16 noses, 36 legs but can’t walk…… newark flat crossing
TRANSCRIPT
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16 Noses, 36 Legs But Can’t Walk……
Newark Flat Crossing Renewal
August 2019
1
Phil Winship Principal EngineerAsset Enhancement TeamSafety, Technical & Engineering
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Doncaster
Kings Cross
Lincoln
Nottingham
Newark Crossing a.k.a:Newark Flat CrossingNewark ‘Star’Newark ‘Diamond’
NOB1 cross ECM1 at a 44.1 degree angle
ELR
:EC
M1
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Comprises 8 x ‘double star’ crossings on longitudinal timber structure
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A Look Back at Previous Renewals……
Renewal History
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1960
Modular joint ?
Nov1972
New crossings + Jarrah packing on existing timber waybeams
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1986-88 ECML electrification Huntingdon to Leeds
May1986
Complete renewal using 13.65m hardwood waybeams
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Aug2003
Complete renewal using 16m hardwood waybeams
2015 Crossing re-design / replacement & heavy re-furb works to remove 80mph CoT TSR
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Renewal / major intervention every 15 to 20 years.
Track quality in the poor / very poor band soon after each renewal.
Ballast degraded below sleeper base (from TBI).
Double Star Crossings – 8 weekly grinding / repair regime in place.
Timbers now life expired / visual inspection not easy (ballast glued) and cannot be maintained –risk of CoT TSR/ESR if not renewed.
Summary
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2019 Specification Timeline
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February 2017 – 1920 LNE Start Up meeting – L4L on timber
November 2017 – Product Acceptance for FFU (Longitudinal timbers)
December 2017 – composite bearer option to be developed.
January 2018 – Informed composite bearers not an option due to current product acceptance (lack offor bespoke arrangement)
March 2018 – Conversation at QSB with RAM [Track] : composite bearers not to be considered dueto long term robustness being unknown.
April 2018 – Advised by STE that composite bearer option ‘back on’ as previous barriers going away.
May 2018 – Sekisui invited to present at LNE DCI Meeting – Request by RAM [Track] to ‘take up thechallenge of incorporating this technology’.
July 2018 – PRS (v4.1) issued (T-56).
Domestic Renewal – CP6 Year 1 – Life Expired Asset (timbers)
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Like for Like – Based on 2003 Design Drawings
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Double star crossings all replaced in 2015
Fastening system - screws inserted at a 1:20 angleBy 2014 – 45% of screws had failed Re-designed crossing
fastening system
Crossing Replacement 2015
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Crossing Fastening System Changes
Redesigned crossing fastening arrangement 2015
Refined crossing fastening arrangement 2019
Old crossing fastening Arrangement 2003
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Renewal - Changes Incorporated
Composite (FFU) bearers with under bearer pad in lieu of Greenheart timber.
Bespoke trackbed design.
HP rail specified including adjustment switches.
SG iron baseplates with Pandrol e-plus clips.
Concrete sleepers / bearers with under sleeper pads.
Crossing profile optimisation study (Huddersfield University).
Crossings pre-drilled for continuity bonding.
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Why Composite?
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Unable to source timber!
2102 clause 6.5.2(Longitudinal Timbers)
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FFU Option
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What is FFU?FFU synthetic wood is made up of long glass fibre strands soaked with poly-urethane and then cured at an elevated temperature. The synthetic wood can bemachined and/or worked using the same techniques and tools as those used for natural wood.
FFU is a material developed for the Japanese Railways and introduced in Japan in the 1980s. FFU is much more durable than natural timber and most importantlydoes not rot. It has a design life in excess of 50 years which is in stark contrast to hardwood timber.
Fibre reinforced Foamed Urethane
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NRAP re-classified project as CSM significant due to FFU & unique configuration.
Project lacked experience of CSM significant projects. STE led process Ricardo Rail appointed As-Bo
Sekisui needed design approval / order by Dec 2018. STE led design approval process – RE/PW drawings will be produced
Product acceptance needed for bespoke arrangement.
Size of bearers needed.
Challenges
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We needed 16m length x 700mm wide!FFU is only currently manufactured in Japan, and due toshipping limitations is produced to a maximum length of 10m.
Solution:
The individual pieces were shipped over to the UKand assembled at the Progress Rail Ilkeston facilityin Derbyshire, to form the final matrix for thedouble star crossings. This was the first time theyhave ever been built outside of Japan.
The design was complex with interlocking designedto ensure that the construction matched that ofthe specification, along with having two densitiesof FFU layers to give increased compressivestrength near the surface.
Available Sizes
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Design Drawing Example
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Trackbed Design Solution
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The track system at Newark is a ballasted track system, the design recommendation aims toreduce ballast settlement, future maintenance interventions and the development of significanttrack geometry faults.
Track Bed Investigation, on site deflection measurements, and FEM undertaken.
Results have determined: Poor track quality caused by high dynamic forces and ballast attrition. Existing geocells in good condition.
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Option chosen
Under Sleeper Pads to reduce ballast deterioration especially in ‘top’ layer
Ballast compacted in 2 layers Additional geocell layer on to of existing geocells to minimise ballast
deterioration in ‘bottom’ layer. Dependent on high accuracy of installation. Deterioration is expected as it is a ballasted system and settlement
cannot be entirely eliminated.
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New 100mm geocell
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Supply & Manufacture
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Route Services placed a contract with Progress Rail to:
Supply new double star crossings (EDH’d).
Sub-contract with Sekisui to supply, laminate, and assemble FFU bearers in UK (PRS facility atIlkeston) including supply of tooling etc. First time this has been undertaken outside of Japan.
Facilitate demonstrations of workability of FFU material etc.
Assemble complete layout at PRS.
Deliver layout and re-assemble lineside with assistance from CRSA.
Build all external panels including adjustment switches and slave panels.
Sub-contract with Huddersfield University to undertake wheel rail interface study to optimise crossing profile.
Scope
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Build Programme: Week 05: FFU starts arriving at Ilkeston Week 07: Start lamination process Week 13: Complete bearer assembly Week 15: Start fitting crossings etc. Week 16: Complete fitting crossings etc. Week 17: Strip layout and send to Beeston for
loading to train.
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Week 17: Load to train at Beeston
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Plain line panels ready for loading
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Development Plan
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Keep BAU. Site build area and land requirements. Kirow crane(s) or mobile crane. Kirows chosen:
no need to take OLE down limited space – land sold off more resilience to weather (high winds) contingency options – able to lift with 1 crane
Removal of old flat crossing – saving cast crossings / how to lift / space constraints. Temporary track panels for haul road(s). Construction height differences between adjacent plain line and crossing area. Slave rails. Temporary clamping of joints during construction & check rails. Continuity bonding of crossings. Staged possession handback – Newark Chord.
Considerations
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Plan for lifting old crossing
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Panel Arrangement incl. temporary panels
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591mm371mm
Bespoke panel to cater for height differences
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Lifting of new crossing
Initial lift from build area
Travelling
To/from temp laydown area
Changes in the position of the centre of gravity of the layout, proved challenging during the lift as can be seen in later photo’s !
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Prep Works
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Build Area & Temporary Laydown Area
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Week 12 to 15: Prep build area
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Week 18: Offload bearers on site
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Week 18 & 19: Lineside rebuild
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09/08/19 (Wk19) – Layout complete & inspected
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Core Works August Bank Holiday 24th – 27th August 2019
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Possession Handback Tuesday 27/08/2019
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Follow Up & Monitoring
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Getting back to linespeed:
Opened with 50mph TSR.
T+1 tamp Tue night [ECML] & Thu night [NOB1] week 23.
Visual inspection of crossing under traffic with STE / TME reps Friday week 23. Voiding evident.
TSR eased to 80mph weekend 24 after follow up works: grinding / Inspection of crossings (crossings were not EDH’d) Robel hand tamping of flat crossing
Visual inspection Monday week 24 – minimal voiding following Robel hand tamping.
Further visual inspection of crossing under traffic with STE / TME reps Friday week 25.
T+4 tamp planned weekend 26 – raise to linespeed [100mph].
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Thank You!
RAM Support & Maintenance