Polystyrene Processing at Ashley Down Station

Processing and preparing 300 bespoke EPS polystyrene components to support the rapid installation of the Ashley Down station platform system.

About BEWI

BEWI Polystyrene is a large UK manufacturer of expanded polystyrene, supplying high-volume EPS solutions across multiple sectors. Known for producing dense, large-format polystyrene blocks, BEWI supports major construction and infrastructure projects where precision, durability and scale are critical.

For the Megatech Ashley Down station project, BEWI was tasked with supplying multiple full lorry loads of high-density EPS blocks. These were delivered in full-size moulded blocks and required processing into bespoke sizes and detailed shapes. Each individual component needed to be cut, collated and numbered to align with post production processing and on-site installation sequencing.

The project demanded significant material volumes, fast turnaround and exacting detail to support encasement in concrete and the integration of pre-formed M&E ductwork.

Ashley Down project in numbers…

900m2

area

900+

blocks processed

900m

cut

The
Challenge

The Ashley Down station development required 260 metres of expanded polystyrene platform system to be installed within a short timeframe. BEWI faced several operational pressures:

  • Large volume of high density EPS blocks to be processed into bespoke formats
  • Approximately 300 individual EPS blocks and slabs, with around 50 percent being unique variations
  • Short lead times
  • Space limitations and handling constraints
  • Strict delivery and collection schedules

The scale and complexity of the requirement meant BEWI could not internally manage the processing volume and turnaround within the required timeframe. They needed a specialist partner to transform bulk deliveries into fully prepared, installation ready components while maintaining programme certainty.

The solution

Perudo supported BEWI by processing full-size EPS blocks into precisely cut components ready for installation within the Ashley Down station platform system. Each element was shaped to accommodate drainage runs, M&E services, the station lift shaft and the pedestrian footbridge, then collated and numbered to align with the installation sequence.

Despite the logistical challenge of transporting around 300 concrete-encased EPS components from a material storage compound located one kilometre from the station, installation progressed efficiently and exceeded the minimum installation target of two linear metres per hour.

In total, 260 metres of EPS platform system were installed in just four days. The two platforms, some sections reaching up to six metres in width, were completed within eight working shifts and delivered ahead of programme.

Here’s what our
clients have to say…

Civil Engineering Client

“Thank you for your prompt and highly professional service. The items have worked well, we will certainly be in touch with any future requirements.”

Tim – Director of Bespoke

Manufacturing Client

“We were all blown away by the quality of the product you have produced. Congratulations and thank you”

Bryan – Sales Manager

Retail & Events Client

“Thank you for all the hard work. The final push on an ever-changing design ensured that everything was finished and delivered on time.”

Paul – Project Manager

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