Signalling
Minimum Viable Product achieved by FLI gantries, with a 48% weight reduction and faster installation times from simpler foundations.
Reduced weight over older designs, for reduced cost.
With a virtuous circle of reductions in weight, enabling simplified foundations, resulting in further weight reduction. FLI's complete range of signal structures and screw pile foundations, developed as part of Network Rail's MVP intitiative, are delivering steel savings of up to 48% over legacy products.
These more efficient structures have simpler interfaces, resulting in shorter installation times.
No concrete is used in the screw pile foundations, which means only one possession for the entire structure. No excavation, no curing times, no problems with slopes or poor ground.
The elimination of concrete, less steel and a foundation as well as the superstructure that is 100% recyclable; gives a CO2 saving of over 70%*
* Lower CO2 and more sustainable foundations
Cambridge gantries, design, manufacture & install.
Challenges from a tight deadline and a crowded and shared site, were addressed by screw pile foundations, removing concrete from the project.
Design detailing prioritised installation speed, with lifting points, lifting beams and extensive RAMS.
Pre-assembly, light plant and no wet trades, provided a project resilience that enabled installation of foundations and gantries to be carried out within schedule, despite incomplete enabling works.
All three sites were completed within tolerance and within the planned timeframe.
Rail case studies
Maidenhead cantilever gantry, design and manufacture.
FLI Structures was contracted to design and manufacture a TTC with a span of 9m for Crossrail at Maidenhead. The structure incorporated a maintenance access walkway and access platforms. It supported two sets of signals, one in the dropper cage and one on the mast, all mounted on a rapid install FLI screw pile and grillage foundation.
Added Value:
FLI designed Easy-Fit dropper cage connection, allowing safer, faster and simpler install using less plant.
Hoisting points and levelling aids to assist install process.
Pre-assembled components minimising work at height and on-site labour.
Learning/Innovation:
FLI went back to basics with the entire superstructure to assist the client in achieving significant cost and programme efficiencies.
Blackpool, adjustable 2/3 track portal gantry on driven pile foundations.
FLI Structures was awarded the contract to design and manufacture an adjustable 2/3 track portal signal gantry for the NWEP at Blackpool. The 11m span structure supports one set of signals and stands on driven piles. It was designed to be versatile and offers a range of spans dropper heights using the same set of parts.
Added Value:
Friction clamp dropper connecons that can be positioned at any point along the boom.
Hoisting points and welded tabs to assist install, earthing and support of OLE return conductor.
Learning/Innovation:
We successfully produced a design that would provide a solution to complex needs at short notice.
Straight Signal Posts
Simple design reducing cost, mounted on a single screw pile, reducing time on site.
Maintenance Platform:
912mm, 1215mm or 1500mm
OLE Guard
Ladder & Anti Climb
Access Gate
Lightweight Signal Post
Mounted on a single screw pile.
Suitable for level & sloping sites.
Install several in a single shift.
Form 003 approved.
Screw piles remove the need for concrete foundations, are installed in minutes and can be removed or relocated just as quickly.
Screw Piles and H Piles
Steel foundations enable straightforward complete installations on sloping sites in a single shift. Screw piles can be installed with an RRV in poor ground and require no curing time. They meet sustainability criteria with a much lower carbon footprint than concrete and unlike driven piles, are easily recovered, delivering a 100% recycle rate.
Learn about Screw Piles
