http://www.railwaygazette.com/news/...n-time-tracklaying-poised-to-set-records.html
Just-in-time tracklaying poised to set records
01 Sep 2001
INTRO: A demanding schedule has been set for installing track and M&E equipment on the first section of the Channel Tunnel Rail Link. Murray Hughes visited the tracklaying base at Beechbrook Farm near Ashford
VISITORS to Britain arriving by Eurostar consistently express surprise at the slow pace of travel between the Channel Tunnel and London compared with the 300 km/h line speed in France. Not for much longer. Britain's first dedicated high speed railway is making good progress - and Eurostar passengers can see for themselves the construction sites parallel to the existing line between the Tunnel and Ashford.
The 70 km Section 1 of the 109 km line is set to open in May 2003, cutting 20min off journey times from London to Paris and Brussels. Parts of the formation are already complete and awaiting tracklaying, due to start on November 12.
Once the first track is laid, work will proceed rapidly as the contractors have an access window of just 11 months for use of the worksite at Beechbrook Farm near Ashford. This summer saw the site buzzing with furious activity as the tracklaying and other equipment teams prepared for the day when they begin laying steel.
One small milestone was passed on June 10 when a Class 37 diesel loco propelled a train of 24 tonne ballast wagons into the site. Carrying several hundred tonnes of ballast for the worksite's own tracks totalling 14·8 km, it gave the staff a foretaste of what is to come. For ballasting will be crucial to the whole process.
Bob Doty, CTRL Contract Manager for Contract 570, says that 'ballast delivery drives everything'. Every morning 6000 tonnes of granite will arrive in four trainloads from the Isle of Grain, where it is stockpiled en route from quarries in Scotland. In case of problems, there will be one week's additional stockpile at Sevington east of Ashford and two trains with 1500 tonnes of ballast 'on standby'.
Such measures are needed because the tight timescale for tracklaying and installing other equipment leaves no room for delay. 'We have come up with plans to deal with anything we can think of', says Doty, who believes that records may be set for the speed of work.
Doty, whose railway project management experience dates back to the 1970s, sees the job in terms of minimising risk and balancing this stricture with cost. 'We are trying to minimise risk by sticking with known, but best-case, technology'. But he acknowledges that this is 'inconsistent with engineering - you can sum it up in the saying that better is the evil of good, and I have worked on jobs where they engineered until the paint was dry.'
Doty has no intention of that happening with the CTRL. Next month the Beechbrook Farm site will be in full swing, but given the 11-month deadline there will be no room for mistakes or delays - 'the programmed work must be completed every day as a day lost cannot be recovered', he says. 'The two primary challenges are that the site is rather small and that it has to be managed on a just-in-time basis; we are not allowed to store materials, and this makes it almost a factory environment.' When the site is at full throttle with up to 2000 people at work, 'up to 20 different units will be dispatched every morning'.
Anglo-French team
Doty says that the tracklaying teams 'will use SNCF methodologies', and indeed contractor AMEC Spie Rail Systems has a number of French staff at Beechbrook Farm, some of whom had worked on TGV Méditerranée. Deputy Construction Manager for Contract 570 David Taylor feels that the combination of British and French expertise 'has worked very well with a genuine meeting of minds'. Bringing the international team together has meant 'taking the blinkers off' and has included language courses at all levels 'as nothing must be lost in translation - and all this had to be incorporated into the planning.'
The tracklaying and equipment installation process along the alignment begins with cable troughs, cross channels and cable-laying, followed by footings for overhead line equipment. Tracklaying can then begin, followed by erection of masts and 25 kV 50Hz catenary, which is to the standard SNCF design for 300 km/h. Finally, the TVM430 signalling, communications and other M&E equipment will go in, although some communications equipment at sites off the alignment was in fact installed in July.
The first track will be laid from Beechbrook Farm towards Ashford, but this will be just for staff training. The head of steel will proceed first towards Fawkham Junction, and only then will the teams work back from Beechbrook Farm towards the Channel Tunnel.
Doty says that tracklaying must go forward at 'a minimum of 1100m a day' (550m of double track), with peaks of 1300m expected. The process entails assembly at Beechbrook Farm of temporary panels that are laid out along the alignment to form one track over around 7 km. Sleeper and rail trains then use this to install the permanent track consisting of Stanton Bonna concrete sleepers spaced at 600mm intervals. Long welded UIC60 rail from Thyssen-Krupp (taken over by Voest-Alpine in July) is then installed and affixed with Vossloh fastenings. Final ballasting then takes place.
As many as seven ballasting passes will be needed to achieve the nominal ballast depth of 350mm with six 16 wagon trains a day leaving Beechbrook Farm in the charge of Class 66 locomotives, hire of which Doty was negotiating in July.