Feltham Resignalling Project Phases 3-4 Advanced Civils

Principal Contractor Global Rail Construction Limited (GRCL), has completed Feltham Resignalling’s largest civil engineering programme of works, on behalf of Network Rail (NR) Southern Region Capital Delivery.

In October 2020, Global Rail Construction commenced works as the Principal Contractor for the Design and Construction (D&C) of the Advanced Civil Engineering scope of works for Feltham Resignalling Project Phases 3&4. These phases form part of a major Resignalling project to renew life expired signalling, telecoms, and electrical assets for Network Rail, comprising the renewal of 538 Signalling Equivalent Units (SEUs) over 80 miles of railway lines, alongside the introduction of a brand-new signalling system from Atkins – Elix. 

Design activities commenced at pace and site works were meticulously planned as part of a compelling tender methodology and approach utilising weekdays and nights, Saturday nights and several 28 and 52-hour railway possessions during a most challenging project timeframe.

The construction works were further extended to September 2022 to include several additional location case hardstanding’s, PSP compounds, new signal installations, new cable duct routes to existing station platforms and the installation of various new troughing routes – all effortlessly absorbed by GRCL’s in-house D&C team.

Having a railway design and build team, including dedicated project and site management across the civil and structural engineering scope, familiarity with the scheme, having delivered several previous phases and having delivered time pressurised resignalling schemes across Network Rail infrastructure, allowed Global Rail Construction Limited to provide the necessary turnkey solution and complete the project to meet Network Rail’s requirements

Chertsey, Camberley, Rusham & Stroude (CCRS) Level Crossings

Global Rail Construction Limited (GRCL) has completed the signalling and telecoms installation and associated civil construction works for the renewal of the following 4No Level Crossings:

  • Stroude – a bridal crossing without any barriers that required extensive resurfacing and fencing works and the replacement of 30No track sleepers
  • Rusham – a complex crossing that included design and installation of pilling, extensive hardstanding and fencing 
  • Camberley – a barrier crossing requiring modification, new bases, cable routes, associated fencing and surfacing works
  • Chertsey – minor signalling and civils works as there was no new barrier or RTL bases 

The works were completed for long-term client Atkins Global, on behalf of Network Rail’s Wessex Route. The completed crossings fall within the Feltham & Wokingham Resignalling project which comprises the renewal of all signalling assets controlled from Feltham Area Signalling Centre (ASC) and Wokingham Signal Box (SB), replacing 9 RRIs with new centralised ElectroLogIXS (CBI) interlockings controlled from Basingstoke ROC.  


Signalling Installation Works Package 1 – Feltham

Global Rail Construction Limited (GRCL) successfully secured a significant Signalling installation sub-contract on behalf of its UK client Atkins. The contract is for Package 1 covering Phases 3 & 4 of the Feltham to Woking Resignalling Scheme and also includes Telecoms, Permanent Way, E&P and associated minor civils installation scopes of work

The contract includes the provision of key engineering resources – using in house personnel – in accordance with the Engineering Management for Projects standard NR/L2/RSE/02009. This includes the necessary disciplined Contractors Responsible Engineers, who are accountable for the day-to-day management and co-ordination of the technical and engineering activities, Construction Managers, Temporary Works Co-ordinators, and a Responsible Manager to fulfil the duties as defined in NR/L3/OHS/019. 

This success was awarded following Global Rail Construction Limited’s recent completion of the early advanced scope for Phase 2 covering Sunningdale MCB-CCTV – a full level crossing renewal – in which GRCL completed trackside signalling equipment installations and civils works in early November 2021 and the company was of course delighted to be working once again in partnership with its long-term customer Atkins.

The overall Feltham to Wokingham Resignalling Project covers the renewal of all signalling assets, covered by seven scheme plans, with delivery broken down into six separate Phases that align approximately to the Signalling Scheme Plan boundaries, Feltham ASC Signallers panels and Wokingham Signal Box.


Gibbets Lane – Plain Line Track Refurbishment Works

Network Rail (NR) Principal Contractor, Global Rail Construction Limited (GRCL), were contracted by NR Wessex Works Delivery Track for a £200k Plain Line Refurbishment of Gibbets Lane on the Frimley Line.

Global Rail Construction engaged with supply chain partner, KGJ Price, in order to support Network Rail to deliver this track package of works on the Wessex Route. 

During CP6, Global Rail Construction has also successfully supported Works Delivery in both Wessex and the South East with discrete work banks which have included re-sleepering, S&C refurb works and rerailing.

Minor Track Works (Renewal & Replacement) – Redhill

Due to maintenance DU capacity during week 50, Global Rail Construction Limited were engaged to deliver a £100k fixed diamond replacement project to remove track defects, crippled joints and track quality issues. The project demonstrated Global  Rail Construction’s ability to rapidly mobilise, undertake detailed planning in tight timescales and deliver a professional and quality project in collaboration with the Network Rail teams.

Global Rail Construction were responsible for the detailed planning of the works, providing safety documentation, hour by hour programme and inspection and test plans for the works. The company carried out the surveying and marking out of the works, and supported logistics for plant and materials deliveries. 


Minor Track Works (Renewal & Replacement) – Pratts Bridge

As part of the Sussex Region’s ongoing maintenance and renewals programme, Network Rail Works Delivery Unit (DU) engaged with Global Rail Construction Limited (GRCL) as their Principal Contractor to deliver a £100k contract for a critical sleeper renewal at Pratts Bridge near Eridge, East Sussex, 35m 1672yards.

The works required the removal of redundant 23nr PAN 8 sleepers and installation of new NRS1 base plated sleepers, ballast installation and tamping. The work was delivered as a package including planning, material management, logistics, survey and design validation, pre-works and engineering controls, delivery, and hand-back. 


Power Supply Upgrade – West Ham, London

Global Rail Construction Ltd (GRCL) was awarded a £3m design and construct contract associated with eight existing and one totally new substation at West Ham on the Metropolitan & District Line. Having worked closely with the client at tender stage in support of their bid to LUL, GRCL fully project managed all aspects of the design and construction of the civil and building elements of the work. The existing substations were: Campbell Road, East Ham, Heathway, Hornchurch, Plaistow and Upminster Bridge.

In general, works at these substations were to strengthen and alter the existing buildings and structures to allow the positioning of new transformers, switchgear, cables and ancillary equipment or provide new bases, structures and building extensions to support and house the same.

Sunningdale Level Crossing Renewal

Global Rail Construction Limited (GRCL) was awarded a multi-disciplinary contract on behalf of Atkins Global for the Civil and S&T installation works for a new level crossing at Sunningdale, which falls within Feltham Resignalling Phase 2.

The overall Feltham Resignalling Project covers the renewal of all signalling assets. Its area is covered by seven scheme plans, with delivery broken down into six separate Phases that align approximately to the Signalling Scheme Plan boundaries, Feltham ASC Signallers panels and Wokingham Signal Box.

Within the early advanced scope of Phase 2 was Sunningdale MCB-CCTV, which is subject to a full level crossing renewal – due for completion in November 2021. The scope encompasses life extension works with addition of barrier repositioning and narrowing of carriageway.

Clacton Resignalling Scheme

Global Rail Construction Limited (GRCL), has successfully completed a railway civil engineering design and build programme of works on behalf of partner Atkins Global, to support the upgrade the signalling systems in the Clacton-on-Sea area. 

The Clacton Resignalling Projects’ principle driver was the asset condition of the interlocking and associated track infrastructure at the throat of Clacton-on-Sea station.

Much of the signalling in the area dated back to 1958 and utilised a lever frame dating from 1891. There was a mixture of semaphore and colour-light signals, controlled by a mechanical/electro- mechanical lever frame. There was also a mechanical ground frame at Clacton Station. The existing signalling equipment has been previously subject of life extension works in both 1996 and 2004.

Many components were obsolete and only available on a repair and return basis. Most of the existing location cases had considerable corrosion. The signalling uses some single-cut circuits which are the subject of ORR concern. Searchlight signals were installed on this line, with known Wrong Side Failure (WSF) modes. P-Style relays in the lower portion of the box were recognised as susceptible to sliver migration. So, these works, will minimise maintenance and reduce whole life costs.

Greenwich SVC – Enclosure Design and Build

Global Rail Construction Limited (GRCL) has successfully completed the Design and Build of a Static VAR Compensator (SVC) Enclosure at Greenwich Generating Station. Under Power Upgrades Package 5C, Siemens, as Principal Contractor, appointed GRCL to deliver the project, to house the new SVC within a disused turbine hall. 

Access to the substation was via the Old Woolwich Road, which was challenging. An internal substation access road was used for all construction logistics and deliveries with minimum disruption caused to the local residents.

Whilst on site, GRCL were awarded a variation to provide further civils installation works associated with the extension to the existing 22kV Switch room located on the 1st Floor of the Sub-Station.  These works included the demolition of the existing wall, strengthening of the floor using steel support and concrete screed, blockwork walls, self-levelling screed, door installation and plinth foundations.