Overview
Kilnbridge was appointed by Skanska, on behalf of Network Rail, to deliver major structural works for the replacement of Clifton Bridge in Penrith, a key component of a significant infrastructure upgrade on the West Coast Main Line.
The programme required exceptional engineering precision, rigorous planning and close collaboration to ensure the new structure could be constructed safely and efficiently, while minimising disruption to both rail operations and the M6 motorway below.
Clifton Bridge is a vital crossing point for passenger and freight services, forming part of one of the UK’s busiest rail corridors. Network Rail’s upgrade programme required the removal of the ageing structure and its replacement with a modern, resilient bridge designed to meet long‑term operational demands.
Kilnbridge’s track record in complex reinforced concrete works and high‑risk infrastructure environments made the company a trusted delivery partner for this high‑profile scheme.
Prior to the demolition of the existing bridge, Kilnbridge’s scope focused on the construction of the new bridge, located adjacent to the original structure on the northbound carriageway of the M6. The works included the installation of reinforced concrete pad foundations to support the trestle system for the self‑propelled modular transporters (SPMTs), which were used to transport the 4,200‑tonne bridge into position with millimetre‑level precision.
The package also included extensive structural strengthening of the existing abutments and piers, together with the precision installation of 55 precast concrete deck units onto 130‑metre steelwork beam sections. These were completed with in‑situ concrete stitching and the installation of galvanised handrails to the edge of bridge.
This approach enabled the new 4,200‑tonne bridge to be fully assembled off‑site, allowing it to be transported, positioned and commissioned within a matter of days.
Following the demolition of the existing bridge over a single weekend possession, Kilnbridge immediately commenced the final structural works to the piers and abutments in preparation for the historic installation of the new bridge the following weekend.
Working within a critical 72‑hour window, the team undertook significant structural alterations to the existing ballast wall and installed new precast ballast wall sections. This was completed alongside the construction of new abutment and pier bearing plinths, designed to carry the full load of the new bridge.
Despite working in a demanding environment, in terms of proximity to a motorway and major rail line, and battling the worst of the British weather, Kilnbridge demonstrated its ability to deliver the construction of a large-scale steel and concrete structure with efficiency and accuracy.
The new bridge was moved into position during a nighttime possession, aligning exactly with the new piers and abutments, a reflection of the skill employed by Kilnbridge during the construction of the bridge elements.
Due to its location and time critical phasing, the project required exceptional coordination. Kilnbridge collaborated closely with Skanska, supply chain partners and Network Rail to maintain a unified approach to planning, sequencing and risk management with daily coordination briefings ensuring alignment across all teams.
All activities were sequenced around rail possession windows and motorway traffic management requirements, ensuring progress without unnecessary disruption. A key consideration was the weather, with cold weather affecting curing times of the bearing plinths and craning dependant on wind conditions.
Safety remained the project’s defining priority, with Kilnbridge playing a central role in sustaining a proactive, risk‑aware culture throughout the programme.
Outcome
The successful installation of the new Clifton Bridge demonstrates Kilnbridge’s capability in delivering complex, large‑scale structural works within demanding operational environments. The completed structure will enhance the resilience of the West Coast Main Line and support Network Rail’s long‑term infrastructure strategy.
Kilnbridge’s performance reinforced its reputation as a trusted partner for major contractors and infrastructure owners, delivering high‑quality engineering with precision, reliability and an unwavering commitment to safety.