Alstom is celebrating the opening of a new train component overhaul and repair facility at its Crewe factory.
As well as a state-of-the-art heating, ventilation and air conditioning (HVAC) refurbishment facility, Alstom has also developed a number of new offices as part of a multi-million pound investment in the future of the Cheshire town's historic site.
HVAC area
An HVAC unit controls a train's air temperature, humidity and quality. These systems draw in air, heat or cool it, and then circulate it back into a cart while simultaneously controlling ventilation and filtration. Alstom's newly installed equipment in Crewe allows for expert inspection of trains' HVAC units before they are regassed and soldered.
As part of a complete overhaul and repair, employees change the refrigerant and replace worn parts to restore systems to optimal performance and extend their lifespan. In addition, Crewe's bespoke test cells enable climate chamber investigations as they replicate various onboard conditions to which the systems are exposed during passenger operations.
Prior to opening the new facility, Crewe Works was able to process approximately 16 HVAC units per week. Now that number has doubled to 35 and will reach about 50 by January as the HVAC division continues to expand to meet demand. 70 new skilled workers have already been created to operate the system, and there will be around 110 in the new year.
Employees are currently overhauling the HVAC units on Class 334, 375, 377, 387 and 390 trains. Work on Class 222 and 378 trains will follow in 2026.
“As the UK's leading provider of train services, we are proud to have invested more than £2 million in new technology and offices at Crewe Works. This expansion not only future-proofs our operations, but also enables us to better serve customers across the country with improved capacity and performance,” said Steve Harvey, Services Director UK and Ireland at Alstom.
He added: “Crewe has played a crucial role in Britain's railway history and this latest development will ensure the company remains at the heart of train maintenance in the UK. We are excited about the opportunities this presents – it is a game-changing investment in both technology and talent.”
Crewe Works was originally opened in 1843 by the Grand Junction Railway to manufacture steam locomotives and was instrumental in the town's development. The population grew from 500 in 1841 to over 40,000 in 1900.
In addition to the new HVAC area, Crewe Works is now home to Alstom's UK bogie, wheel and traction motor overhaul center of excellence, which has overhauled over 20,000 bogies for the UK rail market over the last decade. In future, the bogies – which house a train's wheelsets – for the High Speed Two (HS2) rolling stock will be manufactured by Alstom at its Crewe factory. This is the first time these have been made in the UK in almost two decades.
New offices
Alstom has also partnered with Woodhouse to undertake a refurbishment of its main office space on the Crewe Works site. Woodhouse developed a design for the 20,000 square meter space that enabled the office area to adapt and support Alstom's growth plans for the site.
The design honors the building's industrial heritage and reduces it to the former steam locomotive production and repair facility by exposing the distinctive steel structure. A new mezzanine has been created to accommodate a range of modern meeting rooms, whilst the ground floor houses a spacious open plan office, additional meeting rooms and a welcoming reception area designed to enhance the visitor experience. The renovation also includes a vibrant break and tea area that encourages collaboration and connection between employees.
“It has been an absolute pleasure working with the team at Alstom to create this inspiring, future-ready workplace that reflects the company’s values and vision,” said Ralph Dummer, Project Manager at Woodhouse.
Alstom said the project successfully united displaced teams (as a result of the HVAC expansion), incorporated sustainable design principles and improved the digital experience for the more than 300 employees at Crewe Works.
The new HVAC area and offices were officially opened on Tuesday 28th October by Rob Whyte, Managing Director for UK and Ireland. Steve Harvey, service director for UK and Ireland; and Steve Hadfield, project manager at Alstom. The ribbon cutting ceremony was attended by local dignitaries including Councilor Stuart Mackay, Deputy Mayor of Crewe; Councilor Kevin Murray, Crewe City Council; and Paul Colman, chief executive of the South and North Cheshire Chamber of Commerce and Industry. The site is led by Mark Derbyshire, General Manager, who also gave a passionate speech at the launch event thanking the teams at Alstom, Woodhouse and their contractors.
TV appearance
Crewe Works will continue to be in the spotlight as the site will feature in an episode of 5's popular documentary series Britain's Most Scenic Counties: Cheshire. During a shift at Mark Derbyshire, viewers will get an insight into the work required to successfully overhaul a bogie and get it back into passenger service within a week. The Crewe Works episode will air on Friday November 7th at 9pm in the UK and will then be available on demand.
