SP3 Design and implementation of solutions at test sites WP3.5 Bremen tram track replacement techniques operator: BSAG presented by Ingo Schnieders, BSAG and Nils Jänig, TTK at the Urban Track Final Conference June 24, 2010 in Prague
Objectives Challenges: Bremen track replacement works, state of the art: track replacement during action weekend (app. since 2000) total closure for individual traffic during construction phase full closure during action weekend performance of app. 200 m per action weekend Challenge for Urban Track replacement of a 375 m double track section plus 25 m adaption to link to the existing track section (with smaller track centre distance) 4 weeks closure for individual traffic, but open for tramway operation 57 h full closure action weekend Final Conference, June 25, 2010 - Prague 2
Description Overall situation Final Conference, June 25, 2010 - Prague 3
Description Overall situation Final Conference, June 25, 2010 - Prague 4
Description Local situation i Access to site Final Conference, June 25, 2010 - Prague 5
Description Initial situation: mixed operation with maximum speed of 50 km/h worn out rails and defective substructure high maintenance effort for paved surfaces noisy surface with car traffic narrow track centre distance (2,75m) Final Conference, June 25, 2010 - Prague 6
Description Beginning and end of replacement section including crossroads Bei den drei Pfählen / Stader Straße End and connection to existing track Beginning incl. crossroads Final Conference, June 25, 2010 - Prague 7
Planning Layout plans beginning end Final Conference, June 25, 2010 - Prague 8
Planning Cross sections Final Conference, June 25, 2010 - Prague 9
Planning Composition of Superstructure 3,5 cm mastic asphalt as top layer 0/11 S, PmB 45A separating layer (e.g. fibre glass) 3,5 cm mastic asphalt as sub-layer 0/11 S, PmB 45A 3 cm Underpour e.g. Icosit KC 340/65 Fillings (e.g. SEDRAPUR SPEZIAL) 14,5 cm base layer made out of concrete C30/37 with high resistance to frost and de-icing salt 20 cm concrete base plate C30/37, rapidly setting concrete with gritting material and high resistance to frost and de-icing salt, not reinforced 25 cm mineral layer B2 Final Conference, June 25, 2010 - Prague 10
Planning Reference to STUVA testing Final Conference, June 25, 2010 - Prague 11
Test facilities (circuit-machine) green track: V = 30 km/hr Axle Load 7t 18,000 crossings Embedded tracks V =50 km/hr Axle load = 10t 1 Mio crossings Axle Extra weight Revolving turret, drive Rubber wheels 16 Test bodies 35 cm Video Final Conference, June 25, 2010 - Prague 12
Planning Reference to STUVA testing rail underpour: Icosit 340/65 fill in material: Edilon Sedra, prefabricated, glued to the rail mastix asphalt as top layer on concrete base plate rail 59 Ri 2 STUVA recommends: The tested construction is suitable for streets with a low percentage of heavy load traffic Final Conference, June 25, 2010 - Prague 13
Planning Time schedule construction sequence working hours 6:00 22:00 working hours action weekend 0:00 24:00 working hours 6:00 22:00 week 1 week 2 week 3 week 4 time assembly of parts, Preparatory work 57h action weekend subsequent work, evacuation of building site facilities Tramway operation of the concerned 2 lines stopped only for the 57 h on the action weekend Final Conference, June 25, 2010 - Prague 14
Preparation before construction Coordination with local authorities and residents Public relations utilities detour of individual traffic detour of public transport road marking accessibility of residents emergency accessibility coordination of working times night shifts coordination with local events e.g. football matches Final Conference, June 25, 2010 - Prague 15
Planning Preparation Phase 15.09.2008 19.09.2008 2-shift operations between 6:00 a.m. and 10 p.m. Preparation of construction site Delivery of all material necessary for action weekend Cutting and removal of paving and asphalt Removal of old ballast Mounting of track sections Glueing of fillings Determination of ductwork and piping positions Final Conference, June 25, 2010 - Prague 16
Construction sequence I Preparation Phase 15.09.2008 19.09.2008 Final Conference, June 25, 2010 - Prague 17
Construction sequence I Preparation Phase 15.09.2008 19.09.2008 Final Conference, June 25, 2010 - Prague 18
Construction sequence I Preparation Phase 15.09.2008 19.09.2008 Final Conference, June 25, 2010 - Prague 19
Construction sequence I Preparation Phase 15.09.2008 19.09.2008 Corrosion at old tracks due to stray current Final Conference, June 25, 2010 - Prague 20
Construction sequence I sequence plan for 57 h action weekend Final Conference, June 25, 2010 - Prague 21
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Activities during action weekend 3-shift operations Dismantling of tracks Earthworks Ductworks Pouring of concrete base plate Installation of tracks Connection to existing tracks Underpouring of rails Connection to drainage Pouring of concrete surface in junction Stader Straße Final Conference, June 25, 2010 - Prague 22
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Friday, 19 September 2008 Last tram passing construction machinery Friday, 19 September 2008 Cutting off of rails Final Conference, June 25, 2010 - Prague 23
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. loading of worn rails Final Conference, June 25, 2010 - Prague 24
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. ductwork for wires Prefabrication of ductwork Final Conference, June 25, 2010 - Prague 25
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Sat 20 September 2008 Preparation for concrete slab Sat 20 September 2008 delivery of track sections Final Conference, June 25, 2010 - Prague 26
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Sat 20 September 2008 continuous earthworks along section Final Conference, June 25, 2010 - Prague 27
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. installation of shuttering and adjustment Final Conference, June 25, 2010 - Prague 28
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Sat 20 September 2008 Pouring of concrete slabs at starting point Sat 20 September 2008 Laying out the track sections Final Conference, June 25, 2010 - Prague 29
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Sat 20 September 2008 welding St 20 September 2008 drilling holes for fixations Final Conference, June 25, 2010 - Prague 30
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. drainage Final Conference, June 25, 2010 - Prague 31
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Sat 20 September 2008 fixation Final Conference, June 25, 2010 - Prague 32
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. underpour rails Sun 22 September 2008 Final Conference, June 25, 2010 - Prague 33
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Facts: mass: length of site: 375 m (+25m adaption) length of rails: 800 m Fillings: 4,300 tie bars: 500 weldings: 110 fixations: 1.300 concrete slab: 2,400 m² (or 750 m³) underpour: 9,000 l mastic asphalt: 100 to ground: 1,000 m³ pipings: 1,750 m drainage 50 incl. pipes staff workers on site: 80-100 Final Conference, June 25, 2010 - Prague 34
Action weekend 19.09.2008 7 p.m. to 22.09.2008 4 a.m. Re-start of public transport services: Monday 4 a.m. Final Conference, June 25, 2010 - Prague 35
Construction sequence II Activities from week 2 to 4 2-shift operations between 6 a.m. and 10 p.m. Connection welding to existing track Run cables Pouring concrete base layer Building in 2-layer mastix asphalt Pouring joints Cutting asphalt alongside Road marking Clearing construction site Final Conference, June 25, 2010 - Prague 36
Construction sequence II Finished Final Conference, June 25, 2010 - Prague 37
Summary and lessons learned Replacement of 400 m double track within a 57 h action weekend is possible! The length of the track to be converted was close to what is possible and sensible from a staff and technical feasibility point of view. In future Bremen will choose rather shorter conversion lengths (300-350 m) to be on the safe side. Final Conference, June 25, 2010 - Prague 38
Summary and lessons learned To achieve objectives all logistic activities have to be planned precisely and optimised accurately all the coordination work with local authorities and residents has to be done in advance weather conditions have to be favourable the contractor has to be reputable, skilled workers and technicians are essential the construction firm must be well equipped unforeseen circumstances have to be kept in mind a permanent physical presence of the employer at any time is essential Final Conference, June 25, 2010 - Prague 39
Thank you for your attention! Final Conference, June 25, 2010 - Prague 40