DLR CITY AIRPORT EXT.
Colin Burnikell9th Feb. 2021Ashford Section Meeting
DOCKLANDS LIGHT RAILWAY – CITY AIRPORT EXTENSION (DEC 2005)
Facts & FiguresMain Contractor – Amec Spie RailProject Value - £6mConstruction of:4.5km viaductNew Stations including:• West Silvertown• Pontoon Dock• London City Airport
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SITE OPERATION - PRE-CAST YARD
OverviewSite located at: Dock Road, Canning Town. London E16.• Office facilities & factory set up
on site.• Manufacture of the various
concrete products.
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CIVIL ENGINEERING
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SITE OPERATION – CONSTRUCTING THE VIADUCT
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SITE OPERATION – CONSTRUCTING THE VIADUCT
Constructing the viaductThe viaduct segments were cast on site, stored & installed over the first phase of the project duration.
Services.Cable penetrations for services were catered for to eliminate any external fastening to the structure.
Alignment.This was essential & each segment was moulded from the previous section to ensure an exact fit.
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THAMES WHARF VIADUCT
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TRANSITION SLAB
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TRACK BED PREPERATION
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TRACK BED CONSTRUCTION
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Permanent Way installation could take place once the viaduct was assembled.Various light rail components were utilised.Preparation was key.• Resourcing.• Logistics (delivery).• Availability of products.• Storage.
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TRACK BED CONSTRUCTION
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Permanent Way installation could take place once the viaduct was assembled.Various light rail components were utilised.Preparation was key.• Resourcing.• Logistics (delivery).• Availability of products.• Storage.
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Drainage
TRACK BED PREPARATION - SCABBLING
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• Scabbling of the concrete surface was part of the preparation works.
• This would provide the ideal base for the grout that was going to be installed.
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TRACK BED PREPARATION - SCABBLING
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• Scabbling of the concrete surface was part of the preparation works.
• This would provide the ideal base for the grout that was going to be installed.
• Working in a controlled fashion although a manual process a template was used.
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TRACK BED PREPARATION - SCABBLING
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• Scabbling of the concrete surface was part of the preparation works.
• This would provide the ideal base for the grout that was going to be installed.
• Working in a controlled fashion although a manual process a template was used.
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TRACKWORK PREPARATION
Component parts laid out.On both the curved track & straight.
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TRACKWORK PREPARATION
Track geometryTrackwork set up to represent the initial layout.
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TRACKWORK PREPARATION – PANDROL VIPA BASEPLATE
Plain line track assembly• Pandrol Vipa 2 hole baseplate was used.
• Shown here suspended from the rail above the prepared ‘scabbled’ concrete.
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ANCHOR TESTING
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TRACKWORK – ANCHOR PROOF TESTING
Anchor testing (70kN)• 5 different chemical anchors tested with an M24 anchor.
– Injectable resin & Capsule.• Results were quite ‘variable’…….• Bond failure in some cases.
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TRACKWORK – ANCHOR PROOF TESTING
Anchor testing.• 2 Hilti chemical anchor variants were tested with Hilti HRT anchors:
– Injectable resin (RE500) & Capsule (HVU).• Concrete cone failure was the mode of failure.• 150kN achieved (RE).
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TRACKWORK – ANCHOR PROOF TESTING
Replication of ‘poor workmanship’.• 28mm Dia. holes were drilled. Holes were filled with water.
– Hilti Injectable resin (RE500) was installed into the holes with standing water.• Once cured, the anchors were tested.
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TRACKWORK – INTERNAL/INDEPENDENT ANCHOR TESTING
Test Reports.
Internal (Schaan)• 3m cycles.
External• TUM submitted.• Joseff Eisenmann.
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TRACKWORK – HOLE CLEANING
Anchor hole cleaningEssential for when using chemical anchors.
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DRILLING TRIALS
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TRACKWORK – DRILLING TRIALS
Options for drilling holes for holding down bolts.• Diamond drilling (DD150 & DD200).
• Percussive (TE80).
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TRACKWORK – DRILLING METHOD CONFIRMED
Preference Hilti ‘rig mounted’ drilling wagon.• Perpendicular to slab.• Percussive Hilti TE80 drill with TE-YX 28 drill bits were attached (x 2).
– Reduced HAV’s.• Depth stop was attached to prevent over drilling & minimize resin wastage.
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TRACKWORK – DRILLING METHOD CONFIRMED
Preference Hilti ‘rig mounted’ drilling wagon.• Perpendicular to slab.• Percussive Hilti TE80 drill with TE-YX 28 drill bits were attached (x 2).
– Reduced HAV’s.• Depth stop was attached to prevent over drilling & minimize resin wastage.• Drilling jig used.
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VIBRATION TESTING
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TRACKWORK – VIBRATION TESTING
Testing set up.• Wired up to rig.• Vibration measured over several trials.• Results ave. 7ms2.
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TRACKWORK INSTALLATION
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TRACKWORK INSTALLATION – PART 1 (HOLDING DOWN BOLTS)
Installation of M24 holding down bolts• Using Hilti RE500 injectable resin.• Piston Plugs were also supplied.• P8000 pneumatic dispenser.
– Dosage meter.31PWI Ashford Section Mtg – Colin Burnikell | Feb 2021
TRACKWORK INSTALLATION – PART 2 (GROUT BED)
Grout bed installation• Shuttering applied confirming ‘footprint’.
• For inclement weather, covering was used.
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TRACKWORK INSTALLATION – PART 2 (GROUT BED)
Grout bed installation• Grout mixed & applied.• Plasticine used to prevent any overflow.• Sand around the base.
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ADDITIONAL P. WAY COMPONENTRY
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TRACKWORK – S. & C. COMPONENTRY
S. & C. Baseplate• Cologne Egg 4-hole baseplate was specified.• Installed with Hilti RE500 injectable resin.
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TRACKWORK – ADDITIONAL COMPONENTRY
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TRACKWORK – ADDITIONAL COMPONENTRY
Third Rail• Brecknell Willis system deployed in pre-cast spacing.• ‘Pick up’ from the underside.• Fastening ‘cast in’.
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ANCHOR INTEGRITY
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TRACKWORK – ANCHOR INTEGRITY
Testing & Recording• 5% of anchors tested.• Independent Company used.
– Sheer load recorded.39PWI Ashford Section Mtg – Colin Burnikell | Feb 2021
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STATION WORKS
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DOCKLANDS LIGHT RAILWAY – CITY AIRPORT EXTENSION (DEC 2005)
Station ConstructionSilver Town & Pontoon Dock
Presentation title | Month 202x 41
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SUMMARY
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DLR CITY AIRPORT EXTENSION – TRACKWORK SUMMARY• 80Lb Rail used.• Plain line.
– Pandrol Vipa 2-hole baseplate.• S. & C.
– Cologne Egg 4-hole baseplate• Drilling wagons & Hilti TE80’s with TE-YX
28/81 drill bits.• Hilti RE500 (1400ml) injectable resin.• M24 HDG Holding down bolts.• Grout – SBD Epoxy plus.• Third Rail – Brecknell Willis
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THANK YOUContactColin BurnikellStrategic Key A/c Manager - Rail
Hilti GB Limited1 Trafford Wharf RoadTrafford Park, Manchester, M17 1BY
Tel: 07801 913 [email protected]