Soho Depot – Modular GRP Walkway System for Rail Maintenance Depot

The challenge

A major rail operator required a GRP walkway system to provide safe access alongside trains within a busy maintenance depot. These train maintenance walkways would be used by depot personnel carrying out overnight servicing activities, including train cleaning, inspections, maintenance checks, and restocking onboard supplies.

In addition to pedestrian traffic, the client needed the walkways to support the movement of sand trolleys used to replenish locomotive and tram sandboxes. These mobile sand dispensing units carry significant loads when fully filled with traction sand, creating high point loads that had to be considered during the walkway design process. The client therefore required a robust GRP grating walkway capable of delivering long-term structural performance without compromising safety.

The project also presented a logistical challenge. To minimise installation time and disruption on site, the client requested a fully modular, pre-cut rail depot walkway system that could be installed quickly and efficiently. This required the design and manufacture of hundreds of bespoke walkway components, all tailored to the depot layout and supplied ready for installation.

Could we deliver a solution that combined strength, speed of installation, and long-term durability?

Our solution

Bespoke GRP Walkways for Rail Infrastructure

Working closely with the client, we designed and supplied a fully modular GRP walkway system engineered specifically for the train depot environment.

The solution utilised yellow GRP grating panels supported by GRP C channels and pedestal supports, creating a highly visible, slip-resistant surface suitable for daily maintenance operations. The bright yellow finish also helps improve visibility within the depot environment, contributing to overall site safety.

A key requirement was ensuring the walkway could safely support the high point loads generated by fully loaded sand trolleys. Our technical team carefully assessed the loading requirements and specified a GRP grating solution capable of accommodating both pedestrian traffic and operational equipment used throughout the depot.

To maximise installation efficiency, every grating panel, support beam, and structural component was manufactured to bespoke dimensions before leaving our facility. Hundreds of individual sections were cut and prepared in advance, eliminating the need for extensive alterations on site.

Each component was assigned a unique identification code and matched to detailed installation drawings. This modular approach enabled installers to quickly locate and position every section according to the design layout, significantly reducing installation time while helping ensure a smooth and accurate build process.

The result was a turnkey rail maintenance walkway system that combined strength, durability, and rapid installation with the long-term benefits of corrosion-resistant GRP materials.

The outcome

The completed GRP train maintenance walkway provides safe and efficient access throughout the depot, supporting a wide range of servicing activities including cleaning, inspections, maintenance, and replenishment operations.

By designing the system to withstand the demands of both pedestrian traffic and heavily loaded sand trolleys, we delivered a practical solution that meets the day-to-day operational requirements of a modern rail facility.

The client particularly valued the modular nature of the system. The pre-cut and pre-labelled components, combined with comprehensive installation drawings, enabled a faster installation programme and reduced the amount of labour required on site.

Today, the depot benefits from a durable, low-maintenance GRP walkway system that offers excellent slip resistance, high load-bearing performance, and long-term reliability. The project demonstrates how bespoke GRP grating walkways can provide an effective solution for demanding rail infrastructure environments where safety, efficiency, and durability are critical.