OnSite Rail was contracted by Forestry, Rail & Civils Ltd (FRC) to complete UV lining works on a pipe underneath Cardiff Airport.
A pipe running underneath the airport taxiway had started to crack and break under the weight of the aircrafts and required strengthening.
Scope of works
OnSite was called upon for its UV lining expertise which was an ideal solution to strengthen the pipes using no-dig technology. The 32m and 30m liners were designed to a thickness of 9.2mm to allow for aeroplane loading.
To access the pipe, the six-man team had to carry out confined space entry to a manhole on the site. To prepare for the lining installation, the team jet cleaned the pipe to remove concrete and scale before the lay-flat liner was pulled through the pipe using an electric winch. Once the liner was in place, end caps were installed and the liner was inflated and cured with UV lights, creating a reinforced and durable pipe.
Challenges
The work took place during periods of downtime at the airport to allow the team to access the taxiway safely. The team had to work to strict timescales to get the job completed during these periods.
The weight and thickness of the liner was challenging to work with, and the team attending needed to collaborate effectively to deliver the work safely. This included communicating frequently with each other and the client, holding relevant certificates in confined space entry, setting up equipment efficiently on site and wearing the correct personal protective equipment (PPE).
Outcome
The work on site was completed successfully and to a high standard in eight hours over a space of four days during the periods of airport downtime, using time outside of this to plan and prepare for the works.
Testimonials
I just wanted to pass on my thanks for the lining works that Onsite assisted FRC with at Cardiff Airport. The feedback received was brilliant and I really wanted to communicate that, and I would appreciate if you could pass this on to those involved.
I attended site on Tuesday night and on the previous CCTV shift and I was particularly impressed with Conor. His attitude and work ethic were fantastic, and he was a pleasure to work with. The install team were the team from up North (Kev, Danny, Mike and Steve) and they were also fantastic. As soon as they got on site they got on with the task in hand, efficiently and effectively. This was one of the strongest teams I have worked with, who all understood each other, looked after one another and really understood the meaning of teamwork.
Rachel Bampton, Business Development Manager, Forestry, Rail & Civils Ltd
It’s not often I take the time to write a note like this, but after visiting the Cardiff project this week and seeing your team in action, I felt it was well deserved. The lining team were exceptional. I honestly can’t recall seeing a team of this size working together so seamlessly. From the outset, they were a pleasure to deal with. Conor had everything under control — ensuring all preparations were completed before entering the airfield and maintaining clear, professional communication with our supervisors.
Once on site, the team knew exactly what to do. They set up safely and efficiently, using edge protection, plant nappies, safe access to lorries, confined space entry equipment, and the correct PPE — all without needing to be prompted.
Every member of the crew was approachable and took the time to explain each stage of the process. It was clear they took real pride in their work, which is something we don’t see often enough these days.
Please pass on my sincere thanks to the entire team. Their professionalism, attitude, and teamwork were a credit to your organisation.
Tom Jones, Director, Civicon (Cardiff Airport)
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