Standen Hey Bridge is a vehicle access bridge spanning a live railway line, providing essential access while operating within a highly constrained rail environment. The existing structure required replacement to meet modern loading standards and improve long-term performance, while minimising disruption to rail operations.
CRL was commissioned by Birse Rail to deliver an innovative replacement bridge deck solution using fibre reinforced polymer technology. Designed by Tony Gee & Partners, the new deck was developed to achieve full Eurocode vehicle loadings within a lightweight, rapidly installable form. The scheme represents a significant milestone as the first fully composite road deck installed over rail in the UK, supporting progressive asset management objectives.
Procurement of pultruded FRP sections supplied by Fiberline
Off-site assembly of fibre reinforced polymer bridge deck
Adhesive bonding of FRP sections with strict quality control
Assembly of multi-layer deck and parapet edge system
Logistics planning and preparation for rail installation
Collaboration with Birse Rail for transport and placement of the deck
Delivery of the first fully composite road deck installed over rail in the UK
CRL’s scope centred on the procurement, assembly and quality-controlled delivery of a pultruded FRP bridge deck system. The structural design, developed by Tony Gee & Partners, utilised Fiberline pultruded FRP sections manufactured in Denmark. CRL managed the purchase and logistics of these specialist materials before undertaking off-site assembly close to the installation location. This approach reduced on-site risk and ensured programme certainty ahead of the rail possession.
Assembly of the bridge deck was technically complex and required strict sequencing and workmanship control. Two layers of Fiberline sections were assembled to form the main deck structure, with a third layer incorporated to create the parapet edge. High-performance structural adhesives were used to bond the pultruded sections together, demanding precise surface preparation, controlled application and curing to achieve full composite action. Quality assurance was critical throughout, with checks in place to confirm complete adhesive bonding across all interfaces before the deck was approved for installation.
Once assembly was complete, the finished deck, measuring 10 metres in length, 4.9 metres in width and weighing 12 tonnes, was transported to site by Birse Rail. Installation was undertaken during a tightly planned 9-hour rail occupation, requiring seamless coordination between all parties. The lightweight nature of the FRP deck was a key advantage, enabling rapid placement within the restricted time window while minimising imposed loads on lifting equipment and supporting infrastructure.
CRL’s role demonstrates its capability to work beyond traditional concrete repairs, applying the same technical rigour, sequencing discipline and quality control associated with structural repairs UK projects. By successfully delivering a pioneering composite structure over rail, CRL supported a durable, low-maintenance solution that reflects modern asset management principles.
“We have worked closely and successfully with CRL for over twenty years in the UK and Middle East. They occupy a special position in the market and are clear about where they add value.”
Graham Nicholson | Executive Managing Director | Tony Gee and Partners LLP
The use of fibre reinforced polymer provided inherent long-term protection advantages compared to conventional materials. FRP is resistant to corrosion, moisture ingress and many forms of chemical attack, removing the need for traditional corrosion protection systems and significantly reducing future maintenance requirements. Adhesive bonding of the pultruded sections eliminated mechanical fixings that could introduce stress concentrations or long-term durability risks.
Designed to full Eurocode vehicle loadings, the composite deck offers high strength-to-weight performance and excellent fatigue resistance, enhancing resilience under repeated traffic loading. The lightweight construction also reduces demands on supporting structures, extending their service life. By delivering a fully composite road deck solution, CRL helped create a robust, future-proof asset with an extended design life and reduced whole-life costs, supporting sustainable infrastructure investment.
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