Keeping people safe is a top priority at Elite Precast, both at our own facilities and out on site. So, when an opportunity arose to use our standard product range to improve safety for rail maintenance teams, we acted quickly, says Owen Bathan, Sales and Marketing Director.

Our interlocking walling systems have since become a vital part of safety and efficiency measures across the rail industry. The innovative Legato® and Duo™ concrete blocks offer a number of benefits for railway infrastructure projects.

Improved Safety for Adjacent Line Open (ALO) Operations
The Legato® interlocking block system has proven to be highly effective in creating solid, secure barriers between live rail lines and those undergoing maintenance. This allows work to continue safely next to operational lines, reducing the need for full line closures and keeping disruption to a minimum. The system is especially valuable for ALO and All Line Open operations, which are essential in busy areas of the network.

Enhanced Protection for Workers
These barriers provide vital physical protection for railway workers, addressing concerns highlighted by incidents such as the Surbiton station accident in 2021. As a result, they contribute to improved safety standards during track maintenance.

Durability and Flexibility
Manufactured from high-strength concrete and incorporating integrated lifting points, Elite’s interlocking blocks are built to last. Their long design life provides a cost-effective and robust alternative to in-situ concrete, avoiding the delays and disruption of more traditional methods.

Rapid Deployment
Thanks to their interlocking design, these blocks can be quickly installed and dismantled. This was clearly demonstrated in a recent Network Rail project, where the blocks were used to create a “real virtual wall” along half a mile of track. This approach avoided a planned 72-hour possession and significantly reduced disruption to passengers.

Versatile Applications
Elite’s interlocking blocks offer wide-ranging uses in the rail sector, including:

• Creating refuges

• Building retaining walls

• Constructing fire breaks

• Forming blast and push walls

• Providing security and traffic management solutions

Flexible Options
Both the Legato® and Duo™ interlocking block systems are readily available from our Shropshire-based manufacturing facility, with the choice of block tailored to each project’s specific requirements. Each block includes a cast-in lifting pin for easy loading and placement, removing the need for expensive lifting equipment and helping to reduce site costs and delays.

Sustainable by Design
Our Legato® and Duo™ blocks are manufactured from 100% natural materials, sourced from local quarries, and are fully recyclable at the end of their lifespan. Combined with their long-term durability, this makes them a smart choice for projects with sustainability targets.

Reliable Service and Quick Delivery
With large stocks held in-house, Elite Precast can offer fast delivery to suit your needs, whether by articulated or rigid vehicles, with or without crane offload options.

Fire Resistance
Our blocks are Class A1 Fire Resistant and are often used as part of Fire Prevention Plans (FPPs). They’re also recommended by many insurers for use as fire breaks.

RISQS Approved
All of Elite Precast Concrete’s products are approved under the Railway Industry Supplier Qualification Scheme (RISQS), ensuring they meet the strict safety and reliability standards required for use on UK rail infrastructure projects.

Additional Safety and Access Control Solutions
Beyond interlocking blocks, Elite also supplies Jersey Barriers, which are ideal for preventing unauthorised access, vehicle incursions and other site threats. These barriers are also used for traffic management, flood defences and edge protection on railway sites.

The Jersey-Lite™ barrier offers a more compact solution with integrated cable channels to accommodate lighting, making it ideal for train stations where pedestrian access needs to be restricted while signage remains visible at night.

By using Elite’s interlocking walling and barrier systems, rail operators can significantly improve safety for workers, shorten project timelines and reduce service disruptions—while maintaining the flexibility to adapt to the needs of each site.