CASE STUDY: Site 18 London City Airport

Client: DLR / Principal Contractor Oversight

Duration: 22 July – 10 August 2025

Scope

• Delivery and installation of new 60ft rails and 9.144 Breather Blades & Track Components
• Replacement of a Structural Breather Switch Blades in Engineering Hours
• Welding programme (W1–W24), grinding, and ultrasonic testing & Visual Inspections
• Installation of clips, fishplates, Robels, clamps, and Netlon fencing
• Completion of clamp inspections, conductor survey, and PTD–LCA amber trolley run
• Site clearance, tool recovery, and safe handback
• Removal of redundant rail and scrap management

Outcomes

• 100% of rail installation and welding scope successfully delivered
• All welds ultrasonically inspected and Visually Inspected and passed
• All safety inspections (TCC, clamp, Conrail, UT, PTD–LCA survey) completed with no defects
• Scrap rail and debris safely removed, sites left tidy and clear
• Zero accidents or incidents recorded
• DLR confirmed acceptance following final amber trolley run

Challenges

• Due to the proximity of residents, noise management measures were implemented, including the distribution of noise letters and reinforcement of noise control through team briefings
• Specialist S&T support within tight timeframes proved a key challenge, alongside managing late possession handovers.
• Precise engineering setting out was required to avoid weld location creep caused by tight radii, including leads and lags
• Condensed working within tight timescales meant small plant and tooling calibration and compliance was a key challenge.