Alstom invests in advanced train repair facility at Crewe Works

HVAC Area 2. Photos: Scopic Productions and Richard Gennis

The global mobility company Alstom has opened a new train component overhaul and repair facility at its historic Crewe Works site, marking a significant investment in the future of UK rail maintenance. The multi-million-pound development includes a ‘state of the art’ area dedicated to refurbishing heating, ventilation and air conditioning (HVAC) units, alongside a suite of modern offices designed to support the company’s growth plans.

HVAC systems regulate a train’s air temperature, humidity and quality by drawing in air, heating or cooling it, and circulating it back into the carriage while managing ventilation and filtration. The new equipment installed at Crewe enables HVAC units to be expertly inspected before being regassed and brazed.

As part of a full overhaul, operatives replace worn parts and refrigerant to restore systems to optimal performance and extend their lifespan. Crewe’s bespoke test cells allow climatic chamber examinations, replicating onboard conditions experienced during passenger service. Prior to the new facility opening, Crewe Works processed around 16 HVAC units per week; this has now doubled to 35 and is expected to reach 50 by January when the HVAC area is expanded further — 70 skilled roles have already been created, and this will rise to around 110 in the New Year. Operatives are currently overhauling HVAC units on Class 334, Class 375, Class 377, Class 387 and Class 390 trains, with work on Class 222 and Class 378 trains scheduled for 2026.

Pictured right: HVAC Area 1

Steve Harvey, services director Alstom’s services director for the UK and Ireland, said: “As the UK’s leading supplier of train services, we are proud to have invested more than £2 million in new technology and offices at our Crewe Works. This expansion not only future-proofs our operations but also enables us to better serve customers across the country with enhanced capacity and capability.

“Crewe has played a pivotal role in Britain’s rail history and this latest development will ensure it remains at the heart of train maintenance in the UK. We are excited about the opportunities this creates — it is a landmark investment in both technology and talent.”

Bogie manufacture to return to Crewe
Crewe Works, originally opened by the Grand Junction Railway in 1843 to manufacture steam locomotives, has long been central to Britain’s rail industry. Today, it is home to Alstom’s UK Centre of Excellence for bogie, wheel and traction motor overhaul, having overhauled more than 20,000 bogies in the past decade. Looking ahead, bogies for HS2 rolling stock will be manufactured at Crewe — the first time in almost 20 years these components have been made in the UK.

Pictured left: Crewe Works

Alstom has also partnered with Woodhouse to deliver a transformative refurbishment of its general office space within Crewe Works. The 20,000ft² redesign pays tribute to the building’s industrial heritage by exposing its steel structure, while introducing a mezzanine level with modern meeting rooms and a spacious open-plan office on the ground floor. The refurbishment includes a welcoming reception area and vibrant breakout spaces to encourage collaboration.

Ralph Dummer, project director at Woodhouse, said: “It has been an absolute pleasure to work alongside the team at Alstom to deliver this inspiring, future-ready workspace that reflects the company’s values and vision.”

Globally, Alstom supports customers across the entire asset lifecycle, maintaining over 35,500 vehicles worldwide and offering tailored maintenance services for both Alstom and non-Alstom rail assets.