Milestone Project: Innovative rolling stock storage covers

Shrink-wrap rolling stock storage covers for Angel Trains

At Tufcoat, milestone projects mark key moments in our evolution—from overcoming new technical challenges to delivering industry-first applications that shape how we approach future work. One such project at Angel Trains was a defining moment: our first-ever shrink-wrap application on a rail carriage. This proved to be a technically complex and logistically challenging undertaking, ultimately becoming a landmark success for our team.

The project

We were approached to provide shrink-wrap rolling stock storage covers for Angel Trains, one of the UK’s leading rolling stock asset managers. Their requirement was straightforward on paper; the trains needed robust, long-lasting weather protection while being stored outdoors. However, the practicalities of the job posed a unique and complex set of challenges.

The carriages were already positioned on their tracks, tightly packed into a siding for storage. At first glance, this setup seemed typical, but it quickly became apparent that the spatial limitations would significantly influence our working methodology. With the trains in situ and almost no clearance between them, the usual access methods, such as scissor lifts or cherry pickers, were simply not viable. There was insufficient room to deploy these machines without disrupting the surrounding infrastructure or risking damage to the carriages.

The challenge

Working at height is always a critical consideration in any project and this job was no different. In this case, we were not only dealing with the standard safety concerns, we also had to factor in the restricted space and the impossibility of using conventional access equipment.

To deliver high-quality shrink-wrap rolling stock storage covers under such constraints, our team needed to innovate. Safety could not be compromised and neither could the integrity of the weatherproofing solution. It was clear that traditional approaches were off the table, so we had to think creatively and engineer a method that would:

• Allow safe and practical access to the carriage roofs,
• Comply fully with stringent health and safety regulations,
• Avoid any interference with the shrink-wrap rolling stock storage sheeting during application.

The solution

After careful planning, risk assessments and brainstorming, our team developed a bespoke system that addressed all three core requirements; a series of tensioned straps engineered specifically for the environment.

These straps were installed across the top of the carriages, creating a safe anchoring system. This enabled our operatives to traverse the rooflines securely and efficiently, without relying on any ground-based machinery. The strap system was designed to remain elevated and out of contact with the shrink-wrap rolling stock storage sheeting, ensuring that the finished cover would maintain a smooth, sealed surface with no compromise to durability or finish.

This innovative, non-intrusive method allowed us to safely and effectively apply shrink-wrap rolling stock storage covers. The result was a clean, weather-resistant seal that would protect the carriages during long-term outdoor storage, regardless of the environmental conditions.