Coleraine to Derry~Londonderry ROUTE UPGRADE WORKS Alan Cudlipp CEng FICE FPWI Technical Director - Professional Head of Track Engineering, Mott MacDonald Coleraine to Derry~Londonderry Route Upgrade Works Contents • Introduction and project summary • Background • Project Development • Design • Construction • Conclusion Coleraine to Derry~Londonderry Route Upgrade Works The line • Single line - Coleraine (61¾MP) to Derry~Londonderry (95¼MP) • Passing Loop and Station at Castlerock (68¾MP) • 27 miles of single line with no means of passing trains • 1600mm / 5ft 3ins gauge • 13 miles directly on the coast • Coastal Route along the River Bann estuary from Coleraine and then along Lough Foyle into Derry • Eight 3-car trains in each direction providing a 2-hourly service Coleraine to Derry~Londonderry Route Upgrade Works The line Featured in Great Railway Journeys where Michael Palin described the train journey between Londonderry and Coleraine as… “one of the most beautiful rail journeys in the world” Coleraine to Derry~Londonderry Route Upgrade Works The line History of the Line: • Construction started in 1845 • Line opened from Derry to Limavady in 1850 and completed to Coleraine on the west of the River Bann in 1851 • Bridge over the Bann built in 1855 • Linked to Belfast in 1861 • Bann Bridge replaced with an opening bridge in 1924 to allow access for shipping into Coleraine Coleraine to Derry~Londonderry Route Upgrade Works Railways in Northern Ireland Northern Ireland Railways • Own and maintain infrastructure and trains • Operate services • Passenger services only • 3- and 6-car sets comprising CAF 3000 and CAF 4000 diesel units. • Cross-border services to Dublin shared with Irish Rail (Iarnród Éireann) – loco hauled 8-car sets Coleraine to Derry~Londonderry Route Upgrade Works Northern Ireland Railways Network • 200 Route miles • Four lines radiating from Belfast • Formerly only CWR on Central Network - jointed track elsewhere Coleraine to Derry~Londonderry Route Upgrade Works Problems with existing track • Line last relayed in mid 1970s using CIE 50kg/m rail on concrete sleepers • Rail joints every 60ft • Geometry Faults • Broken sleepers and wet spots • Slope stability • Ballast retention • Sea and river defences • Drainage Coleraine to Derry~Londonderry Route Upgrade Works History of the project Ø 2000 - Review of Railways • Line north of Ballymena considered for closure • Reprieve granted, but line designated non-core and funding for maintenance and renewals severely limited • Linespeed reduced from 70 to 60mph Ø 2008/09 - Refurbishment of line from Ballymena to Coleraine • Wet spots treated – 4000 sleepers Ø Translink push for full renewals on Coleraine to Derry line • Included in Capital Works programme and approved in principle by Government Coleraine to Derry~Londonderry Route Upgrade Works History of the project Original Project • Full renewal of entire route section • New rails and sleepers • Renewal of ballast and drainage • Bridge replacement and refurbishment • Complete renewal of signalling system • New passing loop Project Cost £75M • Arup appointed to develop project Coleraine to Derry~Londonderry Route Upgrade Works History of the project Track Safety Improvement Works • Campaign to gain funding resulted in £7M promised. • NIR felt that most benefit derived from elimination of rail joints • Substantial part of the route could be converted to CWR with minimal civils works. • Options examined and decided to re-rail 18 miles of track. • Remaining 13 miles deemed unsuitable for re-railing due to problem achieving adequate ballast shoulders. • Works planned for midweek nightshifts using external contractor Coleraine to Derry~Londonderry Route Upgrade Works History of the project Track Renewals • Due to the curving coastal route, the only option for the ends of the line was full renewal • Translink continued to campaign for additional funding. • Safety issues highlighted: • Threat of severe speed restrictions • Reduced frequency to five trains per day Ø Outcry from politicians in Derry Coleraine to Derry~Londonderry Route Upgrade Works History of the project Track Renewals • A couple of very helpful factors: • Derry elected as “UK City of Culture” in 2013 • Cancellation of a major cross-border road scheme (which was to be joint funded by Irish Government) Money offered, provided work was completed in time for 2013 City of Culture Coleraine to Derry~Londonderry Route Upgrade Works Project Summary • Full scale renewal of track, ballast, formation and drainage of 13 miles at each end of the route • Conversion of 18 miles of jointed track to CWR (between Castlerock and Eglinton) in the central portion of the route • Renewal of S&C at Coleraine • Bridge replacement and refurbishment • Bann Bridge refurbishment • Seven month closure agreed Coleraine to Derry~Londonderry Route Upgrade Works Funding allocated Government Funding committed to date: • Track Safety Improvement Works £ 7.65M • Track Renewals – Phase 1 £ 26.70M • Bann Bridge Refurbishment £ 3.94M • Replacement of UB20 and Culvert 3 £ 0.24M • Total funding allocated £ 38.50M Coleraine to Derry~Londonderry Route Upgrade Works Procurement Track Safety Improvement Works • Documents prepared by Arup • Tenderers pre-qualified • NEC Contract Option A – Activity Schedule • Tender award: • Cost 60% • Quality 40% • Contract value £ 1.3M • Contactor McLaughlin & Harvey • Contract period • Complete works in blockade by end September 2012 • Facilitate follow-up tamping in September 2013 Coleraine to Derry~Londonderry Route Upgrade Works Procurement Renewals Contract 2-stage tender process NEC Option C – Target Cost Design & Build Tender Evaluation: Quality 60% Cost 40% Preferred Bidder McCann / Bam JV • P. Way and Civil Designer Mott MacDonald • Signalling Invensys Contract Awarded July 2012 • Target Cost £16M Coleraine to Derry~Londonderry Route Upgrade Works Track Renewal Design Scope Permanent Way • Jointed to CWR • Value Engineering • Look beyond ‘on top’ relaying • Maximise re-use of fill materials for bank stabilisation • Proximity to river and sea – ballast retention • Formation and drainage renewal Coleraine to Derry~Londonderry Route Upgrade Works Civils Design Scope Bridges Blast cleaning, steelwork repairs, re-waterproofing and repainting of Milburn Road; - concrete repairs and re-waterproofing of the Faughan Bridge; - concrete repairs, re-waterproofing and scour protection works to the Roes Bridge. Culverts Replacement and upgrading as part of the drainage works, with new headwalls and larger diameter concrete pipes at lower inverts. Other Works Slope improvement works, including regrading of cutting slopes, extending embankments to accommodate a cess walkway and new retaining walls. Coleraine to Derry~Londonderry Route Upgrade Works Signalling Existing system is token block - almost as old as the railway! Separate project to fully upgrade the system – current project includes provision of a new ducted cable route to accommodate like-for-like replacement of existing signalling cables while facilitating the future re- signalling works. Mott MacDonald - civils design; Invensys - Signalling design. Coleraine to Derry~Londonderry Route Upgrade Works Advance works by NIR Detailed topographical survey • Boundary to Boundary Detailed track walk of entire route by Arup and NIR for original full scale renewal • Limits set on track lifts in problem areas • Identified drainage requirements • Set requirements for detailed designer Further track walk for re-rail site • Focus on ballast shoulder issues Coleraine to Derry~Londonderry Route Upgrade Works Application of cross-sections Coleraine to Derry~Londonderry Route Upgrade Works Lock Level Crossing Track Lowered 700mm Coleraine to Derry~Londonderry Route Upgrade Works Construction - TSIW Trackwork • Distribute rails • Unclip old rails – difficult in coastal environment • Set out old rails Coleraine to Derry~Londonderry Route Upgrade Works Construction - TSIW Trackwork • Set in new rails • Trim rail ends • Flash butt weld • programme for 60 welds per day, but record is 84No • Clip up anchor, stress new rails and clip up Coleraine to Derry~Londonderry Route Upgrade Works Construction - TSIW Trackwork • Remove old rails to scrap • Facilitate tamping (by NIR) Coleraine to Derry~Londonderry Route Upgrade Works Construction - TSIW Trackwork 10No Public Road Level Crossings • Rerail 3No • Tamp • Stress through • Road Closure and reinstatement of road surface 19No Accommodation crossings • Agree closure periods with farmers • Reinstate stone surface on completion Coleraine to Derry~Londonderry Route Upgrade Works Construction - TSIW Trackwork • Insulated joints 44 No.: • Refurbish 39 No. 6-hole Benkler joints in 113lb rail • Install new Benkler joints at five locations • S&T • Disconnect track circuit cables • Reconnect and test Coleraine to Derry~Londonderry Route Upgrade Works Construction - TSIW City Of Derry Airport Coleraine to Derry~Londonderry Route Upgrade Works Bann River Bridge Coleraine to Derry~Londonderry Route Upgrade Works Bann River Bridge Structures • Bann Bridge Coleraine to Derry~Londonderry Route Upgrade Works Construction - Track Renewals Contract Trackwork • Drainage and Ducts Coleraine to Derry~Londonderry Route Upgrade Works Construction - Track Renewals Contract Trackwork • Excavate to formation Coleraine to Derry~Londonderry Route Upgrade Works Construction - Track Renewals Contract Trackwork • Bottom Ballast Coleraine to Derry~Londonderry Route Upgrade Works Construction - Track Renewals Contract