Dura Composites Ltd

Non-Conductive, Anti-Slip Flooring and Walkways | Case StudyArena Events Group chose Dura Composites to supply the tiered structure stadium decking for the seating and platform areas, manufactured from our high quality and corrosion-resistant Glass Reinforced Polymer (GRP) Dura Slab 40 and 20 products which provided an anti-slip, fire-tested and load-tested alternative to the Buffalo® Board and traditional plywood used previously. Dura Composites’ ability to be able to meet a range of stringent test requirements including flare resistance tests and FEA analysis made us the ideal choice for this high profile project which not only allows for future changes to seating configurations, but also improves access to amenities on the concourse. The two types of Dura Slab used on this project are precision engineered GRP structural flooring systems that provide an incredible strength to weight ratio. High strength fibreglass composite is pultruded in one mass to produce a consistent quality flooring structure that is also non-corrosive, chemically resistant – and has an anti-slip walking surface.

GRP End of Platform Steps | Case StudyContractor AmcoGiffen selected Dura Composites to design and fabricate 6 sets of GRP End of Platform Steps for Kings Cross Station in London, which were installed by Amco in a very short time frame to meet the needs of the tight project timescales. Weighing up to 80% less than steel and 30% less than aluminium, Dura Composites End of Platform Steps offer equivalent performance for considerably less weight. This results in major savings including lower installation costs due to more economical transportation, handling and on-site positioning.The client was delighted with the quality of the design and workmanship and with Dura’s ability to turn the fabrications around in such a short space of time, describing the structures as having “gone in like a dream”. As well as fully fabricated non-corrosive and non-conductive single unit GRP end of platform steps Dura Composites can also supply in component or flat pack kit form ready for quick assembly on-site.

GRP Rail Station Platform - Mountbridge Install | Case StudyThe Island Line and its associated infrastructure on the Isle of Wight in the UK has recently been upgraded to offer a more frequent service and introduce a refurbished fleet of Class 484 trains. Key to the project was creating improved accessibility between the train and the station platform to allow the new trains to operate effectively. This was achieved by deploying GRP Dura Platform panels from Dura Composites in conjunction with the Mountbridge™ system from Hammond ecs ltd to raise the platform gauge by up to 400mm at 5 stations on the Island Line, including Ryde Pier Head.The patented 40mm Dura Platform solution (Patent No GB 2 523 381) has a span of 1.5m per 5kN/m2 UDL and delivers multiple benefits in terms of faster, safer and easier installation, reducing time on site, therefore reducing disruption to passengers, and providing major cost savings versus traditional materials such as concrete. The platform panels can accommodate fully integrated tactile recesses, illumination of the coper and integrated heating to remove frost & ice build up and reduce the future maintenance burden of the platforms.

Bespoke Access Structure | Case StudyThis two-level access structure with staircases, cladding, edge protection handrailing and anti-slip grating flooring was designed by Dura Composites in conjunction with our client ENGIE Fabricom UK, who provide engineering and construction services to sectors including renewables, oil and gas, power, chemical and energy from waste.With the ability to supply both composite timber cladding for the containers and all the required GRP elements for the project, Orsted chose to work with Dura Composites. Although steel had previously been considered, the rising cost of steel versus GRP and its tendency to corrode in coastal environments made composite materials a far more durable and cost-effective option.The resulting access structure is safe, looks attractive and is non-conductive and non-corrosive. With a long design life and 25 year warranty, the GRP components are part of the latest d² range from Dura Composites which offer safer, stronger, faster and proven properties.

Dura Grating Riser Installation | Case StudyShard Place is the third phase of the £3.5 billion redevelopment of the estate next to London Bridge station, known as Shard Quarter. Reinforced concrete frame and groundwork specialists Getjar were appointed as the formwork contractor by the principal contractor Mace and chose the Dura Composites Riser Install team to take on some of the complex install challenges of the service risers.Dura’s unrivalled expertise and full install capabilities meant they could deliver a bespoke solution for a large triangular shaped riser on all 26 storeys that required the use of galvanized steel supports and bracketing in conjunction with GRP Dura Grating to allow for cutouts to be performed whilst maintaining the integrity of the riser.

d² Dura Grating Mini Mesh, Dura Profile & Dura Platform 40 | Case StudyDura Composites was engaged by Premier Marinas to work with their engineering company to produce a composite floor structure around their travel hoist supported by large 305mm GRP Dura Profile beams between 6-10m in length. The team chose the GRP material over steel due to its superior performance in corrosive salt-water environments. Unique in the market, Dura Profiles exceed the higher performance E23 grade requirement of the BS EN 13706 standard.Also central to the efficient operation of the washdown and hoist are Dura Grating and Dura Platform 40 flooring made from moulded and pultruded high-performance GRP panels which are unique in design to Dura. The open mesh section utilises 55mm d2 Dura Grating Mini Mesh in dark grey, which facilitates drainage whilst maintaining strength and unrivalled anti-slip properties. The solid surface sections were created using patented d2 Dura Platform 40, which are crankable to create an in-built fall to aid water runoff.

GRP Rail Station Platform - Hybrid Install | Case StudyRobroyston station features two brand new platforms constructed using the Dura Composites recommended hybrid GRP and steel solution which is designed to meet the requirements of Network Rail standard NR/L3/CIV/030 and combines the strength of a steel foundation with a Glass Reinforced Polymer (GRP) Dura Platform surface. The platform surface has incredible durability and anti-slip properties which is shown to reduce by only 5% after a million footfalls (tested to BS 7976-2:2002+A1:2013).AmcoGiffen were responsible for delivering the design and build works for the development, with funding for the station coming from Glasgow City Council, Network Rail and the Strathclyde Partnership for Transport.In choosing the GRP/Steel system from Dura Composites, the platform installation for the project (using GRP Dura Platform and steel trestles) has been able to take place largely while the line is open, minimising the impact on customers using the line.

Dura Deck Flip® Composite Decking | Case StudyThe Lock at Greenford Quay is a development of 194 waterfront apartments, located in the London Borough of Ealing in West London. It features a beautifully landscaped garden with innovative seating areas and a stunning rooftop terrace with panoramic views.Landscape Architects and Environmental Planners Standerwick Land Design worked with landscape services specialists Valley Provincial to bring the new areas to life. With over 45 years’ experience, Valley Provincial has won multiple awards for its high-end commercial and residential projects.The company was responsible for the installation of Dura Composites’ Class Bfl fire-rated Dura Deck Flip decking and A2 fire-rated substructure system on the terrace and within the communal garden. Wanting to create a natural look and feel that enhanced the pretty waterside setting, but which met stringent safety protocols, Valley Provincial chose Dura Deck Flip in the Weathered Cedar and Pebble Grey colour pairing.

Composite Decking - Interlocking Dura Deck Tiles | Case StudyThe RHS Chelsea Flower Show is a renowned annual garden exhibition held for five days each year by the Royal Horticultural Society (RHS) in the grounds of the Royal Hospital Chelsea in Chelsea, London.Gorilla Carts and Kiosks were chosen to supply anti-slip modular flooring to enable safe access around the food courts. Using the innovative fast-fit interlocking Dura Deck Tile product designed and manufactured by Dura Composites, Gorilla Carts and Kiosks were able to quickly and easily install hundreds of square metres of outdoor flooring which provided clear demarcation of pedestrian standing and seating areas. Anti-slip, durable, and with an attractive woodgrain composite timber finish, the tiles interlock quickly and easily for set up and removal – and can be laid on virtually any existing hardstanding to create a simple decked area.

Dura Deck Flip® Composite Decking | Case StudyOver the past six years this Georgian property has been lovingly restored by Ciara and her husband Ben, including underpinning work to the foundations and a new roof.Journalist Ciara’s passion for the unique and creative really shone through in her design for her composite decking area. With a love for creamy based neutrals to complement the earthy red brick tones the house, she chose pretty Dura Deck Flip composite decking in the colour Weathered Cedar for the main decking area. UV resistance, scratch and stain resistant and with a Class C fire rating, it was installed on rot-free Dura Deck Aluminium pedestals and bearers for a low-maintenance ‘fit-and-forget’ decking solution.

Non-Conductive Fencing, Trench Covers and Access Structures | Case StudyPower and Energy Infrastructure Contractor Morgan Sindall was appointed to design, build and commission the new converter station and chose to work with Dura Composites to provide safe, non- metallic Glass Reinforced Polymer (GRP) utility fencing for the AC/DC Halls, as well as a range of non-conductive access structures, utility trench covers & handrailing across the site.The IFA2 project aims to connect the electricity systems of Great Britain and France using high voltage subsea cables and will be capable of exporting or importing 1000MW of power between the UK and France, enough to power up to 1 million homes. In this project, the client specification mandated the use of non-conductive and non-metallic materials which could be used to construct removable fencing, permanent fencing and sliding gates to enable access to specific authorised personnel, whilst preventing others from accessing high-risk areas.

d² Dura Grating Mini Mesh and Solid Top Raised Flooring | Case StudyNew Glass Reinforced Polymer (GRP) Mini Mesh and Solid Top d² Dura Grating is the ideal raised flooring solution for luxury car valeting centres, car workshops and other automotive facilities thanks to its lower cost, weight saving and improved visual inspection capability versus previous generation grating.The Dura Composites raised flooring solution is a full design and supply system, incorporating both the raised pedestals, floor grating and mounting system. The unique d² Dura Grating design also allows for improved visibility of the substructure below, offering a clear view of draining liquids from the valeting process from a much wider range of angles than were previously achievable.

Bath Spa Station is a Grade II* listed building built in 1840 by Isambard Kingdom Brunel with huge historical significance. It serves as Bath’s mainline station connecting to Bristol and London and services 3 million passengers each year. The existing timber station canopies on platforms 1, 2 and the station entrance were badly in need of repair due to extensive weathering and rotting.Dura customer MLG were appointed to replace the canopies and chose us to 3D laser scan the station so that we could create an exact replica of the heritage design that is such an iconic feature of the station.Once the scan had been completed, we were able to create a sample section for client approval made from our ultra-low maintenance Dura Daggerboard in a matching cream colour. Made from durable composite material with a Class B fire rating, our daggerboard was the ideal replacement for the badly worn timber which had started to present a hazard to station users.The feedback was great, and we were commissioned to begin full scale production using our CNC technology. As the Dura Daggerboards mimic the appearance of the traditional wooden valance boards but are lighter, simpler to install and require virtually no maintenance, they provide a much better lifecycle value than timber daggers. The client feedback on the installation by MLG and the daggerboards themselves has been spectacular, and the Bath Spa design has been added to our extensive daggerboard library.

Bury St Edmunds is so iconic that Shakespeare himself used the infamous Cathedral for two scenes in Henry VI. The train station itself, dating back to 1847, was equally steeped in history, which is why when it came to replacing the rotting timber canopy, nothing but an exact Victorian replica design would do.This historical landmark was in need of an upgrade, so HA Marks came to us. Using our Dagger boards, our expert fabrication team were able to exactly replicate the design. The design they went with, Florence, is now available as standard as part of the Dura Composites Daggerboard library.Several years on, after this project was featured on the front cover of the Railway Heritage Trusts Annual report and nominated for multiple heritage awards, the canopy remains to this day as good as the day it was first installed.Since then, we have expanded our range and now have over 30 designs as standard and you can now select our new additional heritage colours, like Light Beige and Flint. Our ability to create bespoke designs has only increased too. Our new 3D laser scanning service, working in tandem with our state-of-the-art CNC (Computer Numerical Controlled) Machine technology, is able to exactly replicate the design whilst vastly reducing the time needed on site and overall project costs.Class B fire-rated, our Dura Daggerboards are better than ever, they are lightweight, non-conductive, efficient to install in comparison to traditional methods, and require virtually no maintenance over their 60 year design life. The project at Bury St Edmunds was a great project to be involved with and we have learnt a lot since then. We have developed our daggerboard product range to make them look even more authentic. We’ve invested in new tools like laser scanning, so that we can restore like for like designs and in some cases even restoring the original heritage look of century old canopies.The legacy of this project and many more since is testament to our commitment to innovation. We are very proud of being able to provide modern materials with all the fire safety standards, low maintenance features to today’s standards, without compromising the character of the past.

Work to restore Harlow Town rail station’s faded exterior to its former glory has won a national award. Train operator, Greater Anglia, which manages the Grade II listed station, replaced all the old station canopy fascias with new ‘Hollybush Green’ colour Dura Dagger Board fascias – which will be maintenance free and prevent the colour from fading for many years to come. The work, which was made possible thanks to funding from the Railway Heritage Trust, has received the BAM Nuttall Partnership Award at the National Railway Heritage Awards.The original plywood of the fascias was over 60 years old and had come to the end of its life. At some point, the original green colour had been painted white, dramatically altering the look and character of the station. In close collaboration with Greater Anglia and historical building consultants, we prepared samples and designs for approval.With Dura Composites able to replicate the old hollybush green colour in a composite material without the need for regular repainting, the Railway Heritage Trust supported the upgrade work to make the station fascias fit for the future. Composite fascia replacements were carried out across all platforms, the overbridges and on the station forecourt.

West Runton station serves the charming village of West Runton and features a rare railway sign, known as a running-in board which is thought to be the only surviving structure of its kind still in existence on the national rail network. The board has been welcoming passengers to West Runton Station in North Norfolk since 1921, and in 2021 was given a new lease of life using Dura Composites d² Dura Daggerboard material.The project was a collaboration between the Bittern Line Community Rail Partnership, rail operator Greater Anglia and Dura Composites, and involved carefully researching the sign’s history to ensure that the new lettering was an authentic and respectful visual representation of the heritage design. All CNC work and installation was performed by Dura Composites, whose in-house graphic communications specialist was able to identify the closest modern-day typographic match to the original 1920s lettering so Dura could replace the degraded timber with a hardwearing no-maintenance composite.The aim was to provide renewed running-in board using composite materials that will withstand the effects of the coastal climate, so that the sign could continue to be a familiar landmark for future generations of rail users. The successful project won first place at the National Railway Heritage Awards 2021.