National Level Crossing Risk Reduction Programme – Barnt Green Footbridge

Barhale Construction Services Ltd were contracted by Network Rail (with Kier as the principal contractor) to fabricate and install a new double-span footbridge near Bromsgrove, North Worcestershire. The existing footbridge needed to be replaced with a new, higher structure so overhead lines can run underneath to power electric trains.

The project was part of a £100m Network Rail investment to electrify the lines between Barnt Green and Bromsgrove in the north of Worcestershire. The existing structure remained open for station pedestrians, whilst the project was being carried out.

Midland Metro Alliance

The Midland Metro Alliance is a team of planning, design and construction specialists responsible for building a number of new tram extensions over the coming decade, on behalf of the West Midlands Combined Authority. These exciting extensions will help deliver a lasting legacy, aiding social and economic regeneration across the region.

There are a total of six projects that form the work of the alliance, specifically Wolverhampton Interchange, Wednesbury to Brierley Hill, Birmingham Eastside, East Birmingham to Solihull, Birmingham to Centenary Square and Centenary Square to Edgbaston. These projects form a significant part of the ‘Movement for Growth’ strategy through which Transport for West Midlands will work to limit the effects of congestion, by improving the availability of modes other than the private car.

Britannia Road – Collapsed Sewer Under Railtrack

Network Rail informed Yorkshire Water that foul sewage was leaking
to the surface and onto the railway track. After CCTV investigation and attempts at unblocking the pipeline, it was found that the 225mm
diameter foul sewer had collapsed due to its 100 year old age and
ground pressure caused by the trains. The sewer was shallow at only
1.5m depth and had been affected by a Network Rail track drainage

Following an optioneering process, the damaged sewer was reinstated at its existing alignment and was relayed in sections, with live flows. This required the use of a temporary overpumping system.

The sewer line crosses the main MVL3 Manchester to Huddersfield line, so the works were carried out over a series of short Rules of Route (ROR) night possessions.

Great Moor Sailing Club

As part of the legally binding Undertakings and Assurances (U&As) for HS2, Barhale were contracted by Fusion JV (Morgan Sindall, BAM Nuttall and Ferrovial Agroman) to construct a temporary road, a vehicle and boat car park, a drainage system, and a new pontoon with a concrete slipway at Great Moor Sailing club in Buckinghamshire.

The team innovated to resolve several constraints related to the project, and in the process saved money and finished construction on programme, while fully complying with stringent client specifications. The team also reduced the import of virgin materials’ by eliminating the need to remove spoil from site.

Centenary Square

The Midland Metro Alliance is working on a ten year programme of
work to deliver tram extensions across the West Midlands. Barhale are
a sub-alliance partner whose remit is to deliver the civil engineering
elements of the work.

One of the projects is the first phase of  the Birmingham Westside Metro extension, which will see the line extended from Grand Central to Centenary Square. These works will aid regeneration across the city and prepare for the Commonwealth Games that Birmingham will be hosting in 2022.

Turnham Green Station Signalling Equipment Rooms

During a recent project at Turnham Green Tube Station for FM Conway, on behalf of London Underground (LU), Barhale were able to demonstrate how Early Contractor Involvement (ECI) enabled the development of a realistic and successful cost plan. This in turn led to collaborative interaction at design stages and the delivery of a successful project in line with the agreed cost.

The scope of works required excavation of the existing rail embankment under the six arches and installation of extensive temporary works formed by sheet piles braced by frames against the viaduct wall.

This was a high risk project. The works would be taking place in a restricted area with limited head-room, and in very close proximity to live railway lines (District Line and Piccadilly Line on the Underground network).

National Level Crossing Programme – Kemps Footbridge

Barhale’s subsidiary, BCS Fabrications, were contracted by Network
Rail (with Kier as the principal contractor) to design, fabricate and
install a new footbridge near Balcombe in Sussex, as part of the overall
National Level Crossing Programme (NLCP). Kemp’s foot crossing,
which links the B2036 road with Stumble Field Wood and Balcombe
village, was used previously to cross the dangerous 90mph main
Brighton railway on a bend.

Network Rail were under pressure from the local authority to maintain
a local right of way, but with only three disruptive possessions
available during the final quarter of 2014, it provided a sizeable
challenge to complete the construction in the shortest time possible.

Yews Lane Bridge Replacement

Barhale were awarded this design and construct project by Network
Rail, to replace the railway bridge along Yews Lane in Helsby, Cheshire.
This occupation bridge provides the only access route to Hope Farm.
Having failed its capacity assessment, there was a need for it to be
replaced due to the weight limits imposed. This stopped vehicles in
excess of 6 tonnes accessing the farm, creating problems with feed
and livestock movements.

The scope of work comprised demolition of the existing bridge,
design, fabrication and installation of the new structure. Design was
undertaken by our sub-consultants, Crouch Waterfall and Partners,
whilst all other key elements were delivered in-house, including
fabrication of the new steel deck at our fabrication workshop in

Roundtree and Greenford Road

Barhale were contracted by Network Rail to undertake a construct
only package of two schemes in North London. The first scheme on
Roundtree Road involved the demolition of an existing footbridge, the fabrication and installation of a replacement steel structure, as well as the construction of associated foundations, footpath and

The second scheme on Greenford Road consisted of the
refurbishment, grit blast and painting works to an existing footbridge,
as well as de-vegetation and brickwork repairs.

Rickmansworth MR88 Underbridge Replacement

Barhale were awarded the construction project by LUL to replace the railway bridge along the Metropolitan line in Rickmansworth, Hertfordshire. The bridge is part of the railway line between Rickmansworth and Moor Park station. The major concerns with the existing structure were the capacity to resist two horizontal loads, vertical displacements and the load capacity of the old deck.

Barhale carried out a detailed work programme for the possession period, including contingency plans to ensure that the works will be completed on time. During the bridge replacement works, not only did Barhale succeed with its works but we also made up for third parties delays and provided other subcontractors with their own resources to achieve the target delivery.
Along the project, Barhale demonstrated a hands-on spirit with a permanent collaboration with the client on the several design issues and challenges.