Case Study

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Crystal Palace

The project at Crystal Palace Train Station was commissioned from a requirement for the station to upgrade passenger capacity improvement works.

The work was carried out while the train station and booking hall were fully operational, without disrupting the train service or passenger experience. The existing vegetation was cut back by a specialist contractor to create the area required for the new canopy. The existing brick walls underwent essential repairs and cleaning prior to the main works starting. New bespoke steel columns were pre-finished off site and positioned onto new concrete pad foundations during a planned weekend possession as was the canopy covering across platforms 3-8.

The existing Victorian booking hall had a complete refurbishment along with the installation of a new ticket gate-line, CCTV and information display monitors. The works consisted of removal of the existing vinyl floor area where the new gate line and glass barrier were to be installed; installation of a new steel plate structure within the booking hall floor screed to accept an additional 3 No. ticket barriers of the same design as the existing; repairs to the vinyl flooring system as required by the installation of the new steel structure to support the ticket gates and glass barrier; modifications to CCTV to ensure the levels of coverage required were maintained and to ensure that the PAM displays views of the new gate. All this work was carried out while the station ticket hall was fully operational.

Having a designated design coordinator throughout the project made the process of information flow far easier and more streamline which aided the contract to stay on programme.

For safety reasons and segregation site hoarding needed to be installed onto the platforms, but due to the narrow platforms the minimum distance from hoarding to platform edge could not be achieved. We liaised closely with the train operating companies (LORL & Southern Trains) who agreed to install a temporary car stop sign for the duration of the works while maintaining the platform lighting area for the trains.

The works contained within the booking hall were located over a Victorian Jack Arch, this information was not known at time off tender or contract award, and only came to light during the excavation and construction of the foundations for the new gate-line extension. To overcome this we engaged with the designer's collaboratively to design out the structural issues and actually installing betterment to the project design.

At design state the following items were overcome:

During the CAT III design check carried out, the Structural Engineer determined that the CHS gullwing beam joints detailed in the architectural drawings and WSP drawings were in the incorrect position.  The position detailed in the WSP drawings would cause excessive bending movements in the joint causing failure.  To overcome the issue the joints had to be moved outwards, this created a central section that included a column which was too large to transport.  A spliced section therefore also needed to be added.
In the WSP drawings and architectural designs a simplified RHS was shown spanning the gull-wings.  The design did not allow for the incorporation of the ETFE fixing brackets.  Five types of bespoke brackets therefore had to be designed and fabricated to allow for the ETFE fixing.
The Pendle plates detailed in the WSP drawings were structurally inadequate and incapable of supporting the necessary loads and were also not capable of being built.  A full re-design was carried out and the thickness of the plates increased.

Both the architectural designs and WSP drawings showed an RHS fixed directly to the train shed wall.  Following the design checks it was found that if the ETFE pillows were inflated, the tension created would cause a failure of the masonry.  In order to overcome this issue a complete re-design of the end section was required.  An additional CHS gullwing section, 2 no. Pendle plates and a new central column were used to create and independent section.

Working in the rail industry is extremely challenging, but with efficient and well directed collaboration, liaison with staff on a daily/shift basis and careful planning, the benefit of achieving the completion date and delivering the project to the highest specification and professionalism.