Burnham-on-Crouch Station

Client: Greater Anglia

Location: Burnham-on-Crouch, Essex

Value £400k

In January 2024 Capel CS Ltd were awarded the design and build contact for the replacement of the canopy at Burnham-On-Crouch station.

Design & Build

We were contracted to carry out a full structural and architectural design for the refurbishment of the new canopy lineside structure. Our design included to adopt the original client preliminary design and output this into a combined Form G for the project. To establish the required designed works, we initially implemented early site surveys and assessments which consisted of 

• Topographical survey including track, OLE equipment and lineside structure existing alignment. 
• Hazardous and harmful material assessments including for lead and asbestos.
• CCTV and Jetting Drainage surveys 
• Ground penetration surveys to establish existing and their party underground services.
• Redundant service survey for all Mechanical, Electrical and SISS equipment.
• Lux level and Lighting surveys.
• Structural defects and condition survey.
• Station Bonding survey and requirements.

Structural Works

On completion of the intrusive structural surveys the canopy had various sections which were defective, due to water ingress, or sections which had dropped or sagged due to incorrect or old construction techniques. There was also a section of the canopy where the substructure had failed and was to be completely removed.

In areas where timbers were rotten or decayed, we implemented basic temporary works, cut out the defective areas and scarfed in new like for like sections of timber. These repairs were installed in accordance with current joinery techniques and also in line with our developed design. 

In other areas where the canopy had dropped, we implemented a more robust repair solution comprising of steel flitch plates bolted to each side of the defective members. These were fully designed to align with new design life periods and withstand the required loadings of the canopy support.

The design and future loading requirements were also reviewed so as to maintain future maintenance access for the lineside structure.

Heritage aligned works

As part of the scheme, it was the intention to bring the structure back in line with its heritage aesthetic look so the modern style plain timber facias were changed to a more suitable Florence style dagger board. This Florence style pattern aligned more closely to what the original canopy would have looked like. Due to material technology advancement, we were also able to select a GRP material, to replace a timber product, so as to mitigate future works in restoring and repairing a timber material which decays quicker over time. 

The structure also required a full refurbishment of the painted coatings so a two tone paint scheme was developed and implemented to so as to transform the station back to how the original structure may have looked. These painted finishes were implemented to the station timber works, the station building and the existing steel support brackets.

Lead Paint Management

Due to the age of the structure, we identified from our early design surveys that the current painted surfaces contained lead paint. Due to the restriction of working in a complete closure of the operational railway then our methods and preparation were limited so as not to add unnecessary time or money to the scheme. We implemented a wet abrade preparation method, protected by bunded working areas and a fully operational decontamination unit as additional welfare. 

Timber replacement works.

As the structure had been missing a permanent roof for a long period of time most of the top subframe timbers and all the soffit timbers were showing signs of water damage. As part of the scheme, we designed and replaced all these elements with new sustainably sourced timber replacements prior to replacing the final roof covering. During the design process we were restricted by product thicknesses and weights due to not exceeding the original canopy design structure loadings.

New Roofing System.

As part of the scheme a new permanent roofing system was required and specified in the original client scope. We proposed a Resitrix Single ply EDPM system which provided the required 20-year life span and is a system which can be installed quicker than multiple felt systems. As full closure of the operational railway was required for these works then the use of a single ply product reduced our install time and minimised the risk for additional or unplanned possession access. This product was also used in re-lining the newly constructed box gutter 

Mechanical, Electrical Works

Due to maintaining the current lighting levels, whilst our strip out and refurbishment works were being carried out, we developed and installed a fully designed temporary lighting scheme. These works were installed over a period of weekend possessions as elements of these works encroached on the operation platform areas.

Once all the refurbishment, structural and preparation works were complete we designed and installed a new Permanent lighting scheme to the underside of the canopy structure. Whilst developing the design we incorporated split compartment containment so as utilise this for other station services like the CCTV, Data & Comms  cabling and equipment. This reduced the previously untidy look of excessive cables, different types of cable containment and badly installed additions. The Colour of the Containment was also matched to the surrounding timber paint finishes so as to blend in with the surrounding station finishes. 

Station Bonding

Due to the canopy being supported by steel elements the station bonding arrangements were not fully known so we carried out a full station bonding study and site survey. In preparing and completing the report we demonstrated that the steel elements of the lineside structure did not impact the current Overhead line equipment and no further works would be required.

Future maintenance and access

Whilst we considered the current canopy allowable loadings for future maintenance there was no approved or safe access arrangements to get onto the roof. To assist with future access we designed and installed a single line man safe fall restraint system so as when accessing the roof, the maintenance operative could not stray near open edges. Initially this was designed to be in the brick parapet wall but due to the bricks being of a soft nature we had to amend the design to a roof fixed system.

Brickwork repairs

Whilst we were carrying out the scheme works it was apparent that areas of the station had suffered brick deterioration so we implemented a site survey and scope report for these areas. We developed, designed and carried out a working plan and repair schedule in line with current network rails standard repair details. 

Pidgeon protection.

The station had previously suffered from perching pigeons on elements of the canopy sub frame so we firstly looked at different types of protection to implement. There are 3 main types of system to implement but we decided to supply and Install Pidgeon spikes as these not only allow for easier future access to areas but were more suited to the singular beam areas we need to protect.

Drainage remedial works.

From our initial design surveys, we identified that the existing platform drainage had some existing blockages and some of the pipework was misaligned. We carried out a full jetting operation, clear all the obstructions and re-lined the platform drainage so as to mitigate future movement of the pipes and mitigate future obstructions forming in the drainage run.

Capel CS Ltd acted as the Principal Contractor on this project with a project structure as follows:

• Project Manager
• Full-time Site Supervisor
• Visiting HSQE manager
• Visiting Commercial manager
• Site Labour/Sub-contractors

The design works including structural surveys and assessments were undertaken by our design partners Haydn Evans with whom we have completed numerous projects on the rail infrastructure.

The majority of the site works were carried out by Capel CS Ltd own workforce with the following specialist packages being carried out by our supply-chain partners:

• Mechanical and electrical Installations.
• Roofing membrane works.
• SISS Works.

The project team, headed up by our Project Manager, co-ordinated and managed all aspects of the works from site surveys through the design stage and finally the implementation of the site works. The location of the works necessitated the need to carry out the majority of the works during night-time possessions. These possessions were booked and managed by Capel CS ltd in conjunction with their safety-critical works partners.

Weekly progress meetings were held with the Client to review the works to date, discuss changes to the work scope and plan the forthcoming works. By holding regular meetings, any issues that could potential affect the progress or cost of the works was high-lighted early on and agreed mitigation measures implemented.