HolcimUK Limited - KGJ Price Railway Contractors Ltd

Client:

Holcim UK Limited

Client: Holcim UK Limited

Contract: Replacement of Hand Points (Switches and Crossings)

Duration: 72-hour weekend rail closure

Project Background

Torr Works Quarry in Somerset is one of the UK’s most intensively used freight rail facilities, supporting the daily movement of aggregates across the national rail network. During routine weekly inspections, Mendip Rail Inspectors identified fatigue and deterioration within critical components of Hand Points 20 and 21.

Given the frequency of traffic movements and the operational importance of the quarry, Holcim required a robust, fast-tracked solution to mitigate risk, prevent unplanned asset failure, and maintain continuity of freight operations. KGJ Price Railway Contractors were appointed to deliver a complete design, manufacture, and installation package within a tightly controlled possession window.

Pre-Construction Collaboration

KGJ Price Railway Contractors worked in close partnership with the client during the pre-construction phase to develop a robust, well-planned delivery strategy. Early engagement allowed the project team to fully understand site constraints, operational requirements, and programme pressures, ensuring risks were identified and mitigated from the outset. Through collaborative planning, technical input, and clear communication, a safe, efficient, and buildable solution was agreed before works commenced on site. This proactive approach played a key role in the successful delivery of the project, supporting programme certainty, safety assurance, and overall quality outcomes.

Scope of Works

KGJ Price delivered a full turnkey solution, managing the project from initial engineering assessment through to final handback. The scope included:

Detailed site surveys and condition assessments of the existing hand points
Engineering design and assurance for replacement assets
In-house manufacture of two new BV8 Switches and Crossings units
Manufacture and supply of all associated timber bearers, rails, and fittings
Proof-laying and pre-assembly of S&C units at KGJ Price’s Bedwas facility
Planning and execution of removal and replacement works during a 72-hour rail closure
Provision of qualified engineering management, supervision, and skilled labour
Final inspection, testing, and compliant handback to the client

All works were planned and managed in accordance with Network Rail standards, including NR/L2/OHS/0044 (Planning and Managing Construction Works) and NR/ L2/RSE/02009 (Engineering Management for Projects), with Contractors Responsible Engineers appointed for both Track and Civils disciplines.

Project Statistics

A key element of the project’s success was KGJ Price’s in-house manufacturing capability. By producing the new BV8 S&C units internally, the team was able to significantly reduce lead times, maintain full quality control, and respond quickly to programme constraints.

Two BV8 Switches and Crossings units were manufactured at KGJ Price’s Bedwas workshop
All timber bearers were selected, machined, drilled, and treated in-house
Rails, panels, and fittings were sourced from accredited RISQS suppliers and inspected on arrival
Full proof-laying was completed prior to delivery, allowing installation risks to be minimised
Components were pre-assembled and quality assured to enable rapid installation during possession

This approach reduced traditional supply chain delays by over 10 weeks and ensured that all materials arrived on site ready for immediate installation.

Project Statistics

2 × BV8 Switches and Crossings units manufactured and installed
Over 1,600 working hours completed
22 KGJ Price personnel deployed
100% of S&C units manufactured in-house
0 accidents, incidents, or safety infringements
Works completed 8 hours ahead of schedule

Project Outcome

The successful delivery of the hand points renewal significantly reduced asset risk at Torr Works Quarry and ensured the continued safe operation of a critical freight interface.

By combining in-house manufacturing, experienced project management, and specialist installation teams, KGJ Price delivered a high-quality solution that met Holcim’s operational, safety, and programme requirements.

The project demonstrated KGJ Price’s capability to deliver complex S&C renewals in demanding industrial environments while maintaining full compliance, quality, and programme certainty.