Network Rail's Flow Bridge

Project Overview

Network Rail embarked on an innovative project to create a more environmentally friendly bridge – the Flow Bridge. This initiative aimed to reduce traditional environmental impacts by minimising concrete use and employing sustainable materials. Traditional bridge construction relies heavily on concrete foundations, typically requiring 3 cubic metres of concrete for each support. However, for Flow Bridge, Network Rail sought a concrete-free design, turning to a unique combination of hemp and carbon fibre for the bridge’s structure. This material choice offered strength, lightweight properties, and rapid installation.

With an entirely new approach to bridge building, the project required an equally innovative approach to monitoring environmental impact. AWE Technologies provided an early baseline analysis of noise, dust, and vibration levels using the Sentry Camera System and MOKO Vibration Detectors. The Flow Bridge was constructed at the Long Marston Rail Innovation Centre, an isolated location that allowed for uncontaminated environmental measurements, effectively serving as a laboratory for assessing impact.

The Role of Sentry and MOKO

The deployment of Sentry and MOKO systems early in the project played a crucial role in collecting baseline data. AWE Technologies set up four Sentry Cameras to monitor noise and dust in real-time, while two MOKO Vibration Detectors captured vibration levels from the piling equipment necessary to secure the bridge supports. The MOKO devices offered an integrated feature with the Sentry cameras – by clicking on any point in the vibration graph, Network Rail could view four simultaneous images from the cameras, pinpointing the cause of any spikes in vibration.

This integration was pivotal for Network Rail, providing not just data but context. Instead of interpreting vibration solely through abstract graphs, Network Rail could see exactly which construction activities were generating impact and to what extent. This depth of insight facilitated informed decisions, enabling the team to design out excessive noise, dust, and vibration from future installations.

Benefits and Key Outcomes

1. Baseline Data for Planning Applications: The isolated testing environment enabled Network Rail to obtain untainted measurements, giving them an accurate baseline of environmental impact. This meant that future planning applications for installing the Flow Bridge could proceed smoothly, backed by hard data. With these known levels of noise, dust, and vibration, authorities could make faster, evidence-based decisions, confident in the anticipated environmental impact.

2. Commitment to Minimising Community Impact: By monitoring environmental impact at the design stage, Network Rail demonstrated its proactive approach to protecting lineside neighbours. Unlike traditional projects, which often rely on reactive measurements after installation has begun, Flow Bridge was designed with environmental impact in mind from the outset. This proactive stance supports Network Rail’s commitment to reducing the impact of construction on surrounding communities.

3. Enhanced Safety through Pedestrian Crossing Alternatives: The Flow Bridge presented a safer, more sustainable solution to replace pedestrian level crossings. By providing this low-impact, structurally sound alternative, Network Rail can reduce pedestrian access points across rail lines while ensuring a lighter environmental footprint.

4. Efficiency in Construction and Installation: The hemp and carbon fibre structure of the bridge was not only lightweight but also quick to install, reducing time on site and thereby lowering the overall environmental impact of construction. With precise data on the noise, dust, and vibration produced during installation, Network Rail is better prepared to mitigate these factors on future sites.

A Model for Sustainable Infrastructure

The Flow Bridge project set a new standard in environmentally responsible design and construction. By gathering early data on environmental impacts in a controlled setting, Network Rail has established a model for future projects, highlighting how proactive planning and the right monitoring tools can mitigate disruption. Sentry and MOKO’s real-time monitoring systems offered Network Rail a precise, actionable view of environmental impact, allowing them to make data-driven decisions long before reaching populated sites.

Discover more about this groundbreaking bridge structure and watch the project’s film here: Flow Bridge on YouTube.

Concrete & Piling Improvements for HS2

Project Overview

This case study details the deployment of the Sentry Camera System at the Beechwood and Poolwood sites on the HS2 project, managed by Balfour Beatty Vinci (BBV). The two-week deployment was initiated to address recurring delays in concrete delivery and piling operations at four key sites. These delays posed a risk to the project’s timeline and budget, with potential knock-on effects on critical follow-on tasks, including structural construction and the development of embankments and cuttings.

Challenges Encountered

Programme Delays in Piling Operations: Delays at several piling sites had led to significant setbacks, with one location losing up to a day of progress each week. This loss represented around 20% of planned productivity, jeopardising project timelines and risking potential months of delay. The primary causes were inefficient sequencing of piling activities and inconsistencies in concrete delivery, which left piling machines idle and exposed drilled holes to the risk of rain damage.

Concrete Delivery Delays: Interruptions in concrete delivery not only slowed piling but also risked penalties from suppliers due to vehicle delays. Coordination between concrete batching plants and construction sites was inconsistent, contributing further to timing issues.

Supplier Cooperation: While piling teams were cooperative, responses from concrete suppliers varied. Some suppliers obstructed monitoring efforts by parking vehicles in camera view, preventing clear tracking of deliveries and on-site processes.

Solutions Implemented

Sentry Camera System Deployment: The Sentry Camera System was positioned at key locations to monitor concrete delivery and piling operations. Cameras tracked concrete delivery sequences, the duration of on-site washouts, and on-site times for each concrete wagon. Additional cameras recorded the number of piles drilled, sequenced piling operations, and captured travel times from batching plants to the sites.

Identification of Core Issues: Analysis of the Sentry footage enabled the BBV Lean Team to identify inefficient sequencing in piling as a primary issue. Movements of piling machines were not well-coordinated, leading to delays as machines often waited for concrete to set before progressing. Additionally, it was necessary to drill holes according to immediate demand to prevent rain-related compromises overnight.

Introduction of Concrete Agitators: A significant recommendation from the Sentry deployment was to introduce concrete agitators on-site. These agitators allowed concrete to be delivered and held until required, reducing waiting times for delivery vehicles and enabling drilled holes to be filled immediately. This solution mitigated rain risks, enhanced efficiency, and streamlined operations.

Results and Key Takeaways

Improvement in Concrete Delivery and Piling Operations: The deployment achieved a 20% improvement in concrete delivery times and a 30% improvement in piling operations across the sites. By optimising the sequence of drilling and delivery, the team regained lost time, enabling the project to return to schedule and reducing the risk of further delays.

Avoidance of Penalties and Enhanced Supplier Relations: More efficient delivery coordination helped avoid penalties from suppliers due to vehicle delays. Although supplier cooperation varied, Sentry system insights enabled BBV to manage relationships effectively, reducing disruptions and improving communication with suppliers.

Recognition and Innovation Awards: The success of the Sentry deployment received industry-wide recognition. It was shortlisted for an innovation award at the National Construction Awards and included in a group of innovations that received a judge’s award at the Tech Fest Awards hosted by the New Civil Engineer (NCE). This recognition underscored the impact of innovative technology on complex infrastructure projects like HS2.

Long-term Benefits: Insights and improvements from this short deployment will have lasting benefits. By streamlining delivery and piling processes, the team ensured that future works could progress without similar delays, enhancing overall productivity on the HS2 project.

Conclusion

The deployment of the Sentry Camera System at the Beechwood and Poolwood sites demonstrates the power of technology and innovation in resolving complex challenges on major infrastructure projects. Through real-time data and detailed analysis, Sentry enabled Balfour Beatty Vinci to identify and address key issues in concrete delivery and piling operations, resulting in substantial time savings and productivity improvements. This deployment not only mitigated immediate risks of delay but also provided valuable insights to benefit future HS2 phases.

Protecting Residents and support our clients at Haywards Heath

Project Overview

Network Rail commissioned the Haywards Heath project to conduct essential geotechnical works over two weeks. The primary objectives were to clear dense vegetation from the railway cutting and stabilise the embankment to prevent soil movement, which could disrupt railway operations and potentially threaten nearby homes. This involved vegetation clearance and implementing pinning and sheeting on the cutting to reduce landslip risk, ensuring safety for both the railway line and adjacent residential properties.

Challenges Encountered

Dense Vegetation and Cutting Instability: The cutting had become heavily overgrown, with branches encroaching dangerously close to the railway. Signs of embankment instability increased the risk of collapse, which would not only disrupt railway operations but also endanger nearby residential properties. A landslip could result in soil spilling onto the railway line or into the gardens of nearby homes, raising significant safety concerns for residents.

Environmental and Safety Considerations: Due to the cutting’s proximity to residential areas, safety and environmental impacts were critical concerns. The team needed to prevent any potential slope collapse from encroaching on local gardens and homes, and the work had to meet strict environmental guidelines, particularly with regard to noise, to minimise disruption to residents.

Noise Restrictions and Environmental Health Officer (EHO) Standards: Scheduled for Easter to reduce commuter disruption, the project had to manage noise carefully, as many residents would likely be at home. The local EHO imposed a stringent noise limit of 60dBA Leq after 11 PM, so restrictive that even simple on-site conversations could breach it. This created a significant challenge in completing the works efficiently.

Solutions Implemented

Vegetation Clearance and Embankment Reinforcement: The project team carefully cleared the overgrown vegetation, allowing access to the cutting. Once accessible, they stabilised the embankment using pinning and sheeting to reinforce the slope, mitigating the risk of landslip. This approach ensured the railway line and surrounding residential areas remained secure.

Collaborative Efforts with Local Authorities: AWE collaborated closely with the local EHO to set realistic noise limits, presenting a case for manageable noise thresholds that still protected residents' comfort. This proactive negotiation allowed the project to proceed within revised noise guidelines, balancing efficiency with local regulations.

Innovative Noise Monitoring Using Sentry Cameras: To adhere to noise regulations, AWE deployed Sentry Cameras on the opposite side of the railway, positioned halfway between the cutting and the residential properties. This setup enabled real-time noise monitoring, capturing data at property boundaries and allowing site management to receive alerts if levels approached the threshold. This setup not only maintained compliance but also minimised disturbances for local residents, ensuring the project could continue without delays.

Results and Key Takeaways

Successful Project Completion: The project achieved its objectives within the planned two-week period. The cutting was stabilised effectively, with the reinforced embankment significantly reducing the risk of landslip, ensuring safety for the railway line and nearby homes.

Efficient Noise Management: Through effective negotiation and the use of advanced noise monitoring technology, AWE adhered to noise regulations while maintaining efficient workflows. The Sentry Cameras allowed the team to manage noise proactively, providing a model for balancing regulatory requirements with operational efficiency on future projects.

Collaboration and Proactive Problem-Solving: This project underscored the importance of collaboration among contractors, local authorities, and environmental health officers. By engaging in proactive problem-solving and advocating for achievable standards, AWE successfully implemented practical solutions that benefitted all stakeholders.

The Haywards Heath project exemplifies the value of careful planning, negotiation, and innovative technology in managing complex geotechnical works in sensitive residential settings. This case study demonstrates how projects in proximity to communities can achieve safety, compliance, and efficiency, setting a strong example for future infrastructure projects where environmental and public safety concerns are critical.

Our Proudest Moment...protecting sick children at Newington Cutting...in ALL weathers

Introduction

In January 2021, an emergency landslip occurred at Newington Cutting, Kent, resulting in 2,000 tonnes of soil collapsing onto the railway line. This significant disruption prompted an urgent response from Network Rail and Balfour Beatty Rail, who faced the challenge of restoring rail operations swiftly to avoid extensive delays and safety hazards.

Project Overview

Client: Balfour Beatty Rail and Network Rail
Location: Newington Cutting, Kent, UK
Project Duration: 2 weeks
Notice Period for Sentry System Deployment: 1 day

The cutting's instability required immediate action. Network Rail and Balfour Beatty initially attempted temporary stabilisation using bags of ballast. However, it became clear that a permanent solution was necessary as the cutting continued to shift. Thus, Balfour Beatty opted for a rapid deployment of The Sentry System to provide comprehensive monitoring and support during the repair works.

Implementation

The Sentry System, known for its advanced monitoring capabilities, was deployed with just one day’s notice. Its role was crucial in offering a live view of the ongoing repair works and in monitoring various environmental factors including noise, dust, temperature, pressure, and humidity. The deployment also encompassed drainage works, which were integral to preventing prolonged disruption.

To enhance the monitoring process, our ‘Aura’ Noise Monitor was placed 300 metres from the site, while ‘Moko’ Vibration Sensors were installed adjacent to the works. This setup allowed for simultaneous measurement of noise and vibration: when a pile was driven into the ground, Moko recorded the vibrations, and Aura measured the noise at a distance, ensuring comprehensive data on the impact of the repair operations.

Challenges

The project faced multiple challenges. The landslip had left the site with steep and slippery banks, making it difficult to find stable locations for the Sentry Cameras. Additionally, access to these areas was unprepared and hazardous, complicating the installation process. The project endured a range of weather conditions, from 80mph winds and heavy rain to bright sunny days and a final blizzard that damaged fencing. Despite these adverse conditions, The Sentry System remained operational throughout.

Community Impact

The site was in close proximity to sensitive areas, including local residences and Demelza Hospice for Children, located 600 metres away. The potential noise impact on the hospice, which cares for critically ill children, was a significant concern. To address this, the Aura Devices were strategically placed at mid-distance from the hospice, allowing for accurate noise level modelling without direct intrusion.

On the fifth day of operations, a noise complaint was received from local residents at 2 am. Using data from The Sentry System, it was confirmed that the noise levels at that time were not high enough to warrant concern. Further analysis showed that noise from a car in the hospice car park exceeded the noise from the repair works throughout the entire project.

Outcomes

The deployment of The Sentry System proved highly successful. It enabled site management to monitor the progress of the works in real-time, facilitating timely adjustments without the need for frequent site visits. The system also ensured minimal disruption to the local community and provided reassurance to vulnerable groups, including the children at Demelza Hospice.

Key Achievements:

• Swift and effective deployment with one day’s notice.

• Comprehensive environmental monitoring throughout diverse weather conditions.

• Effective noise and vibration management, protecting sensitive locations and addressing community concerns.

• Successful completion of essential repairs with minimal disruption to rail services and local residents.

This project exemplified our commitment to delivering essential infrastructure repairs while safeguarding community wellbeing. The successful integration of The Sentry System into this emergency response underscored its capability to manage complex, high-stakes scenarios efficiently.

Security and Efficiency at Bexley Emergency Bridge Repairs

Project Overview

In January, an emergency arose at Bexley in London when a derailed goods train carriage caused extensive damage to an aging bridge. Large portions of the bridge's steel structure were displaced, prompting immediate repair needs. With only one day's notice, the Sentry Camera System was rapidly deployed to monitor and support the bridge repair. The primary goals were to improve process efficiencies, enable remote management, and ensure site safety and security during these urgent repairs.

Challenges Encountered

Short Notice and Reactive Planning: Due to the emergency nature of the project, the repair plans were minimal and reactive. With limited time for detailed scheduling, the team relied on real-time insights from the Sentry System to make swift, on-the-fly decisions that would prevent delays and further structural issues.

Site Security Concerns: The exposed derailment site, along with the urgency of repairs, heightened the need for robust site security. With numerous workers and machinery present, it was essential to control access and monitor for any unauthorised entry to ensure safety.

Environmental Hazards: Dust disturbances posed health risks to workers and could impact the surrounding environment. It was vital to monitor dust levels continuously to maintain a safe workspace and promptly address any safety issues.

Solutions Implemented

Active Monitoring with the Sentry Camera System: Sentry cameras were strategically deployed across critical points of the bridge site, providing live monitoring that allowed remote managers to track progress and make necessary adjustments in real-time. This was invaluable given the project’s tight timeline and need for flexible programme management.

Real-Time Security Alerts: During the first week, the Sentry System detected an unexpected sequence of dust disturbances across the cameras, starting with Camera 1 at the site’s east end and progressing through Cameras 2, 3, and so on. This prompted the Sentry operator to alert the site manager, who verified that no authorised personnel were scheduled to be on-site at the time.

After investigating further with nearby station security footage, the team confirmed that two individuals had trespassed onto the site around 4 AM. Using the timestamps from the dust disturbances, the team estimated the trespassers’ walking speed and pinpointed their entry location. Network Rail quickly secured this access point, preventing further unauthorised entry and enhancing overall site security.

Enhanced Process Efficiencies: Sentry's continuous site coverage empowered the project management team to make informed decisions without needing to be physically present. This ability to remotely manage and adjust the programme led to efficient resource use and minimised delays. By facilitating real-time adjustments, the Sentry System ensured the project stayed on track despite the reactive nature of the initial plans.

Results and Key Takeaways

Improved Security and Safety: The Sentry System enhanced site monitoring and unexpectedly served as a security measure by detecting unauthorised entry through environmental changes, such as dust disturbances. This allowed for the prompt identification of trespassers, enabling Network Rail to secure vulnerable points and protect the worksite. This incident highlighted the potential of the Sentry System as a security tool.

Operational Efficiency: Real-time monitoring from the Sentry System facilitated swift decision-making, boosting operational efficiency. Remote management could oversee progress and make programme adjustments quickly, reducing downtime and improving workflow continuity during the emergency repairs.

Innovative Security Applications: The deployment revealed a new use for the Sentry System—detecting human presence through environmental changes. This capability opens up new applications for Sentry in remote or high-risk sites where traditional security methods might fall short.

Scalability for Future Projects: The success of the Sentry System in this emergency deployment underscores its potential for future infrastructure projects. Its flexibility, real-time monitoring, and security features make it an effective tool for managing urgent, complex operations.

Conclusion

The emergency deployment of the Sentry Camera System at the Bexley Bridge repair site demonstrated the value of real-time monitoring and remote management in critical infrastructure projects. By enabling swift decision-making, enhancing site security, and improving operational efficiency, the Sentry System played a vital role in the successful completion of the repairs. Additionally, its unexpected security applications suggest broader uses in safeguarding high-risk locations. The deployment not only addressed the immediate needs at Bexley but also established the Sentry System as a valuable asset for the construction and security industries.

Protecting Residents at Euston Station Piling Works

Project Overview: This case study examines the piling operations conducted at Euston Station as part of the infrastructure improvements for HS2 access. The works, managed by Colas Rail, Network Rail, and HS2, were essential for replacing the overhead line system at the west end of the station, which had reached the end of its operational life. The project spanned two weekends and involved the removal of existing support structures, deconstruction and cutting of these structures for removal by train, and the installation of new overhead line (OH) structures. Given the proximity of local residents to the site, noise and dust management were key concerns, leading to the deployment of the Sentry Camera System.

Challenges Encountered:

1. Noise Pollution During Piling Operations: The installation of new OH structures required driven piles to support them, which generated significant noise, particularly during the pile-driving process. One pile, located just 60 metres from a Sentry Camera, registered a noise level of 102dB(A) with each strike. This level of noise was a major concern for local residents, who were already complaining about the overnight preparatory works. Managing and mitigating this noise pollution was a critical challenge.

2. Environmental Compliance: The local Environmental Health Officer (EHO) had set strict noise and environmental limits, making compliance a top priority for the project team. Any breaches in these limits could result in fines, legal action, or project delays. The need for constant noise and dust monitoring was paramount to ensure that the site adhered to the environmental guidelines.

3. Resident Relations: Local residents had voiced concerns about the impact of the works, particularly the noise generated during the night. With a complex and busy site, maintaining a positive relationship with the community while minimising disruptions was a significant challenge.

Solutions Implemented:

1. Deployment of Sentry Camera System: The Sentry Camera System was strategically deployed to provide a live view of the works, with continuous noise and dust measurement. This real-time monitoring allowed the project team to ensure compliance with environmental limits and respond quickly to any issues that arose. The cameras were placed in four key locations around the site: one at the northern end of the works and three on the west side to protect the closest 'lineside neighbours'.

2. Proactive Engagement with Local EHO: On Sunday morning, the local EHO visited the site following a noise complaint from the previous night. The Sentry footage proved invaluable in this situation, as it clearly showed that no piling works were taking place at the time of the complaint. Instead, the cameras captured noise coming from a private members club adjacent to the site, where rowdy customers were disposing of waste bottles into a skip between 2 AM and 4 AM. This evidence not only helped avoid potential prosecution for noise breaches but also strengthened the project team's credibility with the local EHO and residents.

3. Post-Analysis for Future Improvements: Beyond compliance, the Sentry footage was used for post-analysis to identify efficiencies and improvements for future deployments. By reviewing the footage, the team could pinpoint areas for lean improvement, reducing downtime and enhancing the overall execution of the works.

Results and Key Takeaways:

1. Noise Compliance and Issue Resolution: The deployment of the Sentry Camera System successfully ensured compliance with environmental noise limits, despite the challenging nature of the piling operations. The real-time monitoring and ability to provide evidence during the EHO visit were crucial in resolving the noise complaint and avoiding penalties.

2. Improved Relations with Local Residents: The accurate and transparent monitoring of noise levels helped improve engagement with local residents. By addressing concerns promptly and providing clear evidence of compliance, the project team built trust with the community, which will be beneficial for future works in the area.

3. Lean Improvement in Operations: The post-analysis of the Sentry footage led to valuable insights into worksite efficiency. Identifying areas where time and resources could be saved contributed to a more streamlined approach for future operations, ultimately reducing the project's impact on the local environment and community.

4. Additional Benefits: The Sentry System provided benefits beyond noise compliance, including enhancing safety, documenting the worksite for future reference, and enabling better planning for subsequent projects. This multi-faceted approach demonstrated the system's value as a comprehensive tool for project management.

Conclusion:

The piling operations at Euston Station showcase the importance of proactive environmental management and community engagement in complex infrastructure projects. By deploying the Sentry Camera System, the project team successfully navigated the challenges of noise pollution and compliance, while also improving operational efficiency and resident relations. This case study highlights how technology can play a critical role in ensuring successful project delivery while minimising the impact on the surrounding community.

Saving Time for London Underground - Paddington

Project Overview

This project focused on replacing the concrete track and points at the entry to Paddington Station’s District Line platforms. Conducted over two weekends with a two-week gap in between, the objective was to renew aging points and crossings that had reached the end of their operational life. Track Partnership, a collaboration between London Underground and Balfour Beatty Rail, commissioned the project.

Challenges Encountered

Complexity of Track Replacement: The project required a phased approach—cutting into one half of the points during the first weekend, with completion scheduled for the second. This approach added complexity, as ensuring precise alignment between the new and existing track was crucial to avoid service disruptions.

Concrete Curing Requirements: To maintain safe operations, newly laid concrete needed a minimum of six hours to cure before train services could resume. Delays in curing risked over-runs, which were not acceptable to London Underground. During the first weekend, the project narrowly avoided an overrun, revealing a need for increased efficiency in the second phase.

Logistics of Concrete Delivery: The delivery method was innovative yet challenging. Concrete was transported from the roadway above Paddington Station through the ventilation shafts and laid directly in the tunnels, requiring tight coordination to ensure efficient delivery and proper curing.

Solutions Implemented

Sentry Cameras for Process Analysis and Improvement: The Sentry System, a video monitoring tool, was used to capture and analyse both above and below-ground operations. While underground, Sentry ran on the tunnel’s 110V power supply. Four cameras monitored the points and crossings replacement site, while two cameras above ground tracked concrete delivery to the tunnels.

Concrete Curing and Temperature Monitoring: New concrete thermometers accurately monitored curing progress, ensuring the concrete set properly within the required timeframe. This innovation helped prevent delays in returning the railway to operational status.

Efficiency Improvements from Video Analysis: Between the two weekends, the team analysed footage from Sentry Cameras, identifying inefficiencies in work movements and processes. Adjustments were made for the second weekend to streamline operations, reduce downtime, and improve overall efficiency.

Results and Key Takeaways

Timely Completion of Works: The first weekend’s work narrowly avoided overruns, with the handover completed only five minutes before the deadline. For the second weekend, the adjustments made from video analysis led to finishing four hours ahead of schedule, a significant improvement given the increased workload.

Additional Works of Opportunity: The time saved allowed the team to complete additional tasks within the same closure period. This reduced the need for future closures on the line, minimising disruption for commuters and generating additional income for Balfour Beatty Rail.

10% Program Time Savings: The project achieved a 10% reduction in total programme time, even before accounting for the extra works completed. This efficiency gain underscored the value of using innovative monitoring systems like Sentry to optimise work processes.

Client Satisfaction and Future Opportunities: Alistair McLoughlin, Head of Delivery at Track Partnership, praised the Sentry System’s role in transforming project delivery. The system offered valuable real-time insights that allowed the team to refine future projects and improve safety planning. Additionally, its “Safety Cam Mode” provided minute-by-minute details to enhance safety and enable thorough incident investigation. McLoughlin noted that Sentry’s deployment at Paddington Station saved four hours against the 52-hour planned schedule, showcasing its significant benefits for infrastructure projects.

Conclusion

The Paddington Station project exemplifies how innovative technology and detailed analysis can drive efficiency in complex railway works. By using the Sentry System to monitor and refine work processes, the team overcame challenges, completed the project ahead of schedule, and delivered long-term advantages for both the client and the public. This success highlights the potential for similar technology applications in future railway projects, setting a standard for efficient and safe project delivery.