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Rebuilding bridges for larger container sizes

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142094

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A photo by murmar had me thinking about the work being done in some areas to convert routes from standard clearance to a larger clearance for the bigger container sizes. Surely this is quite costly, would it not be easier and possibly cheaper to excavate the track near to the bridge so there is a greater height between the track bed and bridge?

Common sense tells me that if it was cheaper and easier it would be the best method, but what are the reasons against it (stabillity problems, time for closure of the track etc)?
 
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rebuilding the bridge is to em the more sensible idea manly because it does not (generally) disrupt the flow of rail traffic beneath, it would also be cheaper because you are only replacing a small amount of stuff, IE you are not digging up the track, digging a big hole, rebuilding the bridge's foundations, relaying the track in the big hole and testing it blah blah blah
 

Trog

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Lowering the track is often the cheaper option, in the short term.

But digging away the capping layer over the formation and leaving the track in a water collecting dip. Often leads to long term problems with track stability.
 

Tomnick

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If I'm not mistaken, the clearance through Penmanshiel Tunnel was being increased in exactly the way you describe when it collapsed.
 

fsmr

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I believe that an original proposal at Melton Mowbray was to lay a bi directional centre track in the middle of the arch for containers only i.e 3 tracks but the option now being used is to build a new bridge next to Leicester road, and slide the bridge into place thus causing the least disruption to the busy A607 above
 

DaveNewcastle

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If I'm not mistaken, the clearance through Penmanshiel Tunnel was being increased in exactly the way you describe when it collapsed.
Quite correct.
Mechanical diggers were scraping away the top layers of the formation and some of the underlying rock.

Its a technique which has been used sucessfully elsewhere.
 

142094

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I was also thinking that it could be a gradual process across the network, that everytime there was track replacement going on, the track under a bridge and the surrounding area could be lowered. In the long term it would work out cheaper I would think.
 

furryfeet

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...gradual process across the network, that everytime there was track replacement going on, the track under a bridge and the surrounding area could be lowered.....

Can anyone state as to whether this is now Railtrack policy ?

Two advantages of lowering the track, underpinning the bridge and leaving the top deck untouched is that
a) road traffic disruption is minimised
b) no need to re-route any statutory cables and pipes which are running across the bridge.

These two factors explain why it took nearly two years to rebuild Gungate bridge in Tamworth as part of the TV4 project.
 

LE Greys

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Would lowering cause problems where bridges need to be underpinned in some places? I can understand it if they want to preserve the bridge for some reason, but it might be much better to raise the bridge clear of both a W10 container and any wires that might go up in future. Incidentally, I think the Paris RER EMUs would just about fit into W10 LG if they were a bit narrower in places. Does that not suggest the possibility of double-deck EMUs on SWT one day?

Can anyone state as to whether this is now Railtrack policy ?

Er . . . I doubt it somehow.
 

Wyvern

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There isnt a simple answer to all this, because each bridge and tunnel has its own conditions. Many have masonry inverts because of the ground conditions.

Hag Wood Tunnel is an example I can think of where modifications would be difficult.

http://en.wikipedia.org/wiki/Toadmoor_Tunnel
 

sprinterguy

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As well as the other issues mentioned above concerning drainage and bridge stability, but if you were to lower the track, then wouldn't you have to do it gradually for a reasonably large distance either side of the bridge so that the gradient wasn't too severe? Plus wouldn't there be potential issues with trackwear and things with trains suddenly changing gradient at the bottom of the dip at high speed.
 

Ploughman

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I was working in a short tunnel that needed a 75mm track lower, shallow depth sleepers were already in place so that was not an option to help achieve the lowering. However structures dept of Network were concerned about the state of the tunnel wall foundations so we had to have one of their people monitoring the dig at all times using laser gear to check for movement of the walls.
At one point the dozer driver slewed the wrong way and hit the wall, the monitoring guy ran he was that scared.

The state of the foundations on any older overtrack structure is a largely unknown factor.

As a further example in 1993-4 due to having to go under 4 bridges in a row between Shipley and Bradford we proposed one lower for the lot to achieve electrification clearance. This was overruled and we had to do 4 separate lowerings. What this meant was that with the ramp in and out for each scheme every sleeper on the stretch had to be taken out anyway. Did that save anything?
 

222007

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Surely this is quite costly, would it not be easier and possibly cheaper to excavate the track near to the bridge so there is a greater height between the track bed and bridge?


The problem is that with the photo of Mumrars (taken south wigston) is that theres a junction a couple of meters further up the line which would mean more work. At the end of the day replacing the bridges means they should last longer than the older structures
 

Trog

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Quite correct.
Mechanical diggers were scraping away the top layers of the formation and some of the underlying rock.

Its a technique which has been used sucessfully elsewhere.


Most of our local tunnels have brick inverts, in the case of the older ones the invert is often only a few inches under the sleepers. This is one reason why you often see hardwood sleepers used in tunnels. The only way to get a decent lower in such tunnels is to fit slab track, which is a very expensive option.

Once when reballasting through a local tunnel that does not have an invert I was warned by the Works Dept. not to dig too deep. When I asked how I would know what was too deep. I was told that I would know I was too deep when the tunnel would closed on me like a book.
 

GearJammer

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The route from Southampton to the Midlands is being upgraded to allow high cube containers to be transported on standard wagons, the cost i suspect is running to hundreds of thousands if not millions to do this work, but high cube boxes have been running to/from Southampton for years, Freightliner put them on Low Liners and in pocket wagons, so why not just carry on useing this method? They say the amount of high cube containers in use is riseing (and being as i haul them i can agree with this) what i don't understand is instead of doing all this upgrade work to the infrastructure why not just build more Low Liners and/or Pocket wagons???????
 

Peter Mugridge

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I think the lowliners or pockets can only carry one container compared to up to three for a conventional conflat? So in the long term the rebuild of the infrastructure should provide a greater return on the investment.
 
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swt_passenger

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The route from Southampton to the Midlands is being upgraded to allow high cube containers to be transported on standard wagons, the cost i suspect is running to hundreds of thousands if not millions to do this work, but high cube boxes have been running to/from Southampton for years, Freightliner put them on Low Liners and in pocket wagons, so why not just carry on useing this method?

£70m is the overall cost, according to the current Modern Railways, with Southampton tunnel being £14m or so.

Length for length, pocket wagons lose 33% of the train's capacity. (That's 2 TEUs, ie one 40ft or two 20ft, rather than 60ft capacity.) I think that's the basic issue with them.

However the delivery of lowliners seemed to stop a good few years ago now, although on the face of it they are the answer, but then again are the small wheeled bogies a maintenance nightmare, or might they have track force issues?
 
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GearJammer

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However the delivery of lowliners seemed to stop a good few years ago now, although on the face of it they are the answer, but then again are the small wheeled bogies a maintenance nightmare, or might they have track force issues?

I don't know but i would'nt have thought so, surely if there was then they would'nt be allowed to use them in the first place!
 

Wyvern

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Low-liner wagons, which Freightliner and First GBRF are using to solve the problem are expensive and have a short lifespan. Additionally, there are still constraints on some routes.

Interesting article here : Ifw
 

GB

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The use of the likes of Megafrets, Lo-liners and Pocket Wagons are really only a stop gap measure. They are more expensive to maintain and to hire, they cost the customer more to book space, they have less loading capacity and you can't have quite as heavier boxes as you can with FEAs.

It should also be said that with Megafrets when loading a High Cube container, it only brings the gauge down to 9'.

Its far better to alter the infrastructure for the longer term benefits.
 

Old Timer

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It is now the policy during renewals to gain any infrastructure clearance that may be obtainable through simply actions such as lowering the track through where possible, although as Trog has already stated this is not always a available, viable, or indeed optimal solution at some bridges.

Any modification work to a route requires all new Structures to be built to the latest larger Structure Gauge, as this is in line with EU Directives which are aimed at enlarging the Structure Gauge where possible.
 

Intermodalist

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All of you together answer the question as to why there is justification to enlarge the British loading gauge to accommodate 9ft 6in high boxes on 'standard' wagons, when wagons with small wheels exist, but I thought I'd join in anyway.

It's true, that although small wheel wagon designs exist, the 'Low-Liner' units in use with Freightliner being the prime examples, it's almost certain that in comparison to 'standard' 60ft platforms, these wagons:


1. Cost more to maintain
2. Incur higher track access charges
3. Impose more restrictive payload conditions
4. Are more expensive to rent/buy


An important thing to bear in mind I think is that the port operators of Southampton and Felixstowe must not have genuine cause for concern that 'the other' port has an inland transport advantage over 'their port'. At the moment, in intermodal terms, Felixstowe has a real advantage - Freightliner can, in theory, from Felixstowe form a 750m train made up entirely of 60ft flat wagons, where as those trains from Southampton have to include either the Finnish pocket wagons and/or the low-liner wagons to transport the 9ft 6in boxes. So therefore, the Southampton trains are of a lower capacity.

This means on competition grounds alone, there is reason to upgrade the Southampton route to a larger loading gauge.

But the issue of the loading gauge is not one that relates just to the height of shipping containers, which indeed will, as time goes on, consist more and more of 9ft 6in high boxes.

The loading gauge is also relates to the length of containers.

For example, observers of Freightliner trains from Felixstowe - a port already benefiting from a 9ft 6in-cleared route via London - will see that every so often there will be, sitting aboard on a 60ft wagon, a Maersk-owned 45ft-long, 9ft 6in high container, normally a reefer unit.

Now admittedly these particular 45ft containers are not in fact road-legal in the UK/EU, due to issue of their corner castings and the EU regulations relating to HGV turning circles, and so they remain 'special cases'. But one has to expect that one day, the 45ft deep-sea containers will be of a similar design to the EU-friendly 45ft designs that already exist, serving the internal EU trade.

Operators of these EU-friendly designs include Ge-eX, for example. See: www.ge-ex.com.

In other words, the 40ft pocket wagons and low-liner wagons are clearly also of no help when it comes to carrying 45ft boxes, and this is another reason why the route from Southampton needs to be made as flexible as that from Felixstowe.

By the way, the Megafret and Multifret wagon designs are not officially small-wheeled wagons. Although they employ wheels that are smaller in diameter to those on 'standard' 60ft platforms, they are not so small as to make them undesirable from a infrastructure viewpoint. The French authorities, for example, would not allow them to run over French metals if they were - in fact, both the Megrafret and Multifret wagons are actually French designs and they first ran in France!

But of course, the platform heights of the Megafret and Multifret wagons are too low to cater for 9ft 6in traffic from Southampton. In addition, they cannot carry the heaviest of containers, and they clearly are not as 'space-efficient' in comparison to 60ft units, at least when it comes to 20ft/40ft deep sea trade.

Oddly enough, just as Network Rail steams ahead with both the Southmapton upgrade and the Nuneaton upgrade, WH Davis comes out with a wagon design that solves just about all these problems. See: www.whdavis.co.uk.

The 'Super-Low' design of wagon that WH Davis has built can carry 45ft high-cube units, within an unmodified loading gauge, while employing wheels that are not too small as to make a civil-engineer responsible for track maintenance scream.

It remains to be seen how much these wagons will cost to buy or rent, but if they had come out about ten years ago, you may well have seen Freightliner investing in a fleet of these instead of having to remain dependent on the classic 60ft wagon design. This would have possibly meant that Network Rail would have not felt any pressure to commit to any loading gauge upgrades.

With this in mind, I would imagine that because of the arrival of the WH Davis design, we are not going to see Network Rail quickly agree to upgrading the loading gauges that connect to the other container ports in the UK, such as Teesport. I would expect that Network Rail will argue that any intermodal operator wishing to serve Teesport, and any other port like it, ought to invest in the WH Davis wagons to serve them.

While this option may be less desrable from viewpoint of the port owners themselves, it is true that in the case of Teesport, most of the existing trade is already 45ft traffic - both 9ft-high and 9ft 6in-high in nature - because the port caters for intra-European trade. So the WH Davis design is actually a more efficient option for this traffic than the classic 60ft design.

Yes, Teesport plans to open a deep-sea container terminal, which means it will in the future handle more containers that are 20ft or 40ft in length, but the chances are that intermodal operators will wish to run trains that will be a mix of this 'new' traffic and the European traffic, so again, this favours the WH Davis wagon design.

In summary, it's all good.

Which ever way you look at it, Britain is on the up-and-up when it comes to intermodal road-rail transport. The only question-mark area remains the transport of standard 4m-high piggyback trailers, but that's another story.
 
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LE Greys

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All of you together answer the question as to why there is justification to enlarge the British loading gauge to accommodate 9ft 6in high boxes on 'standard' wagons, when wagons with small wheels exist, but I thought I'd join in anyway.

It's true, that although small wheel wagon designs exist, the 'Low-Liner' units in use with Freightliner being the prime examples, it's almost certain that in comparison to 'standard' 60ft platforms, these wagons:


1. Cost more to maintain
2. Incur higher track access charges
3. Impose more restrictive payload conditions
4. Are more expensive to rent/buy


An important thing to bear in mind I think is that the port operators of Southampton and Felixstowe must not have genuine cause for concern that 'the other' port has an inland transport advantage over 'their port'. At the moment, in intermodal terms, Felixstowe has a real advantage - Freightliner can, in theory, from Felixstowe form a 750m train made up entirely of 60ft flat wagons, where as those trains from Southampton have to include either the Finnish pocket wagons and/or the low-liner wagons to transport the 9ft 6in boxes. So therefore, the Southampton trains are of a lower capacity.

This means on competition grounds alone, there is reason to upgrade the Southampton route to a larger loading gauge.

But the issue of the loading gauge is not one that relates just to the height of shipping containers, which indeed will, as time goes on, consist more and more of 9ft 6in high boxes.

The loading gauge is also relates to the length of containers.

For example, observers of Freightliner trains from Felixstowe - a port already benefiting from a 9ft 6in-cleared route via London - will see that every so often there will be, sitting aboard on a 60ft wagon, a Maersk-owned 45ft-long, 9ft 6in high container, normally a reefer unit.

Now admittedly these particular 45ft containers are not in fact road-legal in the UK/EU, due to issue of their corner castings and the EU regulations relating to HGV turning circles, and so they remain 'special cases'. But one has to expect that one day, the 45ft deep-sea containers will be of a similar design to the EU-friendly 45ft designs that already exist, serving the internal EU trade.

Operators of these EU-friendly designs include Ge-eX, for example. See: www.ge-ex.com.

In other words, the 40ft pocket wagons and low-liner wagons are clearly also of no help when it comes to carrying 45ft boxes, and this is another reason why the route from Southampton needs to be made as flexible as that from Felixstowe.

By the way, the Megafret and Multifret wagon designs are not officially small-wheeled wagons. Although they employ wheels that are smaller in diameter to those on 'standard' 60ft platforms, they are not so small as to make them undesirable from a infrastructure viewpoint. The French authorities, for example, would not allow them to run over French metals if they were - in fact, both the Megrafret and Multifret wagons are actually French designs and they first ran in France!

But of course, the platform heights of the Megafret and Multifret wagons are too low to cater for 9ft 6in traffic from Southampton. In addition, they cannot carry the heaviest of containers, and they clearly are not as 'space-efficient' in comparison to 60ft units, at least when it comes to 20ft/40ft deep sea trade.

Oddly enough, just as Network Rail steams ahead with both the Southmapton upgrade and the Nuneaton upgrade, WH Davis comes out with a wagon design that solves just about all these problems. See: www.whdavis.co.uk.

The 'Super-Low' design of wagon that WH Davis has built can carry 45ft high-cube units, within an unmodified loading gauge, while employing wheels that are not too small as to make a civil-engineer responsible for track maintenance scream.

It remains to be seen how much these wagons will cost to buy or rent, but if they had come out about ten years ago, you may well have seen Freightliner investing in a fleet of these instead of having to remain dependent on the classic 60ft wagon design. This would have possibly meant that Network Rail would have not felt any pressure to commit to any loading gauge upgrades.

With this in mind, I would imagine that because of the arrival of the WH Davis design, we are not going to see Network Rail quickly agree to upgrading the loading gauges that connect to the other container ports in the UK, such as Teesport. I would expect that Network Rail will argue that any intermodal operator wishing to serve Teesport, and any other port like it, ought to invest in the WH Davis wagons to serve them.

While this option may be less desrable from viewpoint of the port owners themselves, it is true that in the case of Teesport, most of the existing trade is already 45ft traffic - both 9ft-high and 9ft 6in-high in nature - because the port caters for intra-European trade. So the WH Davis design is actually a more efficient option for this traffic than the classic 60ft design.

Yes, Teesport plans to open a deep-sea container terminal, which means it will in the future handle more containers that are 20ft or 40ft in length, but the chances are that intermodal operators will wish to run trains that will be a mix of this 'new' traffic and the European traffic, so again, this favours the WH Davis wagon design.

In summary, it's all good.

Which ever way you look at it, Britain is on the up-and-up when it comes to intermodal road-rail transport. The only question-mark area remains the transport of standard 4m-high piggyback trailers, but that's another story.

One of the odd things about that is that Felixstowe's lack of a motorway does not really affect this. That used to be a competitive disadvantage, but if these containers cannot use roads anyway, then that is all the better for the railways.

The piggyback trailers issue is curious. 4m is almost precisely 13ft 1½in, which is about the highest loading gauge allowed for locomotives (that comes up a lot in steam operations - some used to have boiler fittings that projected higher than that). I'm beginning to wonder if it's possible to re-use the pocket wagons to carry trailers at some point. Not sure how to load them, but I think it might work, but only with some considerable enhancement.
 

Intermodalist

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One of the odd things about that is that Felixstowe's lack of a motorway does not really affect this. That used to be a competitive disadvantage, but if these containers cannot use roads anyway, then that is all the better for the railways.

The piggyback trailers issue is curious. 4m is almost precisely 13ft 1½in, which is about the highest loading gauge allowed for locomotives (that comes up a lot in steam operations - some used to have boiler fittings that projected higher than that). I'm beginning to wonder if it's possible to re-use the pocket wagons to carry trailers at some point. Not sure how to load them, but I think it might work, but only with some considerable enhancement.



Thanks for your response.

Firstly, with respect to your comment about the lack of a motorway link with Felixstowe, the port does have the A14, which in road haulage terms, is just as good as a motorway.

Plus in any case, the deep sea Maersk, 45ft-long, 9ft 6in-high containers I write of are too few in number to be something to jump up and down about, and in the future, if shipping lines wish to introduce 45ft containers en-mass to the Europe-Asia/Far East market, they will wish to adopt a design that is road-legal across the EU, thus taking this unique rail advantage away.

As for the 4m-high piggyback trailers, the reason why they cannot 'fit' within any of the British loading gauges, and indeed within almost all the lines within France and Italy, is because of the corner height restrictions.

In other words, road trailers are flat across their tops, where as the classical railway loading gauge in Europe has curve across the top.

So, while the centre-point positions of the various loading gauges that are to be found Britain, France and Italy may well exceed 4m, the corner parts do not, hence the problem.

Before anyone says I'm wrong about France and Italy, research into the issue yourselves via the UIRR. See: www.uirr.com.

It may comes as surprise that Switzerland, that most intermodal-friendly of states, also has a loading gauge problem that in particular the UIRR company Hupac is keen to highlight. See: www.hupac.com.

Although a new base tunnel is being built along the Gotthard route beneath the Alps, the connecting lines to it are going to restrict intermodal operators to carrying just the specially-built 3.8m-high trailers for some time to come. Only a handful of companies operate these particular trailers.

A solution to all of Europe's loading gauge problems is for there to be an EU-wide rail infrastructure body that has some political and financial clout, but that is a long, long way off from being even under consideration I think.
 

bluebottle

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Now admittedly these particular 45ft containers are not in fact road-legal in the UK/EU, due to issue of their corner castings and the EU regulations relating to HGV turning circles, and so they remain 'special cases'. But one has to expect that one day, the 45ft deep-sea containers will be of a similar design to the EU-friendly 45ft designs that already exist, serving the internal EU trade.

That might be news to all the hauliers who routinely carry these containers. They're also slightly narrower than the EU style ones so I'm not sure what your source is for them not being road legal.

Edit: Found one!

World Cargo News Feb 06 said:
Leading 45ft palletwide container supplier Unit45 BV is warning the industry that time is running out in Europe for 45ft deepsea containers. With effect from 1 January 2007, it will be illegal to move any 45ft containers fitted with conventional corner castings by road within the EU. It was in July 1996 that EU Directive 96/53/EC came into force, setting out the maximum dimensions and weights permissible for road vehicles operating in national and international traffic. Directive 96/53 states that the maximum length of the trucktrailer combination must not exceed 16.5m and that the distance from the kingpin to the rear of the trailer must not exceed 12m. Furthermore, the swing radius from the trailer kingpin must not exceed 2.04m. Standard 45ft x 8ft wide containers are some 81mm too long to meet the requirements of Directive 96/53. Only by using chamfered Euro castings and similarly profiled corner posts at the front end can a 45ft container meet both the length and swing radius restrictions, Unit45 says. In order to safeguard existing assets, the EU agreed to a “grandfather” clause whereby containers built before July 1996 would be allowed to continue to operate for a period of approximately ten years. It is this derogation that expires at the end of 2006. Newer 45ft containers with conventional corner castings have been illegal on Europe’s roads since July 1996, but, says Unit45, there has been little enforcement of this aspect of 96/53 since it requires the relevant agencies to stop vehicles and carefully check the date of manufacture of the suspect containers. From 1 January 2007, however, the situation will change dramatically as it will become very easy to spot illegal containers, even those on the move in heavy traffic. Simply put, any 45ft container that does not feature the visually distinctive Euro corner castings and chamfered corner posts will be illegal and the road haulage operator will be breaking the law. According to Unit45, January 2007 is unlikely to present problems for European shortsea/ intermodal operators since they reacted swiftly to the impending legislation and began ordering 45ft palletwide containers fitted with Euro castings and chamfered posts. This patented solution has been adopted almost 100% by Europe’s shortsea/intermodal operators and any old 45ft units are being phased out before the deadline. Deepsea lines have shown less interest in building 45ft containers that would be road legal in Europe - whether palletwide or of standard 8ft width. Partly, this may be attributable to a lack of recognition of the problem and partly because only a small percentage of the 45ft deepsea container fleet is employed on the trades to Europe.

It appears that nobody will bother about 81mm.
 
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Intermodalist

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Are you sure about road hailiers carrying these? It's not that I'm insisting I'm right, but as far as I know, the only EU-legal 45ft containers in operation were those for internal European trade, not those in use for deep sea trades.

This is, after all, one of the reasons why none of the other shipping lines as yet operate 45ft containers in Europe. If the Maersk units are being conveyed by road as well as rail, this can only mean they are not of a standard ISO design.

Next week I'll contact Maersk and ask them about the containers, and where they are being run to-and-from.
 

90019

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I'm beginning to wonder if it's possible to re-use the pocket wagons to carry trailers at some point. Not sure how to load them, but I think it might work, but only with some considerable enhancement.

There are already wagons built specifically for carrying artic trailers, but I think most, if not all of them are sitting in sidings in Edinburgh now, they were originally used by Royal Mail.
IIRC there are 20 of them, they are articulated and can carry 4 trailers each.

I have a photo of them from a couple of years ago, they've been sitting there unused for a few years.
 

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Intermodalist

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I remember well the period of the launch of the Thrall Europa wagon designs, and spoke with the Thrall people in Europe about them on several occasions.

In my view they were a success, simply because they led to the launch of the first piggyback trains in Britain capable of carrying standard-width road trailers, albeit road trailers with cut-down roofs. In contrast the preceding swing-bed pocket wagon design of Tiphook could only carry specially built trailers that had a narrower width than the norm.

In theory, therefore, the Thrall wagons meant that the British market for piggyback transport was laid open to all those road transporters and forwarders who would be able and willing to operate low-height trailer fleets. This of course was and remains the problem. Only the Royal Mail chose to embark on tests, and this, I speculate, may have had much to do with the fact that the Royal Mail had been, as it still is, the state-run monopoly provider of letter services, and legacy monopoly provider of parcel services. Perhaps this meant that at the time the Royal Mail had the necessary volumes for a London-to-Scotland service, and perhaps also it was at the time, more rail-friendly in comparison to the more commercial express parcel operators.

Another problem is that the Thrall wagons, while capable of carrying 40ft/45ft-long swap bodies and containers, can only do within a loading gauge far larger than the largest gauge to be found in Britain. The more recent Babcock ‘Mega 3’ pocket wagon design overcame this problem, and you will see these units in operation with TX Logistik across Germany especially. See: http://www.txlogistik.com.

I think it’s extremely unlikely that any operator in Europe will wish to use the Thrall wagons again, and so I wonder why they have been left to rot. Surely the bogies on them are of use to someone somewhere.
 
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