Case Study
Train Station, London
Core Details
SECTOR
DURATION
Contract Model
Challenges
- Bespoke manufacture and installation of three 500L calorifiers with immersion heaters within a highly constrained plantroom. Restricted access and limited space demanded a complete redesign of the layout to integrate pumps, de-stratification units, and fan connections within IP66-rated control panels. This required close collaboration with the control panel supplier to ensure all components were efficiently arranged and safely accessible.
- The complexity of the control systems also posed a significant challenge. The hot water generation setup included multiple immersion heater circuits, de-stratification pumps, and secondary hot water pump controls managed via timeclocks, switches, and safety interlocks. Calstan Mechanical worked closely with M&H Technical Services to refine panel designs, sequencing, and commissioning procedures to ensure safe and reliable operation.
- During installation, variations in sensor positioning and flush plate specifications prompted mid-project RFIs, leading to procurement and installation delays. These were mitigated through rapid design adjustments and prompt coordination with suppliers to maintain progress.
- Programme and access constraints at the busy Stainer Street section of London Bridge Station required phased works and meticulous logistical planning. and daily coordination to ensure safety, minimise disruption, and deliver the project to the required standard.
The Brief
The project involved the development of a new WC block at London Bridge Station, designed to accommodate the station’s high passenger volume. The facilities included male, female, accessible, and unisex cubicles, all built to deliver improved functionality and comfort within the busy transport hub.
Calstan Mechanical was appointed to deliver all mechanical and public health services (PHS) for the project. This included the full supply, installation, testing, and commissioning of ventilation ductwork and fans, hot and cold-water services, PHS infrastructure, and a complete plantroom installation—ensuring efficient, high-quality systems built for long-term reliability.
The Scope
The project works included the full provision and installation of new ventilation and water service systems to support the upgraded WC facilities at London Bridge Station. A new ventilation system was installed, comprising 600 x 600mm extract ductwork, twin extract fans, attenuators, and volume control dampers and grilles, designed to deliver a minimum of eight air changes per hour—ensuring odour control and maintaining a fresh internal environment.
Calstan Mechanical also supplied and installed all domestic hot and cold-water services, including 42mm boosted cold-water pipework, three 500-litre 36kW three-phase immersion tanks, and a complete plantroom installation with fully insulated pipework. Additionally, the works covered the installation of 35 WC units, urinals, wash hand basins, sink units, and specialist sensor-operated taps and soap dispensers for trough systems, along with all associated copper pipework and above-ground drainage.
The Outcome
Despite the spatial and technical challenges, Calstan Mechanical successfully delivered a fully coordinated plantroom and WC installation for this large Network Rail managed station, integrating bespoke calorifiers, advanced controls and public health services to specification.
The final system included automated sensor taps, soap dispensers and cistern controls, ensuring water efficiency and reduced maintenance. Ventilation achieved 8 air changes per hour, maintaining a fresh environment for high passenger volumes.
Close collaboration with suppliers, consultants, and subcontractors enabled successful problem resolution on RFIs and late design changes without impacting final delivery. Despite revisions to programme and scope, the project was commissioned, tested, and handed over within the specified budget, meeting all client requirements.
Client Feedback
Cem Davis, Network Rail station manager for London Bridge, said: “As part of our wider investment to modernise stations and give people a better experience, we are delighted to have opened the new toilets, which has almost doubled toilet capacity at the station.
“The new toilets include a mix of male and female facilities. New and roomier toilets have been installed for passengers with non-visible disabilities, and a new accessible toilet and baby changing facility is provided for people with impaired mobility, the elderly, and parents with children.
“The new facilities provide a much more pleasant experience for customers and have been designed to better meet the needs of all passengers at this busy station.~
“We were delighted to have them opened in time for the London Marathon.”
