Key Info
Project: Hayle Viaduct Restoration Works
Type of Service: Specialist Rail Access & Infrastructure
Location: Hayle, Cornwall
Client: Dyer & Butler
Main Contractor: Dyer & Butler
Completion Date: February 2015
Scope of Work: Complex scaffold access, temporary roofing, and encapsulation to support critical rail refurbishment works on a Grade II-listed viaduct.
Delivering Rail Access Solutions on a Historic Structure
In early 2015, Chris Sedgeman Scaffolding Ltd was appointed to support major refurbishment works on the Hayle Viaduct—one of Cornwall’s key railway crossings, originally constructed in 1852 and rebuilt in granite in 1886. Commissioned by infrastructure specialists Dyer & Butler, the project involved a full restoration of the viaduct’s upper structure, including the replacement of over 1,000 life-expired deck timbers, 4,500 rivets, and the renewal of the track, ballast, and handrails.
Given the structure’s heritage status and critical role within the region’s rail network, the scaffolding solution required precision, efficiency, and a high level of adaptability. The project was carried out under a strict six-week possession window, adding significant pressure to deliver without compromise on safety or quality.
Our Approach
The team designed and erected a 300-metre-long, 12-metre-wide, and 12-metre-high scaffold system using the versatile Plettac Contur system. Over 10,000 individual scaffold components were used, alongside 5,500 short boards and 1,000 plywood sheets. Six integrated access staircases ensured safe and efficient movement for contractors across the site, while a secondary birdcage scaffold allowed for focused works on the viaduct deck.
To support the replacement of the track and ballast, a bespoke rolling temporary roof was also installed. This structure, which could be moved along the length of the viaduct, enabled work to continue in poor weather conditions and allowed for approximately 25 metres of progress per shift. Erected and dismantled in just six days, the temporary roof played a crucial role in maintaining the tight programme timeline. Additional encapsulation works included full shrink-wrapping of the underside and sides of the viaduct to provide weather protection and containment for steel replacement and repainting.
Challenges and Coordination
The project presented several unique challenges. The viaduct itself curved over 10 metres along its length, requiring careful planning and adaptive design solutions. Access to the site was highly restricted, complicating the delivery of materials and necessitating efficient scheduling. Furthermore, the viaduct spanned three active public roads, which remained open throughout the works. Close coordination with local authorities and the use of stop/go boards ensured minimal disruption while maintaining public safety.
Despite these complexities, the scaffolding team—working in twelve-hour shifts—completed the main scaffold in just five weeks. Their ability to maintain pace while navigating logistical constraints exemplified the company’s commitment to safe, high-quality delivery.
Industry Recognition
Chris Sedgeman Scaffolding Ltd was recognised for its outstanding work on the Hayle Viaduct by winning Access & Scaffolding Specialist of the Year at the Construction News Specialist Awards 2015. This award reflects the technical expertise, planning, and execution that defined the project from start to finish.
A Landmark Achievement in Temporary Works
The Hayle Viaduct project remains a standout example of how innovative scaffolding can support essential infrastructure improvements while respecting the historic fabric of Cornwall’s built environment. It was a project that demanded speed, skill, and a collaborative spirit—qualities that remain at the heart of Chris Sedgeman Scaffolding’s operations today.