The sustainable freight railway: Designing the freight vehicle – track system for higher delivered tonnage with improved availability at reduced cost SUSTRAIL Grant Agreement n°: 265740 FP7 - THEME [SST.2010.5.2-2.] Project Start Date: 2011-06-01 Duration: 48 months D2.3 Track design requirements for reduced maintenance Due date of deliverable: 31/05/2012 Actual submission date: 22/10/2012 Work Package Number: WP 2 Dissemination Level: CO Status: Final version Leader of this deliverable: ADIF Prepared by: Roberto Loiero, UPM Juan Andrés Brunel Vázquez, UPM Juan de Dios Sanz Bobi, UPM Andrew Jablonski, NR María García Santiago, ADIF Enrique Mario García Moreno, ADIF Ed McGee, Tata Steel Ross Walker, Tata Steel Nick Coleman, Tata Steel Adam Beagles, USFD David Fletcher, USFD Per-Anders Jönsson, KTH Sebastian Stichel, KTH Verified by: [CO] Page 2 of 177 Dissemination Level CO Confidential, only for members of the consortium (including the Commission Services) Document History Version Date Author/s Description Rev1 2012-04-27 Roberto Loiero Draft tasks 2.3.1, Juan Andrés Brunel 2.3.2, 2.3.3 Vázquez Rev 2 31-05-2012 Roberto Loiero Complete draft tasks Juan Andrés Brunel 2.3.1, 2.3.2, 2.3.3 Vázquez with Andrew review Andrew Jablonski and the Bulgarian data. Rev 3 15-06-2012 Roberto Loiero Andrew review, and Juan Andrés Brunel references reorder by Vázquez chapters. Andrew Jablonski Rev 4 5-07-2012 Roberto Loiero OTMs table for NR Juan Andrés Brunel included (page 42) Vázquez Draft task 2.3.5. by Andrew Jablonski USFD included Adam Beagles (Chapter 6). David Fletcher Appendix A included. Rev 5 20-07-2012 Roberto Loiero KTH contribution Juan Andrés Brunel (Chapter 5) Vázquez Per-Anders Jönsson Sebastian Stichel Rev 6 27-07-2012 Roberto Loiero Andrew chapter 5 Juan Andrés Brunel review. Vázquez Ross chapter 3, 3.5 Andrew Jablonski review. Ross Walker Conclusions by UPM Rev 7 22-10-2012 Roberto Loiero Review section 3.6 Ross Walker Nick Coleman Disclaimer The information in this document is provided as is and no guarantee or warranty is given that the information is fit for any particular purpose. The user thereof uses the information at its sole risk and liability. The document reflects only the author’s views and the Community is not liable for any use that may be made of the information contained therein. [Deliverable D2.3] [CO] Page 3 of 177 Table of contents 1. INTRODUCTION ............................................................................................................................. 8 2. IMS’ TRACK DUTY REQUIREMENTS ....................................................................................... 1 2.1 IMS MAINTENANCE, INTERVALS AND INTERVENTION LEVELS ............................................ 2 2.1.1 Examinations and monitoring or prevention operations ...................................................................... 3 2.1.2 Maintenance operations ....................................................................................................................... 4 2.1.3 Renewal operations .............................................................................................................................. 6 2.1.4 Intervals and intervention levels ........................................................................................................... 7 2.1.5 Gathered information regarding the selected routes ............................................................................ 7 2.2 IMS REQUIREMENTS AND EQUIPMENT FOR MAINTENANCE .............................................. 20 2.2.1 Means for preventive maintenance. Auscultation vehicles ................................................................. 20 2.2.2 Track advanced equipment. ................................................................................................................ 29 2.2.3 Means for corrective maintenance and renewal ................................................................................. 33 2.3 MAINTENANCE AND RENOVATION COST .......................................................................... 38 2.3.1 State of the art .................................................................................................................................... 38 2.3.2 Gathered information regarding the selected routes .......................................................................... 42 2.4 MEASURES THAT SUPPORT SUSTAINABLE ACHIEVEMENT OF “TOWARDS ZERO MAINTENANCE” ..................................................................................................................... 47 2.4.1 Track state and type ............................................................................................................................ 47 2.4.2 Influence of traffic speed and types of traffic...................................................................................... 47 2.4.3 Unsprung mass of the rolling stock .................................................................................................... 49 2.4.4 Tolerable defects in rails .................................................................................................................... 49 2.4.5 The role of vertical track stiffness ...................................................................................................... 54 2.5 REFERENCES CHAPTER 2 .................................................................................................. 54 3. TRACK DESIGN AND DUTY REQUIREMENTS TO MEET THE IMPACT OF CLIMATE CHANGE AND ENVIRONMENTAL LEGISLATION.................................................................. 56 3.1 INTRODUCTION: OBSERVED CHANGES IN THE CLIMATE ................................................... 56 3.2 ASSESS CLIMATE CHANGE AND ENVIRONMENTAL LEGISLATION IMPACTS ON FUTURE TRACK DESIGN ....................................................................................................................... 59 3.3 IDENTIFY IMPACTS OF CLIMATE CHANGE ON ACTUAL RAILWAY STRUCTURES.:- BACKGROUND PROJECTS ....................................................................................................... 62 3.4 IDENTIFY DUTY REQUIREMENTS THAT WILL CONTRIBUTE TO MITIGATING CLIMATE CHANGE AND ENVIRONMENTAL LEGISLATION IMPACTS ......................................................... 65 3.5 IDENTIFY CONSTRAINTS THAT LIMIT THE RE-MELTING OF RAILS ...................................... 69 3.5.1 Life Cycle Greenhouse Gas Emissions of Railway Systems ............................................................... 69 3.5.2 Life Cycle Assessment (LCA) of Steel Production .............................................................................. 71 3.5.3 Legislative perspective ....................................................................................................................... 72 3.5.4 Designing Rail for Low Carbon Footprint ......................................................................................... 73 3.5.5 Carbon footprint assessment of different rail and sleeper types......................................................... 74 3.5.6 Summary ............................................................................................................................................. 77 3.6 A REVIEW OF THE STUDY ‘ASSESSING THE CO2 IMPACT OF CURRENT AND FUTURE RAIL TRACK IN THE UK’ [3.32] ...................................................................................................... 78 3.7 REFERENCES CHAPTER 3 ................................................................................................. 80 4. TRACK COMPONENT DUTY REQUIREMENTS. .................................................................. 82 4.1 INTRODUCTION ................................................................................................................ 82 4.2 MAIN TRACK COMPONENT DUTY REQUIREMENTS ............................................................ 83 4.2.1 Ballast and/or sub-ballast .................................................................................................................. 83 4.2.2 Sleepers .............................................................................................................................................. 86 4.2.3 Rail fastening ...................................................................................................................................... 90 [Deliverable D2.3] [CO] Page 4 of 177 4.2.4 Rails .................................................................................................................................................... 93 4.2.5 Electrification equipment, catenary and contact wire ...................................................................... 101 4.2.6 Track equipment - Switch and Crossings ......................................................................................... 104 4.2.7 Track Geometry quality .................................................................................................................... 107 4.3 BRIDGES AND OTHER CIVIL ENGINEERING STRUCTURES ................................................ 116 4.3.1 Bridges and other civil engineering structures for the selected routes............................................. 116 4.3.2 Intervention criteria .......................................................................................................................... 117 4.3.3 Life cycle cost ..................................................................................................................................