CAF train manufacturing depot

Llanwern, Newport

Our client was looking to build this 46,000ft2 manufacturing depot on a complex former steelworks site with highly challenging ground conditions.

Geotechnical & environmental engineering
Backfill specifications, materials management plan, slag reuse strategy, gas protection recommendation note and verification report for completed earthworks. Piling risk assessment and 15m precast concrete pile design.

Civil engineering
Sub-structure design to enable the stable construction of five new railway lines. Drainage design including water testing bay. Design of access roads and circulatory yards. Service pits and paint shop design.

Structural engineering
Design of large steel-frame structure, with suspended reinforced concrete slab, including embedded rail tracks and testing pits. Two-storey office building design, future proofed so an additional storey can be added if required.

Adding value
This was an extremely challenging site, with tidal flat deposits of compressible clay, peat and expansive slag. We worked closely with specialist rail engineers to design the foundations and carried out settlement monitoring and detailed testing to ensure high load tolerances for the structure and its sensitive equipment.