Supporting Network Rail

to Deliver the Driffield Skerne Road
Mechanical Barrier Conversion

Client: Network Rail
Principal Contractor: Amey Rail
Location: Driffield, Hull to Seamer Line, North-East England
Sector: Rail Infrastructure – Signalling
Services Provided: Signalling Design (ES5), Technical Assurance, Consultancy Support
Project Duration: May 2024 – March 2025

Overview

Mosaic Rail partnered with Network Rail to deliver the Driffield Skerne Road Mechanical Barrier Conversion, a modernisation project aimed at improving safety, reliability, and maintainability on the Hull to Seamer route.

The works involve replacing an obsolete mechanical wheel-operated level crossing with a new HIMA HiMatrix® PLC Based Manually Controlled Barrier (MCB) system.

This scheme also supports Network Rail’s broader asset strategy by introducing strategic spares, modern safety equipment, and updated control interfaces, ensuring compliance with current standards and long-term operational resilience.

The Challenge

Driffield Skerne Road Level Crossing was controlled from Driffield Signal Box, which still operated via a mechanical 3-lever frame and barrier wheel dating back several decades.

Challenges included:

  • Replacing legacy mechanical systems with modern SIL4-rated safety PLC technology while maintaining full interlocking integrity.
  • Integrating new HIMA control systems into an existing Route Relay Interlocking (RRI) commissioned in 1986.
  • Managing space constraints within the relay room, requiring innovative location case design.
  • Addressing power supply limitations and ensuring adequate capacity for new electrical loads.
  • Delivering design and assurance to a tight programme aligned to a January 2025 commissioning window, minimising disruption to operations.

Our Approach

Mosaic Rail’s signalling design team produced the full ES5 detailed design in accordance with NR/L2/SIG/11201 (Signalling Design Handbook) and NR/L2/SIG/30035 (Scheme Approval Process).

Our structured and collaborative approach ensured that all works were safe, compliant, and buildable, with key activities including:
Detailed assessment and correlation of existing relay room records, resolving legacy discrepancies.
Production of comprehensive design deliverables covering scheme plans, control tables, power calculations, LCU design, and HiMatrix® system interface specifications.
Collaborative working with Amey Rail to define and assure the HIMA HiMatrix® integration, supported by Network Rail’s engineering and testing teams.
Application of CSM and CDM principles, embedding safety and maintainability into all design outputs.
Active participation in Interdisciplinary Design Checks (IDC/IDR) and Design Gateway Reviews, ensuring alignment with route engineering and Level Crossing Management teams.

The Solution

Mosaic Rail successfully delivered detailed signalling design solutions that enabled the safe conversion of the Driffield Skerne Road Level Crossing to a modern, power-operated HIMA HiMatrix® MCB system.

Scope included:

  • Installation of four new half-barriers, LED Road Traffic Lights (RTLs), and audible warning devices.
  • Provision of a new Crossing Control Unit (CCU) and Local Control Unit (LCU) for operation and maintenance control.
  • Implementation of a new HiMatrix® location case and interface circuitry to integrate with existing BR930 relay interlocking.
  • Upgrades to the power supply architecture following detailed loading assessments.
  • Introduction of Remote Condition Monitoring (RCM) via a new Omnilogger system, capturing barrier motor, temperature, and earth leakage data.
  • Addition of Train Stop System (TSS) at protecting signals D5 and D6 for enhanced safety protection.

All equipment installed was Network Rail-approved, meeting SIL4 safety integrity and product acceptance requirements.

Results & Impact

Through technical excellence and disciplined delivery, Mosaic Rail supported Network Rail in achieving a seamless transition from mechanical to digital operation, without compromising existing signalling integrity or operational safety.

Key Takeaways

Early collaboration between Mosaic Rail, Amey Rail, HIMA Sella and Network Rail ensured successful management of technical interfaces and constraints.
Proactive handling of Technical Queries (TQs) and Requests for Information (RFIs) mitigated design and programme risks.

Partner with Mosaic Rail for signalling design and assurance services that modernise infrastructure, enhance safety, and improve operational resilience across the UK rail network.

contact@mosaicrail.com
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Key Outcomes:

  • Safe removal of all mechanical crossing equipment and integration of modern MCB technology.
  • Enhanced system safety through SIL4-certified HiMatrix® PLC control.
  • Maintained operational reliability with minimal disruption during commissioning.
  • Improved maintainability via digital documentation, condition monitoring, and accessible equipment housings.
  • Supported Network Rail’s asset modernisation and resilience objectives across the Hull maintenance area.