A major UK infrastructure project required a specialist training environment that would prepare personnel for work in a complex tunnelling operation. The client wanted a solution that closely replicated real site conditions while allowing training to take place efficiently and safely away from the live working environment.

Working collaboratively with the client's safety team, Breathe Safety designed, built, installed and operated a bespoke tunnel-entry training facility tailored to the specific challenges workers would encounter on the project.

The facility was developed to provide a highly realistic training experience. Features included a refuge chamber, multi-level tunnel boring machine simulation, gas monitoring and alarm systems, CCTV, smoke effects and operational background noise designed to replicate conditions within the tunnel environment. By creating a realistic setting, candidates could gain practical experience and confidence before entering the live workplace.

Locating the facility on-site delivered significant operational benefits. Delegates were able to complete training without travelling away from the project location, improving efficiency and reducing disruption to operations. Keeping training local also helped reduce the environmental impact associated with transporting personnel to external training centres.

The facility provided value beyond workforce training. Throughout the project, it was used to support stakeholder engagement, enabling visitors and project representatives to gain a better understanding of the tunnelling environment without entering operational work areas.

Alongside the practical training environment, Breathe Safety supplied a dedicated classroom facility complete with air conditioning and Wi-Fi, creating a comfortable and effective learning space for theoretical instruction and briefings.

At the conclusion of the project, the containerised facility was carefully removed and retained for future deployment on similar projects. This approach maximised the value of the investment while supporting a more sustainable model for specialist training infrastructure.

Outcomes

• Bespoke tunnel-entry training facility designed around the client's specific operational environment.
• Realistic practical training incorporating simulated tunnel hazards and conditions.
• More than 500 candidates trained throughout the duration of the project.
• Improved training accessibility by providing facilities directly on-site.
• Reduced travel requirements and associated environmental impact.
• Additional value delivered through stakeholder and visitor engagement opportunities.
• Integrated classroom and practical training facilities in a single location.
• Training infrastructure repurposed for future projects, supporting sustainability and long-term value.

The Breathe Difference

Effective training should do more than satisfy a compliance requirement. It should prepare people for the realities of the environment they will work in.

 this project, Breathe Safety designed a training solution around the client's specific operational challenges, creating a realistic on-site environment that improved competence while reducing disruption to the project. By combining practical experience, operational efficiency and long-term value, we helped develop a safer workforce without taking people away from the work that mattered.

The result was a training facility that delivered benefits beyond compliance, supporting workforce readiness, project efficiency and better outcomes for everyone involved.