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Project: Oxted Viaduct, Surrey

Client:  Bam Nuttall

The 140 year old Oxted railway viaduct in Surrey is constructed from wrought iron girders on brick piers and has spans comprising four parallel, diamond trusses supporting the bridge deck.

A multi million-pound refurbishment project began in 2020 to refurbish the structure to maintain operating performance by lifting bridge spans, strengthening steel work, replacing 12 bearings, track monitoring and removal of the old timber deck.

Contractor BAM Nuttall chose d2 Dura Grating and Dura Profile for the replacement of the timber, creating a future-proof durable GRP solution that enhances safety and is quicker and easier to install.

Dura Composites in-house structural engineer supported the project team with FEA studies to ensure the proposed solution met the requirements of this historic refurbishment, and to date, over 600 sqm of Dura Composites standard mesh 38mm d2 Grating has been installed on the viaduct.

The cleverly value-engineered grating features an anti-slip surface tested to 1 million footfalls and a patented design which allows for better visibility of the substructure below than any other 38mm grating on the market, meaning future asset inspections can take place at an accelerated pace.

The Dura Grating is supported by almost 2000 linear metres of d2 Dura Profile –including the patented male and female Web Stiffener sections, Wide Flange Beam and Box sections which exceed the e23 grade specification of the BS EN 13706 standard and offer unrivalled performance and a superior strength to weight ratio than any other GRP profiles on the market.

Lightweight and easy to manoeuvre they are well suited to a project of this kind where they needed to be lifted to a high position well above street level.

Before & After

Before After

d2 Standard Mesh 38mm Yellow & d2 Dura Profile WFB

38mm Standard Mesh Dura Profile WFB

Commenting on the success of the project, Marc Shergill, Agent at BAM Nuttall said;

Overhauling the viaduct is essential to the safe and efficient full speed running of the railway line. Like any structure of its age, it needs periodic maintenance and servicing to ensure passengers and freight can continue to move safely over it in the future.

The work we have carried our using modern materials such as GRP Dura Grating and Dura Profile will ensure that the viaduct continues to welcome railway traffic well into the future, helping to maintain a good level of service with for the many passengers who use this route

Unlocking the Power of Composites™ With the Exclusive d2 Product Range

Dura Composites’ are two time winners of the Queen’s Awards for Enterprise and have extensive experience in the provision of anti-slip walkways and gantries. Our latest d2 range of products deploy unique patented designs and the latest composite technology to deliver the safest, most cost-effective and durable solutions on the market.

We have a vast range of products in stock now for easy call off or for vesting, to help keep your rail project on track.

We can provide detailed technical information for all our d2 products based on real-world testing criteria – including loading, span information and technical drawings.

Unique Trackside Solutions

Discover the benefits of d2 Dura Grating


Dura Grating Standard Mesh
26mm, 38mm & 50mm


Dura Grating Mini Mesh
23mm, 35mm, 45mm & 55mm


Dura Grating Micro Mesh
23mm


Dura Grating Solid Top
29mm, 41mm & 53mm

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 (excludes 23mm). 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.

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

Send us your Technical Enquiry

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.

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