Enhancing Operational Reliability
At TES, we specialise in delivering precision engineering solutions for the most critical points of the rail network. Our recent project at Ilford Depot, commissioned by Greater Anglia, exemplifies our commitment to safeguarding operational integrity and extending the life of key infrastructure through expert planning and execution.
The Challenge: Life-Expired Assets Threaten Depot Operations
Ilford Depot is an integral operational hub for Greater Anglia. A routine inspection, conducted in accordance with Greater Anglia’s lease requirements with Network Rail, revealed a pressing issue: the 60/61 and 65/66 points, comprising 95lb obtuse crossing, 1 in 7 double slips, had reached their life expiry.
Having been in service for over 50 years, these double slips were exhibiting substantial movement under load. Given their essential role in the depot's daily operations, a prompt and precise renewal was not just advisable, but crucial to prevent future disruptions and ensure the continued reliability of Greater Anglia's services.
TES 2000's Solution: Precision Pre-Fabrication and Strategic Logistics
As Principal Contractor, TES undertook this crucial renewal on behalf of Greater Anglia. Our approach blended meticulous planning with an innovative strategy for the installation of the new S&C (Switch & Crossing) units:
Off-Site Fabrication & Quality Assurance: To enhance efficiency and control, the S&C ironwork was installed using the tried and tested "loose laying" method. TES facilitated the fabrication of the unit at Lillie Bridge Depot in London. Once complete, our team visited Lillie Bridge to meticulously measure and gauge the entire unit. Every component was precisely labelled, and all necessary holes were pre-drilled.
De-risked Delivery: Once the unit was fully assembled and inspected off-site, it was carefully disassembled and delivered by lorry to Ilford Depot. This off-site pre-assembly significantly de-risked the on-site installation, reducing trackside time and enhancing overall program efficiency.
Proactive Material Management: Upon delivery to Ilford Depot, our teams secured track access to remove a buffer stop and expertly ran out all materials, strategically placing them in pre-agreed positions of safety. This forward-thinking logistics provided crucial time contingency, ensuring all components were ready for seamless installation at a later date.
Meticulous Planning & Comprehensive Scope of Works
Before any physical work began, TES developed a robust project plan and cost build-up, submitted to Greater Anglia alongside examples of our rigorous Work Package Plans (WPPs) and Task Briefing Sheets (TBS) – demonstrating our proven track record. An outline programme was produced and integrated into the Construction Phase Plan, also populating the comprehensive Primavera P6 programme submitted to the client. Detailed methodology WPPs and associated risk assessments were provided for all activities, outlining precise control measures.
The scope of works included:
Implementation of the 019 Standard (Network Rail's engineering standard).
Preliminary survey and precise setting out.
Pre/Post Heights & Staggers and Bonding Surveys.
Installation of a temporary RRAP (Road Rail Access Point).
Full site mobilisation, including welfare arrangements, lighting, waste management, security fencing, and comprehensive Health & Safety signage.
Delivery of heavy plant and aggregates.
Isolation of OLE (Overhead Line Equipment) to the buffer stop and its subsequent uninstall.
Removal of old S&C units and 59 old longitudinal timbers.
CAT scanning and removal of existing track bed to a dig depth of 200mm below sleeper level.
Installation of a new formation with a 1 in 30mm crossfall to the cess, compacted at 100mm intervals.
Installation of 42 new timbers and the new S&C units.
Disperse top stone into bays and cribs.
Lift & pack track to the required design levels.
Final box-in.
CRT Management (Controlled Resting Temperature) with continuous track monitoring and void meters to record any track disturbance or dynamic movement under load.
Completion of comprehensive As-built drawings and undertaking official track handback.
Our in-house technical team played a pivotal role throughout, conducting the Hallade survey for the unit, and producing the detailed track, top and line, and scheme designs, alongside all necessary heights and staggers surveys. TES has the unique ability to produce both Hallade and 3D track designs, selecting the most effective survey and installation methods for each project – for Ilford, this involved precise 2D methods.
Achieving Operational Continuity and Lasting Safety
Following the successful completion of these works, TES submitted a full Health and Safety file to Greater Anglia, marking the successful handback of Ilford Depot. The renewed 60/61 & 65/66 points are now robust, stable assets, free from substantial movement under load, and ready to support Greater Anglia’s critical operations for decades to come.
This project underscores TES's commitment to delivering complex infrastructure renewals with meticulous planning, advanced technical capabilities, and a relentless focus on safety and long-term reliability.