Selhurst Depot - Wheel Lathe Project

The Challenge

GTR Rail identified the need to replace its aging underground wheel lathe at Selhurst Depot, Europe’s largest and busiest rail depot. The existing lathe had reached the end of its service life, and the new installation had to meet the growing operational demands of the Gatwick Express service, which transports approximately 21 million passengers annually.

Objectives

  • Install a new tandem wheel lathe pit with an integrated inspection pit.

  • Minimise disruption to depot operations and Gatwick Express services.

  • Ensure strict environmental controls for noise, dust, and fumes during construction.

Challenges

  1. Access Restrictions: Selhurst Depot has a single access road that could not be blocked by construction traffic.

  2. Operational Continuity: Downtime had to be kept to an absolute minimum to maintain service reliability.

  3. Environmental Sensitivity: The work zone was adjacent to the paint shop and repair road, requiring stringent controls on noise, dust, and fumes.

Our Solution

RCA leveraged its extensive experience with wheel lathe projects to develop a comprehensive plan:

  • Installed a network of fume sensors and noise monitoring equipment.

  • Erected scaffolding with dust-suppression sheeting to protect sensitive areas.

  • Produced a detailed traffic management plan and a rolling two-week lookahead schedule to avoid conflicts with depot activities.

  • Utilised advanced 3D modelling for precise planning and execution.

The Result

RCA delivered a modern, efficient wheel lathe system that meets current and future demand. Additionally:

  • The project was completed within a 10 month timeframe.

  • Zero noise or dust complaints during construction.

  • No disruption to Gatwick Express operations

Key Takeaways

  • Early and detailed planning is critical for projects in high-traffic, operational environments.

  • Collaboration with depot management and use of advanced modelling tools can significantly reduce risk and downtime.

  • Environmental controls are essential for maintaining safety and operational integrity during construction.

  • Govia Thameslink Railway

  • London, England

  • Rail & Infrastructure

  • 2023-2024

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