Hitachi Rail Manufacturing Facility

Project Overview

Rainton Construction was appointed as the subcontractor to undertake an extensive civil engineering package at the Hitachi Rail Europe Vehicle Manufacturing Facility at Newton Aycliffe. Surfacing was undertaken by our in-house team, and the material was provided by Tynedale Roadstone.

Scope of Works

Our full scope of works included:

• Floor slabs
• Various foundations for the structural steel frame
• Rail foundations
• Both internal and external traverser foundations
• Construction of reinforced concrete structures, including a water test facility
• Construction of a bogie pit
• Construction of various narrow and wide pits and test line walls
• Drainage works
• Installation of five pumping stations along with respective pipework.
• External works, including reinforced concrete roads, car parks, and hard and soft landscaping

Challenges

Setting out and executing the works required extreme precision. With tolerances of just +/—5mm, the most technically challenging aspect was the construction of a 23m diameter concrete rail turntable and accompanying 4m wide concrete hardstanding around the perimeter. Our dedicated team carried out the work with zero defects.

The works were carried out in the winter months, creating an extra level of difficulty. This meant particular attention had to be paid to the weather constraints when installing the concrete and, in turn, protecting the concrete once installed. This was done by procuring designated tents, which were positioned over the finished concrete to protect it from any inclement weather.

We adopted a proactive approach throughout the project’s lifecycle, and all obstacles were overcome thanks to our flexibility regarding the programme and our attention to detail.

Sustainability

Sustainability initiatives implemented for this project included a rainwater harvesting supply to the site cabins and the use of solar power to the site toilets. 73,000m³ of excavated material was crushed, tested, and reused on site. This saved approximately 8,000 wagon loads of imported fill being transported to the site, a total of approximately 240,000 miles.

This was not only a cost-saving exercise but also a significant reduction in the project’s carbon footprint. In addition, over 90% of construction waste was diverted from landfills.

Summary

The original contract programme was 36 weeks; however, this was extended to incorporate additional works such as upgrading the site’s existing infrastructure and, most notably, the construction of the rail turntable pit. The final project duration was 60 weeks, and works were completed to meet the overall completion date and handover.

We are delighted to have supported this prestigious construction project, which marked the triumphant return of rail manufacturing to the region. Our work on this project was ‘Highly Commended’ in the Civil Engineering Contractors Association (CECA) North East Awards 2016.