Our GRP solutions save over 100 tonnes of embodied carbon for new Brent Cross West Station

The project used 595 grating panels, totalling 2,412m².

We were delighted to be approached by sustainable construction company, VolkerFitzpatrick to provide our innovative and sustainable products for London’s first new-build station in over 10 years.

Both Covid and Brexit had negatively impacted the procurement lead times for the formwork system that was originally intended for the project, so supplying our GRP formwork was a matter of urgency. Taking into consideration the required spans, loads, allowable deflection limits and overall design life expectations, we were able to identify suitable products from our d² Grating range. These products then went through both in-house testing and on-site practical demonstrations. We supplied over 2000m² of d² Dura Grating Solid top 53mm and 41mm ahead of the tight deadline.

We also devised a GRP barrier solution between the working platform and live OHLE equipment on site, using non-conductive 29mm d² Dura Grating Solid Top supported by Dura Profile Wide Flange Beam brackets. This meant that work could be carried out during the day without needing railway possession, saving four months of construction compared to alternative methods.

The project used a total of 595 panels in a mixture of thicknesses and sizes, totalling 2,412m². Using our d² range instead of the previous generation grating available elsewhere in the market, the project saved a remarkable 100 tonnes of embodied carbon. Offsetting this amount of carbon would necessitate the combined effort of 4500 trees removing CO² from the atmosphere for an entire year. This is equivalent to the space occupied by nearly three football fields. Another way to visualise this achievement is by comparing it to the carbon emissions of 297 economy flights from London Heathrow (LHR) to Dubai (DXB), or the distance covered by driving 488,000 miles in a petrol car.

About Brent Cross West

Brent Cross West is a new Thameslink station in North London between Cricklewood and Hendon stations on the Midland Main Line. It’s the gateway to the new neighbourhood, Brent Cross Town. The impressive 12-minute journey time from London and Brent Cross isn’t the only notable feature of the station, as it also features a new, public overbridge, providing the first pedestrian access across this stretch of the Midland Main Line since it was first built in the 19th century. The Mayor of London, Sadiq Khan officially opened the station on 10 December 2023.

I can confidently say that collaborating closely with Dura Composites’ Design and Engineering team led to highly successful outcomes on the Brent Cross West project. The level of engagement and cooperation was exceptional, and it played a pivotal role in achieving remarkable sustainability, programme and cost savings.

Tom Jaffray

EngTech MICE Site Agent and CRE-C at VolkerFitzpatrick

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