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Black Bridge Cambrian Line, Machynlleth, Wales

GRP Grating & Supporting Beams Rail Bridge CESS & Trackside Walkway | Case Study

Project: Raising of Black Bridge, Wales

Client: AmcoGiffen

For the first time ever, a railway bridge in Wales has been raised away from rising river waters to prevent flooding on the track.

Black Bridge, on the Cambrian Line, near Machynlleth now stands one metre taller than before, after Network Rail engineers and contractors AmcoGiffen worked day and night to lift it away from a river flood zone. AmcoGiffen chose Dura Composites to provide safe, non-metallic Glass Reinforced Polymer (GRP) structural beams and grating for the newly raised bridge deck and CESS walkway, which provides a safe area for authorised workers to stand when trains approach.

Dura Composites specialise in the design, supply, fabrication and installation of advanced GRP products and have a wealth of experience in the Rail Sector. In this project, the client specification mandated the use of standard mesh grating with a Class B fire rating in accordance with BS EN 13501 as well as E23 grade GRP profiles.

As the only manufacturer-supplier on the market with these features in-built as standard into our range, Dura Composites was able to work closely with AmcoGiffen to ensure fast deployment of 38mm d² Dura Grating combined with Dura Profile Wide Flange Beams and Dura Angle as the supporting structure.

The Dura solution delivered multiple benefits in terms of faster, safer and easier installation, reducing time on site, therefore reducing disruption, and providing cost savings versus traditional materials such as steel beams and grating.

The success of this high-profile resilience project will improve passenger journeys and secure the future of this vital transport link between Mid Wales and the rest of the UK.

Unlocking the Power of Composites for the Rail Sector

Dura Composites’ are two time winners of the Queen’s Awards for Enterprise and have extensive experience in the Rail sector. The d² range of Dura Composites products for railway stations and trackside environments deploy unique patented designs and the latest composite technology to deliver the safest, most cost-effective and durable solutions on the market.

Key benefits include a superb strength to weight ratio, lightweight, non-corrosive, non-conductive and a low maintenance lifecycle. With a wealth of detailed technical information based on real-world testing criteria, Dura Composites can provide extensive loading data, span information and technical drawings to support the document control system requirements for any project.

Richard Compton, project manager for Network Rail Wales and Borders:

Black Bridge has repeatedly flooded over the years during periods of heavy rainfall, causing regular closures and long delays for passengers. We experienced this flooding first-hand during our work, which shows exactly why raising the bridge is so important. Improving the resilience of Black Bridge means we can continue to provide a safe and reliable railway for passengers for many years to come.

Andy Crowley, Operations Director Wales and Western at AmcoGiffen, added:

With nine months from concept to completion, we knew from the outset that it was going to be challenging to deliver this scheme in such a short time-scale. It’s important to acknowledge the true team spirit that has been part of this intense scheme from start to finish.

Discover the benefits of d2 Dura Grating

Designed, developed and manufactured by Dura Composites, d2 Dura Grating offers outstanding safety, performance and durability and is more cost-effective than traditional GRP grating in almost every scenario.

It can be applied in all industries where GRP mesh grating is used today and has an industry-leading Class Bfl-s1 fire rating as standard (in accordance with BS EN 13501). As with all our grating, it can be supplied with a range of stainless steel clips, clamps and hold down fixings to suit all install scenarios.

A comprehensive range of load testing data is also available within our searchable Online Product Selector database to help you make decisions based on real data to ensure maximum safety for your project.

  • Micro Mesh: 23mm
  • Mini Mesh: 23mm, 35mm, 45mm & 55mm
  • Standard Mesh: 26mm, 38mm & 50mm
  • Solid Top (Covered): 29mm, 41mm & 53mm

Contact our Specialist Rail Team about our Composite solutions

Dura Composites are helping to answer the major challenges facing Britain’s railway network such as capacity, reliability and efficiency. Composite materials are a realistic long term alternative across a wide range of applications within the Rail Industry in replacing traditional materials.

Call us on 01255 440291

Richard Palmer

Rail Sector Sales Manager

Megan​ Hewett

UK Rail Structures Manager

Martin​ Strawford

Technical Solutions Manager

Victoria Lockyear

Rail Sales Executive