Building HS2 Beyond Steel: GRP Structural Profiles, Walkways and Flooring for Long-Life Rail Infrastructure
Introduction
HS2 is not being built as a short-term transport solution. It is a piece of national infrastructure designed to operate for more than a century, carrying high-speed services through tunnels, across viaducts and into complex station environments day after day. When infrastructure is expected to perform for that long, the question is no longer simply whether a material works today, but whether it will still be working safely, reliably and economically decades into the future.
Across HS2, this long-term mindset is influencing material selection in areas that have traditionally defaulted to steel. Structural profiles, walkways, flooring systems and access platforms may not attract the same attention as tunnels or rolling stock, but they play a critical role in safety, maintenance and operational resilience. Increasingly, these elements are being designed around Glass Reinforced Plastic rather than metal, and for good reason.
The Hidden Challenge of Access Infrastructure on HS2
Every major rail project relies on access infrastructure. Walkways for inspection, platforms for maintenance, handrails for safety, cable routes, ladders and structural supports are essential to keeping the railway operational long after construction ends.
On HS2, much of this infrastructure is located in challenging environments. Viaducts expose components to weather, wind and difficult access. Tunnels combine high humidity, restricted ventilation and limited space for maintenance. Platforms and stations see constant footfall, cleaning regimes and chemical exposure. Lineside environments bring vibration, pollution and long-term exposure to the elements.
In these settings, steel components introduce well-known issues. Corrosion begins early and progresses steadily. Protective coatings degrade. Inspections become more frequent. Repairs require access planning, possession time and safety controls. Over decades, these interventions add up to significant operational cost and disruption.
HS2’s scale magnifies this problem. When access systems stretch for kilometres and sit in locations where maintenance is complex or risky, reducing future intervention becomes a design priority rather than a cost-saving exercise.
Why GRP Structural Profiles Are Being Specified
GRP structural profiles offer a fundamentally different performance profile to steel. Manufactured through pultrusion, GRP profiles deliver consistent strength, dimensional accuracy and long-term stability without the vulnerabilities of metal.
One of the most immediate advantages is corrosion resistance. GRP does not rust, rot or degrade when exposed to moisture, salts or pollutants. In tunnel environments where humidity is constant and access is restricted, this alone removes a major long-term maintenance burden.
Electrical non-conductivity is another critical factor. HS2 operates in a 25kV electrified environment, and structural components located near power and signalling systems must not introduce electrical risk. GRP profiles are inherently non-conductive, eliminating stray current pathways and simplifying safety considerations around access infrastructure.
Weight also matters. GRP structural sections are significantly lighter than steel equivalents, reducing dead loads on viaducts and bridges. This not only benefits structural efficiency but also simplifies installation, handling and future modification where required.
Across HS2, GRP I-beams, channels, box sections, angles and tubes are well suited to forming the backbone of access platforms, equipment supports and secondary structures that must perform reliably without constant attention.
GRP Grating and Flooring in Tunnels and Viaducts
Walkway and flooring systems are among the most heavily used elements of rail infrastructure. On HS2, they are essential for inspection, maintenance and emergency access across tunnels and elevated structures.
GRP grating provides a combination of strength, slip resistance and drainage that is particularly suited to these environments. Open mesh GRP grating allows water and debris to pass through, reducing standing water and improving safety underfoot. In tunnels where moisture is unavoidable, this is a practical advantage over solid steel flooring.
Unlike steel grating, GRP does not corrode. There is no gradual loss of section, no weakening of load capacity over time and no need for recoating. Anti-slip surfaces are integral to the product rather than applied as temporary treatments, maintaining performance throughout the life of the installation.
On viaducts, GRP walkways reduce structural loading while providing durable access routes that do not require regular intervention. Over a 100 plus year asset life, this reduction in maintenance activity has a measurable impact on cost, safety and operational availability.
Platforms, Stations and High-Footfall Areas
HS2 stations and platforms represent another demanding environment. Flooring and access systems must cope with heavy foot traffic, cleaning chemicals, weather exposure and strict safety requirements.
GRP flooring systems offer consistent slip resistance, chemical resistance and durability without the deterioration seen in timber or steel alternatives. They do not absorb moisture, do not rot and do not require surface treatments to maintain performance.
In platform edge systems, service access covers and cable management zones, GRP provides a stable, long-lasting solution that maintains appearance and function without ongoing refurbishment. For an operator managing stations over multiple decades, this consistency reduces lifecycle cost and disruption.
Handrails, Ladders and Integrated Access Systems
Safety systems such as handrails and ladders are integral to HS2’s access strategy. These elements must remain structurally sound, visible and safe in all conditions.
GRP handrail systems are lightweight, corrosion resistant and electrically safe, making them particularly suitable for electrified rail environments. Their modular nature allows rapid installation and straightforward replacement if layouts change, without hot works or specialist treatments.
GRP ladders and vertical access systems offer similar benefits. They remain stable in damp or polluted environments, do not conduct electricity and require no painting or corrosion management.
When combined with GRP structural profiles and grating, these components form complete access solutions that are designed as systems rather than individual parts.
Whole Life Performance Over Habit
The recurring theme across HS2 is whole life performance. Traditional materials often appear cost effective at installation stage but introduce predictable maintenance and replacement cycles over time. HS2’s design life forces a different approach.
By specifying GRP for structural profiles, walkways, flooring and access systems, engineers are reducing future inspection, repair and replacement activity. They are also improving safety by removing corrosion and electrical risks from access infrastructure.
These decisions are not about novelty. They are about selecting materials that align with the realities of operating a high-speed railway for more than a century.
What HS2 Signals for Future Infrastructure
HS2 is setting precedents that will influence future UK infrastructure projects. The adoption of GRP in access and structural applications demonstrates a move away from default material choices and towards performance-led specification.
As the rail industry faces increasing pressure around safety, sustainability and long-term cost, the lessons from HS2 will not remain isolated. GRP structural systems, grating and access solutions are already proving their value in environments where steel struggles to deliver long-term reliability.
Conclusion
HS2 is not just redefining rail travel, it is redefining how infrastructure is designed for longevity. Structural profiles, walkways, flooring and access systems may sit in the background, but their performance over decades is critical to the success of the railway.
By integrating GRP solutions into these applications, HS2 is reducing maintenance burden, improving safety and building infrastructure that is genuinely fit for a 100 plus year service life. It is a clear signal that modern rail projects require materials chosen for how they perform tomorrow, not just how familiar they are today.
