Professional Documents
Culture Documents
Hubert Rhomberg
MSc (civil engineering)
Board member of the Austrian Transport Institute (OEVG)
Managing Director of Rhomberg Bahntechnik
SUMMARY
As in many other industries total life cycle cost considerations are predominant today in the rail
infrastructure industry.
As a result clear-cut requirements in terms of construction, operation and maintenance of railway
facilities are fundamental for the cost-efficient construction and operation of railway installations. A
design based on these requirements, high quality execution of works and optimised maintenance of
railway installations with an overall life cycle cost (LCC) approach are increasingly important. Due to
ever more stringent safety standards and introduction of new technologies, railway engineering
projects are also becoming more complex and have to be carried out and commissioned in ever-
shorter time spans.
The planning and construction of new infrastructure and renewal of existing assets by competent
Design & Build (D&B) contractors with a proven track record in construction and maintenance offers a
real opportunity for the customer and during operation, systematic maintenance of new and existing
railway installations by specialised companies guarantees the required availability at an economical
price. The experience gained in construction and maintenance, together with a thorough know-how of
managing complex projects and logistics provide thus an ideal basis for a contractor to offer a total
service package in delivering railway technology.
The benefits of railway projects managed by such total services contractor are described, taking the
example of the Lötschberg base tunnel amongst others.
A detailed list of requirements can be found in For the selection and design of the track in
the “DB-AG Track Strategy” Team study.[2]. connection with the lifecycle costs described
below, the following parameters are presented
Next to the mandatory requirements including
as key criteria.
the mandatory fulfilment of speed and load
requisites, the existing regulations, as well as Investment costs
the safety requirements regarding safety in Geometry and design of the earthworks
tunnels, water drainage and environmental and construction works (e.g. smaller radii
protection (noise and vibration emissions) and used when laying ballastless track on new
any tolerated requirements will be evaluated lines)
and added into a matrix in order to define
Maintenance expenditure
priorities.
The requirements and criteria were arranged Costs relation to operational hindrances in
according to the following aspects case of scheduled or unscheduled
Overall operational model availability
Construction and maintenance strategies Measures to limit acoustic and structure-
Risk and failure management borne sound (particularly next to track
infrastructure in urban areas)
Requirements arising from the outer field
Operational benefits of geometric profile
(e.g. higher speeds by installing ballastless
tracks on existing routes/ lines)
From the above key criteria, one can subsume
that after direct investment costs, maintenance
and operational hindrance costs are the main
economic parameters for replacement
decisions, and these shall be discussed in
more detail below.
Further parameters determining horizontal and
vertical profile are essentially linked to the
prevailing topography and the overall network
structure and thus have to be analysed
separately on a project specific basis.
Investment
Inspection Maintenance
Emergency
Repairs
Figure 2: Interaction of LCC components
differing durability, over longer periods of time It shall be noted that on dedicated passenger
and then summarised to a net present value at traffic lines schedules do not usually call for
the time of investment, taking into account operation at night, allowing maintenance to be
inflation and interest rates. carried out without significant operational
hindrances. On freight-only lines, on the other
The model allows therefore a comparison
hand, track possessions for maintenance can
between different track systems (for example:
generally be scheduled to allow for the
ballasted track vs. ballastless track), and can
operational requirements.
be used to represent different maintenance
strategies and comparing these by using Especially on mixed traffic lines, the required
different scenarios. track availability is very high around the clock.
As passenger traffic is normally dense during
As figure 2 shows, there is a high
the day, and freight traffic dense at night,
interdependence between the different
neither during the day nor at night traffic
elements of life cycle costs. As a result pure
volumes are low enough for effective
optimisation of one single component could
maintenance. Maintenance work on this type of
lead to an imbalance of the whole system and
line almost always causes operational
thus have a negative effect on the overall life
hindrances.
cycle costs.
Depending on the operational environment,
3.2 DIAGNOSIS AND INSPECTION
these operational hindrances are taken into
For track infrastructure with high availability account as operational hindrance costs in the
and traffic load requirements, availability is LCC models.
maximised by corresponding diagnosis (e.g.
track inspection train running) and visual 4 TRACK CONSTRUCTION AND
inspections. MAINTENANCE
4.1 MAINTENANCE INTERVALS
3.3 EMERGENCY REPAIRS The objective should be to achieve the longest
possible intervals between systematic track
Emergency repairs are avoided as far as
maintenance cycles.
possible, as the necessary unscheduled ad-
hoc measures are very costly and cause In this respect, it should be remembered that
significant operational hindrance costs with low frequent and often unnecessary tamping of the
efficiency. track wears the ballast and the sleepers down,
which leads to an inferior track stability in the
long run.
3.4 SCHEDULED MAINTENANCE
The average tamping interval ranges between
The objective is to positively impact the total 4 and 7 years in Germany, Switzerland and
life cycle costs by scheduling and preparing Austria.
maintenance intervals based on the actual
track condition.
trafficked lines are only insignificantly shorter quality) due to a lack of elasticity. This leads to
that those on lines with light traffic loads. shorter maintenance intervals, which generally
also means a reduction in the service life of the
The tamping interval is much more dependent
track.
however, on the quality of substructure
(uneven track geometry due to settlements or A remedy to these affects may be the
substructure movements). reinforcement of the ballast bed using sleeper
pads or inserting mats under the ballast, in
Major factors influencing maintenance intervals
particular on bridges.
are a high initial track quality and a high quality
of systematic track maintenance. Tracks embedded in ballast can be regarded
as floating in a floating support. Uneven
Modern high performance machines, able to
settlements will be occurring within the ballast
treat up to 3 to 4 sleepers simultaneously,
bed and on the substructure level under the
have an output of up to 2000m/h and offer the
subsequent traffic loading. For this reason the
highest quality in track geometry and track
use of a dynamic track stabilizer anticipating
stability. This quality can be further improved
the initial train loads and the so-called
when using a stabiliser.
stabilisation tamping have proven to be very
Additionally, special attention has to be paid to effective. Tamping for stabilising the track is
high quality track surveying, which is a carried out a few weeks and then a year after
prerequisite for achieving a high quality and the line has been reopened to traffic. Thus,
durable track geometry on new tracks or during initial faults resulting from uneven settlement of
systematic maintenance. the ballast bed are compensated and the
highest possible initial track quality is achieved.
It is essential, particularly with respect to rail
stresses that the track is delimited Due to the inherent high quality of the track
(geometrically monitored) over its entire there are few dynamic forces acting in the
service life and thus can be reset to its original track, which in turn is supporting the strategy of
alignment during each maintenance operation. long maintenance intervals.
Should this not be the case, the curves of the
track may move either to the inside or to the
4.3 PERMANENT WAY BALLAST
outside during maintenance operations, which
leads to changing rail stresses and inner forces On ballasted track special attention needs to
within the track. be paid to top quality ballast requiring high
edge resistance to be able to direct the forces
acting on the track into the substructure, while
4.2 INITIAL TRACK QUALITY maintaining the elasticity within the ballast bed.
As systematic maintenance, including sleeper
When laying new track or during track tamping, necessitates high stresses on the
renewals, special attention has to be paid to components, frequent maintenance operations
the following factors. have a negative impact on the quality of the
Bearing capacity and stability of the ballast bed material and the bed within which
substructure the sleeper is positioned.
Drainage and for Europe also frost For this reason track tamping should only be
resistance carried out when it is absolutely necessary.
Uniform elastic characteristics of the
substructure
Avoidance of settlements and movements 4.4 MAINTENANCE OF THE RAIL SURFACE
in the substructure After laying the track, the initial quality of the
Sufficient quality of the ballast used rail surface is improved by grinding the rolling
skin while at the same time treating the
It has been found that the service life of track, welding joints. Simultaneously the impurities
and in particular maintenance intervals, are due to the production process (unevenness
negatively impacted by a sub structure that is caused by crushed ballast) are also removed.
too hard (either a ballast bed laid directly on
bridges or on earth construction of too high
The grinding also helps produce the rail head 4.6.2 Sleeper pads
cross sections of new rails according to the
specifications. Particularly on high-speed lines, Over the past years, further innovations in the
the initial profile needs to be as accurate as field of permanent way have allowed for the
possible in order to guarantee the required development of improved ballasted track.
wheel-tread conicity. The use of sleeper pads in particular has
These measures have a positive impact on the yielded very positive results with just slightly
service life of the rail and in particular help increased investment costs. These pads can
reduce the incidence of corrugations and rail be installed using existing and well-proven
surface faults. track maintenance machines.
Observations made so far indicate extended
maintenance intervals and possibly also a
4.5 INFRASTRUCTURE ELASTICITY longer overall service life.
Another aspect is the uniform elasticity of As empirical results covering several decades
infrastructure, consisting of substructure and are not available yet , it is impossible to
track. Under standard load conditions, the rail present final conclusions for the time being.
deflection should be 1 to 1.5mm.
Only this deflection allows the rail to optimally
fulfil its longitudinal load-distributing role, which 4.7 EXECUTION OF WORKS WITH SPECIALISED
CONTRACTORS
minimises the load on both the ballast bed and
the substructure and thus reduces the strain on Construction and maintenance operations are
the track and the subgrade. carried out by specialised contractors using the
4.6 ALTERNATIVES TO BALLASTED TRACK
most modern and high capacity machines (e.g.
MDZ units) operated by qualified and very well
trained staff within a framework of medium-
4.6.1 Ballastless track
term operational work programmes.
In the area of tunnel systems, ballastless or
These highly specialised contractors guarantee
concrete tracks are a well-proven and common
highly efficient and state-of-the-art construction
practical alternative to ballasted track.
and maintenance work to the railway
According to studies carried out by DB, infrastructure owners..
ballastless track is – in terms of LCC - also a
Usually the works of these contractors are
cost-efficient alternative in the open primarily
carried out within long-term framework
on lines requiring a high availability around the
contracts, which are essential should the
clock, which in the case of heavily trafficked
contractors be required to invest into
lines require extremely high track reliability.
expensive machinery and train the highly-
Uniform substructure conditions are essential, qualified personnel necessary for the work.
where no settlements or movements would be
expected in the substructure. Current methods 5 GENERAL CONTRACTOR IN RAIL
of construction require higher investments, ENGINEERING
which can only partially be compensated by
5.1 POTENTIAL BENEFITS
lower maintenance cost.
In Germany, Switzerland and Austria, the
Only by using the comparatively high
laying and upgrading of lines are frequently
operational hindrance costs in the LCC is the
outsourced to general contractors.
long-term cost-efficiency of ballastless track
achieved. This is of great importance The benefits to the customer derive from risk
particularly on mixed traffic lines, which are minimisation by awarding the contract to a total
being used by passenger traffic during the day services contractor which provides the
and dense freight traffic at night. following:
No planning and functionality risk, due to
centralised planning and execution by the
general contractor
A high level of schedule reliability for the maintenance intervals and maintenance
construction and commissioning of the schedules. This maintenance was not only
entire railway installation. restricted to the ballastless track itself but
The complex logistical and construction included complete maintenance of the system
site safety issues, especially for tunnel like signalling, air conditioning, catenary
projects, are centralised. equipment, high and low voltage equipment,
cabeling, etc., in principal you can say,
Use of synergies between different areas everything around the track in that tunnel.
within the general contractor for railway
technology
Reliable budgeting by avoidance or
minimisation of supplements.
By doing so BLS AG achieved a twofold goal:
The customer incurs fewer risks regarding
additional costs and delays, as project a) they could test and evaluate the
management acts as an interface between prospective bidders competence as an
traditionally separate project areas. overall contractor
with the least amount of risk and a measured ballastless versus ballasted track for the Swiss
amount of opportunity. Federal Railways); ETR 6/2005 pages 348-354
Principles in regard to achieving the optimum [4] Ablinger P, Ganzheitliches Prozessdesign im
intervals of track maintenance cycles may Bereich der Bahntechnik (Overall process
apply to infrastructure requirements elsewhere, design in the area of railway technology);
whereby materials are being installed to design Eisenbahningenieur 9/2001, page 14
by the appropriate techniques to allow for the [5] Ablinger P, Vermessen und Einrichten von
asset to perform to its maximum service life. Festen Fahrbahnen – Systemkonzept
Experience gained in both construction and (Surveying and installation of ballastless track –
system concept) ; Eisenbahningenieur 9/2001,
maintenance, together with bringing innovation
page 15 – 21
together with a thorough knowledge of
[6] Ablinger P, Rhomberg H, Kleboth C,
managing complex projects proves to provide
Spezifische Anforderungen an die Herstellung
the right background and sufficient benefits for des Füllbetons bei Festen Fahrbahnen (Specific
a total services package being delivered on requirements on the production of filling
behalf of a railway infrastructure owner. concrete for ballastless tracks);
Eisenbahningenieur 9/2001, pages 22 – 30
6.2 WHAT DOES THAT MEAN FOR [7] Knittel S, PLASMA – das Vermessungssystem
AUSTRALIA? zur effektiven und ökonomischen
Qualitätsbeurteilung von Bahngleisen (PLASMA
The principles of designing, constructing and – the surveying system for efficient and
maintaining a railway infrastructure may not economical quality appraisal of railway tracks) ;
differ greatly to systems being delivered Eisenbahningenieur 7/2004 pages 55-57
elsewhere in the world. [8] Foege T, Flatscher T, Feste Fahrbahn Rheda
The demands by the operator and the users in 2000® auf der NBS Nürnberg Ingolstadt
respect to provide a cost effective railway (Ballastless track Rheda 2000 ® on the new
infrastructure will need to be met line Nuremberg Ingolstadt); ETR 1/2/2005
unconditionally. pages 44 – 54
From the operator to the maintainer and from [9] Zuppiger J, Orsenigo V, Bahntechnik im
the client to the contractor, all have to have Lötschberg-Basitunnel (Railway technology in
sufficient know how and understanding of the the Lötschberg base tunnel); Der
Eisenbahningenieur 8/2004, pages xx –xx
system as a whole. Only then can they share
the tasks and the risks to fulfil the challenging
requirements of a high competitive The literature as well as further information can
environment, in a perfect manner.. be downloaded to a large extent from the
website:
LITERATURE http://www.bahntechnik.com/Englisch/news.html