Railway-News eMagazine Issue 4 2022 - Track & Infrastructure

The latest news & reviews from the industry

Railway-News M

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Inside:

Under Construction: Sydney Metro West. . . p.6 A look at the Sydney Metro West project, one of ultimately four metro lines in the Australian city that is currently under construction and is due to enter passenger service in 2030.

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AusRAIL 2022. . . p.8

ISSUE FOUR 2022: TRACK & INFRASTRUCTURE

MOBILITY WITH VISION Together with you, Goldschmidt masters all challenges of modern, railbound mobility – for safe, sustainable and long-lasting railways of premium quality.

Goldschmidt offers you products and services worldwide for the joining of rails, modern construction of railway track, and inspection of your track infrastructure and its maintenance. The unique global network of experts gives you access to the international range of products and services of Goldschmidt – at your location, with your local contact person and the power of the whole group.

www.goldschmidt.com

Letter from the Editor For this issue we are also taking a look at AusRAIL 2022, which will take place in Brisbane, Australia next month. Read our feature to find out about all the interesting panel discussions and talks taking place at the conference and exhibition.

Dear Readers, For our last rail magazine of the year, we’ve revamped our format!

Previously we’ve covered the whole industry in one single magazine – quite a tall order and increasingly challenging given our magazine’s popularity. As a result, we’ve made the decision to give each major area its own magazine. They are: Rolling Stock, Data & Monitoring, and Track & Infrastructure.

You’re currently reading our Track & Infrastructure magazine, but please also enjoy our Rolling Stock magazine and our Data & Monitoring magazine.

As per usual, we open with a feature editorial. In this issue, we take a look at the Sydney Metro West project that is currently under construction.

This metro line will ultimately form part of four metro lines in the city.

Recent milestones include the arrival of the first tunnel boring machines and planning approvals. A “once-in-a-century investment”, Sydney Metro West is due to enter passenger service in 2030.

Our Track & Monitoring feature section shines a spotlight on industry developments and innovations within that area. For example, Dialight illuminates us on depot lighting, GEOfabrics discusses trackbed stabilisation, and Presto Geosystems presents a case study of where its retaining wall managed to eliminate track instability and reduce maintenance.

We hope you love the new format.

Please do get in touch with your thoughts. If you would like our rail news straight to your inbox, make sure you’re subscribed to us here. As always, if you want to be featured on our site or in our e-magazine, please email Andrew Lush or call +44 7432 725001. If you enjoy our website and magazine, you might also be interested in our sister sites – Bus-News, Future Transport-News and Airport Industry-News.

Our first Railway-News magazine of 2023 will be published on 28 February.

Josephine Cordero Sapién, editor-in-chief

Meet the Team!

ANDREW LUSH

Director al@a2bglobalmedia.com

JOSEPHINE CORDERO SAPIÉN Editor-in-chief jcs@a2bglobalmedia.com

NICOLA BROWN

Head of Sales nb@a2bglobalmedia.com

ZOE GRIFFEY

Head of Design zg@a2bglobalmedia.com

LAURA KINGDOM

Head of Client Accounts lk@a2bglobalmedia.com

a2b Global Media Ltd The Generator Hub, The Gallery Kings Wharf The Quay, Exeter EX2 4AN

Office: +44 (0)1392 580002 Mobile: +44 (0)7432 725001 Email: info@railway-news.com Website: railway-news.com

To subscribe to our newsletter, visit railway-news.com/subscribe COVER: © Siemens Mobility & © Sydney Metro

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As part of our Railway-News Issue Four 2022 series we’ve also published the following magazines:

Data & Monitoring In our interview with Icomera and GoMedia, we explore Visor, an accessibility solution that helps the blind and visually impaired navigate railway stations independently using low-tech hardware and high-tech software.

Read it here.

Rolling Stock Read our feature editorial, H2goesRail – On the Way to the Hydrogen Age, in which DB’s Marc-André Sahba and Siemens Mobility’s Jochen Steinbauer provide insights into the two companies’ joint project that explores hydrogen technology for the rail sector.

Read it here.

Features p.6 Under Construction: Sydney Metro West A look at the Sydney Metro West project, one of ultimately four metro lines in the Australian city that is currently under construction and is due to enter passenger service in 2030.

p.8 AusRAIL 2022 A look at what’s in store at this year’s AusRAIL, which will take place in Brisbane next month.

p.11 Track & Infrastructure Directory A directory of railway suppliers for track & infrastructure.

Read about all the latest innovations and product developments in the rail sector.

Depot Equipment p.12 Stations & Station Furniture

p.21

Track Inspection & Repair

p.22

Geotechnical Solutions p.24 Maintenance & Equipment

p.30

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ONTENTS

Issue Four 2022: Track & Infrastructure

Under Construction: Sydney Metro West The Sydney Metro West project is currently under construction and has a planned opening date of 2030.

It will connect the city’s central business district with Westmead, an outer suburb to the west.

The Project Described as a “once-in-a-century infrastructure investment”, the line will be 24km long and will have 9 accessible stations, connecting Greater Parramatta and the Sydney CBD. It will form part of the Sydney Metro network that will ultimately comprise of four lines: Sydney Metro Northwest, Sydney Metro City & Southwest, Sydney Metro West and Sydney Metro Western Sydney Airport. Of these, Sydney Metro Northwest is the only one currently in operation, having opened in 2019.

Construction Start Work officially began on the Sydney Metro West project in November 2020. The first step has been to prepare The Bays Station site for the arrival of tunnel boring machines. In total, there will be six tunnel boring machines working on the project.

Planning Approvals In March 2021, the Sydney Metro West project achieved two major planning approvals: one for the Sydney Metro West Project Concept,

Once complete, the new metro line is set to double rail capacity between Parramatta and the Sydney CBD with a target travel time between the two of about 20 minutes.

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from Westmead to the Sydney CBD, and for the station excavation and tunnelling between Westmead and The Bays.

Then, in September 2022, the project obtained a further major planning approval, this time for station excavation and tunnelling between The Bays and Sydney CBD. A planning application has been submitted for rail infrastructure, stations, precincts and operations between Westmead and the Sydney CBD. This is currently under assessment.

Planning has also begun for over

Rendering of Hunter Street Station © Sydney Metro

and adjacent station development at Parramatta, Sydney Olympic Park, Hunter Street (West and East) and Pyrmont in the form of scoping reports.

Construction: Tunnelling The Sydney Metro West line will run in twin tunnels for its entire length, from The Bays to Westmead.

The project’s Central Tunnelling Package is for 11km of twin tunnels between The Bays and Sydney Olympic Park. The two tunnel boring machines for this package arrived last month. Operating 24 hours a day, they will excavate an average of 200m per week.

Tunnelling is set to commence in the first half of 2023, with the TBMs arriving at Sydney Olympic Park in late 2024. The contract for this package has been awarded to Acciona Ferrovial JV. This will be the first of two major

Rendering of Pyrmont Station © Sydney Metro

tunnelling packages, the other being the Western Tunnelling package: 9km of twin tunnels between Sydney Olympic Park and Westmead. This package was awarded to Gamuda and Laing O’Rourke joint venture in March 2022.

A third tunnelling contract, the Eastern Tunnelling Package, was put out to tender in 2021.

Sydney Olympic Park On 24 October 2022 Sydney Olympic

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Park reached a major milestone with large-scale excavation starting.

In what is estimated to take around 13 months, construction of a 200m-long, 37m-wide, 27m-deep station box has begun.

This undertaking will require the removal of 468,000 tonnes of rock.

Once complete, the station box will be used as the extraction site for four of the six tunnel boring machines that will construct the twin tunnels.

Excavation has also started on the station boxes at Burwood North.

Where: Brisbane, Australia When: 5-7 Decemeber 2022 AusRAIL is the national conference and exhibition of the Australasian Railway Association (ARA), “organised annually to bring the industry together to engage on key issues in the rail industry”.

AusRAIL 2022 will take place at the Brisbane Convention and Exhibition Centre, in Brisbane, Australia from 5 to 7 December. It is set to see more than 2,000 attendees, 60+ speakers and 90+ exhibitors.

Speaking about this year’s event, Caroline Wilkie, ARA CEO said: “I am so delighted to welcome you to Brisbane to celebrate AusRAIL 2022. After a tumultuous two years, AusRAIL 2022 will bring together industry en masse to celebrate,

network, discuss and engage on the latest issues facing our sector.

With borders open and a long lead time to prepare, we expect a large Australian and international cohort to attend AusRAIL in Brisbane 2022.”

What’s in Store This Year?

The event will kick off with welcome drinks on the first day along with pre-conference technical tours and workshops, before the AusRAIL exhibition opens fully on 6 December. The Chair of the Australasian Railway Association, Danny Broad, and Minister Catherine King from the

Background Image: Brisbane © Lachlan Fearnley under licence

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Commonwealth Government will give the welcome address.

Following that event, Alstom will host a panel discussion, entitled ‘Industry Leaders Setting the Scene’.

It will be chaired by Caroline Wilkie, CEO of the Australasian Railway Association.

Over the course of the day there will be many concurrent talks and panel discussions, covering a wide breadth of topics such as sustainability, asset management, the energy transition to solar, effective knowledge transfer, synthetic fuels, predictive maintenance, signalling and pandemic effects such as getting passengers back to the rail network

© CAF

and testing and commissioning a train during the pandemic.

the Practical Role Rail Can Play in the Future of Mobility’.

on ‘Heavy Haul – Collaborating for Shared Innovation’.

The day will be rounded off by the panel discussion ‘Addressing industry resilience when one in one hundred year weather events have become the norm’. The panellists for this event will include Benedicte Colin, CEO of Transport Asset Holding Entity of NSW, and Murray Cook, CEO of ARC Infrastructure.

The plenary session will be completed by a panel discussion on priority rail safety issues.

The event’s final plenary session will focus on the future of the SEQ rail network, and the West Australian rail transformation, and feature a panel discussion on ‘Achieving Operational Excellence’, chaired

by Rochelle Reynolds, Executive Director Operations, V/Line.

The final day of the conference will open with the Young Rail Professionals breakfast.

During the first plenary session of the day, Caroline Wilkie will give an update on the Australasian Railway Association. Graeme Newton, CEO of Cross River Rail, will give a keynote presentation, as will Andrew Barr, CEO of Hitachi Global.

The latter talk is entitled ‘Hitachi Rail – Innovations, Successes and

The second plenary session will address how to establish and deliver the National Rail Manufacturing Plan and hold a panel discussion

Supplier Spotlight Supplier

Stand

Frausher Sensor Technology 86-91 Hitachi

48-49,52-53 Nokia 20-23 Pandrol 95-98 STAUFF 183-184

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AMBERG TGS EVO „MORE THAN JUST A TOOL“

Amberg Technologies introdudes the new Amberg TGS EVO. The Amberg TGS EVO is the worldwide first carbon-fiber trolley for 3D route surveys with highest demands in quality, accuracy, and performance – especially mobile mapping projects to create digital twins.

Its captivating industrial design is combined with highest quality sensor technology to ensure the best quality work on the track. www.ambergtechnologies.com

WE ARE AMBERG. AMBERG ENGINEERING

AMBERG LOGLAY

AMBERG TECHNOLOGIES

HAGERBACH TEST GALLERY

Directory Depot Equipment Dialight p.12 Assenta Rail p.15

Totalkare p.18

Stations & Station Furniture Auweko p.21

Track & Inspection Repair ENSCO Rail p.22 Zetica Rail p.23

Geotechnical Solutions Presto Geosystems p.24 GEOfabrics p.27

Track & Infrastructure Maintenance Equipment Amberg Technologies p.30 Complete Composite Systems

p.32

Robel p.35

Distek p.36 11

Directory

How LED Lighting Prevents Common Industrial Accidents

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pgrading to Modern Industrial LED Lighting Improves Plant Safety & Saves Money Safety is the number one priority in facilities across all segments of the manufacturing industry. Every year, companies invest millions of dollars in equipment upgrades and safety programmes aimed at preventing injuries and lost time accidents by increasing awareness of risks and incentivising safe work practices.

Yet still, an average of over 477,000 injuries and 328 fatalities occur in manufacturing plants across the US each yeari . These incidents not only have a devastating impact on employees and their families, but also on the company’s reputation, recruiting/hiring efforts and profitability. In fact, workplace injuries and deaths have cost US manufacturers 170.4 billion USD over the last 10 years.i Aiming to improve plant safety, many companies have found that upgrading facility lighting to modern, high-efficiency industrial LED fixtures can have a major

impact on lowering the risk and incidents of workplace accidents.

Here’s how state-of-the-art LED lighting can improve safety: •

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A brighter work environment improves visibility. Poor visibility is the leading cause of slip, trip and fall hazards and contact with moving objects – some of the biggest risks in any facilityii. With so many distractions, like excessive noise that forces workers to rely on visual information, it’s hard to keep an eye out for these kinds of risks. Adding to the problem, conventional highpressure sodium fixtures create a dark, drab atmosphere that makes it difficult for workers to spot hazards around them.

LED fixtures, on the other hand, produce bright, white, uniform light that improves visibility, helps workers spot hazards and stay out of harm’s way.

LEDs can combat fatigue and improve alertness. Fatigue is a major risk for workers, especially those who work night shifts or a rotating schedule. When workers are

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tired, they’re less perceptive and have slower reaction time, which makes them less able to spot and avoid hazards on the job. The bright daylightlike quality of LED lighting has proven to encourage alertness and reduce fatigue by 5x compared to HPSiii, to help staff feel more awake and aware of their surroundings. In fact, the American National Standards Institute (ANSI) recommends bright white lightingiv to combat worker fatigue and reduce accident risk.

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Improved colour rendering reduces risk. The inability to distinguish colours clearly is a huge safety risk. For example, warning placards and signs often rely on colour-coding to communicate danger, and electrical wiring is colour-coded so that crews may work safely.

But, the low colour rendering of HPS lights creates an unnatural orange glow that makes it very difficult to distinguish colours, which puts workers at risk of misinterpreting colour cues. Unlike HPS, LED lighting produces near-daylight-quality

Depot Equipment white light that makes colours appear natural and easily distinguishable. That means workers can interpret signage clearly, and there’s much less risk that an electrician will cut the wrong wire.

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LEDs dramatically reduce lighting maintenance. By its very nature, changing lightbulbs is dangerous work in an industrial facility. Not only must crews work at high elevation, they often must do so overtop production equipment. The risk of a catastrophic fall is very real. And because conventional fixtures fail frequently under high-vibration and highheat environments, lighting maintenance is an ongoing chore. By contrast, industrial LED fixtures are built to last.

Because they don’t rely on a delicate filament, they’re much more resistant to shock and vibration, and some of the best products on the market can last up to 100,000 hours. This long-life performance could essentially mean the end of lighting maintenance and an end to the risk of performing

this dangerous job.

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LED fixtures contain no hazardous materials. Did you know that a single HPS bulb contains enough mercury to poison an entire classroom of children?v Even fluorescent bulbs contain toxic levels of mercury, phosphorous and other rare-earth minerals.

And, of course, when HPS or fluorescent bulbs are broken (which happens frequently, especially during maintenance), those hazardous materials are released into the air, exposing everyone in the vicinity. Switching to LED lighting fixtures is a much safer alternative because LEDs

contain zero hazardous materials. This not only makes for a safer environment inside the facility by eliminating the risk of exposure, but outside as well by eliminating these pollutants from the Earth’s atmosphere.

Improving facility safety should be a top priority for every industrial manufacturer, and making do with mediocre, antiquated lighting could be putting employees at unnecessary risk. Upgrading to modern, high-efficiency, industrialgrade LED lighting is a worthwhile investment that can lower the risk of accidents, injuries and even fatalities inside the plant, and save money in the long run.

References i

U.S. Bureau of Labor Statistics, National Safety Council, ECG Analysis

U.S. Dept. of Labor, Census of Fatal Occupational Injuries Summary, 2016; Occupational Health and Safety Administration, Mine Safety and Health Administration ii

Falchi, “Limiting the impact of light pollution on human health, environment and stellar visibility” iii

iv

ANSI/API RP 755: Fatigue Risk Management System

U.S. Dept. of Labor, Occupational Safety and Health Administration 29 CFR 1910.1000, Table Z-2; ECG analysis v

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PROSITE LED FLOODLIGHT The ProSite series is currently available in 12,000 – 65,000 lumen models, reaching up to 165 LPW, for mounting heights of up to 30 meters (100 ft), providing superior visibility to worksites with crisp, near daylight illumination to keep their operations safe and secure.

10 year warranty CE / RCM UL 1598/A, CSA C22.2 No. 250.0 UL 844, CID2, CIID1, CIID2, CIII IP66/67, NEMA 4X IK10 (PC optic/lens/lens cover), IK08 (glass lens cover) Up to 165 lm/W Up to 65,000 lumens

VIGILANT & SAFESITE LED BULKHEAD Ideal for illuminating walkways, stairwells, platforms, tunnels, subways and exit routes, the Dialight LED Bulkhead fixture is designed to enhance facility safety with reliable, maintenance-free pathway lighting. Offering a low-profile, rugged design for maximum durability and shock/vibration resistance.

10 year warranty CE, RCM, ENEC IECEx/ATEX (Zone 1, 21, Zone 2, 22) IP66/67 IK10 Up to 149 lm/W 3,000 & 6,500 lumens

www.dialight.com

Directory

Assenta Rail

Bridging the Gaps in the Rail Industry

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rom the adoption of modern technologies to the increased focus on green initiatives, we have seen more change in the rail industry over the course of the past twenty years than we could ever have imagined.

Creating a Hub for Change Engineering specialists at heart, since 2001 we have been enthusiastic about solving challenging engineering problems.

This led us to establishing our depot in Hamilton, Scotland as a base for our operations in 2019. One of only two independents in Scotland, the depot has enabled us to bring our engineering offering in-house and provide an end-to-end turnkey service to our clients.

Since its opening, we have installed a paint shop and conducted extensive upgrade works to tracks and sidings. We have also seen an increase in new clients and requests to use the depot for a diverse range of activities.

Our depot also provides benefits to

local industry. Maintaining vehicles in Scotland as opposed to being transported elsewhere is enabling operators to reduce emissions and increase skills and capabilities, much closer to home.

Nurturing Local Talent At Assenta Rail, we are committed to nurturing local talent. Our depot provides employment opportunities for local engineers, technicians and artisans.

We are proud to take on apprentices and trainees and guide their skills and development through

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partnering them with existing team members, enabling new employees to soak up the knowledge and guidance that our more experienced people can provide.

The local community reaps benefits, retaining the minds that keep the railway moving in Scotland and developing the next generation of engineering talent.

Harnessing the Power of ECM As defined by the ORR (Office of Rail and Road), people or organisations who are responsible

This requirement is revolutionising the rail industry for better. We are proud to have achieved our ECM certification in 2017 initiated in part through our work with the Commission for Railway Regulation (CRR), and remain the only independent, and arguably one of the smallest, companies in the UK to achieve this.

As a certified ECM for freight vehicles and an attested ECM for passenger stock, we always adhere to strict control processes and systems to ensure works are conducted safely and in line with regulatory requirements and defined maintenance specifications.

Continuous auditing ensures that we consistently deliver a reliable and premium service to our clients, a core objective at Assenta Rail.

Customers can be confident when they partner with us that we deliver results that make a tangible impact on the day-to-day running of their operations, alongside improving

efficiencies and driving innovative ways of working.

Evolving Engineering Solutions for the Rail Network Driven by the socio-economic climate, the rail industry is encountering challenges that we have never seen before. The need for goods that are no longer available or easily accessible is one such challenge that we have recognised.

For example, the industry has been experiencing a lack of access to axle-boxes. We viewed this as an opportunity to create something new, taking the existing design and modifying it to suit current requirements. This has resulted in a product that is cheaper, efficient, and more importantly, available, and will provide benefits to the industry for many years to come.

We have also been working closely in conjunction with the ORR on an innovative central door locking (CDL) project, exploring how we can retrofit CDLs on older rolling stock, to comply with new legislation.

We have designed a bespoke CDL system that can be adapted to different vehicle types, ensuring safety underpins each engineering

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design decision we make. This was initially due to be completed by 2023, however due to delays posed by the pandemic, development has halted, and we are working closely with the ORR to secure extensions for our clients to 2025.

CDL will become a standard in the future, and we are proud to play a part in enabling this to happen.

Looking Ahead to the Next Twenty Years The myriad and complexity of challenges we are experiencing is likely to be of no surprise. However, through the power of innovative engineering solutions, we can tackle these head on and make a positive change, not just now, but for the future.

If you would be interested in learning more about how Assenta Rail can support you with your needs, get in touch with Lewis Rodger, Compliance Manager, via l.rodger@assenta-rail.co.uk

Depot Equipment

for the maintenance of vehicles used on the mainline railway are known as entities in charge of maintenance (ECMs). Most vehicles on the mainline railway are required to have an ECM assigned to them in the National Vehicle Register (NVR) and depending on the type of vehicle, the ECM may also be required to obtain an ECM certificate from a certification body.

Directory

Totalkare

Rail Depot Solutions from the Workshop Equipment Experts

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otalkare has been supplying workshop equipment in the UK for more than 40 years, with a proven track record for product quality and after sales support.

commercial vehicles, Totalkare entered the UK rail market at the start of 2019 after partnering with experienced Italian manufacturer Emanuel, themselves boasting more than 100 years in the industry.

Railway Lifting Jacks

service coverage, combined with Emanuel’s longstanding reputation for build quality, represented an impressive proposition for rail manufacturers and the UK supply chain alike. Orders followed from the likes of Hitachi Rail and Mirage as awareness of Totalkare’s entry into the market grew.

Leveraging its position as the UK market leader for the supply of mobile column lifts for heavy duty

Initially offering railway lifting jacks, Totalkare’s mechanical knowledge and established UK-wide field

Available in a range of lifting capacities from 5,500–50,000kg per jack, Totalkare’s railway lifting

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Depot Equipment jacks can be configured in sets of four to 128 (facilitating the lifting of a single carriage or an entire train) and are designed to meet Machine Directive 2006/42/CE and approved to European standard EN1493.

inspection pits for rail depots. A bespoke offering manufactured to customer requirements, Totalkare’s rail inspection pits make access to the underside of a railed vehicle easy, allowing engineers to work in a safe, well-lit environment.

Available with fixed or movable anvil, the electromechanical lifting jacks are supplied with a computerised control unit with event storing and recording that can be upgraded with selfprogrammed maintenance.

Fully welded construction prevents water ingress. The pits are installed with a unique bond of steel to concrete for a long-lasting rolling stock maintenance solution that offers a more permanent alternative to railway lifting jacks.

Rail Inspection Pits In 2021, Totalkare extended its product offering in the rail market to include pre-fabricated steel

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Do you require support with your rolling stock maintenance?

Contact Totalkare on 0121 585 2724, email sales@totalkare.co.uk or visit www.totalkare.co.uk for further information and live chat assistance.

LIFTING

SERVICING

TRAINING

LIFTING JACKS & PIT EXPERTS Lifting and inspection equipment you can rely on for all maintenance of rail vehicles.

With 40 years’ experience on heavy duty lifting solutions, Totalkare combines world class products with industry leading support to facilitate effective maintenance and repair.

RAILWAY LIFTING JACKS HEAVY DUTY SYNCHRONISED RELIABLE

RAIL INSPECTION PITS INCREASE PRODUCTIVITY SAFE QUALITY LIGHTING

Keep it clean and simple Litter bins for train stations

www.auweko.com

Leading the way in autonomous track inspection systems on any platform; locomotives too

ENSCO Delivers.

Reduced Monitoring. Data Driven Decisions. Decreased Safety Incidents.

reber.acacia@ensco.com | www.enscorail.com ENSCO Rail is a wholly owned subsidiary of ENSCO, Inc.

Railway Asset SCanning

Trackbed inspection for condition-based maintenance planning

Trackbed Inspection Report Surface Mud

Rail Corridor Asset Mapping

Turnout Components

Track Geometry & Rail Profiling

Vegetation Encroachment

Structure Clearance

Height & Stagger Zt 123

Level Crossing Condition Ballast Deficit Sleeper Spacing & Angularity

Slope Stability

Ballast Surplus

Ballast Fouling

Track Drainage Wet Bed

Free Draining Layer Sleeper Quality

Ballast Thickness Ballast Pockets

Audits of above- and below-ground assets Quality control of maintenance Monitoring the impact of climate change

Zetica House Southfield Road, Eynsham Oxfordshire, OX29 4JB United Kingdom

zeticarail.com

Tel: +44 (0) 1993 886682 Email: rail@zetica.com

Directory

Presto Geosystems

GEOWEB® Retaining Wall Eliminates Track Instability and Reduces Maintenance Wet Soils Cause Site Problems, Embankment Stability An area along a medium-tonnage route that had a minimum of 14 freight trains per day (at typical speeds of around 81 kilometres per hour) had been an ongoing maintenance challenge for years.

The section of track was on a mainline curve beneath overhead electric wires, which not only complicated maintenance efforts due to limited overhead clearance, but below grade, the track was experiencing settlement issues and profile problems that reportedly coincided with wet weather periods.

During one flood event in May 2010, a portion of the west slope was washed out. Local crews temporarily repaired the area with riprap and dumped rock on the east slope.

The problems subsided for a while, but eventually, the same issues resurfaced, leading to continuous and costly maintenance.

The cause of the instability

appeared to be the steep inclination of the fill embankment and periods of wet weather contributing to the base of the fill becoming saturated and losing strength. Cross-level settlement of the rail resulted as the shoulder dropped and ballast was lost from head of tie, down the slope. Prior attempts by local crews to address the historic instability at this site included driving rail pile, which did not solve the problem.

Additionally, work from track level to drive additional piling would have been disruptive and required substantial co-ordination and site preparation efforts to facilitate equipment access, including temporary removal and rerouting of overhead electric lines.

GEOWEB Geocells Earth Retention Solution After considering several options, project engineers determined that a passive crib wall system along the toe utilising the GEOWEB® Earth Retention System was the preferred option. The engineers based their decision on the GEOWEB system’s

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ability to be constructed less expensively and more quickly than the alternatives, with the added benefit of not disturbing train operations. The GEOWEB system was selected as the facing of the wall due to the system’s ease of installation, tolerance to settlement and ability to minimise downtime.

The design was completed using the GEOWEB® MSE Wall Design Software – a complementary design programme offered by Presto Geosystems that allows users to create vegetated and non-vegetated wall designs for reinforced slopes, as well as gravity and geogrid-reinforced walls.

The software – developed by Dr Dov Leshchinsky, Ph.D., a worldrenowned expert on MSE walls and associated design procedures – contains specific algorithms that capture the unique interaction between the GEOWEB® system, infill and backfill soil, and geogrid reinforcement and specific factors of safety. A complementary copy of the programme can be obtained upon request by visiting the Presto Geosystems website.

Following several years of product testing and development, a new advancement to the GEOWEB® Retaining Wall System was released in July 2022. The ATRA® Wall Key is a specialised geocell connection device used to connect adjacent GEOWEB Retaining Wall sections.

The ATRA Wall Key includes an integrated washer at the base of the handle for coverage of the I-slots when connecting adjacent wall sections, frictional barbs for an improved interlock with the GEOWEB sections, and an ergonomic handle with S-shaped contouring for ease of installation.

Made of non-reactive, chemically inert high-density polyethylene, the ATRA Wall Keys provide a more secure and permanent

Geotechnical Solutions

New ATRA® Wall Key Provides Strong Connection & Enhanced Aesthetics

ATRA Wall Keys

mechanical connection over staples or zip ties, and they are the only geocell connector specifically designed for use in exposed wall face applications. Formulated to withstand weathering and ultraviolet radiation, the ATRA Wall Keys will not corrode or photodegrade, even when exposed to harsh environments. Securing sections with the ATRA Wall Keys is faster than using staples or zip ties, requires no tools, and can be

completed by one installer with one easy turn. The new ATRA Wall Keys offer a natural-looking aesthetic by blending seamlessly into green or tan fascia options. prestogeo.com

GW Wall (Tan) (Installed)

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COMBAT RAILWAY EMBANKMENT CHALLENGES

GEOWEB® Retaining Walls Instability of fill embankments with steep slopes and wet weather exposure can cause saturation, settlement and loss of strength at the base of the fill. The result is a high‑maintenance slope requiring frequent repair.

GEOWEB Retaining Walls keep fill materials stable and are free draining to prevent the negative impacts caused by saturated soil.

Vegetated or hard‑armored fascia.

FREE Project Evaluations www.prestogeo.com

AP-9106

The Experts in Rail Geosynthetics

Tailored solutions for trackbed stabilisation With a broad range of specialist rail products, GEOfabrics deliver proven solutions to trackbed stabilisation problems.

Proven performance n Improved track quality n Durable in extreme conditions n

No specialist equipment required n From the manufacturers of TrackTex: the anti-pumping geocomposite n

www.geofabrics.com

Directory

GEOfabrics

Trackbed Stabilisation Solutions from the Experts A Full Spectrum of Geosynthetic Products GEOfabrics has been supplying the rail industry with trackrehabilitating geotextiles and geocomposites for over 20 years. Working directly with rail authorities, contractors and designers, alongside its comprehensive R&D programme, it has developed leading geosynthetics to provide significant cost benefits to the rail industry.

Geosynthetics comprise an assortment of synthetic polymer materials, specifically fabricated to be used in geotechnical, geo-environmental, hydraulic and transportation engineering applications. And they’ve been employed to perform a number of functions in track construction and rehabilitation for almost half a century.

When properly specified by experts, their use has been proven to significantly enhance the performance of the trackbed in a number of ways – reducing maintenance costs and increasing the lifetime of the design. For this

reason, it’s vital that rail operators work with a geosynthetics expert to get the optimum result and a solution which is specific to the geotechnical issue at hand.

Sector Expertise Meets Robust Solutions GEOfabrics is perfectly placed to offer this kind of specialist advice

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and, coupled with its extensive range of geosynthetic products, provides clients with bespoke solutions to their problem.

It has developed and provided a wide range of tailor-engineered products since 1990. These have been specifically manufactured to address many of the problematic ground conditions that exist beneath railway track and the surrounding areas.

Geotechnical Solutions

A Tailored Approach to Trackbed Problems A full spectrum of products is on offer – from separation nonwoven geotextiles for coarse subgrade all the way up to specialist geocomposites for poorly draining and unstable subgrade.

Every trackbed issue is evaluated individually, to ensure that every problem gets a bespoke solution.

The team of GEOfabrics specialists assists with specifying the correct product, depending on the conditions.

The product range includes RK4 – a solution used in trackbed applications for ballast confinement, subgrade stabilisation and filtration and separation between track ballast and subgrade. To find out if RK4 could stabilise your subgrade – or for information on any of the other rail products that we specialise in – please contact us to arrange a technical seminar here.

A design guidance document, featuring all GEOfabrics’s railstabilisation products is also available on request – this enables customers to make an informed decision and select the most appropriate product. Get in touch to request your copy now.

GEOfabrics rail products solve a broad range of issues including: • • • • • •

Poor drainage Subgrade intermixing with ballast Mud pumping failure Subgrade strength failure Poor stiffness characteristics Asset protection (erosion and invasive species)

TrackTex – The AntiPumping Geocomposite One of GEOfabrics’s specialist rail products is TrackTex – a patented, anti-pumping geocomposite, which solves the problem of ballast contamination in trackbeds.

TrackTex is widely accepted as the most cost-effective way of preventing and correcting mud pumping failure by many rail operators.

Rob Hepworth, Sector Manager at GEOfabrics explains: “We are in a unique position to offer a wide range of solutions for subgrade issues, providing users time and cost savings over the entire product life-cycle. GEOfabrics assists with product selection and specification using our design guide, ensuring the delivery of best value solutions - providing capital expenditure savings vs traditional methods.

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Reducing or removing geotechnical issues creates increased service intervals, delivering savings on operating expenditure. We also offer a range of other assetpreserving products for rail applications – please contact us for more information.”

Get in touch for more details: Europe, Asia & Africa Rob Hepworth rhepworth@geofabrics.com +44 7836 723 805 USA & Canada Eric Littel elittel@geofabrics.com +1(704) 954-4927

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Amberg Technologies

Amberg Technologies Introduces the Next Generation of Measuring Systems

Amberg IMS Track Pro

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n September 2022, at InnoTrans in Berlin, Amberg Technologies presented IMS Track Pro, the latest track geometry measuring system as well as the TGS EVO, the new iconic measuring trolley for 3D route mapping.

The Amberg IMS Track Pro is a new IMU-enabled track geometry measuring system designed to monitor rail infrastructure

conditions. The base trolley of the IMS Track Pro is the new Amberg TGS FX II, the facelifted version of the proven TGS FX measuring trolley. The TGS FX II features a new gauge measuring system, a new battery concept and some additional details which improve ergonomics and performances making it the optimum base of measuring trolley for track construction & inspection. The IMS Track Pro can be equipped with the AMU 2010, the Amberg IMU category with

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top price-performance ratio for track geometry measurements, pre-surveys for mechanical tamping works, track renewals and basic inventory surveys.

The Amberg Track Pro software for measurement and analysis completes the trolley setup.

The Amberg IMS Track Pro is the first track geometry measuring system on the market ready to convert seamlessly to a 3D track construction and maintenance survey device. It enables the

Maintenance & Equipment Amberg TGS EVO

operators to measure the evolution of the track through 5 main track parameters: gauge, cant, twist, longitudinal level and alignment.

Amberg IMS Track Pro includes the new field software, enabling measurements according to EN 13848-1 and EN 13848-4 standards and a powerful new generation office software for automatic data processing, configurable defect analysis and comprehensive reporting according to EN 13848-5 standards.

The Amberg TGS EVO is the worldwide first carbon-fibre trolley for 3D route surveys with highest demands in quality, accuracy, and performance – especially mobile mapping projects to create digital twins. Its captivating industrial design is combined with highestquality sensor technology to ensure the best quality work on the track.

No more cumbersome screwing or long assembly times before work because this one-piece trolley offers rapid readiness for use.

Amberg Rail GRP System

one trolley can be easily used for different rail measuring tasks on different rail tracks within that gauge range. The trolley’s optimum weight distribution furthermore allows an exceptionally smooth running thanks to its low centre of gravity. The carbon material of the new trolley ensures higher system performance & accuracy, highest durability and better ergonomics for all rail professionals.

The TGS EVO and IMS Track Pro are part of the modular Amberg GRP System series. Amberg Rail combines various precisionmeasuring sensors, industrial designed hardware and specialised application software for track surveying, mapping, and inspection projects. The modular principle guarantees convertibility and subsequent retrofitability of any Amberg GRP system configuration within the full range of the Amberg Rail product line. Amberg Rail thus provides you with optimum support for your projects in every respect, both technically and economically.

The TGS EVO comes with a unique telescopic device with quick-lock pin for completely flexible operations on different gauges ranging from 1000 to 1676mm. This means that

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About Amberg Technologies Amberg Technologies is a global market leader in the area of railway and tunnel surveying founded in 1981 and offering products and services dedicated to building and maintaining civil infrastructures for customers in more than 50 countries. Amberg’s rail systems and solutions address a wide range of needs across the fields of construction and maintenance of slab and ballasted track, asbuilt survey of existing lines, track inspection, clearance analysis and mapping.

Click here to watch our video.

Mr. Goran Buble gbuble@amberg.ch +41 76 722 98 69 www.ambergrail.com

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Complete Composite Systems (CCS)

TouchSAFE – A Robust Barrier for Enclosing Electrical Equipment

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iscover how TouchSAFE composite palisade fencing from CCS saves time and money for rail industry customers needing a robust barrier to safely enclose electrical equipment.

There are significant cost savings to be made from choosing TouchSAFE composite palisade fencing over metallic fencing because no earth bonding is required during installation.

Traditional metal fencing needs to be bonded to the main earthing

system – often at several points every few metres – when being installed in close proximity to electrical installations to prevent electric shocks. An essential safety measure, this physical and timeconsuming process can present a significant cost in terms of both materials and installation, which

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involves the encapsulation of earth rods in materials such as Marconite.

With TouchSAFE composite palisade fencing, there is no need to carry out earth bonding due to the FRP (fibreglass-reinforced polymer) construction of the panels that carry zero metal parts, meaning

Maintenance & Equipment

they don’t conduct electricity – ideal for protecting the likes of railway substations, LOC suites & OLE masts.

TouchSAFE is manufactured and assembled from FRP pultruded profiles conforming to EN 13706 grade E23. The polyester resin matrix is UV inhibited, corrosion resistant and fire retardant, providing protection against harmful sunlight as well as durability in all weathers.

Engineered glass-reinforced polypropylene dowel fixings hold the interlocked pales and cross rails in place to create a structurally robust panel that provides strong resistance against potential vandalism. TouchSAFE fencing is also 75% lighter than steel alternatives and is supplied in fully assembled panels, enabling large expanses of fencing to be installed quickly and easily. Adjustable embankment panels are available.

TouchSAFE composite palisade fencing offers a 40-year lifespan, and throughout that time there is no need to carry out any maintenance on the product. It is manufactured in our ISO 9001, ISO 14001 and ISO 18001 facility, with pre-assembled panels available in three standard heights of 1800mm, 2400mm and 3000mm.

Environmental Benefits TouchSAFE palisade composite fencing offers environmental benefits, with the FRP construction of the product releasing fewer carbon emissions into the atmosphere than traditional metal fencing.

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Reports describing the life-cycle analysis and environmental impact of TouchSAFE are available on request. The reduction in environmental impact can be further enhanced by using TECHNOCRETE® foundation material as a replacement for concrete post mix if using buried fence posts during installation.

Technical drawings of the TouchSAFE system are also available on demand, together with reports on mechanical performance and sustainability. Information such as a parts list detailing product descriptions, sizes, dimensions and the resin systems used, is also available by contacting the team at Complete Composite Systems.

Key benefits of TouchSAFE composite palisade fencing: • • • • • • • • • • • •

Electrically insulating with zero metal parts No earth bonding required FRP (fibreglass-reinforced polymer) construction releases fewer carbon emissions into the atmosphere than traditional metal fencing Robust panels produced using pultruded profiles provide strong resistance to vandalism Lightweight – 75% lighter than steel alternatives Maintenance-free EMI & RFI transparent Supplied in fully assembled panels, enabling large expanses of fencing to be swiftly installed; adjustable embankment panels available Made with a resin that is resistant against corrosion, UV rays and fire, as well as most oils, acids & alkaline chemicals 40-year lifespan Available in light grey or leaf green Standard panels available in 3 heights; double-leaf gates can be supplied to order

Contact the experienced technical experts at Complete Composite Systems, the exclusive UK distributor of TouchSAFE fencing, for enquiries on how to safely contain electrical equipment for your rail project:

Complete Composite Systems Ltd 503 Broadway, Letchworth, Hertfordshire, SG6 3PT +44 1462 379000 or +44 7860 147863 info@completecomposites.co.uk The exclusive UK rail stockist of TouchSAFE is:

Scott Parnell Rail Division Asheton Farm Business Centre, Stapleford Abbotts, RM4 1JU +44 208 8055797 rail@scottparnell.com

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Maintenance & Equipment

Directory

ROWRENCH 30.76 E³ Self-Learning. Strong. Emission-Free.

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t InnoTrans 2022, international interest focused on Robel’s first fully electric precision power wrench with the prominently placed E³ (economic – ecologic – ergonomic) logo.

The claim says it all: a strong 2300Wh battery allows up to 4000 wrenching cycles per battery charge, covering about 1200m of rail, with easy battery change for charging.

Ergonomics begin even before the actual work: the carefully balanced machine is lighter than a comparable model with combustion engine. It can be quickly placed on the track using the foldable handles or the crane lifting point.

The handles for the operator are

In transport position the machine fits on a EUR pallet

Fully electric precision power wrench ROWRENCH 30.76 E³

individually adjustable in height. In transport position, with the frame pushed together, the machine can be loaded on a EUR pallet.

Operation is just as simple. The machine is ready at the push of a button and it literally takes only two fingers and a bit of intuition to operate it. 30.76 is self-learning – it adjusts its tightening torque to the previous screw connections and regulates the power via speed and torque. The machine recognises defective screws, broken spring clips and damaged threads. If necessary, the operator can tear off nuts and bolts that are completely stuck

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without any additional effort. All this is digitally documented and shown on the display – the operator just follows the graphics. Optionally, the measurement data can be documented together with the GPS position of the respective screw connection.

Plasser UK Ltd +44 (0) 208998 4781 robel@plasser.co.uk robel.com

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Distek

Distek Anti-Corrosion Coating Lines Save Energy, Reduce Waste and Lower Costs

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istek thermal diffusion galvanising (TDG) coating lines offer a wide range of time and cost savings.

Not only do customers gain a superior anti-corrosion solution; they also benefit from the improved efficiencies the technology enables, which saves them time and money.

Distek enables manufacturers to run anti-corrosion coating lines in-house thanks to their simple, green operation. This means there’s no need for on-site engineers or permits from environmental authorities.

Save Money by Bringing Coating In-House Of course, the most significant savings come from simply being able to do your anti-corrosion

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coating in-house.

“With our solution you can make anti-corrosion coating an integral part of your production process in-house – you can make your parts, coat them and then they’re simply ready to ship,” says Moshe Shmidov, Global Marketing and Business Development Manager, Distek.

“This way, you save time and all the costs related to transporting

“We are completely green – a great advantage in an industry where environmental issues are of huge importance,” says Shmidov.

the parts back and forth to coating providers. Furthermore, the coating providers should naturally profit too, so they charge extra, but when doing the coating in-house, manufacturers only pay the cost.”

Significant Energy Savings At a time when the cost of energy continues to make headlines, minimising its use is a key priority for businesses across the world.

Distek’s solution can dramatically help with this, as it offers significant energy savings when compared to other market offerings that use the conventional hot-dip galvanising (HDG) method.

provides yet another opportunity to minimise energy use, which not only saves money, but can also improve an organisation’s green credentials.

No Waste In fact, Distek’s entire anti-corrosion coating process is green – no wastewater, hazardous materials or polluting waste come from the procedure.

The closed system includes a water cleaning process that recycles the

This power-hungry approach requires what is essentially a ‘big bath’ of zinc to be consistently maintained at 600 degrees centigrade, whereas Distek’s thermal diffusion coating process is carried out at much lower temperatures.

Meaningful energy savings are clear, but added to this is the ability to simply switch machines on and off as needed, rather than continuously maintain a high temperature. This

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“In the past, anti-corrosion coating facilities would need to get specific permissions and have staff that knew how to safely handle polluting waste. With our solution, because it’s completely green, customers don’t have to deal with anything like this,” he says proudly.

Stronger Corrosion Resistance Distek’s thermal diffusion method also ensures that the final products are long-lasting, which provides benefits of its own.

Omega, a component producer in Croatia, has been running a Distek coating line for over nine years and

Maintenance & Equipment

water, while its dry process ensures there are no acid or toxic elements.

has seen these benefits first-hand.

“Take a steel object used in construction that’s constantly being used – such as a part for scaffolding and supports,” says Marko Premužić, Chief Operating Officer at Omega. “Let’s say you have 10,000 of these on a construction site. If you compare objects processed by thermal diffusion to those that went through the HDG process, you’ll find that the former is much more resistant to wear and will last several times longer.

“This offers some serious savings, as there’s no need to buy expensive new parts when the old ones are still functional and rust-free.”

Ongoing Support As part of a business relationship with Distek, customers are ensured on-going support, which means no concerns around unexpected downtime and its possible related costs.

“When I look back, I can say that we’re not only satisfied with Distek’s

thermal diffusion zinc coating solution, but also our business relationship with them,” says Premužić.

“We’ve been working with them since 2013; we purchase raw materials from them, use their solution almost 24/7, 365, and have so far never had to pay any excesses on the machines and been able to contact them whenever needed via the support line.

“What’s important not only to

me, but every businessman, is not having to worry about the operation of our machines,” he says.

Distek – Your AntiCorrosion Coating Partner Providing an attractive cost-benefit ratio and a superior anti-corrosion solution, it’s easy to see why Distek is chosen by dozens of clients around the world.

Get in touch to learn more about how your organisation can benefit from Distek coating technology – simply email market@distekgroup.com.

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Thank you for reading Issue Four 2022: Track & Infrastructure of the Railway-News magazine.

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