Anchor Systems (International) Ltd manufactured and supplied the Anchor Screw foundation system and GRP handrail interface for Network Rail and Crossrail at Westbourne Park London

A 400-metre segregation barrier was required within the six foot at Westbourne Park Station to divide the Network Rail and Crossrail Tracks. Due to the depth of ballast being over 1,000mm, the proposed segregation barrier solution would utilise multiple concrete foundations, involving multiple RRV’s, ballast removal, waste management, onsite concrete shuttering and mixing. This method of installation was estimated to take more than 20 weekend shifts at a large cost, deeming the works uneconomical for the client and the network.

The solution Following the success of Anchor Systems (International) Ltd foundation systems use within rail sector, the company was approached by Network Rail to discuss the use of its Anchor Screw foundation solution and asked to offer a design and installation cost for the segregation barrier. Anchor Systems worked with the design team at Network Rail to understand the project requirements and work together to develop the solution.

The traditional ‘off the shelf’ Anchor Screw foundations would not work on the project due to the presence of a concrete track drainage located approximately 1,000mm below the ballast level. This challenge was overcome by Anchor Systems conducting a ground penetration radar (GPR) survey of the 400-metre section of works to identify the accurate location and depth of the concrete drain.

During the survey, the (GPR) technician marked out every installation location and gave clearance of services and obstructions (bore hole clearance) to ensure that safe and efficient installation could take place. Following the GPR survey, the Anchor Screw design was modified, reducing its overall length to 850mm to ensure clearance from the existing drain while at the same time being able to achieve the vertical and lateral load requirements for the segregation barrier in line with NR standards.

Following the adoption of Anchor Systems Geotechnical Design, samples were manufactured and onsite acceptability tests of the Anchor Screw were conducted to confirm installation times, foundation capacity and validate the design. A total of five tests were conducted along with five trial pits to confirm the GPR survey results. All five test anchors were installed and tested within one four-hour night shift and removed using the same installation equipment. The product design, manufacture, and mobilisation for anchor suitability testing was all carried out by Anchor Systems and its installation partner within a one-week time frame.

Following on from the test results, the geotechnical design report (GDR) was updated and resubmitted to NR for approval. Approval of the design was granted with Network Rail and all interested parties. Anchor Systems continued to offer the turnkey solution by working with its approved contractor Arbourtech Services Ltd to complete the supply and installation element of the project. The results Anchor Systems worked with Colas Rail and Network Rail to offer a complete solution with one of its approved installers to guarantee workmanship and onsite efficiency.

The entire solution was offered at a saving of 30% for the design, testing, supply, installation, and commissioning of the barrier. Over 300 Anchor Screws were installed at 1,500mm spacings along Westbourne Park within 14 nightshifts, including the erecting of the barrier. Other benefits of the project were: Delivering a massive reduction in project costs compared to the original solution. Huge reduction in relative project ecological footprint through reduction of workforce, heavy machinery/RRVs, concrete, waste management, water consumption and material delivery miles. A saving to the network of over 30 per cent. The environment Over and above the project benefits, the Anchor Screw offers further benefits to the network and local environment, including:

  • On average the Anchor Screw foundation offers a carbon reduction of over 70 per cent. Example project reports with carbon calculated output can be seen at anchorsystems.co.uk.
  • All materials  are recyclable, easily removable, and reusable
  • Made in the UK from one hundred per cent recycled steel, with a minimum design life of 50 years.
  • Anchor Screw can be designed to offer 100+ year design life solution.
  • No wet trades, curing times or excavation.
  • No requirement for RRVs.
  • Materials can all be transported by hand and with track trollies.
  • Portable and lightweight installation equipment.
  • Reduction in hours on site and workforce required during installation.
  • Zero HAVS (Hand Arm Vibration).
  • Installation head offers low noise pollution output offering lower disturbance to local residents.
  • Adjustable domed head to ensure the asset or interface is always level and offers horizontal and lateral adjustment to ensure the route is straight. The patented dome head of the Anchor Screw and interface plate offers 14° overall tolerance.

Tel: 01342 719 362
Email: info@anchorsystems.co.uk
Visit: www.anchorsystems.co.uk