 6Km third line.

The delivery of the civils package was run alongside the multidiscipline scope of OLE and Permanent Way. The scope included:
• Ground stabilisation
• Formation and grading
• Track & Cross Track Drainage
• Deep Drainage
• UTX construction
• Elevated troughing routes
• Bottom ballast
• 4nr concrete OLE gravity bases
• Culvert strengthening
• Geogrid reinforced bund
• Retaining walls for noise barriers

The project was split in nine zones, with a minimum of two zones running concurrently at any time.

Challenges and Solutions
The biggest challenge across the project was access. By working daily with the client, other contractors and our own P-Way/OLE Team, a collaborative team effort enabled all parties to progress with their planned works. Key to this success was the daily logistics meetings to agree phasing of critical activities and sequencing of concurrent packages. At all times the existing lines remained open with work being carried out under ALO and utilising excavators with height & slew restrictors.

West Anglia Main Line (WAML) – Bridge Structures

At four locations on the new line new bridges were identified as being required. The preparation works and installation at each location was delivered by Pod-Trak in advance of our Permanent Way Scope.

Core works included:
• Bridge foundation pile cropping to 1100mm dia piles.
• Sub structure excavation.
• Reinforced concrete pours.
• Crane & piling mat installation and removal.
• New deck installation complete with bearings.
• FRC works to bridge deck.
• Bridge deck drainage.
• Working from temporary pontoons over water.

Bridge Structure 666
The existing redundant bridge was demolished and removed from site. New pile caps were built which tied into bearing slabs north and south. The new bridge structure was then installed using a crane and finished off by pouring a track slab to tie it all together.

Bridge Structure 1391 & 1391S
While the onsite team were constructing the bearing plinths and carrying out remedial works to the existing bearing shelf which included extending the northern plinth, another team was working in the compound at Copper Mill Lane to precast the concrete structures.

Bridge Structure 1393
At 1393 works were carried out to crop the 1100mm dia piles, construct reinforced concrete bearing slabs, bearing shelfs and bearing plinths. The prefabricated deck was lifted into place which allowed the deck slab to be poured along with access stairs north and south. Almost 1000m3 of concrete was poured over the course of the construction works.

This package of works formed part of our overall multidiscipline scope covering Civil Engineering, Permanent Way and Electrification.

Silwood Depot Sidings

Pod-Trak undertook a challenging role in this project to deliver a civils package with large programme and logistical constraints.

An ever-changing P-Way design required tactical installation of the ensuing civils element of the project, with very little re-work or re-visits required by our team.

The walkways consisted of reinforced concrete with ducting and sleeves installed for the lighting columns. Along side the walkways a concrete cable trough was laid for cable management.

The great dedication from our workforce also contributed to Pod-Trak gaining additional scope by being awarded a contract to provide ETE support to complement Cleshar’s electrification works in the sidings.

New Cross Gate LOCIP Depot

The scope of this project included minor civils, P-Way, ETE (third rail) and OLE to enable re-modelling of the existing depot layout including the supply of safety critical staff for the project.

Civil Engineering
Driver walkways, OLE bases, cable management routes & temporary hop-ups.

Permanent Way
Relocation of buffer stops and stripping out existing track to allow service diversions. Extension of the wheel lathe and heavy cleaning building, including installation of a new bogey turntable.

The scope also included the installation of 28nr IBJs to accommodate the signalling upgrade and a new CV40 turnout. Slab track was installed within the maintenance shed and outside.

To facilitate the Permanent Way and Civils scope, modifications were required to both the OLE and Third Rail including the movement of conductor rail for walkway installation and extension of the OLE to the carriage wash road and headshunt.

Thameslink Key Output 2

As part of the redevelopment of London Bridge Station and the reconfiguration of the platforms a significant amount of civils had to be completed along the approach and around the station itself.

The civils scope varied across many items including:

  • De-veg
  • RRAP installation
  • Routeworks
  • Foundations
  • Signage
  • UTXs
  • LOC & REB bases
  • Hardstandings
  • Walkways
  • Access steps
  • Handrails & fencing
  • Signal structures & foundations
  • Equipment staging
  • Retaining walls
  • Cable installation & recoveries
  • Bridge arch repairs

All challenges such as unsuitable access, interface with other contractors and short working windows were counteracted with ‘outside-the-box’ thinking, proactive site teams and close coordination with the client to ensure all milestones were reached.

Hornsey GTR Depot

Pod-Trak undertook successful operational delivery of the civils aspect of the sidings reconfiguration of seven roads.

This included all deep drainage and cross track drainage which involved ‘through the box’ trenchbox utilisation, construction of UTXs, all formation grading and tying into existing levels, geotextile, OLE bases, caissons, bottom ballast and brushedfinish reinforced concrete walkways with cast-in Cubis Multiduct service routes and Cubis Stakkabox chambers.

These walkways were of two varieties – 1.5m wide driver walkways and 2.5m CET aprons – all at 450mm thick, which required careful interfacing with the CET pipework and furniture installer. Further interfaces with the M&E contractor and muckaway via engineering trains and conventional muck-away lorries required a great level of planning and coordination with the client on a daily basis.

Working within a live depot environment required additional care with moving people, plant and materials through the work areas. Contract works were completed a week ahead of Pod-Trak’s target programme and over a month ahead of the client’s latest revised programme.