Level crossing in Sudbury, Staffordshire (UK)
Application: Track through level crossing
Length of track: 80 metres
Material used: SEKISUI FFU® Plain Line Cross Sleepers
Country: United Kingdom
Project location: Sudbury, Staffordshire
Owner: Network Rail
The railway track through Sudbury Level Crossing in Staffordshire presented many problems for its owner Network Rail. These included: track voiding; track geometry deterioration; poor drainage; and cracking of sleepers beneath the crossing decking. SEKISUI FFU® Plain Line Cross Sleepers were chosen as the best solution to resolve these issues. FFU® sleepers are fully approved by Network Rail for all track categories up to and including 1A at line speeds up to 200kph.
A total of 114 number 130mm x 300mm x 2500mm wider FFU® Plain Line sleepers were procured and installed in January 2026. (Wider sleepers help to distribute load on the track bed). These were then fitted with Under-Sleeper Pads (USPs) to significantly improve lateral stability and enhance ballast life. The track underneath Sudbury Level Crossing is exposed to high longitudinal and lateral forces from both heavy rail and heavy road traffic.
However in contrast with concrete sleepers, FFU® does not pose a risk of cracking under continuous cyclic loading or under heavy axle loads. And in wet conditions, in contrast with wooden sleepers, FFU® sleepers don't rot.
This project represents the first ever installation of SEKISUI’s FFU® Plain Line sleepers through a level crossing in the UK and will mitigate severe problems and deliver lasting reliability improvements. With a lifespan of over 50 years, SEKISUI FFU® sleepers will future-proof the Permanent Way at Sudbury for many years to come.
