Jablite is the UK's largest producer of EPS products for insulation and civil engineering applications

Network Rail chooses Fillmaster


Network Rail needed to repair an old, failing viaduct outside Warrington that supports a railway line. |There were two key criteria that had to be met and these were to:

  • Avoid disrupting the train service that runs over the viaduct
  • Ensure the viaduct was safe for ongoing use during the repair works.

The solution chosen was to use Fillmaster under the Four Arches viaduct to support the structure so that it could continue its working life during and after the repair works.

Jablite’s in-house Civil Engineers worked closely with Network Rail and advised on the best design approach.

Job details
Client: Network Rail
Project: Repair of an old viaduct to extend its life
Site: Four Arches Viaduct carrying railway track near Warrington
Block Size: Bespoke designed blocks of varying sizes to fit the arches under the viaduct
Area of Void: 1400m³

Product details
Jablite Product: Fillmaster FM 500
Characteristics of Fillmaster: Robust Lightweight Designed-to-Fit Easy-to-Handle

The Solution

Jablite supplied Fillmaster 500 grade blocks designed and cut to fit exactly into the spaces under the archways. Once the work on site began, the precise design, cutting and shaping of the enormous blocks of Fillmaster by Jablite enabled a successful installation.

The design engineer sent the dimensions to Jablite and our in-house Civil Engineer designed the layout to provide the best-fit solution. The huge blocks of Fillmaster were cut to size and shape in the Jablite factory.

Each block was individually marked and delivered to the Four Arches site with detailed installation instructions describing how to fit the blocks together and the order they should be installed in.

The installation was smoothly carried out by Network Rail’s Civil Engineering Special Projects team with no need to bring in specialist contractors or equipment for the work and – importantly – with no interruption to the train service using that stretch of track.

Once the Fillmaster was installed the blocks were grouted in place using a concrete mix and the whole structure is now covered in earth.

The end result is the old viaduct is given a new lease of life without the need for demolition and the long-term disruption to the train service has been avoided.


Key Benefits

No disruption to the train service over the viaduct

Design and technical advice provided by Jablite in-house Civil Engineer

Blocks cut to size and numbered for an easy installation

Easy to handle and fast installation

No requirement for specialist contractors

No specialist PPE needed

Find out more about this project

or book a CPD

by contacting Darren Evans

07785 624 002