Woodbrook Train Station (DART)

Engineered Safety and Durability and Whole-Life Performance

Woodbrook Station pedestrian bridge and steps required safe, durable and visually distinctive underfoot solution capable of performing in a heavily trafficked outdoor environment.

The bridge which extends over the railway tracks and provides an important pedestrian route through the station. As a public transport structure it is exposed to year-round weather, the flooring needed to remain safe in wet, cold and demanding conditions while also supporting the operational requirements.

The project required more than the supply of standard flooring panels. The bridge incorporated a natural camber, significant structural loading requirements and stairways where clear visual definition was essential.

Drainage, debris clearance, corrosion resistance, slip performance, manufacturing accuracy and future maintenance all had to be considered in great detail to work cohesively as part of one coordinated system.

Graepels responded by creating a new innovative surface pattern and and design in their flooring to meet the specific geometry and performance requirements of Woodbrook Station.

What was Built?

Graepels manufactured the perforated metal flooring used across the pedestrian bridge and stairways.

The main bridge deck was formed using custom cambered SafeDeck panels from the Graepels spike range. and New pattern which we created specifically for the project. Each panel was precision-engineered with a built in curve corresponding to the natural camber of the bridge.

The Stairway incorporated specially developed perforated steps with high visibility yellow ColourGrip nosings. These nosing's were designed as interchangeable components, allowing them to be removed for recoating or replacement without requiring the complete stair thread to be replaced.

The panels were manufactured from mild steel and hot-dip galvanised after manufacture. This provided a durable protective finish suitable for an exposed external application. The nosings received Graepels' three layer ColourGrip treatment, combining an e-coat, coloured powder coating and a protective clear layer.

Together, these elements created an integrated flooring system designed around safety, structural performance, drainage and long- term maintenance.

Key Challenges

One of the principal challenges was the shape of the bridge itself. The curve of the structure meant that conventional flat flooring panels would not have followed the bridge geometry correctly.

Using standard flat panels would have created alignment difficulties, uneven transitions or areas where rainwater might collect. Additional joints could also have been required across the deck width, potentially introducing maintenance points and disrupting the appearance of the finished bridge.

Water management was another major consideration. The bridge is fully exposed to rain, frost and changing weather conditions. Standing water on the walking surface would increase the risk of slips and could contribute to freezing during colder periods.

Leaves , dirt and other debris could also obstruct conventional openings. The flooring therefore needed to provide sufficient open area to allow water and debris to pass through without undermining structural performance or pedestrian comfort.

How the Challenges were solved

The bridge geometry was addressed through custom-cambered flooring panels. Each panel was manufactured with a built-in curve so that it followed the natural shape of the bridge.

This allowed rainwater to drain towards either side of the deck rather than gathering in the centre. It also reduced the requirement for transverse joints across the width of the bridge, creating a cleaner and more continuous walking surface.

The reduced number of joints lowered the potential for debris traps, water accumulation and future maintenance issues. It also improved the visual quality of the completed bridge by allowing the flooring to follow the structure rather than appearing as a series of disconnected flat sections.

Graepels also developed a project-specific 6-6 perforation pattern for the steps and flooring. This provided 44 per cent more surface opening per hole than the comparable standard arrangement, improving drainage and debris clearance.

The increased opening reduced the likelihood of clogging, particularly in an outdoor environment exposed to leaves, dirt and winter conditions. At the same time, the pattern retained a walking surface suitable for different types of footwear, including narrower heels.

Materials

The principal flooring panels were manufactured from mild steel - selected for its structural performance, manufacturing flexibility and the ability to be perforated and formed in the required profile.

After manufacture, the panels were hot-dip galvanised. Galvanising after perforation and fabrication ensured that the completed component, including cut edges, folds and perforated areas, received corrosion protection.

This was particularly important for an outdoor railway project, where the flooring is continuously exposed to moisture, changing temperatures and airborne contaminants.

The yellow stair nosings were protected using Graepels ColourGrip, a three-layer coating system. The first layer is an e-coat, followed by a coloured powder coating and a clear protective layer.

The coating provides colour, grip and resistance to moisture, corrosive agents, chemicals and abrasion. Unlike conventional decorative powder coatings that may reduce slip performance, ColourGrip was developed specifically for use with Graepels’ anti-slip flooring.

The bright yellow finish also acts as an important visual safety feature by clearly identifying each step edge.

Technical Excellence

The flooring system was designed to withstand significant structural loads without compromising drainage, durability or slip resistance.

SafeDeck achieves longitudinal stability through its formed profile, while its load capacity is influenced by material thickness, bend height, internal geometry, perforation and the selected material.

Slip performance was independently assessed. The system achieved R13 and R11 classifications under DIN 51130, together with a V10 displacement-space rating.

Pendulum testing to BS 7976-2 recorded a value of 93 in dry conditions and 71 in wet conditions. These results demonstrate a high level of slip resistance and provide measurable evidence of the flooring’s suitability for demanding pedestrian environments.

The orientation of the panels was also considered, with the preferred direction of travel positioned perpendicular to the length of the flooring plank to optimise walking performance.

- 950m Woven Wire Balustrade Infill

- 112m Graepels Spike

- 500m Special SafeDeck

- 40 Stair Treads Graepels ColourGrip®

Operational Excellence

Graepels brought together expertise across technical sales, product development, engineering, production planning, perforation, fabrication, quality control and logistics.

The project therefore represents more than the manufacture of individual components. It demonstrates the ability to translate a structural and operational brief into a repeatable production solution.

Careful planning and manufacturing control helped reduce the need for site alterations, supported efficient installation and ensured that the completed flooring performed as intended.

Innovation

The innovation at Woodbrook is practical and focused on solving real operational problems.

The cambered flooring panels integrated drainage into the structure of the walking surface. The project-specific perforation improved water and debris clearance, while the interchangeable ColourGrip nosings addressed future maintenance before wear became an issue.

Because nosings experience concentrated foot traffic, they are likely to require maintenance before the main stair structure. Making them removable allows the worn component to be recoated or replaced independently.

This reduces material waste, limits disruption and avoids the unnecessary replacement of complete stair treads. It is a simple but effective example of design for maintenance and whole-life value.

Woodbrook demonstrates why SafeDeck carries value beyond the product name. Its value comes from the engineering, tested performance, manufacturing control and attention to detail behind it.

Graepels did not simply supply flooring. The team developed a dependable solution around the bridge, its passengers and its future operation. The result is safer, more durable and more maintainable public infrastructure, supported by engineering that Graepels can confidently stand behind.