Converted box wagons enter full operational service

A partnership between Porterbrook and Heavy Haul Rail Limited has brought new life to a fleet of old assets, with the conversion of 76 HHA Hopper Wagons into MWA-C box wagons.

The project began in December 2024, with the final unit delivered to Heavy Haul Rail in February 2026.

Carried out at the WH Davis factory in Mansfield, the wagons have been repurposed to carry construction materials and other bulk traffic.

An innovative new design has been used featuring a lighter, stronger, more durable body design that maximises payload while reusing the bogies, brake equipment, and other components from the original wagons.

This sustainable solution aims to prolong asset life and robustness in service.

Max Ordish, Head of Freight and Commercial Projects at Porterbrook, said: “We are pleased to have partnered with Heavy Haul Rail Limited on this sustainable initiative, transforming these assets into market leading boxes with an important role to play delivering volume across the network for many years to come.

“This highlights our ongoing focus to drive growth in the freight industry, and support the increased movement of heavy goods and materials by rail.”

Dave Penney, CEO of Heavy Haul Rail Limited, said: “It is great to see these 76 converted coal wagons now delivering for customers across the UK, as part of our long-term plan to meet growing customer demand for bulk freight.  Delivering materials by rail offers significant carbon reduction and fuel savings compared to road freight because it would take 140 lorries to replace one of our jumbo heavy haul trains.  

“Giving the wagons a new lease of life was not only the more sustainable option, but it also supported the local economy because they were converted at UK based firm WH Davis.”

Andy Houghton, Managing Director of WH Davis said: “It gives us an enormous sense of pride to see these innovative box wagons out in revenue earning service, and we are delighted to have had the opportunity to be part of the collaborative partnership with Porterbrook and Heavy Haul Rail.

These wagons will help support growth in the industry and further strengthen the sustainable move from road to rail for the next 30 plus years.”