UK Rail Track Manufacturer, Installer & Repairs

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Whatley Quarry

Christmas Track Renewal

Client: Mendip Rail Limited
Contract: Plain Line Renewal – Line 1
Duration: Christmas Shutdown Period, 2025

Project Background

During routine weekly inspections undertaken by KGJ Price and Mendip Rail Inspectors at Whatley Quarry, Line 1 was identified as being in increasingly poor condition due to heavy freight traffic and aggregate spill. Components were damaged and track geometry was beginning to fail.

KGJ Price Track Engineers and Construction Managers carried out a high-level site survey to develop a suitable renewal strategy that would not compromise ongoing quarry operations. The works were programmed for delivery during the Christmas shutdown, a critical window to maintain safe loading of over four million tonnes of limestone per year.

Pre-Construction Collaboration

Working collaboratively with Mendip Rail, Heidelberg Quarry Managers, and plant partner Flannery, KGJ Price developed a robust, hour-by-hour programme to deliver the works safely and efficiently within the shutdown period.

Pre-construction activities included:

  • Full site survey and detailed track design
  • Coordination of access without disrupting freight operations
  • Population of an hour-by-hour programme using QSRA methodology
  • Full CDM documentation including Work Package Plans, Risk Assessments and Task Briefings
  • Site-specific inductions and D&A testing for all personnel
  • Engineering compliance planning under NR/L2/OHS/0044 and NR/L2/RSE/02009

KGJ Price’s in-house manufacturing, stock and logistics teams ensured all materials were sourced, prepared, and delivered in advance from head office in South Wales.

Materials supplied included:

  • 50 x new CEN56 rails (18.288m)
  • 680 x serviceable concrete sleepers
  • 1 x new adjustment switch
  • 440m geoseparator
  • 50 x thermit welds

Project Outcomes

All works were delivered on programme with no additional disruption to quarry operations or train movements. The renewed line restored operational integrity, ensuring the continued safe movement of freight and long-term performance of this critical asset.

This project demonstrated KGJ Price’s ability to combine engineering control, in-house manufacturing and logistics, and disciplined project delivery within high-risk, high-output industrial environments.

Project Statistics

  • 440m of plain line renewed
  • 1,620 hours delivered
  • 22 KGJ Price personnel deployed
  • 0 accidents, incidents, or near misses
  • 100% programme delivery

Project Outcome

All works were delivered on programme with no additional disruption to quarry operations or train movements. The renewed line restored operational integrity, ensuring the continued safe movement of freight and long-term performance of this critical asset.

This project demonstrated KGJ Price’s ability to combine engineering control, in-house manufacturing and logistics, and disciplined project delivery within high-risk, high-output industrial environments.