McNealy Brown Ltd, Sittingbourne (2026)

04/06/2026

Project Lookback - Blackwall DLR Station

Taking another of our occasional snapshots of recent projects, McNealy Brown were delighted to be part of the team bringing station improvements to Blackwall.
DLR’s Blackwall station first opened in March 1994 and was a classic design of its time; a high railway accessed by one double set of stairs and two lifts.

As part of Transport for London’s ongoing commitment to improving passenger experience and enhancing safety, and DLR’s capacity upgrade project, the addition of a secondary staircase was needed at the station.

Our scope within the project was to design, fabricate and install structural steelwork for the staircase, consisting of 2no lower flights, support columns, a mezzanine level platform and 2no upper flights. The upper flights were designed with mesh infill screens of plain weave stainless steel 2.5mm wire to enclose the canopy, together with a roofing system consisting of Kingspan roof panels, aluminium flashings and gutter, with polyester powder coated downpipes.

We also supplied and installed double height DDA compliant to ‘not cold to touch’ handrails to all flights, aluminium expansion cover plates at the junction between upper landing and existing platform, and free-issue precast treads and landing planks.

Working with Enable, the two-year project completed with the opening of the new staircase on March 31 2025. Located at the eastern end of the platform, the new access staircase leads from platforms to a mid-level connection, down to the new street-level entrance.

Prior to the works, Blackwall had only one evacuation route for passengers, and an estimated evac time of more than the eight-minute maximum usually required.
Now, the secondary staircase ensures safer emergency evacuation, and future-proofs the station for passenger growth, with further benefits of increasing capacity and improving passenger flow.

29/05/2026

Project Overview – 'Current' Update from Bewl Water

Following climate change analysis after a near-miss situation in Derbyshire, works were needed to Bewl Water reservoir near Wadhurst,to protect Tonbridge and the surrounding areas from future potential flood risk, and to serve as additional protection measures against drought.

In August 2019, heavy rain led to a flood of excess water rushing over the spillway of 300-million-gallon Toddbrook Reservoir, above the Derbyshire Peak District town of Whaley Bridge. As the force of water built up, the spillway eroded, and ballasts started to fall away.

With severe ‘loss to life’ flood warnings issued in fear that the reservoir would burst, 1500 people were evacuated from Whaley Bridge. More than 1000 people, including 450 firefighters, worked 24 hours a day for 7 nights, to save the reservoir by reducing the water level, and also managing to save the town. It became apparent that many reservoirs would require specialist upgrades to future-proof their operation, and safeguard communities. Extensive safety and resilience frameworks for reservoirs have been put in place since the near-disaster occurred.

The team at McNealy Brown were contracted to design, procure, manufacture, deliver and install the supporting framework for a new siphon system at Bewl Water.

Our brief included:
27 no 1600 Pipe Supports (mild steel)
21 no 1700 Pipe Supports (stainless steel)
3 no 1700 Pipe Supports without top strap (stainless steel)

The supports were designed for a series of three 30m-long (98.4 ft), 1.7m-wide (5.8ft) pipes, which serve as the new drainage system at Bewl Water, to ensure the reservoir has both more resilience and the required assurance of safety. When needed, surplus water will be channelled into the River Bewl, from where it will then eventually flow into the River Medway.

The primary chamber at Bewl Water is now drained by these three large siphons, which speeds up the rate of drainage from the old level of 15cm in 5 days to the new rate of 5m in 5 days.

This new spillway will allow Southeast Water to drain the equivalent of an Olympic swimming pool every minute from the dam, which will ensure both Bewl Water, the land around it and settlements nearby are future-proofed against climate change - for many years to come.

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19/05/2026

Stepping up to a bespoke project

At McNealy Brown, we enjoy the occasional niche project that combines precision fabrication with practical design.

For a recent private project in Whitstable, Kent, we were tasked with designing, fabricating, and installing a bespoke galvanised steel staircase to provide future-proofed access to an upper floor flat and increase the upstairs floor space with a balcony.

The project included a straight stair with turn, handrails, and a top balcony area measuring 3370mm x 1650mm - all finished with hot dip galvanising for long-term durability.

A great example of how tailored steelwork solutions can seamlessly combine functionality and aesthetics.

www.mcnealybrown.co.uk

14/05/2026

Project Lookback - Stoneleigh AfA

Taking our occasional lookback at projects completed, the team at McNealy Brown greatly enjoyed working with Octavius on Stoneleigh AfA.

The project to improve Stoneleigh station near Epsom is part of a programme across Wessex railway network - funded through the DfT’s Access for All scheme.

McNealy Brown’s brief was to design, manufacture, supply and install:

• 1 no Covered Footbridge
• 3 no Stairs and Landings
• 3 no Lift Shafts
• Handrails, Canopies and Roofing

Our problem-solving approach to projects was especially valued during the weekend blockade, which demonstrated once again our ability to work as a team to see projects to fruition on time, and with efficiency and skill, as shown by a commendation from Octavius.

“…thanks to everyone involved in this weekend’s works at Stoneleigh. Despite numerous challenges leading up to the blockade, the team managed to complete all planned works lifting in the East and West trestles, link lobbies and stairs using a 650t mobile crane. This is a crucial milestone for the project. Well done everyone.”

Completion of the improvements was officially marked by a ribbon-cutting ceremony in April 2025. Stoneleigh station is now fully accessible, with enhanced step-free access for all passengers, via lifts and stairs to the central platform from both sides of the station.

11/05/2026

Project Update: Hither Green AfA – Milestone Moment

The team at McNealy Brown were part of another significant step towards full Access For All compliance at Hither Green station, with successful installation of the four bridge spans during a possession over the early May bank holiday weekend.

The bridge spans were lifted into place, linking all platforms to the new entrances. Despite the scale and complexity, the operation ran smoothly and is a major milestone in the journey to completion.

Our photo diary of the weekend shows a snapshot of events, including the perfect weather conditions!

We’re proud to be working with BAM and Network Rail to provide access for all at Hither Green – congratulations to all involved.

More progress updates soon!

www.mcnealybrown.co.uk

25/04/2026

A Marathon Achievement at Cutty Sark Station

McNealy Brown are delighted to have been part of the team on the DLR project to transform Greenwich’s Cutty Sark station.

The station was closed from 31st May 2025 for ten months, for the installation of four new escalators. During the closure, DLR also carried out refurbishment works to the station, to give a bright, spacious and modern atmosphere, making the station easier to navigate and more enjoyable to use. Prior to the works, passengers using the station had to navigate 121 steps between station entrance and platform.

Our brief within the project was to:

• supply and install matt white polymeric vinyl to all panelling throughout the station – a total of around 1100 panels across 3 floors
• deep clean panels prior to installation of new vinyl
• remove existing stair panels, powder coat with a matt white finish, and reinstall
• provide escalator infill panels - new flashings and trims between new escalators and wall panelling
• powder coating of existing handrails and balustrade, together with floor painting
• supply and installation of new signage and wall graphics

Although the station was closed to the public, DLR trains still ran, so any trackside works had to be planned in accordance with DLR’s Access Booking & Work Request Form procedures.

Working to a tight schedule, our expertise was put to good use, even in the smaller details such as the design of a new lighting system for the new, open style raised ceiling above escalators. One of the project aims was to make Cutty Sark station bright, spacious and modern, and through the combination of successful ex*****on of design and creative input, the results are clear to see through the before and after photos shown.

The station re-opened on 23 March, a week earlier than the scheduled date of 30 March 2026, in readiness for both Easter and with this weekend’s London marathon in mind. Despite a significant increase in scope during the project, we still achieved this deadline within a 9-week period, much to the client’s appreciation.

Cutty Sark Station is now an upgraded entry point for both Maritime Greenwich World Heritage site and Greenwich town centre – especially relevant for this weekend – as we wish all runners and supporters a successful and enjoyable marathon this Sunday!

21/04/2026

Project Spotlight: Thames Tideway East - Architectural Metalwork Landscaping to Ventilation Areas for Thames Tideway Tunnel

Following the tunnel’s official opening in May 2025, the overground public park areas of the works are now complete. Here’s a look at more areas from this amazing project. Our brief was to design, manufacture and install architectural metalwork and steelwork to five key ventilation point sites of the Thames Tideway super sewer route.

The areas - now gradually becoming officially open to the public – are Earl Pumping Station, Greenwich Pumping Station, Deptford Church Street, Chambers Wharf and King Edward Park foreshore.

Our extensive scope of works included:

Pergola, kiosk and louvre doors
Ventilation columns
Vertical cladding to ventilation points
Balustrade, handrails and security fencing
Staircases, ladders, and fall restraint systems

When needed, the McNealy Brown team’s collective experience provided the design solutions needed to ensure timely delivery of the project to the highest standard during work in progress. This included the design and installation of thicker bars to vertical cladding for a ventilation structure, adding spigots and vertical cross support bars to stabilise the flex of vertical fins. We also redesigned a cantilevered staircase to provide further solutions during the project.

We’re grateful to CVB and the Thames Tideway Tunnel team for entrusting us with key works on this fantastic project. Congratulations to everyone involved!

18/04/2026

Northfields Depot Upgrade – bringing 23% capacity increase to the Piccadilly Line

A major upgrade to Northfields Depot is taking place as part of Transport for London’s £2.9bn Piccadilly Line Upgrade (PLU). The finished works mean the depot can support the new, longer walk-through Siemens Inspiro trains which are entering service in 2026. The trains have been designed with sustainability as priority, supporting decarbonisation and reducing energy consumption by 20%.

The team at McNealy Brown were delighted to work with TfL on this project. Our brief was to design, manufacture in mild steel and install:

• 2 no Platform extensions: 2400mm long x 1300mm wide and 3500mm long x 700mm wide - both consisting of beam supports with 50mm thick GRP grating to tops

• 1 no Landing with stair to two sides, each stair consisting of 3no treads 1240mm wide one side and 980mm wide opposite side, and 1no Landing with stair to one side; stair consisting of 3no treads 880mm wide

• 2 no Kee Klamp style self-closing gates with signs

• 2 no Kee Klamp style handrails to platform ends

• 1 no 112.32m long walkway and 112.32m screen 3.2m high, together with posts 100x100x10mm

All steelwork on walkways and stairs was shot-blasted and galvanised to provide an average coating thickness of 140 microns.

After completion of works, and once the 94 new trains have replaced 86 existing trains, the number of trains on the line through central London will increase from 24 to 27 trains per hour, at its busiest times. The number of passengers that can be carried on the entire Piccadilly line will increase by up to 23% during peak time, resulting in a faster, more reliable and more frequent service.

16/04/2026

Further Update: Hither Green AfA - As It Happens

The McNealy Brown team are proud to share our latest update on Hither Green AfA.

Working with BAM and Network Rail, we're well on schedule for the forthcoming installation of bridge spans.

The AfA project will provide access for all with a new footbridge and a total of four new lifts and staircases at Hither Green, along with two new entrances providing step-free access between platforms - and the Springbank entrance is now in place. The finished result will be life-changing, making Hither Green a station all travellers can use.

More progress updates to come soon!

13/04/2026

McNealy Brown Photo Competition

Our quarterly photo competition within the McNealy Brown team has resulted in more amazing shots, snapped from some of the different projects we’ve recently been undertaking.

Here’s a medley of entries from our most recent batch – as usual there was stiff competition! With so many great photos to choose from, it’s always hard to select one.

This time, congratulations go to winner Adam Pratt with his brilliant photo of Ryde St Johns Station. Thank you to all the team at McNealy Brown who entered the competition.

McNealy Brown Ltd

04/06/2026

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