Crossrail training mock-up

The Tunnelling and Underground Construction Academy (TUCA) provides specialist training for rail, tunnelling and underground construction. Established in 2011 by Crossrail Limited and now operated by Transport for London, it continues to support workforce development for the Elizabeth line and future infrastructure programmes.

DCA was commissioned by VolkerFitzpatrick to design and deliver a full-scale, mobile mock-up of a section of an Elizabeth line carriage to enable realistic, hands-on training for the TUCA facility in London.

The requirement was to create a training environment that accurately reflects in-service rolling stock while remaining robust enough for intensive, repeated use. It needed to support safety-critical procedures such as passenger evacuation, while retaining the flexibility to adapt to a range of training scenarios.

DCA developed a six-metre carriage section mock-up based on a standard vestibule arrangement with bi-parting doors. The interior replicates a typical passenger environment, including a multi-purpose wheelchair area, opposing seating bays with fixed and tip-up seats, and incorporates fully finished internal surfaces using fire-retardant GRP panels, aluminium ceiling systems and integrated lighting.

The structure is built around a steel support frame designed to provide mounting interfaces for all components while ensuring long-term durability. Externally, composite panels and applied vinyls replicate the Elizabeth line livery, creating a consistent and recognisable appearance.

A key aspect of the project was the development and integration of unique fully functional plug-and-slide door systems tailored specifically to the mock-up. These were designed, engineered and tested at DCA as standalone assemblies before being incorporated into the main structure. The doors can be mechanically released using replica emergency controls, allowing realistic evacuation training.

The mock-up is mounted on bespoke flanged wheel assemblies and positioned at representative platform height. Combined with the bespoke manually controlled braking system, this enables the unit to be moved within the facility, supporting different training configurations within a range of replica tunnel environments.

Following manufacture and validation in Warwick, the mock-up was delivered to TUCA in July 2018. It is installed within a purpose-built tunnel and platform environment, forming part of an immersive training setting that includes track and station infrastructure.

The project sits within the wider Crossrail project. Parallel works led by VolkerFitzpatrick delivered a Back-Up Control Facility and expanded TUCA infrastructure, including training spaces and a ‘live’ station environment with integrated systems.

The result is a durable, high-fidelity training asset that supports operational and safety-critical learning. It provides a realistic environment for developing skills while remaining flexible for future use as infrastructure programmes evolve.