South Kensington – Escalator Replacement Civil Works

Project: South Kensington Escalator Replacement Civil Works

Client: TfL

Works Value: £690,000

D&D Rail Ltd were contracted to carry out works in preparation for the removal & replacement of the 5no. existing escalators providing access to the Piccadilly Line at South Kensington Station.

PRE-ROM WORKS

Prior to the commencement of the removal of the existing Escalators (ROM) we were instructed to install temporary propping & new steel columns and to form a new opening through reinforced concrete into the UMC of Escalators 4 & 5 and install a new steel fire door, which was fitted by our FIRAS trained operatives.  We were also instructed to fill existing ducts with concrete where the new escalators would place a load on the area concerned.  This was done using bagged concrete for escalators 1-3 that was delivered via engineering train.

The duct below the engineers’ steps at the side of Escalator 5 was filled with concrete which was pumped into the station.  The concrete was pumped from the road side in Pelham Street, over the Station wall and into the UMC through the new opening we had formed in the wall.  We applied for the relevant licences in advance of the pour via the council including Suspension of Parking Bays and a Mobile Plant Licence and provided traffic management during the concrete pour.

CIVILS WORKS

Following the removal of the escalators by others works commenced with the Demolition Phase.  The concrete motor bases in the Upper Machine Chambers were broken out due to size and configuration of the new escalators and the concrete incline walls in the machine chambers were reduced in height to suit the new escalators.  Waste was removed from site on engineering trains.

Following the removal of the concrete Motor Bases and the reduction of the Incline Walls we then demolished the upper & lower concourse slabs.

New openings were formed in the lower concourse walls at Escalators 4 & 5 for new Fire Doors and steel frame.  There was also a requirement to extend the length of the Incline Walls in Escalators 1-3.

Following the demolition phase we commenced the works for installation of the new support steelwork.

Escalator Support Steels were installed on the Inclines in the locations where we had previously saw cut pockets and cast slabs.

The steelwork was checked for line and level along with the off sets from the TFL datum’s and EWP’s during and on completion of each area. On completion of the erection in each Machine Chamber we arranged for Engineers to visit site and carry out a full survey of the steelwork using Theodolites/Total Stations and reported our findings to TFL.

Following on from the steelwork installation we installed holobrib and cast the new structural concrete slabs on the Upper and Lower Concourses.

We installed and tested floor and side mounted Pulling Points for use by others.

PREMISES WORK

Following the completion of the Civils work we were instructed to carry out part of the Premises Works.  This work was carried out in advance to give a clean, dust free environment for the delivery and installation of the new Escalators.

This work commenced with the thorough degreasing and cleaning of the machine chamber floors, the engineers’ steps and all cut concrete surfaces.  We then repaired holes in the Machine Chamber Floors and damaged steps and sealed all cut concrete surfaces along with the Engineers steps at the tunnel ring sides with an approved sealant.

The engineers’ steps, upper machine chamber floors and lower machine chamber floors were then painted.  The leading edge of the engineers’ steps was then coated with a yellow highlighted band.

LOWER CONCOURSE RESIN WORK

Towards the end of the Project it became apparent that the condition of the Lower Concourses floors was below the required standard.

TFL requested the assistance of D & D Rail in finding and laying an approved, non-slip, hard wearing floor suitable for application in a Section 12 London Underground Station. The solution would need to provide a practical and cost-effective runoff for their new Escalators.

D & D Rail proposed that the Lower Concourses be brought to the required standard by the application of Contar MMA Resin.  This proposal was accepted by TFL and at short notice D & D Rail agreed to supply and lay the MMA Resin on the Lower Concourses of Escalators 1-3 and 4 & 5.  Floor surfaces were prepared and repaired prior to the surfacing works.

Works were mobilised and completed within a week, and available for foot traffic at the end of each shift to minimise potential disruption to the station.

PRE-ROM WORKS:

DEMOLITION WORKS:
E123

E4-5

EXISTING STEEL REMOVAL WORKS:
E123

E4-5

ENGINEERING TRAINS:

CONCRETING:

E123 STEP EXTENSION:

STEELWORK & PERMANENT PROPPING:
E123

E4-5

HOLORIB INSTALLATION:
E123

E4-5

PREMISES WORK:

INCLINE STEPS PAINTING
E123

E4-5

INCLINE PLINTH SEALING:
E123

E4-5

FLOOR PAINTING:

E4-5

LOWER CONCOURSE RESIN WORKS:

E1-3 – Grinding & Preparing Floor Area:

E1-3 – Priming Floor Area:

E1-3 – Floor Area Prepared:

E1-3 – Applying Resin:

E4-5 – Grinding & Preparing Floor Area:

E4-5 – Applying Resin:

 

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