Supporting Aureos
To Deliver the Sherburn in Elmet Level Crossing Life Extension
Client: Aureos Infrastructure Management Services
End Client: Network Rail
Location: Sherburn in Elmet (ELR: NOC, 12m 69ch)
Sector: Rail Infrastructure – Signalling
Services Provided: Signalling Development Design, Detailed Design, Technical Assurance and Supporting Consultancy expertise.
Project Duration: January 2025 – May 2025
Overview
Mosaic Rail partnered with Aureos to support the Sherburn in Elmet Level Crossing Life Extension, a targeted renewal project designed to extend the operational life of signalling assets while maintaining the existing level of safety and functionality.
Sherburn in Elmet is Level Crossing is a unique Manually Controlled Barrier, supervised by CCTV from Milford Signal Box at Sherburn in Elmet Station. Although vehicular access was removed and the through road closed following construction of a bypass in 1993, the crossing has continued to operate with vehicle road traffic lights and barriers but for pedestrians and cyclists. The crossing is fully interlocked with the signalling system.
This project aimed to replace life-expired barrier equipment with modern equivalent, ensuring continued safe and reliable operation in line with Network Rail’s asset management and renewal strategy.
The Challenge
Much of the existing equipment at Sherburn in Elmet was approaching the end of its design life, with the Route Infrastructure Inspection identifying several key components, particularly the barrier mechanisms, as priority renewal items given their increased rate of failure and lack of available spare components.
The challenge was to deliver a like-for-like renewal using modern, approved technology integrating with the existing vintage circuitry while maintaining system integrity, safety assurance, and continuity of operations.
Additional complexities included:
- Managing non-standard site history following partial decommissioning of two redundant barriers and road traffic lights whilst circuitry remaining within the equipment room was of a legacy vintage.
- Ensuring rail operations and CCTV could be maintained whilst the crossing was closed to the public during the construction period integrity remained unaffected during works.
- Delivering to a tight programme aligned with the planned July 2025 commissioning window.
Our Approach
Mosaic Rail’s signalling design team delivered the full ES4/ES5 design stage in accordance with NR/L2/SIG/11201 (Signalling Design Handbook) and NR/L2/SIG/30035 (Scheme Approval Process).
We collaborated closely with Aureos’ engineering and construction teams to ensure all works were technically compliant, practically buildable, and ready for safe commissioning.
Our approach included:
- Detailed assessment of existing signalling principles and assets, correlation of REB records and resolution of legacy discrepancies.
- Integration with overlapping work programmes to ensure safe integration and controlled amendments to the infrastructure.
- Production of comprehensive design deliverables covering scheme plans, control tables, location area plans, control panel design, power calculations and LCU design.
- Integration of safety, environmental, and occupational design requirements to ensure full compliance with CDM and CSM obligations.
- Active participation in Interdisciplinary Checks (IDC/IDR) and Design Gateway Reviews with Aureos, Network Rail, and the Route Engineering team including Level Crossing Managers.
The Solution
Mosaic Rail successfully delivered detailed signalling design solutions that supported Aureos in renewing the following assets at Sherburn in Elmet:
- Replacement of existing barrier machines with Siemens S60 barriers, including new skirts and LED boom lights.
- Provision of Pedestrian Stop Lights (Standing Red Man) at all four corners of the crossing.
- Installation Audible Warning Devices integrated with the pedestrian light circuits.
- Design and placement of a new Local Control Unit (LCU) in a position of safety, accessible without track access.
- Full recovery of redundant RTLs, cabling, signage, and Yodalarms, with new cabling routes and reflective roundels provided.
- Amendments to the Milford Signal Box panel to reflect the revised crossing layout and indication terminology.
All new and re-used equipment was type-approved and compliant with Network Rail standards, ensuring a consistent, maintainable, and safe installation.
Results & Impact
Through meticulous design and collaborative delivery, Mosaic Rail enabled Aureos and Network Rail to achieve a seamless transition from ageing legacy equipment to a modern, maintainable solution with no change to the interlocking or train operations.
Key Takeaways
- Targeted renewals can deliver significant asset life extension without operational disruption.
- Close collaboration between design, construction, and Network Rail assurance teams accelerates safe delivery.
- Mosaic Rail’s flexible delivery model supports Principal Contractors like Aureos with agile, high-quality signalling expertise.
Partner with Mosaic Rail for signalling design and assurance services that extend asset life, improve safety, and optimise renewals across the UK rail network.
contact@mosaicrail.com
www.mosaicrail.com
Key Outcomes:
- Renewed life-expired crossing equipment with modern, approved technology.
- Maintained operational safety and CCTV supervision integrity.
- Delivered ES4 -ES8 design and assurance to programme and quality standards.
- Reduced long-term maintenance costs and risk of asset failure.
- Strengthened client confidence through clear communication and design governance.
