--- title: Bardon Quarry Level Crossing Upgrade url: "https://www.systra.com/ireland/project/bardon-quarry-level-crossing-upgrade/" type: projects date_published: 2025-10-20 date_modified: 2025-10-20 schema: @type: WebPage language: en-IE word_count: 883 reading_time: 5 min canonical: "https://www.systra.com/ireland/project/bardon-quarry-level-crossing-upgrade/" featured_image: "https://www.systra.com/ireland/wp-content/uploads/sites/24/2025/10/bardon-quarry-level-crossing.jpg" type-market: - Transport --- # Bardon Quarry Level Crossing Upgrade ### Quarry redevelopment requires NEW modern level crossing Aggregate Industries was developing its quarry at Bardon in Leicestershire to create the largest quarry in the UK. As part of this development, it needed to upgrade a level crossing over the A511 near Coalville, where the single-track railway line serving the quarry crossed the road. The existing crossing over the two-lane road featured no barriers and only flashing red lights to protect the public. This meant the railway corridor was not physically sealed off from the highway as trains passed through. In conjunction with the quarry developments, the road was due to be widened to three lanes, providing a dedicated right-hand turn into the quarry to ease traffic flows. This meant a significant upgrade to the level crossing was required to ensure the safety of all road users and to meet the standards set by the Office of Rail and Road (ORR). Aggregate Industries did not have the necessary level crossing expertise in-house and appointed SYSTRA to design all aspects of the upgraded crossing. The entire level crossing consultation, design, build and commissioning had to be completed within 18 months, to ensure the crossing was ready for the opening of the new quarry. ![bardon-quarry-level-crossing](https://www.systra.com/uk/wp-content/uploads/sites/11/2023/06/bardon-quarry-level-crossing.jpg) ### Collaboration creates bespoke level crossing solution One of the principal reasons for appointing SYSTRA to the project was the company’s multi-disciplinary expertise – covering all specialisms involved in level crossing design and delivery. Our project engineer liaised with the client and the ORR to understand the requirements and timescales. To achieve the challenging deadlines for completion, SYSTRA followed a proven Network Rail design process, but with a streamlined approach to ensure we delivered a lean yet safe design package on schedule. The design solution we proposed was a manually initiated Traincrew Operated Barrier level crossing. The operation of the level crossing was assessed from first principles, considering the human interaction with the control equipment, to provide a bespoke solution appropriate for Aggregate Industries as the level crossing owner, operator and maintainer. SYSTRA was able to draw on its excellent working relationship with the ORR to keep the department engaged and informed throughout the design process. This enabled us to develop acceptable design proposals, refine our proposed crossing control methods and ultimately gain acceptance from the ORR for the final proposals. ![](https://www.systra.com/uk/wp-content/uploads/sites/11/2024/09/bardon-cross-section1.png) Our level crossing design team also worked in partnership with Aggregate Industries and the ORR to gain buy-in from key stakeholders, such as the local council, throughout the design phase. This involved working with the highway designers, signalling designers and other third parties to share information and design knowledge so the construction and commissioning could be completed as seamlessly as possible. To minimise the risk of disruption during the construction phase, SYSTRA recommended that observation pits were first excavated at the site of the proposed foundations, to identify any obstructions. This ultimately proved a valuable intervention, as services and buried obstructions were found that had not been identified by ground penetrating RADAR surveys. This allowed the proposed foundations and equipment layout to be refined, prior to the main installation – avoiding unforeseen disruption during construction. ### Multi-disciplinary teams deliver detailed plans on schedule Completing all aspects of this level crossing scheme involved specialists from across SYSTRA. In addition to the Level Crossings team, we deployed experts from our Civil Engineering, Track, Electrical & Plant (E&P), Geotechnical, Site Services, Project Management and Project Engineering teams. Overall, we completed three phases of pre-construction work: - Assessing level crossing options to determine the optimum level crossing protection method and producing an Initial Ground Plan, which was used for early consultation with the ORR and other stakeholders. - Developing the Ground Plan into an Approval In Principle (AIP) design, using a streamlined design process and formal consultation with the ORR. - Progressing the AIP design into an ‘Approved for Construction’ (AFC) package to be used by Contractors to construct the crossing with ongoing formal consultation with the ORR. ![](https://www.systra.com/uk/wp-content/uploads/sites/11/2024/09/bardon-quarry-level-crossing-2-768x1024.jpg) ![](https://www.systra.com/uk/wp-content/uploads/sites/11/2024/09/bardon-quarry-level-crossing-3-768x1024.jpg) ### Modern, safer level crossing facilitates quarry expansion Our wide-ranging expertise and collaborative approach enabled us to complete the level crossing Ground Plan and all associated deliverables within the constrained project timescale. Our designs fulfilled all Client expectations and enabled the level crossing to be commissioned on schedule – in time for the new quarry opening. The result is a much-improved and far safer level crossing for road users and pedestrians on the busy A511. The new crossing has barriers to seal off the railway corridor when trains are passing, as well as modern LED traffic lights and a filter lane to reduce traffic delays when HGVs turn into the quarry. The improved level crossing enabled Aggregate Industries to develop the new quarry in line with its aspirations, bringing with it associated employment and economic benefits to the local community. [LEARN MORE ABOUT TECHNICAL SYSTEMS](https://www.systra.com/uk/services/technical-systems/) [Join our community](https://www.systra.com/ireland/register/join-our-community/)