Hemiko - KGJ Price Railway Contractors Ltd

“KGJ Price delivered a tightly controlled programme in a complex dockside rail environment, coordinating design, track works and utilities to the standards our scheme demands. Their planning, communication and on-site execution gave us confidence throughout.” – Robert Hughes – Hemiko Senior Project Manager

Client: Hemiko (Asset Owner on site: Associated British Ports – ABP)

Contract: Design & Build delivery of two under-track service crossings (UTX) at Cardiff Docks (adjacent to Clipper Road) to accommodate Cardiff Heat Network ducts, with interface to install additional electric ducts.

Duration: June–July 2025 (planned works window; completion July 2025)

Project Background

Hemiko appointed KGJ Price Railway Contractors to install two separate service crossings beneath operational dockside rail lines to enable district heating pipework and electrical duct routes as part of the Cardiff Heat Network. The works sit within a live industrial port operated by ABP, with rail movements and third-party operations in proximity.

The scope required full engineering management to Network Rail standards, including design assurance, track temporary works, excavation and installation of duct banks, track reinstatement, site set-up/security, and multi-party coordination (Hemiko, ABP, GGP Consult as designers, and HVSS for electric ducts).

Key Deliverables

Two under-track crossings (UTX) installed beneath separate lines, enabling heat network ducting and electric duct provisions.

Engineering leadership: CEM, CRE(C) and CRE(T) appointments; design integration and construction assurance to NR standards.

Safe work systems: permits (dig/hot works), ALO assessment where relevant, exclusion zones, DECT comms, daily briefings/POWRA, and banksman-controlled plant movements.

Track works: planned removal/reinstatement of rail/sleepers/check rails; joint support where required; compliance handback (A–G forms).

Quality & records: trench geometry, backfill layer control, compaction records, and inspection/test documentation.

Stakeholder management: ABP access and authorisations; Hemiko programme/reporting; GGP Consult (design); HVSS (electric ducts).

Project Statistics

Crossings: 2

Trench size (typical): ~ 2.8 m × 12 m each

Ducts: 355 mm OD track pipe (14TDE-U, ~24 m per UTX) + 150 mm NR-approved twin-wall ducts (~24 m per UTX)

Aggregates: ~ 40 t 10–14 mm pipe bedding; ~ 100 t Type 1A backfill

Controls: Permit to Dig; CAT/Genny; DECT comms; exclusion zones; hot-works permits (cutting/rail works)

People (core): SMSTS Site Manager; SSSTS Supervisor; COSS; Plant Operator (CPCS); 4 × PTS Operatives

Project Statistics

Project Management & Engineering Control: KGJ Price acted in line with NR/L2/OHS/0044 (Planning and Managing Construction Works) and NR/L2/RSE/02009 (Engineering Management), appointing a CEM, CRE (Civils) and CRE (Track) to manage design integration, construction sequencing, and compliance throughout.
Pre-Construction & Set-Up:
Dilapidation survey with ABP and Hemiko to baseline asset condition.
Establishment of mobile welfare (per NR/L3/INI/ CP0036), Heras security fencing, signage, pedestrian routes and exclusion zones at both
UTX locations.
Inductions/briefings: KGJ Price corporate induction; Hemiko/ABP site induction; daily POWRA, toolbox talks and COSS briefings (where applicable).
Track Modifications (per location): Clip removal, rail lifts and sleeper removal (approx. 4–5) to open the crossing footprint.
Temporary support to track joints (scaffold tube) where joint positions required protection.
Re-clipping/re-plating and level/alignment checks on reinstatement; completion of A–G forms by the track handback engineer.

UTX Construction: Permit to Dig and safe-dig controls (CAT4/Genny scanning in 150–300 mm increments; service plan review; no machine excavation within 500 mm of known services).
Trench footprint per crossing approx. 2.8 m wide × 12 m long with stepped sides to avoid temporary works supports.
Install duct banks with 600 mm separation between banks.
Bedding with 10–14 mm pipe bedding to 150 mm above highest pipe; warning tape; Type 1A backfill in 150 mm layers to underside of ballast; compaction per spec (e.g., 120 roller / five passes).
Ballast replacement/compaction and sleeper reinstatement prior to track re-assembly.
Utilities/Third-Party Interface:
HVSS installation of 2 no. electrical ducts per UTX within the same controlled works.
ABP permits to proceed/start work and adherence to local rules and access arrangements.
Coordination with GGP Consult on design clarifications and records, plus sign installation (ABP-provided signage) at each external corner of the UTX.
Close-Out & Demobilisation:
Joint inspection with Hemiko/ABP against the dilapidation record; removal of compounds, fencing, signage; as-built records and handback documentation.

Risk & Control Highlights

Buried Services: Safe dig regime (HSG47 principles), Permit to Dig, scanning every 150–300 mm, insulated tools near services, no machine within 500 mm of service.

Working Near Live Railway: Pre-planned SSOW, PICOS/COSS involvement, competency validation, protection briefings and communications protocol.

Plant/People Interface: 5 mph site limit, banksman-led movements, thumbs-up visual confirmation, defined yellow/orange/red exclusion zones, DECT comms.

Excavations: Daily competent inspections, stepped sides, pedestrian barriers 1 m back from edge, controlled access.

Hot Works/Noise/HAVS: Permits, fire watch and equipment, HPZs and hearing protection zones, HAVS monitoring and trigger-time recording.

Fatigue Management: Planned shift lengths, breaks, and duty time controls aligned to risk profile.

Collaboration & Communications

Daily coordination across Hemiko (Senior PM, Commercial), ABP (Civils Asset Manager), GGP Consult (Design) and HVSS (Electrical Ducts).

Briefings & registers each shift; COSS safety brief for on/near the line activity; mobile/lineside phones and DECT comms for controlled movements.

Hold Points enforced for inductions, sign-ins, daily/task briefings, permits to dig, lifting operations, and hot works.

Sustainability & Social Value

Optimised excavation footprints and backfill to minimise material movements.

Re-use of ballast where suitable and compliance-checked.

Local supply chain participation (plant, fencing, aggregates) to support regional economic value.

Clear segregation of wastes; licensed carriers and transfer documentation.

Project Outcome

The project enables critical enabling ducts for Hemiko’s Cardiff Heat Network by creating two compliant, durable UTX routes beneath operational rail within the Cardiff Docks estate. Despite the complex environment (dockside operations, live rail interfaces, service uncertainty), the works have been safely planned, executed to programme, and assured through Network Rail-aligned processes and ABP site control requirements.

Benefits delivered:
Resilient, future-proof service corridors for heat and electrical infrastructure.

Controlled rail disruption with efficient track removal/reinstatement and assured handback.

Reduced risk through rigorous safe-dig, plant control, and exclusion zone management.

Transparent stakeholder communications and auditable quality records.

Lessons Learned

Early joint dilapidation surveying de-risked close-out and protected stakeholder assets.

Temporary track joint support solution (scaffold tube) reduced risk and aided smoother reinstatement.

Standardised hold points and daily white-board briefings improved clarity and pace on multi-party shifts.

Integrating electric duct installation within the same controlled workface avoided future re-entries.