Video: £35m flat-pack Crossrail station built in a year

Aaron Morby 7 years ago
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Laing O’Rourke has pulled off the construction of Crossrail’s Custom House station in just a year and a day using largely prefabricated off-site components.

Large sections of the station were manufactured at Laing O’Rourke’s facility in Steetley, near Sheffield and then transported more than 130 miles to east London and assembled on site.

The 825 station components were installed using a purpose-built 35 tonne gantry crane. The last section was installed a year and a day after the first piece went in.

The process of manufacturing large sections of the station offsite in pre-cast concrete significantly simplified the process of building the station, saving time, reducing disruption, improving quality and making the process safer.

Mujahid Khalid, Crossrail Project Manager at Custom House, said: “Piecing together the 825 sections that make up the station’s structure has been a bit like a giant jigsaw puzzle.

“It’s been impressive to see the building go up so quickly and efficiently and a lot of hard work has gone in from everyone on the project.

“Now the structure is complete, the focus will turn to fitting out the building with escalators, lifts and everything else to turn it into a fully operating station.”

When it opens in 2018, Custom House Crossrail station will be run by Transport for London as part of London’s integrated transport network. At peak time, 12 trains an hour will make it quicker and easier to get to a range of destinations across London.

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