2022
Bamford,Derbyshire
Network Rail
Keller Group Plc
Mott MacDonald
Rockfall Protection for Rail Infrastructure Hope Valley Line Upgrade at Bamford
Soil nailing of the newly cut rock slope adjacent to the rail line.
Close up of MacMat HS30 P being installed on the rock slope.
Challenge
As part of a major rail infrastructure upgrade, Network Rail carried out significant improvements to the Manchester to Sheffield line through the Hope Valley. A key component of this project was the construction of a new railway loop near Bamford station, designed to allow faster passenger trains to overtake slower freight services and improve overall journey times.
The development of this new rail alignment required excavation into an existing rock slope located adjacent to the operational railway. This created a newly exposed rock face positioned in close proximity to both the existing and proposed rail lines. As a result, there was an increased risk of rockfall, posing a serious threat to train safety, track infrastructure, and service reliability.
To ensure long-term protection of the railway corridor, an effective rockfall protection system was required. The solution needed to provide both slope stabilisation and debris containment while being durable enough to withstand harsh environmental conditions over an extended design life.
Solution
To mitigate the risk of rockfall and stabilise the slope, project designer Mott MacDonald specified a soil-nailed rockfall protection system incorporating Maccaferri MacMat HS30 P. This high-performance drapery mesh system was selected for its ability to combine structural reinforcement with erosion control in a single, efficient installation.
MacMat HS30 P is a composite rockfall protection mesh that integrates Steelgrid HR30 P with MacMat erosion control matting. The steel reinforcement consists of double-twist rockfall netting combined with high tensile vertical wire ropes spaced at 300 mm intervals. This configuration delivers a tensile strength of 119 kN/m with low elongation of just 6%, ensuring effective containment of falling rock while maintaining structural integrity.
For enhanced durability, the steel mesh is manufactured with a Class A Zn-Al 5% galvanised coating and further protected by a 0.5 mm Polimac polymer coating. This advanced corrosion protection system provides a BBA-certified design life of over 120 years, making it ideal for long-term rail infrastructure projects in demanding environments.
A key advantage of MacMat HS30 P is its factory-integrated design. The erosion control mat is pre-attached to the steel mesh, eliminating the need for separate installation stages. This reduces installation time, improves efficiency on site, and ensures consistent performance across the entire slope surface.
The system was installed using crest ropes anchored with soil nails, while additional slope stabilisation was achieved through a defined soil nailing pattern. The mesh was supplied with purpose-designed HS links and rope grips, forming a complete and certified system in accordance with ETA n. 16/0758.
This integrated rockfall protection solution provides long-term safety for both rail operations and infrastructure, supporting the successful delivery of Network Rail’s Hope Valley upgrade and improving reliability along this key UK rail route.
The steel mesh is class A Zn-Al5% galvanized and then coated with an additional 0.5mm thick layer of Polimac high-performance polymer coating to give a BBA-certified design life in excess of 120 years in the harshest of environmental conditions.
The MacMat erosion protection matting is factory fitted to the steel mesh during production meaning only one application of material is required on the slope face rather than first installing an erosion mat, followed by a secondary installation of mesh.
The MacMat HS30 P was connected to the slope using crest ropes secured by soil nails and the face was also further stabilized with a soil nail pattern application. MacMat HS30 P mesh is supplied with specially designed HS links and rope grips to provide the contractor with a complete system approved under ETA n. 16/0758.
Used Products
