Perforated Flooring and Balustrade Infill for a Train Station
Think Perforation, Think Graepels. Precision Perforation for Perfect Results
Graepels supplied durable perforated flooring and balustrade infill for the new pedestrian bridge and stairways at Woodbrook DART Station, delivering safety, weather resistance and a distinctive architectural finish.
Why Choose Graepels?
We have almost 70 years of experience across the UK and Ireland, with expertise in perforated metal, woven wire, metal fabrication, laser cutting, and ISO 9001 certified manufacturing.
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The Project at a Glance
The Client
The Project
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The Brief
The new pedestrian bridge and stairways at Woodbrook DART Station required a safe, durable and visually distinctive flooring solution capable of performing in a heavily trafficked outdoor railway environment. As a key pedestrian route crossing active rail lines, the structure is exposed to year-round weather conditions, including rain, frost, debris and heavy daily use.
The project presented several engineering challenges. The bridge incorporated a natural camber, requiring the flooring system to follow the geometry of the structure while maintaining a consistent walking surface. Effective drainage and debris clearance were critical to minimise slip risks and reduce maintenance requirements. The solution also needed to provide excellent corrosion resistance, long-term structural performance and clear visual definition on the stairways to support passenger safety and accessibility.
Graepels was tasked with developing a flooring system that would address these requirements while integrating seamlessly with the bridge design and supporting the long-term operational needs of the station.
The Solution
Graepels designed and manufactured a bespoke SafeDeck flooring system specifically engineered for the unique requirements of Woodbrook Station. The bridge deck was formed using custom cambered SafeDeck panels manufactured to follow the natural curve of the structure. This approach improved drainage by directing water towards either side of the bridge while reducing the need for transverse joints that could create maintenance issues or interrupt the appearance of the finished deck.
To further enhance performance, Graepels developed a project-specific 6-6 perforation pattern for the flooring and stair treads. The new pattern provided significantly greater open area than standard arrangements, improving water drainage and debris clearance while maintaining a comfortable and secure walking surface suitable for a wide range of footwear.
The flooring panels were manufactured from mild steel and hot-dip galvanised after fabrication, ensuring comprehensive corrosion protection across all perforated surfaces, folds and cut edges. The stairways incorporated specially developed perforated treads fitted with high-visibility yellow ColourGrip nosings. These nosings were designed as interchangeable components, allowing individual units to be recoated or replaced without removing the complete stair tread, simplifying future maintenance and reducing whole-life costs.
The ColourGrip system combines an e-coat, coloured powder coating and protective clear layer to provide excellent grip, durability and resistance to moisture, chemicals and abrasion while delivering a highly visible safety edge for passengers.
The Outcome
The completed installation delivers a high-performance flooring system that successfully combines safety, durability, maintainability and architectural integration. The custom cambered panels follow the bridge geometry precisely, creating a clean and continuous walking surface while improving drainage performance and reducing potential maintenance points.
Independent testing demonstrated the system’s exceptional slip resistance, achieving R13 and R11 classifications under DIN 51130, together with a V10 displacement-space rating. Pendulum testing recorded values of 93 in dry conditions and 71 in wet conditions, providing measurable evidence of the flooring’s suitability for demanding public environments.
The project-specific perforation pattern enhances drainage and debris clearance, helping to maintain a safe walking surface throughout the year. The interchangeable ColourGrip nosings provide a practical long-term maintenance solution, allowing high-wear components to be renewed independently, reducing waste, disruption and lifecycle costs.
Woodbrook Station demonstrates Graepels’ ability to combine product innovation, engineering expertise and manufacturing precision to solve complex infrastructure challenges. By adapting and enhancing the SafeDeck system to suit the bridge’s geometry, environmental conditions and operational requirements, Graepels delivered a dependable flooring solution that will support safe passenger movement and long-term infrastructure performance for years to come.