Horbury Cutting | Rock Face Stabilisation
We were appointed to undertake extensive rock face stabilisation works
The Scope
Working alongside CML and Atkins engineers, Vertical Access was responsible for delivering a comprehensive rock face stabilisation programme to improve slope stability and reduce the risk of rockfall onto the operational railway.
Our scope included vegetation clearance, light and heavy rock scaling, installation and testing of rock anchors, and the installation of TECCO and Maccaferri rockfall netting.
Additional works included the removal of loose material, installation of key clamp fencing and construction of a Geobrugg rockfall catch fence.
Project Challenges
The proximity of the rock face to an operational railway presented significant access and safety challenges, requiring careful coordination to minimise disruption to rail services.
With residential properties neighbouring the cutting, managing the movement of materials, access equipment and construction activities was also an important consideration.
The varying conditions across the six work areas required tailored rope access and anchoring arrangements, whilst existing underground services introduced further restrictions on ground anchor installation.
The complex geological formation, weakened sandstone and presence of existing structures, including retaining walls and buttresses, introduced further design challenges. Due to restricted access and limited visibility of the rock face, the final stabilisation design could only be developed once works had commenced and vegetation clearance had exposed the underlying conditions. Close collaboration between Network Rail, CML, AtkinsRéalis and Vertical Access enabled the development of a comprehensive, integrated rock face stabilisation design package.
Works were coordinated across daytime, nighttime and weekend shifts, including planned railway possessions and blockades to facilitate activities close to the operational tracks.
Our Response | Full Rock Face Stabilisation Programme
1. Rope Access and Safe Working Systems
Vertical Access established specialist rope access systems across the six sections of the cutting, enabling operatives to safely access the rock face for inspection, clearance and stabilisation works.
Under the supervision of IRATA Level 3 operatives, suitable access anchors were selected according to each area's ground conditions and available infrastructure. These included ground stakes, temporary grouted anchors, crest anchors and suitable existing structures.
Where ground installations were required, permits to dig were implemented to account for existing underground services.
Rope systems were carefully managed to prevent interference with passing trains, with access arrangements inspected by IRATA Level 3 operatives throughout the project.
2. Vegetation Clearance and Rock Scaling
Initial vegetation clearance was undertaken to expose the rock face and provide access for detailed inspections by Atkins engineers.
Following inspection, our operatives carried out light and heavy scaling to remove loose and unstable rock material from the cutting.
Larger unstable features identified by the engineers were addressed using specialist breaking and splitting equipment, with dislodged material subsequently removed from the work areas.
This preparation enabled the safe progression of the rock anchoring and rockfall netting installation.
3. Rock Anchor Installation and Testing
Following the clearance and scaling works, Vertical Access undertook the installation of rock anchors and spot bolts to stabilise identified areas of the cutting.
Using specialist rock drilling equipment, our operatives installed the anchors in accordance with the project requirements and engineering specifications.
Anchor testing was undertaken to verify the performance of the installed systems, with results recorded through our live Digital Management System.
This provided CML and Network Rail with a traceable record of testing and quality assurance, supporting transparency throughout the stabilisation works.
4. Rockfall Netting and Catch Fence Installation
With the rock faces prepared and inspected, our operatives commenced the installation of TECCO and Maccaferri rockfall netting systems to secure vulnerable areas and reduce the risk of falling debris.
Suitable exclusion zones were established during installation, allowing the mesh systems to be positioned and secured across the designated sections of the cutting.
Further protection was provided through the installation of a Geobrugg RXE 500 rockfall catch fence, incorporating ground anchors, spiral rope anchors, structural uprights, supporting cables and protective mesh.
The fence uprights were installed during a planned railway possession, with subsequent cable and mesh installation completing the rockfall protection system.
Project Outcome and Feedback
Through detailed planning, specialist rope access techniques and close coordination with CML and Network Rail, Vertical Access successfully delivered the rock face stabilisation works across all six sections of Horbury Cutting.
The combined use of rock anchoring, scaling, rockfall netting and catch fencing provided a comprehensive stabilisation solution, securing identified rockfall hazards alongside the railway.
Both CML and Network Rail expressed satisfaction with the completed works, resulting in Vertical Access being appointed to undertake additional works around the rail cutting.
The project demonstrates our expertise in rock face stabilisation, railway cutting maintenance and geotechnical engineering, delivering tailored solutions to protect critical rail infrastructure and improve long-term slope stability.
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