Tonbridge Maintenance Facility
Cairn Cross built a new £2.5 million maintenance facility in Tonbridge to support GB Railfreight’s growing locomotive fleet.
Customer
GB RailfreightDate Completed
2024Sector
Rail InfrastructureProject Overview
To support GB Railfreight’s growing locomotive fleet, Cairn Cross designed and constructed a new, state-of-the-art maintenance facility in Tonbridge, Kent. This impressive 35-meter by 10-meter structure, finished in GB Railfreight’s distinctive blue, represents a £2.5 million investment in enhanced maintenance capabilities for their Class 73, 69, and 66 locomotives.
Project Details
The Challenge
This new, state-of-the-art locomotive maintenance facility in Tonbridge enhances GB Railfreight’s operational efficiency. Clad in their signature blue, the 35-meter by 10-meter structure houses equipment for servicing their locomotive fleet. Hexagon Consultancy initiated the project with feasibility reports and provided ongoing technical drawings and support.
The facility features a robust steel superstructure supported by CFA piles, a reinforced concrete ring beam, and slabs. To accommodate construction, the team expertly removed, diverted, and re-laid an existing railway track.
The Solution
To enhance access to the new maintenance facility, the team expertly diverted an existing railway track. Within the facility, a 25-meter inspection pit enables thorough locomotive inspections, complemented by an exhaust extraction system, high-bay lighting, a comprehensive electrical fit-out, and a compressed air system. Additional features include fluid dispensing points, CCTV and fire alarm integration, roller shutter doors, a painted floor finish, and branded external signage.
Outside, a 360-degree walkway provides convenient access, and designated areas securely house the fume extraction unit, oil storage tank, air compressor, and fluid dispensing equipment, all protected by an Armco barrier. A comprehensive drainage system efficiently manages stormwater and water discharge.
The Result
Designed and built by Cairn Cross, with construction taking just 7 months, has allowed GB Railfreight to utilise the new facility at the earliest opportunity. Cairn Cross developed this project from feasibility through to completion, with Hexagon Consultancy Limited (formally Epsilon Design Engineers) providing the design, and the scheme was delivered as a complete design and build project.
The facility celebrated its grand opening in August 2024 with a ribbon-cutting ceremony attended by John Smith, Chief Executive Officer at GB Railfreight, and Maggie Simpson OBE, Director General at the Rail Freight Group.
Adam Southern, Delivery Director Track Treatment at Network Rail, said: “Tonbridge is a key location for Network Rail’s autumn and winter services, helping the Southern Region battle against poor adhesion due to leaf-fall and the effects of frost on the running lines. GB Railfreight’s new Maintenance Hub will provide a greater level of resilience and reliability for the seasonal fleet, right where we need it.”
John Smith, Chief Executive Officer at GB Railfreight, said: “Our new facility at Tonbridge demonstrates our commitment to continued investment and innovation in the rail network. The Tonbridge site will lead to increased efficiency for our locomotive fleet, which will benefit our customers, and operation of rail head treatment services will improve passenger experiences and safety across the region.”
Maggie Simpson OBE, Director General at the Rail Freight Group, said: “The rail freight sector is committed to growth – it’s fantastic to see private freight operators like GB Railfreight investing in facilities such as the new maintenance hub at Tonbridge. These facilities will provide additional capacity, reliability and resilience for rail freight customers across the country.”