GWSR Heritage Line Welding Project

“The site (Didbrook Two to Hayles) was re-laid by volunteers for the first time since the route closed (in 1976) back in the mid-1980s. Back then, being a fledgling charity, they had to use whatever materials they could acquire. The sleepers that were used were acquired from Quedgeley munitions depot, which manufactured bombs during WWII and being manufactured in the early 1940s the sleepers were shorter, thinner and had big holes in them (to save concrete mix for the War effort). This was fine when our Railway re-opened using small tank engines but we now run bigger ex-passenger express mainline locomotives and it was thought these sleepers were not of sufficient quality to support the increased weight. At the beginning of January 2025, we lifted the track and removed the sleepers, with them being replaced by slightly newer CS1 sleepers. The idea behind welding every-other-joint is to help save on maintenance time and costs – we are a volunteer run railway and our P-way team meet Wednesdays and Saturdays – and with 14 miles of running line to look after, it can be time consuming to grease all the fishplates! My long term plan is to weld in a similar fashion across the length of the railway over the next few years”. – Paul Fuller, GSWR Track maintenance manager

RSS Infrastructure’s Welding Division delivered expert welding services despite unique challenges such as the use of recycled Bullhead rail and untampered sleepers laid manually by volunteers. The team’s adaptability ensured precise rail alignment and quality welds, overcoming significant obstacles with precision and skill. The volunteers’ support and enthusiasm greatly contributed to the project’s success, as they worked alongside our team to ensure smooth operations and efficient coordination.

The welding work will significantly reduce long-term maintenance demands for GWSR’s volunteer P-way team, allowing them to focus on other essential tasks across the railway’s extensive 14-mile line. With fewer joints to maintain, track stability will be improved, ensuring a smoother and safer experience for heritage locomotives and passengers alike.

Additionally, the completed welds will enable GWSR to operate trains during key events like the Cheltenham Festival, providing an essential revenue boost and supporting the continued preservation of the historic railway. This project has also served as an invaluable training opportunity for RSSI’s welders, allowing them to refine their skills in a challenging yet rewarding environment. RSSI’s commitment to quality, safety, and client collaboration was evident throughout the project, ensuring an efficient, wellexecuted, and future-proof solution for GWSR’s infrastructure needs.