Pipe Jacking Technology Enables Under-Track Crossing on Mainline Rail Upgrade
A drainage improvement scheme beneath a live mainline railway in North Yorkshire has demonstrated the effectiveness of precast concrete pipe jacking technology in delivering complex infrastructure works while maintaining operational rail services.
The project formed part of the Transpennine Route Upgrade, a major programme to increase capacity and improve reliability between Manchester and York. At Ulleskelf Mire near Tadcaster, new drainage tunnels were required beneath a four-track railway to replace 179-year-old brick arch structures located on a floodplain.
Working for Network Rail, the Transpennine Route Upgrade East Alliance appointed specialist contractor Active Tunnelling to undertake the trenchless installation. Three parallel tunnels, each 17.8 metres long and 1.8 metres in diameter, were constructed using microtunnelling techniques. Each tunnel was lined with reinforced precast concrete jacking pipes manufactured by FP McCann at its Alnwick facility.
Trenchless construction beneath operational rail
Maintaining railway operation throughout construction was a critical requirement. The trenchless pipe jacking method eliminated the need for open-cut excavation across the tracks, significantly reducing disruption to passengers and services while improving safety on site.
In a first-of-its-kind UK operation, three tunnel boring machines operated simultaneously side-by-side beneath the railway. The machines completed the drives in approximately 54 hours, removing around 615 tonnes of excavated material — substantially less than would have been generated using traditional trench excavation techniques.
Extensive preparatory works were required, including ground stabilisation and installation of concrete earth-retention structures, which also formed the launch and reception shafts for the tunnelling operation.
Performance of precast concrete jacking pipes
The precast concrete pipes were designed to withstand significant loading from the operational railway above during installation and in service. Their structural capacity and dimensional accuracy supported controlled jacking forces and ensured alignment throughout the drives.
The use of factory-manufactured precast concrete elements enabled rapid installation, predictable performance and minimal environmental disturbance within the sensitive floodplain environment.
Delivering infrastructure resilience
By combining microtunnelling techniques with precast concrete pipe systems, the project delivered a durable drainage solution while maintaining rail operations and reducing construction impact. The scheme illustrates the role precast concrete infrastructure components can play in enabling infrastructure upgrades within constrained operational corridors.