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Overcoming Obstacles: A Digital 48 Sheet Installation for Network Rail in Bexhill

May 12, 2025

2024 saw our team embark on a particularly intricate project in the coastal town of Bexhill, West Sussex. Our client tasked us with the installation of a Digital 48 sheet in an environment that presented a unique set of challenges.
The proposed location was a narrow strip of land situated halfway up a steep railway embankment, immediately adjacent to a busy main road. Adding to the complexity were stringent restrictions imposed by Network Rail engineers, notably the prohibition of any excavation into the embankment.

This immediately ruled out our standard approach of a robust 6m x 2m x 1m concrete base. Instead, we were instructed to utilise pile caps. The steep and uneven terrain, sloping both front-to-back and side-to-side, further complicated matters, requiring the use of unusually long 6m pile caps. This pushed us beyond our typical methodologies, but our team embraced the challenge with focused determination, underpinned by thorough pre-planning.

Our initial priority was establishing a secure working platform at the base of the embankment. This necessitated careful traffic management, the deployment of a Hiab crane, and the delivery and placement of several tonnes of Type 1 aggregate to create a stable foundation for a 5-tonne digger – the largest piece of machinery that could safely operate within the confined space.
The next critical step involved using a crane to lift the mini digger onto the embankment. This enabled us to create a safe and level area from which to operate the core pile drivers.
A key consideration was maintaining the precise level and alignment of the pile caps. Even a minor deviation at this stage could compound as the structure was built upwards, potentially leading to significant issues with the steelwork’s level. To address this, our team devised an ingenious solution: the construction of a bespoke timber jig. This served a dual purpose, accurately marking out the drilling locations and ensuring the pile caps remained perfectly level and securely in place.

With the timber jig in position, the demanding task of pile driving commenced. The limited headroom available to the digger meant we could only utilise 3m core bits, requiring a considerable amount of back-and-forth movement to achieve the necessary depth for each pile.
Once the holes were excavated, cardboard linings were carefully inserted according to the project specifications. The space surrounding these linings was then filled with pea shingle aggregate to provide stability. Following this, the 8m steel posts were meticulously lowered into each prepared hole and secured in to position. Finally, a concrete pump was brought to site to fill the holes, with vibration techniques employed to eliminate any air pockets and ensure a solid foundation as the concrete cured.
To minimise disruption and accelerate the overall timeline, the digital screen itself was constructed off-site. Once the concrete foundations had reached the required strength, the completed screen and its associated steelwork were transported to Bexhill and efficiently installed during a single overnight operation.
The subsequent phase focused on the essential groundworks required to ensure safe and easy access and egress for future maintenance. This involved the construction of a level and secure pathway, complete with handrails and edgings, leading from the roadside to and around the communications and power cabinets. A lockable access gate was also installed.
Following rigorous electrical checks and fault testing of the newly installed screen, a comprehensive handover pack was presented to our client. The culmination of our efforts was a significantly improved site that was not only visually appealing but also safe and well-organised.

The key take-aways for us were that this project highlights the team’s ability to overcome substantial logistical and regulatory hurdles through careful planning, innovative solutions, and a focus on safety and efficiency, ultimately delivering a successful digital signage installation for a key client.

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