Case Study

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Dalston Kingsland Booking Hall

Walker Construction was employed to carry out refurbishment works at Dalston Kingsland Overground Station. The existing booking hall at the station was constructed in the 1980’s. It was decided due to increased usage of the Overground network the existing booking hall and gateline was insufficient to handle the passenger flow at peak times. To the immediate left of station was an existing disused retail unit that was to be incorporated into the station booking wall.

We carried out the works in two phases so that the station could remain operational at all times.

The works included the strip out and demolition of the retail unit partition walls, utilities, curtain walling and the non-load bearing wall between the station and the retail unit. Hoarding was erected to segregate the work site from the public.

Phase 1 construction works comprised of;

  • Installation of new floor, skirting and wall tiling.
  • Internal and external wall/column cladding system.
  • Curtain walling including structural support beam.
  • Installation of structural support frame.
  • Modification of existing station canopy.
  • Electrical works including new light fittings and distribution board.
  • Installation of new tube line ceiling system.
  • Black spayed paint systems to roof sheeting and steel.
  • Installation of 5no new CUBIC gateline systems.
  • Installation of roller shutter.
  • Installation of Gateline Attendant Portal unit (GLAP unit).

Phase 2 construction works comprised of;

  • Installation of new floor, skirting and wall tiling.
  • Internal and external wall/column cladding system.
  • Curtain walling including structural support beam.
  • Installation of entrance matting system.
  • Electrical works including new light fittings and distribution board.
  • Installation of new tube line ceiling system.
  • Black spayed paint systems to roof sheeting and steel.
  • Installation of 3no new CUBIC gateline systems.
  • Installation of roller shutter.
  • Relocation of existing TVM units.
  • Mosaic wall tiling. 

After completion of each phase a full handover and safety validation was carried out by the train operating company (LOROL). 

We also carried out additional works to this project which involved:-

Adjustment of doors – Following installation of the new floor tiling all internal doors and frames were required to be adjusted, the frames and surrounding brickwork were modified to allow the doors to be jacked up to provide required clearance.

Plaster works – Following demolition of the existing retail unit walls, there were several areas of exposed brickwork that required concealing. Walker construction installed plasterboard and applied blackout paint to conceal the exposed brick sections.

Rebuilding electrical cupboard wall – Following removal of the retail unit partition walls it was revealed that the existing station electrical cupboard wall was damaged, Walker Construction bricklayer rebuilt and re plastered the wall in preparation for tiling works.

Adjustment of outside floor levels – In order to install the external floor tiles the existing floor levels were required to be reduced to achieve transition levels in to the booking hall. The substrate formed part of the Kingsland High Road over bridge. Walker Construction needed to cut and remove the existing screed and concrete base without penetrating the bridge deck waterproof layer. The works were undertaken using low vibration hydraulic breakers within the confines of an acoustic sound tent to reduce the effect to the operation station staff and customers.

Soffit Support Frame – In order to install the new canopy soffit panels a new soffit support frame was required, Walker Construction and Cooks Fabrication developed an additional support frame on the West and Eastern ends of the canopy to allow the new soffit panels and canopy returns to be installed.

Installation of containment for Gateline System – Walker Construction’s electrical contractor was engaged to provide a suitable containment route to supply the new gateline system for the ticket office.  A route through the ticket office brickwork wall was surveyed and all containment supplied.

We offered some value engineering on this project involving overlaying tiles.  The existing wall tiles were to be removed and prior to installing the new tiles.  Following site investigations it was revealed that the existing tiles were adhered to thermolite blockwork.  To remove the old tiles would have caused programme delays and excess costs.  In order to prevent this an alternative tile adhesive was sourced that could allow the new tiles to be laid over the existing.

 

This project was challenging as the station had to remain fully operational throughout the works, this meant additional supervision resources were required to be allocated to the job in order to ensure the works carried out in a safe manner at all times to protect all station users. Walker Construction devised a Phasing Plan; all works that would affect the operation of the station were programmed to be undertaken outside of the station’s operation hours. Phase 1 and 2 worksites were segregated with solid panel hoarding.  Additional signage and wayfinding was installed to direct passengers.  Our site management team liaised daily with the station manager and staff to ensure any issues arising were dealt with immediately.

Other challenges we overcame included:-

Diversion of BT optic cable – In order to allow the installation of the new ceiling system the existing BT fibre optic cable supplying the station needed to be diverted. Following installation of the electrical/telecoms containment we engaged with LOROL IT and BT to divert the fibre optic cable around the perimeter of the booking hall and into the ticket office.

Limited space – Dalston Kingsland Station is positioned on the very busy Kingsland High Road adjacent to the Dalston Market.  There was not sufficient space to position a site compound within the vicinity of the station.  We had to investigate and arrange with Hackney Council for the site compound to be set up on a footpath of an adjacent street.  All deliveries were made to the site compound and transferred to the station, outside of peak station hours as and when required. Walker Construction had to manage vehicle and foot traffic during the loading/unloading of site skips during the demolition phase.

Noise complaints – Some works were required to be undertaken outside of station operation hours at night. In order to limit the noise generated from night works the site team installed acoustic barriers and carried out noise monitoring at selected locations around the works.  The site manager engaged with the local council to ensure any complaints were dealt with immediately.

Structural support frame – Following the removal of the internal cavity wall between the station and the existing retail unit it was discovered that there was lateral diagonal bracing between the structural columns. In order to maintain the open plan of the booking hall these diagonal braces needed to be removed and an alternative support system installed. The structural engineers designed a portal frame that was fabricated off site by Walker Constructions steel fabricator. The old braces were removed and the frame installed over two nights without affecting the station operation.

Structural Lattice Beams – Following removal of the existing station and retail unit signage it was discovered that a structural lattice beam was installed in line with where the contractor designed curtain walling was to be installed.  Following a review by the structural engineer it was revealed that the beams could not be removed and that the curtain wall design need to be amended. The curtain wall contractor re designed the position of the frame and utilising the discovered beam as a fixing point was able to reduce the sectional width of the frame. 

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