Challenging convention through innovation to deliver a future-proof bridge within a live operational environment.
Client
Network Rail
Highlights
- Restored a historic bridge and extended asset life using durable, corrosion-resistant FFU waybeams
- Delivered a lean, buildable solution by challenging prescriptive standards
- Enabled faster installation and reduced possession risk through modular detailing and simplified connections
Originally built in 1845, Codshead bridge featured a timber track support system that had significantly degraded due to age and exposure, leading to twist faults and track alignment issues. BakerHicks was appointed to lead the design from GRIP 3 through to construction close-out, with full responsibility for design development, technical assurance and construction support.
To deliver a resilient, low-maintenance solution within a possession-constrained site, BakerHicks proposed Fibre-Reinforced Foamed Urethane (FFU) longitudinal waybeams - a synthetic, high-performance material offering long-term durability with minimal lifecycle costs.
A detailed engineering appraisal, including scenario testing and structural modelling, addressed concerns around lateral bearing stresses without resorting to unnecessary reinforcement. Bespoke interlocking joints were used to connect the FFU members, eliminating the need for tie-bars or traditional hook bolts. The team also designed and checked various temporary works packages required to safely install the FFU system.
