Transforming a live station through a coordinated offsite strategy
The £600m redevelopment of Birmingham New Street Station formed one of the largest refurbishment projects in Europe, transforming one of the UK’s busiest transport hubs while maintaining full operational continuity. NG Bailey’s Engineering division delivered key elements of the scheme, including the replacement of the station’s engine room, providing mechanical and electrical services across all 12 platforms.
Working within a live station environment, combined with significant structural and logistical constraints, required a fundamentally different approach to traditional installation. Early engagement enabled the development of a highly coordinated offsite manufacturing strategy, resulting in the creation of the ‘Spine’ — a 126m long, 8m wide and 3m high modular plant corridor integrating mechanical and electrical services within a single prefabricated system. Formed from 11 primary modules and five risers, the Spine weighed over 300 tonnes and became central to the project’s delivery strategy.
Overcoming structural and logistical constraints through engineering innovation
All modules were manufactured, assembled and tested off site in controlled factory conditions, improving quality and enabling a right-first-time installation approach. Building Information Modelling (BIM) played a key role in coordinating the design, supported by a detailed Bill of Materials that defined components, sequencing and logistics. Factory prototyping further reduced risk, ensuring each module arrived on site fully prepared for installation.
The delivery and installation strategy was equally critical. All works were carried out during night-time possessions to avoid disruption to station operations. Structural limitations presented a significant challenge, with individual modules weighing in excess of eight tonnes and floor loading limits restricted to 3.5kN/m². To overcome this, a bespoke installation methodology was developed using a temporary lattice track system, allowing modules to be manoeuvred into position before being lifted onto pre-installed steelwork. This enabled the safe and efficient installation of over 300 tonnes of services within a highly constrained, live environment.
Driving programme certainty, safety and operational continuity
The offsite approach delivered significant benefits, removing approximately 90% of site-based labour and enabling parallel working between manufacture and on-site activities. Installation of the modular Spine was completed in just three weeks, contributing to an overall programme reduction of eight months.
The approach also reduced vehicle movements to site by 80%, lowering congestion and environmental impact, while all works were delivered with zero accidents and no disruption to passengers or rail operations.
This project demonstrates how early contractor engagement, digital engineering and offsite manufacturing can be combined to overcome complex structural and logistical challenges, setting a benchmark for delivering large-scale infrastructure within live operational environments.
