Crossrail C405 Paddington Station

Scope of works

Paddington Station was the first station to be awarded as part of the £14.8bn Crossrail programme and a key interchange with the existing Network Rail services at Paddington Mainline station and with the London Underground.

Kilnbridge were appointed by Costain Skanska to undertake the following packages:

• Manufacture and installation of 150 tonnes of structural steel in a Grade II Listed Building (Macmillan House), including Blast Load Analysis and decorative N17 paint finish to match existing heritage fabrication
• Manufacturing and installation of a steel support frame to hang from the concrete soffit and support the 3-tonne concrete smoke ducts, whilst also providing the main support for the platform edge screen
• Reduce the levels of the station diaphragm walls using specialist concrete-cutting techniques including plunge wire sawing, diamond drilling and bursting
• Supply and installation of passive fire protection to achieve a range of fire ratings from 1 to 4 hours

Challenges / Achievements

• At the time, this was the largest plunge wire sawing contract undertaken worldwide (370m²)
• Installation of 155 PES frames (circa 800kg each) and 310 precast smoke ducts using a bespoke manufactured mobile platform with scissor table and air skates.
• Design and methodology were heavily influenced by the Grade II listed heritage environment and received timely approval from English Heritage