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Sand and ballast don’t mix

Although ballasted track remains the conventional method of constructing railway lines, the system is susceptible to ballast contamination in desert and wet areas as well as high-wear in heavy use applications. This can lead to high maintenance costs and, sometimes, even track failure.

Since the 1950s, ballast-less track systems have evolved for specialized applications such as high-speed rail and tunnels, but at a significant initial cost premium. What is needed is an affordable solution for areas with poor ground conditions for which conventional ballasted track is not suited.

Ballasted or ballast-less?

Conventional ballasted track consists of cross-lying timber, steel or concrete sleepers on a ballast bed of crushed quarry stone which in turn lies on a wide earthworks formation. Essentially, it is a bridging system whereby sleepers resident on resilient ballast are bridged by rails that are strong (heavy) enough to accommodate the bending stress required by the train’s axle load specification.

Ballasted track is expensive to maintain given that it contaminates easily, requires access to quarries and ballast supply trains and has to be cleaned and renewed using specialised machinery. All of these can present significant challenges to those responsible for railway construction and maintenance in developing countries and in areas of difficult terrain.

Different ballast-less track systems are available and being used around the world, mostly in the category of track slab systems. These include systems with discreet rail support, such as a hand-laid reinforced concrete slab with baseplates; RHEDA2000 – where standard sleepers are cast into a continuous slab; Sonneville Low Vibration Track (LVT) and the Japanese reinforced concrete roadbed system (RCRS) that uses precast concrete slabs.

DSCN0123 [online]Ballast-less track systems with continuous rail support include Paved Concrete Track – PACT and Embedded Rail Structure (ERS) where the rails are embedded in an elastic boot, cast into a continuous concrete slab.

Longitudinal support

The technological debate between continuous vs. bridged support of rails has some of its origins in Brunel’s “Baulk Road” system installed in the 1800s on the Great Western Railway in the UK. In these systems, each rail is supported along its entire length by a baulk or longitudinal sleeper. Gauge is maintained by the use of tie-rods between the two baulks.

The T-Track system, privately developed in South Africa since 1989, is a ballast-less track system that competes on an equal footing with conventional ballasted track on initial and major upgrade costs, whilst maintaining the substantial cost advantage of ballast-less track. It is an integrated track system comprising both the track substructure, characterised by narrower layer works (compared to conventional ballasted track) and the track superstructure, characterised by a modular articulated beam-track arrangement.

Track modules

The basis of the T-Track system is the track module. This consists of a pair of reinforced concrete beams which are wet-cast into geotextile bags and separated by gauge bars. Stirrups take conventional rail fasteners (Pandrol, Vossloh, Unit Rail) and continuous pads along the length of both beams provide a resilient base for the rail itself.

The modules sit directly on a prepared formation that is narrower than that required for ballasted track and are grouted into place. The design and stiffness of the modules and the formation is carefully calculated using finite element analysis to obtain the optimum performance and support for the track modules.

There are three basic designs of module. Tubular Modular Track (TMT) is used on straight and curved sections. Modules are precast using the same mould.

Modular Tubular Turnouts (MTT) are precast in sections using a double-sided mould to accommodate left and right-hand turns. Modular Tubular Level Crossings (MTLx) – these are an adaptation of TMT using precast inserts which fill the void between the beams to establish the level crossing.

All three types are available for standard gauge (1,435mm) and narrow gauge (1,067mm and 1,000mm) although other designs are perfectly feasible. MTTS are designed for UIC and voestapline VAE designs for 1:9, 1:12: 1:20 secant and tangential turnout sets, and will soon be availiable for the range of Vossloh turnouts.

System design

The T-Track structure is designed using a conservative 2D model to an ultimate limit state (including fatigue). This is verified against a 3D model concurrently during formation design. The serviceability limit state is set at soil deformation. 3D tie beam design and analysis is verified by hand calculation.

Design considerations include the required axle load and speed, rail size and the underlying soil stiffness.

The rail-track with the formation is modelled, with three dimensional (3D) finite element models (FEM), to determine the stresses and deflections (behaviour) of the track structure. The FEMs are solved with a transient dynamic solver, with the linear elastic material properties with damping coefficients for the system with moving load applications.

Image2 [online]The FEM has been calibrated extensively over a number of years for heavy haul operations by the Transnet Freight Rail Track Test Centre in South Africa, as well as the University of Pretoria using measurements from instruments such as pressure plates/ cells at the interface between formation layers and multi-depth deflectrometers (MDDs), typically at three stations, with three holes per station and six MDDs per hole.

In use today

T-Track exhibits a low initial cost and overall lowest total cost of ownership when compared to other track systems. Project cost compares favourably with ballasted track, but has lower maintenance cost, exhibiting a doubling in rail and turnout life and an improvement in weld life. The impact of Tubular Modular Track on project cost is significantly less than slab-track, as it requires a narrower formation as ballasted track. Tubular Modular Track project costs decrease with increasing use over the length of track, as less transitions are required and economies of scale in manufacturing and installation logistics increase.

The ballast-less T-Track system represents a major cost breakthrough for use as a generally affordable rail track solution. It has developed a strong multi-disciplinary value proposition to displace conventional ballasted track and slab track systems in many cases.

And it is not new, unproven technology. 600km are in use in the mining industry while the first surface track was laid for freight traffic in 1990. Since then there have been many successful applications in South Africa, USA and Canada with some installations conveying in excess of 80 million gross tonnes per annum with axle loads of up to 32 tonnes.

Turnouts have been in operation at Ermelo Coal Yard since 2000 without any significant maintenance and have now carried more than 950 million gross tonnes.

Ideal in sandy environments, the first T-Track was installed in Saudi Arabia in 2008. Not only does it remain perfectly resilient, it has maintained its original geometry within 2mm tollerance. Today, having endured some 125 billion gross tonne kilometres in extreme conditions over many years, this technology is now fully proven and certified for operations.

With its lowest cost of ownership and scalability into large projects this technology could well revolutionise the way rail track, especially on freight lines and in difficult terrain, is constructed in future.

Innovation conference gets bigger and better

With more than 200 delegates from over 90 organisations and 33 display stands, the Railway Industry Association’s sixth annual Technology and Innovation Conference on 18 and 19 March was a much bigger event than last year. Writes David Shirres

Introducing the conference RIA’s technical director Francis How reflected on the past twelve months being eventful for rail innovation with the formation of the Transport Systems Catapult. With some justification he felt that RIA had played a significant role in placing innovation at the forefront of the UK rail industry’s agenda.

Red, green, yellow or blue

Delegates soon found that this year’s conference was to be more people-focused. Jonne Ceserani of Power & Grace led a number of highly interactive sessions for everyone to find out whether they had Red, Green, Yellow or Blue personalities. The serious side to this was that successful innovation needs collaboration from all types of people who need to be open to each other’s ideas. For example your writer had always considered that rail capacity was constrained by signalling systems but was persuaded that train braking also needs to be addressed. Speaking to The Rail Engineer, Francis How advised that RIA felt this to be an important part of the programme as the way people act can be a significant barrier to innovation.

During this session those present were reminded that it was wrong to consider that Charles Darwin’s theory of evolution concerned survival of the fittest. Illustrating the importance of innovation, he actually said: “It is not the strongest of the species that survives, nor the most intelligent that survives. It is the one that is the most adaptable to change.”

Intelligent mobility

Towards Intelligent Mobility is the aim of the Transport Systems Catapult (TSC) as was recently explained in The Rail Engineer (issue 111, January 2014). Its chief executive, Steve Yianni, explained how the TSC is encouraging a collaborative approach to developing integrated transport systems so as to meet the challenges of population growth, congestion and increased energy costs.

Most of the TSC’s current projects will use the improvements in digital connectivity that was the subject of a presentation by Mike Short of Telefonica. As an example of the exponential growth in data transmission, Mike advised that the data transmitted in one year’s operation of Telefonica’s 4G network was equivalent to the previous eight years of 3G operation.

The big increase in the use of smartphones will result in 80% of the UK population having one by the year end. Such phones are currently used for an average of 128 minutes per day.

Those who use such devices are also getting younger, as Mike illustrated by reference to a popular YouTube clip “A magazine is an iPad that does not work” showing a  one year old trying to get a magazine to do the things an iPad does. All these factors have huge implications and opportunities for the rail industry.

Innovation in Franchising

Peter Wilkinson, director of rail franchising for the Department for Transport (DfT), believes that rail franchising has been a success. Passenger numbers have doubled since privatisation and 60% more freight is carried. He also felt that few, if any, railways operated so well in such a dense mixed traffic network. Nevertheless, he recognised that rail franchising had to change. For example, a major shift in the DfT’s thinking was that it now recognised that passengers had to come first.

The DfT also now believes that franchising has to foster innovation. As a result, the DfT is making it clear to bidders that quality and innovation is required. This requires new rolling stock as extending the life of the existing stock is not a clever strategy. Peter also felt that the railway was considered to be operating at full capacity only because of self-imposed constraints for which innovation is also required.

He announced that the DfT has created a £50 million Innovation in Franchising fund. This will be available over the next three years for projects covering the East Coast, Trans Pennine and Northern franchises. It will fund innovative projects in these franchises that have a difficult business case or which may not deliver a commercial return during the franchise period.

Sharing experience

David Johnson of DGauge shared his experience of developing an innovative product: a dynamic pantograph gauging technique that allowed restricted clearance tunnels to be electrified without excessive cost. His presentation considered the seven tripcocks of innovation to be: the innovative source; the business case; where does it fit; how does it relate to standards; what approvals are needed; what risk does it import and quadruple the time.

Describing innovation from a rolling stock leasing company’s perspective, Mark Hicks of Angel Trains described the short and long-term tensions between franchise period and operational life of assets. In doing so, he made the distinction between incremental innovation (LED headlamps) and driverless trains and, like many speakers, stressed the need for collaboration.

The pods at Terminal 5

For those using Heathrow, the pods at Terminal 5 offer a glimpse of the future today. Since May 2011, they have carried 950,000 people over two million kilometres of driverless operation at reliability level of over 99%. These pods carry up to four people and are part of a Personal Rapid Transit (PRT) system that provides on-demand transport with an averageUltra PRT Pods [online] 10-15 second waiting time direct to the required destination.

Describing the system, David Marron of Ultra Global PRT explained how it could distribute people around busy congested environments at less cost with less disruption. The pods are battery powered and laser guided in a dedicated guideway. A central control manages the driverless system that can have four second headways, enabling it to carry around 2,500 people per hour.

David emphasised that, with this capacity, PRT systems are not intended to compete with light rail. Instead they offer ‘last mile connectivity’ at a cost of around 40% of the typical £20 million per mile for light rail infrastructure.

The chairman’s view

With his extensive experience at Ford Motors in product development and R&D, it is not surprising that Network Rail’s chairman, Richard Parry-Jones, had some fresh insights to offer the conference. His presentation also echoed previous speakers such as the importance of starting with the customer and that there is “no room for work that is not collaborative”.

He felt that Network Rail faced four technical key issues: electrification catch-up; digital asset management; automatic traffic control and the signalling revolution for which it needed to learn lessons from other industries. For example, there are “many factory concepts that belong on the railway.” The industry also needed to imagine a future with free and infinite digital processing and transmission.

He could understand why railway engineers were nervous about the impact of new technology but felt this risk could be controlled with a robust technology introduction process. On the subject of workforce safety, he considered that this had to be improved and that there were safety solutions in the oil, gas and mining industries that Network Rail should adopt.

Looking back, moving forward

David Clarke of the FutureRailway team announced that there would soon be one less acronym to contend with. EIT is to be dropped as his Engineering Innovation Team merges into FutureRail, a programme with a virtual team from Network Rail and RSSB which is working with industry to deliver the Rail Technical Strategy. It has direct funding of £125 million in CP5 which, with industrial match funding, gives £250 million.

The UK supply chain, which generates business worth £7 billion per annum, only exports 10% compared with 60% and 70% for the automotive and aeronautical sectors. FutureRailway aims to get the supply chain to meet the industry’s demand for innovation and as a result also increase opportunities for export into a global rail market worth £100 billion in 2010 and growing at 2.7% per annum.

To date, FutureRail had provided innovation funding of £30 million, matched by an equal sum from industry. This had been used for various competitions attracting a total of 300 entries, 75 days of testing at specialist facilities and demonstrators such as the independently powered EMU. In addition, support had been provided for DfT’s innovation in franchising.

Currently FutureRail has five live competitions, details of which can be found on its website. David also encouraged delegates to support the Young Railway Professionals’ event Next Generation Rail on 11-13 June.

The conference award

As at previous conferences, a key feature was the RIA/ RSSB Innovation Award for which there were four finalists. Brecknell Willis presented their active pantograph proposal which is intended to reduce service disruption, allow high speeds with existing overhead equipment and provide real time monitoring of OLE.

FLE structures described its idea for an OLE cantilever arm made from non-conductive material, thus eliminating the need for an insulator.

A previous winner, Park Signalling, introduced a proposal for remote condition monitoring (RCM) of signalling equipment not enabled for RCM – which is most of that installed on the network. This involved transmitting LED indications on printed circuit boards to a remote technician’s terminal, eliminating the need to visit the location concerned in order to diagnose faults.

Reliable Data Systems presented its proposal for a video train positioning system which analysed a video of track in front of the train to determine distance travelled. It can also determine the train’s location which can then be displayed on a track map.

Anson Jack of RSSB was glad to note that the delegate’s vote matched the view of the judges which was that this year’s RIA/RSSB Innovation Award, worth £300,000, should go to Brecknell Willis. As a result, the winner expects to produce a prototype of its active pantograph in 24 months’ time.

A further prize was the Mystery Shopper award for the best stand. This went to Thales for their display featuring advanced technologies yet to be used in the rail environment. These included precise positioning information which provides the exact location of individuals in hazardous environments. This works through walls and obstructions and its ‘Through-Wall’ radar technology can even detect the gentle breathing of someone sleeping in a room!

Innovate or die

As was made clear at this event, innovation is the only way that the railway can meet its 21st century challenges. So it is good to learn of worthwhile initiatives at the annual RIA conference which is now a ‘must attend’ event for anyone with an interest in this field. Through its conferences and unlocking innovation scheme, RIA is fulfilling a vital role to promote rail innovation.

Yet there remains much to be done. Informal discussions with suppliers revealed that commercial pressures remain a significant barrier to innovation. However, the oft-used word ‘collaboration’ indicates that this problem is recognised. A number of speakers challenged the premise that the railway was full and felt that those in the industry need to come up with radical solutions to the capacity problem.

The conference was certainly an education. Charles Darwin’s comment in his Origin of the Species can be paraphrased as ‘innovate or die’. With the competition now testing road trains of convoyed cars and driverless cars, this is a clear message for the rail industry.

For more information, check out:

www.shift2rail.org

www.futurerail.org

www.rruka.org.uk

Can you teach an old dog new tricks?

A lot has been written about sustainability from a corporate point of view. However, as a mature individual, and one that has held senior positions for a number of years in a variety of industries, sustainability in the environment is a new concept and one that, at the beginning, I struggled with. Writes Barry Dilks

Having delivered a number of substantial projects, I am well aware of environmental issues. I have experienced delays and unplanned expenditure protecting wild orchids, great crested newts and slow worms. I have had to engage a would-be Swampy – camped outside a badger set to establish if it was in use. I even built a 120-room doormouse hotel that ran for 30 metres parallel to the railway so we could assess the potential impact on wildlife. Sadly, the facility was closed down when not a single booking materialised after three months.

These were all necessary steps in today’s environmental culture as a combined commitment to protect our wild life and the environment. But sustainability …. what on earth is this all about?

Corporate policy

I decided to investigate the UK Power Networks Services (UKPN Services) corporate position and, not surprisingly, discovered that we have processes, procedures and guidelines supporting this initiative. We recognise Responsible Procurement, Protection of the Environment, Waste Management, Pollution Control and Conservation, but it was clear that using the word ‘Sustainability’ meant more than that.

So I engaged with the Network Rail Thameslink Programme Environmental team who were in the process of drafting an Environmental and Sustainability Statement with a vision of linking it to a number of Key Performance Indicators (KPIs).

I left that initial meeting with a headache and, I will be the first to admit, a concern that I still did not fully understand what was clearly a hot topic.

It was time for some new blood and a young mind set which could establish a sensible approach and provide clarity and guidance to the delivery team and, just as importantly, me! We recruited a young environmentalist, Maria Siakovelli, and she was given the task of understanding Network Rail’s expectations, map those against our corporate undertakings and provide a gap analysis.

The good news was that the gap analysis demonstrated that our corporate view and Network Rail’s expectations were in general aligned. Phew, that was a stroke of luck – or was it?

Reporting and monitoring

Having established that we (UKPN Services and Network Rail) are aligned in strategy according to Network Rail, the rail industry and government expectations, what do we do next? Like many other companies, we are pretty poor at reporting all the good things that we do and how we do it, collating data and then ascertaining whether we can be more effective through the analysis of such reporting.

Working with the Thameslink Programme and Network Rail’s environmental and sustainability team, Maria established a number of KPIs that would be the subject of continuous monitoring and reported as a dashboard with statistics and trends. Being young, with lots of passion and bags of energy, Maria took a view that we could do more with minimal investment but it would require effort and buy-in from the project and construction teams.

It was Maria’s passion that made me sit up and listen. Not being a natural tree hugger, and having been busy delivering construction projects all my life, I sceptically viewed the concept as a risk to our delivery schedule.

I was initially quite vocal regarding the ‘supposed’ benefits. What difference can we make? We do not execute huge civil-type programmes – we are a highly competent electrical contractor, working generally on small footprints, so how on earth could we make a difference?

Leading by example

What Maria told me was: “A small contribution can make a huge collective difference.” She sat me down, debated the issue, challenged my views, brought me out of my box and took me for a walk in the potentially greener world. Maria convinced me that we needed to encourage everyone to think sustainability within the environment so they had a better understanding. We had to lead by example and tell everyone what we were doing as a company, why we were doing it and the benefits our contributions could make to the greater scheme.

Hmmmm… Knowing that typical construction crews simply want to get the job done to a high degree of quality (in a safe manner of course), I remained a little sceptical. So Maria produced an initial dashboard of what we were already doing as best practice in project management terms. She cited the usual activities such as segregating waste, recycling waste rather than sending it to landfill, utilising temporary electrical connections for welfare units rather than diesel powered generators, managing delivery logistics better, and the like.

The initial report provided statistics of actual compared against ‘what if’, and the results were quite staggering. She modelled the results against the overall number of sites we were scheduled to deliver and demonstrated we could make a difference to our environmental impact if we compiled statistics across several projects and the company overall.

OK, I was convinced. I still wasn’t exactly what you would call a tree hugger, but I have to say the statistics certainly got my attention.

Challenging Maria

But I threw Maria a curve ball and challenged her again by stating that, in everything we do, we must always ensure that expenditure and effort bring short and long term benefits. I asked her to tell me what we could do, what investment was required and how quickly would that benefit be realised.

Maria initially concentrated on ‘what can we do today that can bring immediate benefits with little or no financial investment other than time and effort?’ She set out a strategy of educate, plan, encourage feedback from the bottom up, capture data, educate some more, plan again (think outside the norm), report back on what we have done and then educate everyone again on the impact and benefits provided.

And so Maria started the education process with the project team and site crews. She stressed the benefits of what we were doing using the data from historical works and overlaying future work sites. The feedback was refreshing. Everyone thought it was a good thing to do and even provided suggestions to consider some other savings such as – why do we have empty vehicles? What about ECO cabins? Why do we scrap so much?

When we start on a new site, we initially level the construction area, remove the waste and then fill with appropriate foundations – say type 1 for construction. We looked at this process for one site, namely Ifield in West Sussex. Typically we would arrange for a tipper with a grab facility that would set off from Godstone empty, pick up the site spoil and return to base. That spoil would then be segregated, the recyclable material sent to Gatwick recycling and the remainder despatched to Smallfield landfill centre. Once the site was ready, the same company would deliver type 1 to site and return to base empty.

 

St Pancras – Sheffield Line Speed Improvement Project

Many people, including the author, have long argued that the East Midlands has suffered for too long with a second rate main rail line. In fact, that has been the case ever since the demise of the majority of the Great Central line at the time of Dr Beeching. Writes Chris Parker

The Great Central was the only British main line built to continental gauge, and was constructed from the outset as a main line railway. Its alignment was designed for what were, for the time, high speeds. There were separate tracks on much of the route to keep freight and stopping traffic out of the way of express trains.

Making the best of it

For whatever reason, Beeching decided to destroy most of this route, retaining instead the twisty, tight Midland Railway main line (MML). Why was this the chosen option? It can’t have been about making the railways more efficient and effective.

Whatever the reasons, the option to reinstate the Great Central line is now confined to the ‘too difficult’ category. Too much of the alignment has been sold and built upon or ploughed up for any realistic chance of a revival. The East Midlands therefore has to make the best of what it has, at least until the arrival of HS2.

Track relay 2 [online]

That means making the best of the MML. Network Rail and the other stakeholders in the line, particularly East Midlands Trains, have been collaborating to try to make the line rather more of a silk purse than a sow’s ear. A plan was developed as part of Network Rail’s Control Period 4 (CP4) commitment and The Rail Engineer recently visited the East Midlands Control Centre in Derby to meet scheme sponsor Kevin Newman and look at the achievements and challenges of the project.

The £70 million scheme is intended to cut eight minutes in either direction from the journey time for Class 222 Meridian sets running between Sheffield and London St Pancras. Five minutes of this target is being delivered through infrastructure works along the route. The remaining three are coming from reductions in the timetabled engineering allowances on the route, which are being made available by other transformational programmes on the part of Network Rail.

Planning and collaboration

The project has used the so called ‘third way’ approach to line speed improvement that was the basis of much of the similar work done on the West Coast main line. This involves detailed examination of the theoretical and actual track geometry on each line to determine the most cost effective practicable increase in speed attainable on each section of line (if any). The ruling speed of the line was already 125 mph, but relatively little track was actually running at this speed before the project commenced.

Planning and execution of the works depended heavily upon collaborative efforts between Network Rail, East Midlands Trains and other stakeholders.

For example, there would be no point in increasing the permissible speed at any given place to a speed higher than that practically achievable by the trains. Depending on the circumstances, this might be constrained by the accelerative capabilities of the sets, or by their braking characteristics. There would be no point in a line speed that trainscouldn’t reach by accelerating away from a regular station stop or permanent speed restriction, nor would it be useful to extend a high speed beyond the point at which trains would always need to start braking for a similar stop or restriction.

Implementation has been made easier by collaboration between Network Rail and the train operators. East Midlands Trains, in particular, has been collaborating closely with Network Rail over the various works around Nottingham, and this involvement and assistance has been equally vital in the MML project.

Implementation has been made easier by collaboration between Network Rail and the train operators. East Midlands Trains, in particular, has been collaborating closely with Network Rail over the various works around Nottingham, and this involvement and assistance has been equally vital in the MML project.

Four phase commissioning

The original plan was to substantially complete the whole of the project in time for the last national timetable change on 8 December 2013, commissioning the new works in four phases. The first of these, Derby to Chesterfield, was completed on time on 16 November 2013. Elstree to Sharnbrook was due to complete, and did so a week later, on 23 November. East Midlands Parkway to Derby also finished on time on 30 November 2013.

The missing section was East Midlands Parkway/Sharnbrook, which was originally due to complete on 7 December 2013. However, it was foreseen that there was going to be an issue with track condition between Kettering and Loughborough. Such were the track conditions over this stretch that it was decided that it would be impossible in practice to drive to the increased line speed in between the required condition-of-track speed restrictions.

The decision was therefore made to defer the completion of the affected section until March 2014, to permit the necessary track renewals to be completed. This was a joint decision as Network Rail had flagged up the situation early and discussions with the train operator determined the way forward. Network Rail held a series of roadshows for train drivers and other staff to explain to them why the situation arose, what was being done about it and the timescales involved.

Signalling works 2 [online]Due to this delay to the one section of the project’s works, East Midlands Trains’ performance under the PPI measure suffered some days. With lower speeds than planned on the affected route section, it was difficult to recover from other problems on the route. There was also some impact on the train operator’s ‘right time’ performance measure.

Despite that, East Midlands Trains continued to work co-operatively with Network Rail, for example by assisting in finding the infrastructure operator the necessary access opportunities for the work. Though they would ideally have liked an instant solution to the situation, they understood that this was not practical, and so they helped expedite matters where they could.

Aside from the condition-of-track renewals required between Kettering and Loughborough, there were some S&C renewals (including Flitwick for example) still not complete at the time of the introduction of the new timetable. A number of track realignments could not proceed until completion of planned bridge reconstructions in preparation for the forthcoming electrification of the route.

Whilst there were significant timetable improvements, the full benefits of the project were not input into the December 2013 timetable change, but will enable further enhancements in the future. In the interim, it is heartening to see this further evidence of mature, collaborative working between Network Rail and East Midlands Trains on another major project.

Recognition must also be given to the other players in the project. Carillion, Network Rail’s major framework contractor, undertook signalling and some track works alongside Network Rail Projects. AMCO was the bridgeworks contractor, while Atkins and Babcock were respectively responsible for the signalling and track designs. Signal testing was by TICS.

HS2 PLUS

Sir David Higgins has said he wants to accelerate the construction of HS2 and see Britain be more ambitious with its high-speed rail plans. In his first public outing as HS2 Ltd’s new chairman, Higgins outlined a handful of recommendations for the £42.6 billion project – the most substantial of which was to take the line up to Crewe by 2027 and complete Phase Two by 2030.

As well as arriving in Crewe six years earlier than originally planned, the HS2 PLUS report recommended building a new hub interchange in the city as opposed to the current plan to connect it via a branch line off the main route. By building the 43-mile section north of Birmingham earlier, Higgins believes he can deliver the benefits of the line to the region sooner and start to set right the country’s economic imbalance.

Possible changes at Euston

The report also waded into the Euston debate, suggesting that the best option would be to lower the entire terminal, rebuild the Euston Arch and redevelop the station into something that could rival St Pancras and King’s Cross.

Addressing a meeting in Manchester recently, Higgins discussed the feasibility of the so-called Euston Cross concept which envisages a new sub- surface HS2 line constructed with an east-west platform connecting the terminal with St Pancras and King’s Cross.

Higgins said that new stations at Crewe and Euston should also be backed up by having a major interchange at Old Oak Common – a project that could be a catalyst for regeneration, doing what Stratford did for East London.

Presenting the report, Higgins said: “Phase One of High Speed Two needs to address the capacity challenge. Phase Two must address connectivity and therefore must be integrated with existing and future transport services and also looking to maximise the value added to the local and national economy. HS2 has the potential to transform the North – not just individual cities, but the region as a whole, but only if we have the ambition to think of the big picture. So far the focus has tended to be on individual places and individual stations. I think we need to think broader than that.”HS2 Plus: A Report by Sir David Higgins

How HS2 should connect with HS1 and the rest of the European high-speed rail network was also covered in the report. Higgins recommended the government scrap the current £700 million link, describing it as too much of a compromise because of the impact it would have on freight capacity on the West Coast main line, the future growth of the North London line and the people of Camden.

National benefit

Another central aim of the report was to address questions about how HS2 will benefit the UK as a whole. Higgins said the project needed to work with the Government, Network Rail and

local transport authorities to better integrate high-speed rail with the conventional rail network, creating better transport links not just north-south but east-west from Hull to Liverpool and between Manchester and Leeds.

Speaking to The Rail Engineer about how this could be done without losing the benefits of the high-speed system, Higgins said: “Well that’s a real challenge and we’ve got to look at how that works.

“Much of that is how the big interchanges work, so you have an interchange that connects conventional rail and tram into high speed rather than having everything going onto the high-speed line.”

Talking about the need for HS2 overall, he added: “What we have done is give the alternative to upgrading the West Coast if you don’t do High Speed Two. The figures show you never get anywhere near 18 train paths, you have about 20 years of disruption and it will cost £20 billion plus.”

Lower cost

In November 2013, Higgins was asked to produce a report that would look at ways to not only deliver HS2 quicker than planned but also cheaper.

Currently, the Phase One budget stands at £21.4 billion, with an additional £21.2 billion set aside for Phase Two and a further £3 billion for rolling stock. The report supported the current cost estimates and suggested that it would be “irresponsible” to reduce the contingency that has been built into the budget. However, the former Network Rail chief executive sent a clear message to the government – the earlier a decision is made, the cheaper it will be.

“The simple truth at the heart of this, as any project, is that there is a direct connection between certainty, time and cost,” said Higgins. “The more certainty there is about the timescale, the more possible it is to control cost through economies of scale.”

Following the official launch event in Manchester on 17 March, Secretary of State for Transport Patrick McLoughlin issued a statement backing the recommendations. Comments also flooded in from the industry, with the majority supporting the principles underlining the recommendations.

Dr Colin Brown, director of engineering at the Institution of Mechanical Engineers (IMechE), said: “HS2 is a vital project for increasing transport capacity and improving connectivity in the North. A properly integrated and efficient transport system is critical to creating a balanced economy and accelerating the construction of the northern section of the project, as Higgins suggests, would mean we could help bridge the North South economic divide more quickly.

“Engineering risks are not the cost drivers for the project, confidence and forward planning are key to keeping the costs down and it is down to Government to ensure we get the legislation right to make the HS2 project happen.”

Paul Plummer, Network Rail group strategy director, commented: “The step-change in capacity that HS2 enables across the network as a whole will transform the service on existing lines, creating the space we need to meet growing demand and deliver new and better connections.

“The timetables that might operate are by no means fixed and we will soon announce a programme of engagement with passengers and stakeholders, both inside and outside the industry, to seek their views on what should be prioritised as we start to plan future services.”

Putney station on track

Putney Station is one of the busiest suburban commuter stations in London, with 18 trains per hour passing through it at off-peak times alone. More than 11 million people used the station in 2012-13, making it busier than the stations of several large cities.

The station opened when the Nine Elms to Richmond line came into service on 27 July 1846, and was rebuilt in 1885-6 when the tracks were quadrupled. 130 years later, Spencer Rail began work on an £8 million improvement programme in October 2012. The redevelopment, scheduled for completion by Spring 2014, is being funded under the Department for Transport’s Access for All initiative.

Challenging access

Since the start of the project, Spencer Rail has been working on site to install three new lifts, expand the concourse area, build new ticket gates and install new toilets. Now, as the project nears completion, Spencer Rail has carried out one of the most significant parts of the project. A temporary footbridge with staircases, which was installed to maintain access to all platforms throughout the works, was removed three weeks ahead of schedule.

Half goneAfter serving passengers for 55 weeks, the bridge was removed early despite delays at the start of the project due to access problems. Project director Neil Stuart said: “This was without doubt an immense achievement and a crucial milestone on the way to a vastly improved Putney Station.

“Construction access to the station was restricted by surrounding residential properties and the volume of passengers using the station is high, which presented our  rail team with a logistical headache. The team therefore installed the bridge manually, without the use of any large machinery.

“The Putney project is one of the most logistically challenging Access for All schemes that we have faced but we are now well on course to complete the works in the coming weeks.

“We have worked on a number of Access for All programmes across the country and this is another project we will be able to look back on fondly. However, there are still some works to complete before we leave the site and the team will be working hard to ensure we do not run over our deadline.”

Disassembling the bridge

Work began to deconstruct the bridge at 02:00 on Sunday 23 February and was completed in time for the Monday morning rush hour.

Alex McDermott, senior project manager at Spencer Rail, said: “It is the end of an era at Putney Station.

“As those who know the station will be only too well aware, this was not the location for a set-piece spectacular, where the construction team brings in a huge crane and local residents gaze in wonder as the span is lifted away in a matter of minutes.

“Putney Station is surrounded by private property so bringing in large plant is out of the question. The routine, now familiar to this team is hard, manual effort – and lots of it.”

The teams, which included more than 70 people, arrived on site ready to start at 02:00 but were delayed due to having no access to the track at that time. However, temporary scaffolding was erected on the first pair of tracks at 06:00 and the first span was down and tracks clear by 08:30, putting work back on schedule.

The teams worked through the day to take down the second span and most of the staircases, with passenger walking routes being diverted to the new stairs. Platforms were repaved and new lights were also fitted as part of the work.

New lifts and staircases

The primary objective of the works is to provide step-free access from the ticket office and concourse to the platforms at Putney Station for all passengers, in accordance with the Disability Discrimination Act 2005. A secondary benefit of the scheme will be the increased concourse area, which will alleviate congestion at the gate-line.

PutneyStation-47 (1) [online]As part of the work, a dispersal bridge has been installed which spans all tracks and includes three new lift shafts and staircases. A 16-person lift now goes to each platform – platforms two and three will share the same lift. In addition, there are alterations to communications and passenger information systems and extensive new lighting, and there will be two new public toilets and one for staff.

The concourse now has a masonry and glazed façade and all structures are covered by metal profiled sheet roofing. It will be increased in size
by removing the existing rear wall (the east face) and extending the floor space by approximately 14 metres to the rear of the building. This will make room for the gate-line to be moved away from the front entrance, thereby improving passenger flow at busy periods.

There have been significant alterations at platform level as well. On Platform 1, the old platform canopy was demolished in order to make room for the new staircase.

The existing platform building and canopy on Platforms 2 and 3 were partially demolished as part of the works, as were the existing staircase and rooms beneath on Platform 4. The new lift motor room has been located under the new staircase.

What’s left to do?

With the project team working towards a completion date of 16 May, Spencer Rail is now putting the finishing touches to the station. There is still a lot to do, including the completion of floor and wall finishes (mainly tiling) and the roof cladding. The lifts have to be commissioned, as do the new lighting, toilets and CCTV. The previous customer information screens and PA system has to be reinstated.

Structurally, arches between the ticket office and the concourse will be opened up by removing several piers and the temporary access ramp will be removed so that the canopies and platform surfaces can be made good.

With the new bridge open and the temporary one removed, life is getting back to normal for travellers from Putney. All the work has been carried out without any additional closures other than those already planned for the whole line so, apart from having to use a temporary footbridge and make a few detours, passengers haven’t been unduly inconvenienced. Step-free access will be fully in place by the middle of May and the team from Spencer Rail will be satisfied with a job well done.

A brief history of time

Einstein’s general theory of relativity describes the gravitational effect of large bodies: spacetime curves due to the presence of matter and energy. A similar effect appears to apply to large rail infrastructure programmes. Writes Mungo Stacy

Often these seem to warp into a series of incomprehensibly large attention-grabbing statistics whilst absorbing vast quantities of resources.

Take Thameslink. Or rather, not the whole of Thameslink, but just Thameslink Key Output 2. Running over 93 months from 2011 to 2019, this £2.4 billion programme will, amongst other works, reconstruct London Bridge station and provide capacity for 24 trains per hour in each direction through the core route.

At The Rail Engineer, there’s no denying we like to cover the big stuff. But, as rail engineers know, complex programmes are the sum of their constituent projects. And the small parts can have their own difficulties and complexities, and be just as crucial to successful delivery of the overall programme as the major blockades.

One such project was signal gantry XTD 3736. This was successfully installed by Lundy Projects, working for Balfour Beatty Rail, on the night of Saturday 1 March. Whilst a small element in itself, it had critical links to the overall Thameslink programme and was subject to some interesting spacetime effects.

Long-span gantry

During Christmas 2014, the major LL09 blockade will reconfigure London Bridge station and commission the six low-level platforms. In order to de-risk the blockade, works to install gantry 3736 were brought forward. This was driven particularly by the weather risk, outside Network Rail’s control, which could force the abandonment of crane lifts.

IMG_3454 [online]Three of these large gantries are required to be in place by the Christmas blockade, and 3736 is the second. Once the decision was made to accelerate installation, Lundy Projects were given only eight weeks to design, manufacture and install the gantry and associated substructures. Time was therefore extremely tight.

The gantry is located on the 11-track viaduct approach to the east of London Bridge station. The tracks already occupy most of the structure width so there was limited room for foundations.

Therefore, the gantry spans eight of the tracks with a span of 31 metres. A cantilever over a further two tracks takes the total length to 38 metres spanning 10 tracks. The gantry is a Warren Truss arrangement with two support columns. The design was undertaken by Lundy Projects’ subcontract designer, Aspin Consulting.

There was room between tracks 3 and 4 for a regular pad foundation. At the south side there was no room for a new foundation between the tracks and the viaduct parapet wall. Therefore a new foundation had to be created at road level, some 12 metres below the gantry level. This foundation needed to be piled due to the large overturning moments caused by the height of the support leg and the span of the signal gantry.

Space was extremely limited for the new foundation. Part of an existing building needed to be removed to make room, and even then there was only a nominal three metres clearance between the viaduct and the remaining building.

Time was also short. The building’s tenants, Tower Antiques, only vacated the premises three weeks before the superstructure installation was due. This followed an extremely complicated property negotiation by Network Rail. It also created a key link to the foundation design as it precluded any ground investigation being carried out at the exact location until the tenants had vacated and demolition was complete.

Design and manufacture

Lundy Projects was in charge of the overall signal gantry sub- and superstructure conceptual and detail designs.

“We had to ensure that high level conceptual designs were realistic and achievable by all multi-disciplined parties involved in delivering this structure,” project manager Jamie Lundy explained. “Material availability, procurement of materials, manufacturing timescales, finishes, design approvals, curing times for concrete and so on all had to be taken into consideration to allow an achievable program to be developed, approved and ultimately implemented in such a short time”.

Within a week from starting the design, Lundy, working closely with Network Rail and Balfour Beatty, produced a conceptual 3D design for both the sub- and superstructure ready for structural and detailed designs to start. The procurement of materials and in-house manufacturing offered by Lundy commenced concurrently with detailing the signal gantry to ensure delivery timescales were still achievable and met.

The gantry incorporates some neat features to facilitate future stages of the wider programme. The gantry has been installed prior to re-signalling, therefore the existing signalling remains operational. The underside of the gantry was therefore set high enough to avoid blocking sightlines to the existing signals.

Likewise, the signal platforms are installed in a temporary position higher than their final level. This will allow the signalling contractor to install the signals and cables and undertake soak testing, before lowering the signal heads to their final positions. This will be undertaken using road-rail plant, avoiding the need for large craneage and reducing risk for this stage.

Foundation redesign

Aspin Consulting designed both the foundation and the superstructure. Pile installation was carried out by Aspin Foundations while the pilecap installation was contracted to Terrawise.

Tom Keating, associate at Aspin Consulting, explained: “The south foundation was not at all straightforward. We were very restricted with the working space and this limited the rigs we could use.”

508mm diameter steel piles, which could be twisted into the ground rather than driven, were proposed to minimise disturbance to the adjacent viaduct. However, ground conditions proved to be worse than expected; it had not been possible to carry out boreholes at the site location due to the antiques building so conditions had been inferred from other investigations.

Problems were apparent as the first piles were installed. The recent severe rain had led to a high water table and there were concerns about gravels and fines being removed by pumping, potentially creating voids around the existing foundations. The smaller rigs also had limited power as gravels became trapped between the auger and casing.

Piling was abandoned and a new foundation methodology considered. Now with only two and a half weeks to go until the gantry installation, Aspin Consulting redesigned the foundation in two days. Again, close working with Network Rail gave a swift approval of the design.

The revised design used 150mm diameter grouted steel piles with closed end casings, which avoided the water ingress problems. These were installed by an in-pile Grundomat air-driven piling hammer. A larger number of the smaller piles were needed, and over four days the 24 piles were driven to set at around seven metres below ground level.

With the clock now at T minus 6 days, and Aspin Foundations having completed the foundations, the restricted site was handed over to Terrawise to install the pilecap reinforcement and concrete. The change in pile design meant the pilecap needed to be increased in depth by one metre, and this gave increased complexity around a brick culvert which had previously passed below the pilecap. C50Piling Foundations inside former Antiques business to support gantry concrete was used to achieve the early strength required to install the gantry: the pour was completed at T minus 4 days.

Four hour possession

The possession on Saturday/Sunday 1/2 March was a planned 4-hour window to install the whole gantry. It was due to start at 02:30 but in the event, access was not available until 04:30 due to problems establishing the worksite.

Jon Andrews of Lundy Projects explained: “With a slight delay at the beginning of the possession we had less time than expected. Balfour Beatty were on site as the principal contractor, liaising with the Network Rail site representatives who were
in close contact with Network Rail Operations. We reviewed the situation and took a joint decision to proceed, as we were confident that we could install the gantry in the time available if all went to plan”.

With time being tight and the nearest road-rail access points being some distance from the site, mobile elevated working platforms could not be used for bolting the main boom to the gantry support legs. Therefore, scaffold access towers were designed and would be used as an alternative solution. Once the possession and line block was granted, the towers were lifted into position on track ready for the steel erectors.

The adjacent Druid Street was closed for 48 hours to allow the three sections of gantry to be assembled at ground level and a 1,000 tonne crane set up. Sarens undertook the contract lift.

Signal gantry XTD 3736 was installed on time, safely and the lines handed back within the agreed time scale.

Collaborative working

Afterwards, Jamie Lundy reflected on the collaboration which had led to the successful installation: “I believe the hallmark of Lundy is not in the complexity of the projects we deliver, but rather in the simplicity with which we deliver them. This is credit to, not just Lundy Projects, but also to our client and preferred suppliers. Without close and open collaboration with Network Rail, Balfour Beatty and our supply chain the opportunity in bringing the installation of Signal Gantry XTD 3736 forward to de-risk the Christmas 2014 blockade would have been missed”.

Andy Hoffman of Aspin Consulting agreed: “Complex projects require experienced innovators; driven individuals with collective motivations and aspirations. Trust, empowerment and personal responsibility is liberating to both individuals and to organisations in succeeding on complex assignments. Lundy and Aspin Group shoulder these fundamental ingredients, which bring successes to such projects.”

Chris Ottley of Balfour Beatty Rail added: “Without doubt there were a number of occasions leading up to the possession where the obstacles appeared to be too much and the easier option would have been to delay the installation. Only through a true collaborative approach between all parties and sheer perseverance was this installation possible.”

Lundy Project’s contract includes a total of ten signal gantries, which in turn are just one element of Balfour Beatty’s signalling related minor civils contract at London Bridge. This one has been the most challenging gantry installed to date – but then, everything is relative.

The Standedge experience

Forget IEP, NET and HS2. Give ERTMS a miss. These high-gloss ventures might catch the eye but they have no soul, submerged in binary code. Writes Graeme Bickerdike

What this magazine really needs – apart from a glossary – is a piece on MVL3/40-SFT2/3/7, dripping with history from every mortar joint. We’re talking here about structures; substantial structures, taller than St Paul’s. Thousands of passengers rattle past daily, just feet away, yet they never see them and never will. Intrigued? Grab a torch and slip into something rubber. Ahead of us stands the portal to a sodden labyrinth wherein gangs of men toil. That’s right – dirty work, with proper tools and everything. Theirs is an absorbing tale of… ahem… downpipes and duff brickwork. I’m trying too hard, aren’t I?

Classic misdirection

Standedge Tunnel penetrates the Pennines between Diggle in Greater Manchester and Marsden, West Yorkshire. But just describing the place as a tunnel doesn’t really do it justice. This is a truly unique piece of infrastructure comprising four bores, all over three miles long and connected to each other by dozens of adits and passageways.

Its history goes back 220 years to the development of the Huddersfield Narrow Canal, authorised by Parliament on 4 April 1794 and engineered by Benjamin Outram. Still the country’s longest, highest and deepest canal tunnel, construction was plagued by difficulty, mostly arising from poor working practices and a dearth of funds. Two contractors suffered financial ruin; activity ceased for long periods. Although the surface sections of canal were in use by 1798, it was another 13 years before Lively Lady became the first boat to officially navigate the tunnel.

Standedge-031 [online]
Photo: Four by Three.
To draw water from the workings and provide a drain for the water engines used to hoist spoil, 14 moorland construction shafts were initially progressed; adits and others shafts were then connected to them. But these temporary works proved expensive and something of a distraction. Eight of the shafts were ultimately abandoned and tunnelling thereafter was concentrated largely at the two ends.

Leaving much to be desired was the setting out over the hill. Shafts were displaced from their intended position both laterally and longitudinally, in one case by 40 yards. The elevation at the Diggle end was several feet too high, demanding costly remedial works. Nicholas Brown, the company’s surveyor, was dismissed whilst Outram resigned in 1801. Five years later, Thomas Telford formulated a plan to save the floundering project. He found that two approaching sections of tunnel were out of alignment by as much as 26 feet and only when the excavations were finally joined together in 1809 was an accurate length for the tunnel established: 5,477 yards.

The railway cometh

With its limited load-carrying capacity and the absence of a towpath through the tunnel, the waterway never successfully competed with the Rochdale Canal a few miles further north. The tunnel did however prove its worth when work began on the Huddersfield & Manchester Railway in 1846, running parallel with it on the south side. Thirteen adits were pushed outwards from the canal tunnel, allowing the single-track bore to be driven from their ends. A fleet of boats ferried spoil out and materials in, an approach which brought construction to a conclusion in a little over two years. The nearby Woodhead Tunnel – fulfilled in part by the same contractor, Thomas Nicholson – had been progressed from five shafts and took more than seven years to complete despite being slightly shorter.

As enterprises go, this was a great industrial spectacle. At its peak, 1,953 navvies were involved, mining and lining the tunnel from 36 working faces at a rate reaching 85 yards per week. One account records that “300 yards of the tunnel had to be worked out of a solid stone, extremely hard, being literally without a seam or crack, and is left without either wall or a sustaining arch. The general strata consists of strong posts of millstone grit, and in some places of hard sandstone and beds of shale.”

Nine men did not survive to see the tunnel finished; one had his skull split in two by a rock falling down a shaft from one of the skips. Meanwhile Nicholson and six others had to launch themselves against the sidewall to escape a collision between an engine and the horse-drawn wagon they were travelling in which met head-on in the darkness.

Costing £201,608 (about £17.7 million in today’s money), the tunnel was formally opened on 13th July 1849. Trains were accompanied through by a pilot man or pilot engine, their re-emergence being transmitted to the other end by Henry Highton’s patent telegraph system. The portal was designed with two entrances, underlining the intention to construct a second bore.

That eventuality came to pass in the spring of 1868 when contractor Thomas Nelson successfully tendered for the job. Again, spoil was removed by boat, hauled by four powerful steam tugs, the canal being linked to the new bore by 21 adits passing under Nicholson’s tunnel. The programme suffered from workforce unrest, with both miners and bricklayers separately striking in protest at payment terms and shift length. No fatalities had been reported by the time of its opening in February 1871, discounting miner David Harper who fell into the canal as he staggered back to his lodgings from the Navigation Inn.

Dark horse

With capacity still constrained, the London & North Western Railway embarked on a four-tracking project through Standedge in 1890. This demanded construction of the two-track tunnel used today by TransPennine services. The L&NWR progressed the work itself under chief engineer AA MacGregor, accommodating the 1,800 men involved in the Diggle paper mills and 54 wooden huts assembled at the eastern end. Although navvies were not particularly welcome in Marsden, several hundred locals did gather on 7 May 1892 to enjoy a parade of 40 works horses.

The tunnel’s heading – seven feet square – was again driven from 13 adits, this time connected to the 1849 bore. To expedite progress with the excavation, 40 break- ups were then opened and around 120 tons of gelignite consumed. The bricks – 25 million of them – were fired locally except for an outer face of Staffordshire brindles. Given the honour of placing the first two were MacGregor’s wife and 10-year-old son who were conveyed on a wagon to the tunnel’s midpoint for the ceremony. Can you imagine the paperwork? With the end in sight, a 26-foot length – mined and propped ready for lining – collapsed in April 1894, blocking the tunnel for a week.

Major Yorke, the Government inspector, deemed the tunnel fit for purpose on 1 August. Opening triggered temporary closure of the single-track bores for repair, whilst remedial work continued on the canal tunnel which had suffered considerable damage as a result of the blasting operations.

Closure came to the Huddersfield Narrow in 1944, commercial traffic having evaporated, although the Ailsa Craig managed to complete a passage of it four years later. A £30 million restoration brought the canal’s reopening in 2001, much of the money being invested in the tunnel which had collapsed in places. The Nicholson and Nelson bores last saw trains in the late Sixties and today are used for maintenance access. Located at their midpoint is a place to make U-turns – a full-height connection known colloquially as “the cathedral” due to its vaulted roof.

Clear the air

The canal and single-track bores benefit from natural ventilation via shafts at Cote, Flint and Pule Hill. Additionally, water sprays were used to create an artificial circulation of air through the adjacent Down Cast and Up Cast shafts at Redbrook whereby a system of doors and gratings – operated by the platelayers – regulated the flow through a subway to where it was needed.

Ventilating the operational tunnel are three shafts at Brunn Clough (known as No.2 shaft, 443 feet deep, now capped), Redbrook (No.3 shaft, 495 feet deep, capped) and Flint (No.7 shaft, 515 feet deep, not capped). Being railway owned, these are the focus of the ongoing intervention, their brickwork having deteriorated over many years through incessant water ingress. Initial activity has focussed on works to capture around 70% of this water, involving the clearing or renewal of ring dams and their associated downpipes (some of which were original, made from timber), the water then being discharged into the canal. Additional weep holes have also been inserted. Once the lining dries out, it can then be cleaned of its mineral deposits and repaired. All this should make life more palatable for those who have to enter in future. “By far the wettest shaft I have ever examined” is a notable quote from Flint’s 2008 detailed exam. Whilst the work is not particularly difficult, it is high volume. About 1,000m2 of No.2 shaft’s brickwork needs relining or pressure pointing with a specialist mortar; the figure is 2,600m2 for No.3 shaft – effectively the whole thing.

Standedge-078 [online]
Photo: Four by Three.
The key to all this – and the issue that causes most headaches – is access. When the team arrived on site in September, shafts 3 and 7 opened only into the operational tunnel which is used round-the-clock by Manchester Airport services. Had the project relied on short Saturday night Rules of the Route possessions, the work would have taken years to fulfil given the mobilisation time involved with each incursion. That timescale was untenable in light of the impending North Trans-Pennine Electrification scheme. Removing the shaft caps and descending from the surface would have brought severe restrictions due to the area’s designation as a Site of Special Scientific Interest. Mitigation for the resulting public safety risks would have demanded 24/7 security patrols. But Network Rail and Amco Rail, its principal contractor, collaboratively came up with a solution, digging down to the latter’s mining roots.

You’ve ’ad it

With the 1849 bore already used for access, the logical approach was to connect it to shafts 3 and 7 by driving new adits. To establish a starting point, an initial core was drilled outwards from the shaft; thereafter they worked the other way, opening out the ground with a mini digger and breaker, then installing rock bolts, plates and stainless steel mesh to secure the ground before the next 0.5m advance. Progress was slow – a function of the geology – but methodical.

Once through, work platforms had to be assembled in each of the shafts to enable the workforce to reach every part of the lining. Clad in glamorous PVC, I emerged into the downpour at the base of shaft 7 to be confronted by…a spaceship apparently, surreally floating a few feet off the ground, having descended from the heavens. Contracted to provide these modular structures is the impeccably named Apollo Cradles. Each is powered by four electric motors, enabling the platform to climb wires attached to suspension beams across the top of the shaft, threaded through cores in the cap and then dropped down to anchors at the bottom.

Complicating life further in shafts 2 and 3 are crash decks comprising two layers of bullhead rail, through which openings have had to be cut so the platforms can be constructed above them. In shaft 3, the rails are at an unhelpful height of 16 metres and have themselves required remedial works in order to make them secure. By necessity, Haki stair towers have been deployed to reach their underside but these have in turn brought difficulty with the winching of platform components.

Hats off

What at first might appear to be a mundane job is actually anything but. If you overlook its scale and spectacular setting, yes, the substantive work is routine. But for every obstacle that’s been surmounted, another looms ahead. Amco has risen to each challenge and continues to make headway, somewhat against the odds.

For those labouring in the deluge, modern foul weather gear affords better protection than the navvies who sunk these shafts 120 years ago could ever have dreamt of. The conditions though are probably as close as anyone comes now to those experienced in the Victorian era. And yet these men always have a smile for you or a warming cuppa. I have nothing but admiration…big time.

Sleek lines

It’s often said in engineering circles that, if something looks right, then it is right. When Direct Rail Services (DRS) recently showcased the first of their new 15-strong fleet of Class 68 diesel- electric locomotives the sun shone and everything about 68002 ‘Intrepid’ looked very right indeed. Writes Stuart Marsh

That DRS are proud of the new locomotive was very obvious, and so they should be. Hailed as a ‘new generation’ locomotive, DRS says, ‘The new locomotive is set to deliver a significant performance benefit for both DRS and its clients.’ No kidding – this DRS venture is positively heroic!

UKLight

The Class 68 simply exudes excellence, resplendent in an updated version of the DRS ‘compass’ livery. Its design is derived from the existing Vossloh ‘EuroLight’ four-axle locomotive which offers high power output and a low axle loading. DRS has worked closely in partnership with Beacon Rail Leasing Ltd in order to develop the concept of this new locomotive with Vossloh.

EuroLight uses components from the 20- 22 tonne axle load Vossloh Euro locomotive series, with weight reduction being achieved by switching to a lighter engine of the C175 series from Caterpillar Inc (CAT®) and a lighter alternator set and traction equipment from ABB Group.

In producing the Class 68, the EuroLight design had in turn to be adapted to fit the UK’s more restricted loading gauge. This UK version, which Vossloh calls UKLight, also offers a higher top speed – increased from 140km/h to 160 – and fuel capacity increased from 4,000 to 5,000 litres. It has an axle loading of 21.4 tonnes.

Manufacture of the locomotives is being undertaken by Vossloh España at its Valencia works – the same factory that built the Class 67 locomotives in 1999 when it was part of the GEC-Alstom group. The value of the Class 68 contract is around €45 million.

CAT

Positioned almost exactly at the centre point of the locomotive, the CAT C175-16 ACERTTM diesel engine is a derivative of Caterpillar’s very successful C175 series of 16-cylinder and 20-cylinder engines, used commonly in generator sets and heavy earth moving equipment. The C175 has been installed in locomotives elsewhere, notably the Progress Rail PR43C in the USA. This is, however, its first application in a British locomotive.

The C175-16 is a medium-speed four-stroke engine with a 175mm bore and 220mm stroke, giving a displacement of 84.7 litres and producing 3,755hp (2,800bkW) at 1,740rpm. It uses electronically controlled common rail fuel injection, which allows the injection events to be tuned precisely according to the demands placed on the engine. For instance, it is possible to provide multiple injection events, both before and after the main injection event on each power stroke. This injection strategy is varied depending upon many factors, including load, speed, engine temperature, air temperature and fuel temperature. The engine has four turbochargers with twin stage after-cooling.

The CAT engines meet European Stage IIIA emission standards, and can be modified to meet 2012 IIIB emission standards by replacing the exhaust silencer with a diesel particulate filter. However, because of the UK’s restricted loading gauge, this would involve considerable re-design work if it were to be applied to the Class 68.

Essential considerations for the Class 68 design were fuel consumption and ease of servicing/maintenance. It is claimed by DRS that the 4-stroke fuel-efficient CAT C175-16 should offer a significant fuel saving (on a per horsepower basis) over an EMD 2-stroke power unit, as used in the Class 66. A figure of 7.07% has been quoted, but in practice it will be very difficult, and some would say unfair, to directly compare two engines running at different powers, loads and speeds in locomotives that have different design concepts.

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Engine servicing can be undertaken trackside, with intervals of 1,000 hours for minor services (oil change) and 18,000 hours for major servicing (top end overhaul). Finning UK Ltd is the only UK dealer for CAT equipment and will supply warranty support and parts, although DRS fitters are being trained by Vossloh. A purpose-built shed facility is being constructed by DRS at its Crewe Gresty Bridge depot to accommodate test and warranty engineers from Vossloh, ABB and Caterpillar. It will also house a dedicated stores facility for Class 68 spares and consumables.

In order to reduce fuel consumption even further, the diesel engine is fitted with automatic stop start technology. In service, the engine will shut down after a period of inactivity, for instance at a signal stop, although there is a manual override facility. This system has what DRS terms ‘day and night guard functionality’ – the engine will re-start if the coolant temperature falls below a pre-set threshold. This feature can be augmented by connecting the locomotive to a 415V 3-phase depot supply that will maintain coolant temperature, cab heating and demisters.

AC-DC-AC

Caterpillar has worked closely with ABB in order to reduce the weight of the locomotive for UK use. The ABB alternator has been specifically designed for use with the C175 engine and is bolted directly to it.

Some components of the engine/alternator set have been cast in aluminium rather than steel in order to save weight. The Class 68 diesel engine itself weighs 11 tonnes as opposed to 12 tonnes for the standard C175 engine. A five-point flexible mounting system has been adopted for the engine/alternator unit. There are four mounting isolators at the front mounting point, and one rubber isolator on each of the four rear mounting points.

ABB’s traction system makes use of a WGX560 6-pole 3-phase brushless alternator that is directly coupled to the engine. The alternator supplies two traction packages (ABB Boardline CC1500 DE Compact Converters) each having a rectifier to create an intermediate DC supply. This DC system is required for electric train supply (ETS) and for dynamic braking. The drive electronics (AC800 PEC) incorporates adhesion control (anti slip), backed up by automatic sanding. There are two traction inverters and one auxiliary inverter per traction package, thus giving one traction inverter per traction motor. A traction fault condition will result in power being diverted to the other three traction motors.

Bogies

In common with the Vossloh EuroLight locomotives, a Bo-Bo wheel arrangement has been adopted for the Class 68. The bogies are the same as those used on the RENFE Class 334 (Vossloh Euro 3000) high speed diesel electric locomotives in Spain. Primary and secondary suspension is by means of coil springs.

The ABB 4FRA6063 AC traction motors use squirrel-cage (brushless) technology and each has a rating of 600 kW at 4400 rpm. In order to reduce the unsprung mass, the traction motors are frame mounted and have flexible quill drives. DRS claims that, because of the state of the art adhesion control and braking systems, the 2-axle bogie arrangement will out-perform the three- axle bogies of the Class 66. Braking on the Class 68 is achieved by a seamless blend of rheostatic and disc air brakes.

Testing

Locomotive 68002 was shipped to Southampton docks during January 2014 and was then transported by road to Carlisle Kingmoor depot. Dynamic trials between Carlisle and Crewe began in February as part of an ongoing acceptance process.

At the time of writing, the locomotive had yet to move under its own power on a UK main line. However, since December 2013, number 68001 has been undergoing extensive dynamic testing at the Velim testing circuit in the Czech Republic. At the same time, telemetry from two EuroLight locomotives in service in Germany and Italy was being examined closely. The Class 68 locomotives are fitted with two sets of telemetry equipment, one being exclusively for the CAT diesel engine. This equipment will be fitted to all fifteen members of the DRS fleet for prescriptive performance analysis, as well as hard fault reporting.

Locomotives 68003 and 68004 were expected to be completed in Valencia by mid-March. They were then scheduled for shipment to Liverpool docks and haulage by rail to Crewe. DRS would not be drawn on the anticipated timescale for UK acceptance of the Class 68. Completion date for the build contract remains uncertain too, but all fifteen locomotives are expected to be in the UK by late summer 2014.

Into service

The potential offered by Class 68 to DRS is enormous. It needs to be of course, considering the capital outlay. These locomotives are a true mixed traffic design, combining a 100mph capability with an approximate 300kN tractive effort.

The fleet will need to work seven days per week, so it is anticipated that they will be used on a wide variety of applications. They are ideally suited to high speed container traffic and passenger charter trains, but their high top speed will also make them useful for standby rescue duties.

Two Class 68s can be worked in multiple, but they are unable to work in multiple with other locomotive types. They have been given RA7 route availability.

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The 100mph performance offers the potential for new high-speed freight services. DRS also remains hopeful of expanding its passenger operation, which is currently focused on the charter train market. Neil McNicholas, managing director of Direct Rail Services, has said: “This is another important milestone in the strategic development of Direct Rail Services. The Class 68 locomotives are set to further extend DRS’ capabilities and give our clients an even faster and more efficient service. The Class 68 is just the first component of a wider DRS fleet strategy designed to ensure that we can offer our clients the most efficient and flexible service well into the future.”

Electric version

That strategy includes an electric version of the Class 68, to be designated Class 88. Again in partnership with Beacon Rail, DRS placed an order with Vossloh last September for ten Class 88 locomotives. These will be a direct development of the Class 68, but with 25kV electric and diesel-electric modes. They will have a 4MW rating using ABB AC traction equipment plus a 950hp Caterpillar C27 diesel engine for use where there is no overhead line equipment. This provides more than so-called ‘last mile’ (i.e. shunting) capability. The Class 88 is a true ‘dual mode’ locomotive that has been designed to haul a train using diesel power alone. Indeed, the starting tractive effort is similar in electrical and diesel propulsion modes.

The Class 88 will share many of the features of the Class 68, including the bodyshell, braking system, bogies, traction equipment and control software. Again, these locomotives will be of the mixed traffic type. Delivery of the first Class 88 is expected in late 2015, with completion of the contract by spring 2016.

Expansion

DRS has an option to order further Class 68 locomotives, but no decision on this has yet been made public. Under EU emissions rulings, just 26 further new-build Stage IIIA rated locomotives are allowed before the 31 December 2014 deadline – 16 for anywhere in Europe, plus 10 more for the UK. There is however no restriction on replacement Stage IIIA power units for existing locomotives. The space required for the additional equipment needed to convert the C175-16 engine to Stage IIIB compliance means that the class 68 would require substantial redesign work. A decision from DRS on whether to purchase further Class 68s will therefore be required soon.

With the benefits that the Class 68 and Class 88 locomotives will bring, the success story of Direct Rail Services is set to enter a bold new phase. It’s a story that began humbly in 1995 with just five second hand Class 20 locomotives.

Today DRS is a profitable and dynamic business that is achieving sustained growth. By acquiring new, state of the art locomotive fleets, DRS clearly seeks to consolidate itself at the forefront of rail operations within the UK. It’s not just about technical capability – successful companies also understand the value of image and style … and Class 68 has bags of it!

Back to Victoria

The redevelopment of London Underground Victoria station was first covered in January 2013 (issue 99). In that report, the comment was made that The Rail Engineer would revisit the project to keep track of how work was going. Writes Chris Parker

So arrangements were made to meet with Keith Ramsay, section manager – south ticket hall, at the project offices at 25 Terminus Place. He was only too pleased to give an update on the progress that has been made by the Taylor Woodrow / BAM Nuttall joint venture.

Background

The project is focussed primarily on providing more space and better Victoria Line access for the very large and rapidly increasing numbers of customers seeking to use the station each day. It is already regularly necessary to control access to the station for safety reasons during peak periods due to congestion, which sometimes requires holding customers outside the entrances.

It was predicted that by 2020, if nothing had been done, the station would have been closed more often than open. In addition, there is no step free access to any of the LUL platforms at the station at present.

The project addresses these issues in a number of ways. The first is to open up access to both ends of each Victoria Line platform, there currently being access only to the southern end of each. Next is the construction of an entirely new ticket hall to the north of the station, providing a new large circulation area at the head of the new northern accesses.

The existing south ticket hall is too cramped for today’s needs, and so this is being doubled in size. Nine new escalators and eight new lifts are being provided. An emergency access shaft is being built, with lifts and stairs to provide separate access for the emergency services and for emergency evacuation purposes. The existing stairs to the main line station are being widened and new lifts are to be provided here too.

Work in progress

Transport & Works Act authority for the scheme was granted in late 2009, and work began on site on the Mott MacDonald designed scheme in May 2011.

The Taylor Woodrow / BAM Nuttall JV contract is a significant part of the overall £700 million programme and the new works are due to be completed and opened to the public in full in 2018. Some 420140220_131548 [online]00 people are currently working on the site, about half are employees of the JV and the remainder of sub-contractors which include Cementation Skanska (piling), Keller (jet grouting), T Clarke (electrical installations) and Bailey Rail (mechanical installations).

Around the station site, the enabling works for the project have been demanding in themselves. The area involved is large and is one of the most intensively occupied areas of London. The usual service diversions were complex. Then there is the King’s Scholars’ Pond Sewer close by the site of the new evacuation shaft. Carrying the former River Tyburn, this is a large, old and sensitive structure. New switch rooms for the station needed to go in and be commissioned too.

The north ticket hall is going below ground at the junction of Bressenden Place and Victoria Street. The new access to street level will be from Cardinal Place. Constructing it has meant moving the Bressenden Place highway bodily eastwards, partly onto the roof slab over the new works.

Water, water everywhere

Excavations are mostly in sands and gravels as the London Clay beds here are below the required level of most of the new works. Ground water levels are high; indeed the existing station remains open only by means of the continuous removal by pumping of huge volumes of water.

The new ticket hall structures will be water- tight, but that means that they have to be tied down by piles to prevent them floating when groundwater levels are high. All this water has its uses though – it is proposed to be used in a cooling system for the station as it is significantly colder than the ambient temperature in the tunnels.

Because of the generally wet conditions, the ground is first prepared using jet grouting. This entails the insertion of plastic sleeves in a carefully designed pattern. A drill sleeve is inserted into each one in turn through which the grouting is deployed under high pressure. The grout and pressure are both carefully selected to ensure that the groundwater in the soil is displaced and replaced by the grout, creating a roughly cylindrical zone of strengthened soil. The design of the grouting pattern ensures that each column joins with its neighbours to form an impermeable barrier of material through which tunnelling or excavation may proceed easily without water penetrating into the works.

Getting the necessary pattern of grout tubes into a congested site like this one is tricky. Above the zone to be grouted is a mass of utilities and services which must not be damaged or disturbed. On this site, extensive use has been made of 3D computer modelling (the BIM of which we hear much nowadays, and for which this project won a BCI Award in 2012) to map the positions of these obstructions, model the grouting positions and visualise the expected grout penetration. By this means, it has been possible to avoid conflicts and see where there might be gaps in the effectiveness of the grouting and avoid these occurring.

The introduction of Skanska’s piling rig and handling crane for the secant walls into the site of the south ticket hall extension was tricky. This site is quite small, and the ramp required if the rig was to be driven down into the hole on its own crawler tracks would almost have filled it. In addition, it was estimated that around 280 vehicle movements, equivalent to approximately 3.6 tonnes of carbon and 4,500 litres of fuel, would have been required to get the rig into and out of the site this way, since the ramp would have needed removing once therigwasinplacesoastoallowittodoits work. That would have meant building and removing the ramp twice.

The JV has worked with heavy lifting and transportation specialist Mammoet before, so approached that company for options . The proposal was for a lifting gantry that employed two 100-tonne strand jacks to lift the rig. Once lifted, the rig could be moved laterally by means of carriages running along the gantry beams. This permitted the rig to be lowered into the excavation and for its subsequent removal after Skanska had completed the eight week piling task.

Moving Bressenden Place

The site for the new north ticket hall is larger so Mammoet’s gantry wasn’t required, but there was a different complication here instead. In this case, as already mentioned, there was a road over the top, Bressenden Place. This meant that the ticket hall structure had to be constructed in two parts so that the road could be shifted laterally onto the first completed section before work could commence on the second. The road move from east to west was undertaken over one weekend.

An innovation of this project was the form of protection installed over the roof slabs of the new ticket halls. Instead of the tiles usually installed on top of the waterproofing, the JV proposed a new system which was agreed by the client. After the application of sprayed ‘Pitchmastic’ waterproofing, a 100mm thick layer of red fibrous concrete was added. This is more economical to install and arguably gives better protection against damage by future excavation.

Hand tunnelling

The new emergency access shaft goes down past the King’s Scholars’ Pond Sewer to connect to the existing Victoria Line platform tunnels, bottoming out in between the two of them. The shaft passes so close to the tunnels that its cross-section has to change from circular above them to a narrower elliptical shape as it passes between them. Even so, the cast iron tunnels segments were exposed in places as the shaft was excavated.

There was much concern about this exposure because these sections of each of the tunnels were lined with experimental unbolted cast iron segments when the Victoria Line was built in the 1960s. Due to the care taken by the construction team, close monitoring of the tunnels detected movements of no more than 3mm, so the trains inside were able to continue to run undisturbed throughout the works. The shaft was dug in one metre lifts, and each of these was lined with sprayed concrete before the next could commence.

The connections into the station tunnels of the Victoria Line necessitated digging and lining a 15 metre long passageway from the shaft base parallel to and in between the station tunnels, then a cross-passage to complete the actual connections into them. All of this was hand mined, exposing the tunnel linings either side of the main passageway, and requiring these to be propped temporarily until the permanent works were placed. In this job alone some 1,000 tonnes of clay were excavated while 114 tonnes of steel and 250 tonnes of concrete were placed during 40,000 man hours of work.

More jet grouting20140220_135505 [online]

Extensive tunnelling is required for access passages and escalator tunnels, and jet grouting was judged to be the best way to allow this to be done safely in the conditions, with the water table only seven metres below ground level. Over 2,000 jet grout columns are being installed by sub-contractor Keller to create a safe zone for the tunnelling to pass through.

Piles of challenges

For the ticket halls, the method of construction is to install secant piled walls around the perimeter of each worksite and excavate the new voids ‘top down’. By creating these perimeter walls down into the underlying London clay, the water is cut off from entering the excavations. The necessary internal columns within the site are driven from the top by piling rig, as are the plunge columns intended to support the planned over-site developments. Casting the roof slabs of the new ticket halls will prop the tops of the piles. As excavations below this proceed, lower props will be required, but casting the floor slabs level by level as the correct depth is reached will meet that need.

This, the largest jet grouting project in the UK to date, is nearly complete. The grouting plan was designed in 3D software and the actual results are monitored closely and are similarly modelled in 3D to produce an accurate as-built record. Probing into the grouted area is undertaken to detect ungrouted permeable zones so that, if any are found, they may be rectified. The project won a ‘Ground Engineering’ award in 2013 for this use of the jet grouting technique.

The tunnels, generally six metres in diameter, are being dug through the jet grouted zones and given a primary lining of sprayed concrete impregnated with steel fibres which is applied by robotic equipment. After the installation of a waterproofing layer, an in-situ concrete secondary lining will be applied.

Being neighbourly

The site is very congested and surrounded by heavily used roads, footpaths and, of course, railways. The theatres have matinees as well as the usual evening performances and are particularly sensitive to noise and vibrations while they are taking place. This all means very careful attention to planning and sequencing of the works themselves and the associated movements into and out of the sites.

The project team is very proud of its good record in terms of relationships with neighbours, environmental performance and in respect of health, safety and welfare. The JV partners each have safety and quality programmes and co-operate to ensure that the JV delivers on all of these on this project. BAM Nuttall’s strap-line ‘Don’t walk by’ has been taken to heart across the JV in the pursuance of safety, and Taylor Woodrow’s ‘Defect Free’ programme ensures that quality is delivered. The project itself also runs a safety and quality programme called ‘Beyond Zero’ and an extensive community liaison programme provides regular information to locals and travellers on the trains and buses using the area.

The project has won a number of awards for safety and quality as well as National Skills Academy awards in 2012 and 2013. In October 2012, the project reached a million man hours without a RIDDOR reportable accident, and went on to achieve 1.4 million hours (285 days) before the first reportable incident.