Chorley Rail Cutting
Chorley Tunnel South Rail Cutting Project
Scope
The cutting is located on the Chorley to Leyland line and is the southern approach to the tunnel. The cutting is formed in sand and clays that have suffered from slips and failures for many years that had the potential to disrupt the safe operation of the railway. As part of Network Rail’s Earthworks Asset Management Strategy, a contract was issued in 2022 to stabilise the cutting faces using a design for soil nails combined with erosion control meshing and to improve the slope drainage to cope with the changes to rainfall patterns.
The Challenge
The project followed several years of design development and extensive ground investigations before a stabilisation solution could be approved by the Principal Contractor and Network Rail.
Access presented a significant challenge, particularly on the Downside where much of the cutting had no suitable crest area for the safe operation of soil nail drilling plant. The proximity of OLE cables to the base of the slope further restricted working conditions, requiring key activities to be carefully planned around rail possessions and blockades.
With Vertical Access appointed after the Principal Contractor had already taken control of the site, the programme also required rapid mobilisation to ensure the stabilisation works could commence within the required timeframe.
Our Response
Vertical Access worked closely with Murphy to fast-track mobilisation and establish a coordinated programme of works around the available access, rail possessions and blockade periods.
A dedicated induction and training programme was implemented for all personnel, supported by daily briefings, lessons learned and safety stand-down days. To protect the operational railway and travelling public, Vertical Access also designed and installed a temporary catch fence during planned possessions and blockades.
The stabilisation programme included the installation of 1,850 soil nails ranging from five to seven metres in length, 160 Platipus Earth Anchors and approximately 10,000m² of Maccaferri MacMat R erosion control matting. Slope and base drainage systems, Platipus Plati-Drains and inclinometers were also installed to improve drainage and provide ongoing monitoring of ground conditions.
Permanent access improvements formed part of the works, including two sets of Evergrip GRP access steps, GRP and galvanised steel handrails and GRP retaining walls.
Working alongside Murphy, Vertical Access developed a comprehensive Inspection and Test Plan to manage quality throughout the installation. Live drill logs, grout cube results and soil nail test data were recorded through our app-based contract management system, providing project engineers with current information on ground conditions and allowing soil nail lengths and spacings to be adjusted as the design developed.
Restricted access to the Downside required detailed coordination of plant, personnel and Road Rail Vehicle operations. Primavera P6 was used to programme these activities around the available possession and blockade windows and integrate Vertical Access operations with Network Rail’s wider project schedule.
Outcome & Feedback
The project was extended from the original scope to include significant additional works including GRP handrails, access steps and extended work areas. Its successful delivery has stabilised a rail cutting that has been a risk for the railway for many years. And as mentioned prior, the project was recognised for its huge achievements by Network Rail, resulting in being awarded a ‘Pride in our Safety & Welfare Standards’ banner.
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