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Project: Elephant & Castle Station, London

Client: Hammond (ecs) Ltd, Network Rail

Design & Build Contractor: Hammond (ecs) Ltd

Interesting Facts

  • Elephant & Castle Station services 2,984,814 passengers per year.
  • Out of 2569 stations in the UK, Elephant & Castle is the 199th busiest station. (according to data from Table 1410 – Passenger entries and exits and interchanges by station – updated 22 July 2021)

One of the first ever installations of Dura Platform, Platform 4 at London’s Elephant & Castle station was in urgent need of improvements to the passenger experience and overall safety by reducing stepping distances from the platform to the train.

Hammond and Dura worked together to deliver a stepping distance adjustment of up to 200mm to deal with the varying heights along the platform. Although traditional platform material solutions could have been utilised, they were ruled out on the basis that significant platform closures and line possessions would be required; a process that would have led to many months of passenger disruptions.

The composite Dura Platform system was far less disruptive and quicker to install; not only removing the cost and disruption of the concrete option but also because it was adjustable to suit future rolling stock.

Dura Composites’ aim was to reduce the stepping distance from the platform to the train and make it consistent to ensure that platform 4 conformed to Network Rail’s standards for height and distance X-Y dimensions. Due to the nature of lightweight modular composite flooring panels versus traditional concrete and tarmac and their associated equipment, the majority of the installation of the overlay system was conducted within engineering hours under line block arrangements. The project was a success, accomplishing full compliancy.

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.

Before and After Installation

Improving the Platform Train Interface (PTI)

The risk to passengers at the Platform Train Interface (PTI) is equivalent to nearly 13 fatalities each year, and 48% of the total passenger fatality risk on the mainline railway network.

Network Rail standards specify that new platforms should be 915mm above rail height, have an offset of 730mm (horizontal distance between rail and platform edge) and should not be on a curve of less than 1,000m radius. In reality, only 30% are estimated to meet the height requirements and the dimensions are often considered a trade-off between the requirements of passengers and ensuring that the platforms aren’t struck by any of the different types of trains now in common use.

Dura Platform is a rapid-deployment and maintenance free solution that’s faster, cheaper and easier to install than traditional alternatives. It can cut platform installation time by up to 65% and can be installed in as little as 36 hours! It is suitable for manual handling, eliminating the need for costly RRVs or heavy lifting equipment. Its hidden fixing system minimises trip hazards, and the platform is also crankable to create an instant 1:40 fall to manage drainage.

Dura Platform 40

Dura Platform 40 is suitable to enable the re-gauging of existing platforms to meet PTI requirements by overlaying onto existing structures, or for extension and refurbishment of steel and concrete trestle systems. This innovative modular system is an approved product on Network Rails infrastructure list and meets specifications for composite platforms – spanning up to 1.5 m. This product was selected due to the fact it can be moved into position without heavy equipment, reducing cost and overall installation time.


Why Dura Platform?

After over a century of heavy use, many of the UK’s concrete train station platforms now require replacement as they reach the end of their service life. Even those that don’t require complete replacement need regular maintenance which can drain resources and cause passenger disruption.

Traditionally concrete has been used, but works can require long possessions and Road Rail Vehicles are normally required for the transportation of materials. Even when concrete is used, there is still no easy solution to fixing the problem of stepping distances between the train and the platform when subsidence means they have become out of gauge.

Dura Platform is a breakthrough composite product which solves all of these challenges and more in record time. The solution has a host of revolutionary features and allows contractors to replace or overlay onto damaged or subsided platforms a low maintenance, modular, lightweight, height adjustable structure that enhances safety with anti-slip surface options, in-built water management, integral lines, optional integral lighting and snow melting capability, all with similar or lower overall project costs than concrete.

  • Network Rail Compliant
  • Anti-Slip Surface
  • Low Maintenance
  • Fast Install Times

Rail Products

Rail Platform & Accessories | GRP Products for the Rail Industry

Discover the d2 Dura Composites range of solutions for rail stations including platforms, footbridges, end of platform gates & fencing. The d2 range deploys unique design and the latest composite technology to deliver the safest, most cost-effective and durable solutions on the market.


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