CAF Rail UK, the British subsidiary of Spanish manufacturer CAF, has officially opened a new center for the overhaul and refurbishment of bogies and mounted axles. The GBP 10million investment will support CAF’s fleets in operation in the United Kingdom.
The new CAF facility is located in Lowry Park, Manchester and will perform maintenance and overhaul work on major train components, including bogie assemblies and mounted axles. In the near future, the center’s operations will be expanded to include final drives and other key components.
CAF Rail UK says the investment will increase the overhaul capacity available for its UK projects, reduce turnaround times, and help improve fleet reliability by minimizing periods during which rolling stock is out of service.
Capacity for 1,200 mounted axles per year
The Manchester facility will initially have approximately 30 employees, many of whom will be recruited locally, though that number is expected to double as operations expand. The facility will also serve as a training center for new CAF employees.
According to the company, the facility was designed to meet the entire demand generated by CAF’s projects in the United Kingdom. Operating on a two-shift schedule, the Manchester team will be able to overhaul up to 300 bogie frames and 1,200 mounted axles annually.
The center will be supplied by CAF’s Central Stores Facility in Stockport via a just-in-time delivery model, ensuring that parts and materials arrive at Lowry Park when needed, with minimal on-site inventory.
Complete Bogie Overhaul
The production flow at the new facility is organized in a U-shape. For a complete bogie, the process begins in the receiving and shipping area, followed by an initial inspection.
Work continues in the disassembly area, where the frames and mounted axles are separated, then moves to the cleaning area, which includes a sandblasting booth, equipment for non-destructive testing, and inspection. The area dedicated to mounted axles includes a horizontal lathe and a wheel press.
At the end of the process, components requiring repainting are treated in the paint booth, and the frames and mounted axles are reassembled. The bogies then pass through the bogie press and final inspection before shipment. An additional area for final drives will be integrated in the second phase of the project, in 2027.
CAF Strengthens Its Presence in the UK
“It’s fantastic to see our new overhaul center at Lowry Park completed and ready for operation. This state-of-the-art facility represents a significant investment in our capabilities and will enable us to better support the needs of our customers in the British rail industry,” said Dave Lowe, Managing Director of CAF Rail Services UK.
CAF Rail UK is responsible for technical support, maintenance, and the supply of materials for CAF projects in the UK. The company has approximately 1,000 employees in the UK, a manufacturing plant in Newport, Wales, and provides maintenance services at 14 depots across the network.
The CAF plant in Newport, opened in 2018 following an investment of GBP 30 million, assembles, finishes, and tests rail vehicles, including regional trains, trams, and metros. To date, CAF has produced over 1,200 individual vehicles in the UK for more than 10 major fleets.
The company will also build the UK’s first tri-modal trains, intended for LNER. These trains will run on the East Coast Main Line and will be capable of operating on both electrified sections and sections without an overhead contact line.
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