Installation of 2No Single MV Circuits over 5.3km – Drybridge to Drogheda

Global Rail Services Limited (GRSL) has completed a significant and complex civil engineering project from Drybridge to Drogheda Town Centre, in Co. Lough, on behalf of long-term client ESB Networks.

In their capacity as PSCS for the project, GRSL supplied a secure yard/compound and were responsible for liaison with ESB, Louth County Council and all affected residents and business owners.

Providing a fully managed service including QSE representation for the project duration, the work scope covered the excavation, ducting, backfilling and reinstatement of trenches, including crossing a stream. GRSL also connected two existing ducts that were under the M1 motorway, laid ducts over/under existing services and culverts and installed a 400mm2 XLPE power cable prior to completion of all road and pavement restoration works.

Significant amounts of hand excavation assisted by a vacuum excavator – to help protect existing services – was also undertaken, which were very deep in a number of locations. GRSL were responsible for the design and construction of all temporary works.

Full Traffic Management was provided throughout, which covered 8 different road opening licences and 21 separate traffic management plans.

The project was a necessity for the town of Drogheda; supporting power capacity upgrades to enable future development.

Global Rail Services Limited Project Manager, John Casey added:

“Well done to all concerned for a successful project and with special thanks to supply chain partner Córas Pipeline Services Ltd.”

Repairs to Berth 3 Linkspan Bridge at Rosslare Harbour

Irish Rail, on behalf of Rosslare Harbour, has awarded Global Rail Services Limited (GRSL) a contract to repair damage to the Berth 3 linkspan, which caters for the Stena Horizon and Europe ships.

The existing damaged structural steel elements are being replaced in a like for like manner. GRSL have been tasked with the fabrication of steel to an Execution level 3 (EXC3) for the linkspan with an estimated overall tonnage of 10 tonnes.

GRSL have provided a bespoke temporary working platform fixed to the underside of the linkspan structure for safe access to the front face of the linkspan, aided by the deployment of an MSO (Marine Survey Office) licenced safety boat with P4 certification and a competent trained skipper. The temporary platform was designed to be submerged into the sea when contract works are not taking place, so that the linkspan can remain operational for ships to use.

Works are being carefully managed and sequenced to allow ferries to operate normally, while the remedial works are being carried out and due for completion later this year.

Cambridge Re-signalling GRIP4 Survey Contract Award

Global Rail Construction Limited (GRCL) are delighted to announce the award of a new rail contract for long-term client Alstom, for GRIP4 ECI survey works on the Cambridge Inner and Outer Re-Signalling & Re-Control Project.

The overall project aim is to improve the reliability and performance of the signalling system in the Cambridge interlocking area. As part of the project, the existing assets are to be surveyed and their continued use validated. Geographically the project covers roughly the track on the approaches to a triangle between Cambridge, Ely and Bury St Edmonds.

In summary, GRCL’s survey works include the following items:

  • Surveying, rodding and roping 42No Under Track Crossings & provide condition and capacity report
  • Surveying, rodding and roping 33No Under Road Crossings & provide condition and capacity report
  • Surveying existing S&T Troughing & providing a condition and capacity report (inc. vegetation management where necessary), where proposed new feeder cables are to be installed – approx. 100km
  • Conducting Ground Investigation and providing condition reports at Signal locations, Level Crossings, Station Platforms, PSP and REB sites
  • Trial Hole Pits at each new UTX or URX Chamber location
  • Conducting Load Monitoring and providing condition reports
  • Topographical surveys
  • Conducting Ground Penetrating Radar surveys
  • Conducting Lighting Lux Level surveys
  • Conducting GPR surveys
  • Conducting gauging surveys
  • Undertaking soakage tests and slit trench surveys

Works will be carefully co-ordinated and delivered during Rules of the Route published possessions/line blockages and isolations with safety critical support, during both midweek and weekend days/nights. Additionally, there are a number of longer, disruptive possessions with isolations to be utilised.

There are many risks associated with working on the rail infrastructure. GRCL’s in-house project management team will be responsible for the delivery of this package of works and will seek to carry out a full assessment of the risks in order to feed into the overall design process.

GRCL’s approach is to think about health and safety in terms of buildability, maintainability and usability at all stages of the design process, so it becomes a natural part of the design. At each stage, GRCL’s delivery team will identify and eliminate hazards. They aim to maintain close communication with key project stakeholders, to support the reduction of the risks that may arise during construction work, which will enable the plan to be kept on track without exception.

 

Global Rail Services Completes Arklow Emergency Bridge Repair

Following a road traffic collision (RTC) in the early hours of 17/07/2020, where the granite wall of Overbridge 254 was knocked down onto the track below following an impact from a van that struck the wall, Global Rail Services Limited were tasked, by Irish Rail, with removing the debris from the track and repairing the wall.

Global Rail Services’ emergency response unit, swiftly mobilised to site to secure the works area, which was hazardous with a high and open edge over the track, installing traffic management on the road leading to and from the bridge to prevent further incidents.  With close collaboration and following an inspection of the wall with Irish Rail’s Structural Engineer and the Local Authority Engineer, it was decided that the wall would need to be immediately repaired and the road surface would need to be cut and excavated to allow the wall to be reconstructed to its original position.

With the Local Authority Engineer granting an immediate 10-day window for the road to be reduced to one lane, the affected area of track was then closed off and removed from use, to prevent trains from entering where loose masonry had the potential to fall and strike a train.

Global Rail Services engaged their established supply chain partner – stonemason Rock Road Stone Company Ltd –  to strip down and rebuild the lime mortar granite wall.  A Global Rail Services civils team and a responsible Project Manager were also mobilised to both carry out the excavation and assist with the safe execution, co-ordination and management of the works.  The works could only be carried out under TIII absolute possession, the hours of possession were 8pm to 5am.

Global Rail Services full scope of works for the emergency repair included:

  • Setting up and maintenance of traffic and pedestrian management
  • Removal of masonry from the track
  • Fencing off the track
  • Supply a boom lift MEWP for access to the track face wall
  • Supply tower lighting to illuminate the road and track
  • Stripping down the existing in situ damaged wall
  • Excavating the road surface adjacent to the wall
  • Rebuilding the lime mortar wall reusing the existing granite cut sections
  • Painting the wall with a black reflective paint
  • Installing chevron signage along the full length of the bridge wall
  • Reinstating the road surface to Local Authority and Purple Book specification

Despite being given a 10 day window, the team rebuilt the wall over the course of 3 nights and then completed the painting, chevron sign installation and road reinstatement over the following 4 days by the 23/07/2020, thereby completing the works 4 days ahead of schedule.

Irish Rail’s Regional Manager for the area commented about his satisfaction with the completed works, saying: “we should have asked you to repair the rest of the wall, because the repaired wall looks better than the rest of it”. This demonstrates the quality of the work carried out by the entire Global Rail Services team.

Global Rail Services Completes Unique Project for Rosslare’s Europort – Replacement and Extension of the Berth 1 Linkspan Transition Ramp

Global Rail Services Limited (GRSL) are pleased to confirm that the first passengers were able to use the newly constructed Linkspan Bridge on 3rd July 2020, just 4 weeks after it was taken out of commission, following the successful completion of their contract for the complex replacement of the Berth 1 Linkspan upper deck transition ramp for Irish Rail. Although the works are contracted by Irish Rail, because the location was inside Rosslare Harbour, GRSL were working under the daily jurisdiction of Rosslare Europort.

The works to the upper tier, which were conducted to a demanding berthing schedule, where the lower tier had to remain operational, to enable ferries to operate normally. Activities were planned around a live working International Ship and Port Facility (ISPS), and specifically comprised the removal of the existing and installation of a new transition ramp at Berth 1, on the Upper Tiered Linkspan, to accommodate the new WB Yeats Ferry.

GRSL’s contract, which commenced on 4th June 2020, provided for the following civil works:

  • Prefabrication and delivery of the new ramp, torsion beam, fingers and handrails;
  • The removal of existing transitional ramp, torsion beam, hydraulic arms, and mid bearings;
  • Installation of the new ramp on site;
  • Commissioning and testing of the new transitional ramp;

Following completion of this contract, GRSL have increased the previous linkspan by 1.6m and in doing so, installed nearly 40 tonnes of heavy structural steel section to an Execution Level of 3 (EXC3) standard.

During the project a number of challenges were encountered and expertly met by GRSL’s team of structural, civil and project managers, whilst still maintaining program, these included:

  • The structural steel was required to be at an Execution Level of 3 (bridge standard), which required ultrasonic testing of the welds and third-party inspections;
  • Conducting the works in a restricted access facility and by its very nature a live port and marine environment;
  • Delivering a project which was effectively a moving bridge, that actually connects to the back of a boat when moored and with vehicles traversing between;
  • The work was at the water’s edge;
  • Project and site requirements for both the client (Irish Rail) and at the harbour for Rosslare Europort;
  • Due to Covid-19, structural steel deliveries were challenging, which meant GRSL had to send lorries to the UK to collect the steel;
  • All connections and bolts on the existing bridge were welded, so the elements had to be cut out as they could not be unbolted;
  • On removal of the existing torsion beam, the bearings were unserviceable on first inspection and had to be replaced at short notice;
  • The as-built drawings were incorrect, which meant adaptations to design after site investigations, internal strengthening of the torsion beam, alternate lifting points and alterations to the actuator arms.

GRSL Contracts Manager Paul Connell, was closely involved and added:

“This complex, fast-track project has been successfully completed within the allocated shut down. We have worked closely with our sub-contractor JA Engineering, Irish Rail & Rosslare Harbour to deliver these works.

“Despite the unforeseen challenges faced, particularly in the current climate, the works have been completed to the delight of the customer – Irish Rail – and the end user Rosslare Europort. I take my hat off to all those involved in successfully executing a very bespoke project.”

 

Ely to Peterborough – GRIP 4 Design Civils and E&P Award

Global Rail Construction Limited (GRCL) has been awarded a contract to deliver the Ely to Peterborough Design for both E&P and Civils (GRIP 4) on behalf of our client Atkins Global. The Civils design covers the review of GRIP 3 designs, surveys and Form 001. E&P Design includes surveys, load monitoring and cable calculations, Form A’s for several Level Crossings and power supply schematics.

The Ely to Peterborough scheme is aimed at increasing safety at a number of Level Crossings and increasing the remaining life of the Signalling assets in a number of interlocking areas.

The interlocking areas covered by this project are Downham Market, Kings Dyke, Kings Lynn Junction, Littleport, Magdalen Road, Manea, March East Junction, March South Junction, Stonea and Three Horse Shoes. The Level Crossings to be renewed in this project are Littleport MGH, Magdalen Road MCB, Manea MCB, March East MCB, March South MCB, Whittlesea MGH and Hargham AHB.

Having a multi-disciplinary workforce including design, civil and structural engineering and E&P expertise, along with in-house project management and having previously delivered time-pressurised, highly co-ordinated schemes, allowed Global Rail Construction Limited to provide the necessary solution in order to complete the works to meet the client’s requirements.

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Global Rail Australia Complete Track Upgrade for Yarra Trams

Global Rail Australia has undertaken a project to remove and replace worn rail on curves on ballasted track at Queensway St Kilda and we are pleased to confirm that all works have been successfully accomplished within the rail occupation, provided by Yarra Trams, with no technical issues. The project was complicated by remote working; however, this was managed through a meticulously safe approach and a management presence throughout the works.

Works included rerailing both the Up Track and Down track curves, which covered the following managed scope:

  • Unclipping rail
  • Replacing worn rail with new 41Kg rail
  • Welding and restressing
  • Weld testing

All works were completed utilising in-house resources, supervision and plant over a single weekend and supported by a staging program and procurement plan, which were key to the success of the project. We are pleased to say that no reports or incidents were raised by the public or client.

ARTC Culvert Lining Completion, New Port, Serviceton

Global Rail Australia has successfully completed a project for Australian Rail Track Corporation for the removal of mud from steel culverts and providing a new bottom concrete layer using the shotcrete process.

The scope covered culvert lining for 24 culverts at 7 different locations in the Geelong and Ararat regions of Victoria. The following activities were undertaken by Global Rail Australia in a live operational railway environment:

  • Culvert cleaning
  • Sand blasting
  • Painting
  • Installation of steel mesh
  • Concreting works

All activities were fully coordinated with the client and delivered on time and to budget, aided by a fully sequenced, detailed program and Global Rail’s supervisory team. We are delighted to say that the works were completed to meet the client’s satisfaction.

Thameslink Points Heating Success – Design and Installation Works

Global Rail Construction Limited has secured a Points Heating remedial contract with BAM on the Thameslink Project. The E&P design and build package of works, forms part of a requirement to upgrade and rectify the railway systems infrastructure to support the capacity improvements recently made in the London Bridge area.

The 26-week programme, includes an 8-week procurement period in order to secure all necessary RCM equipment and parts for the project and covers the following activities:

  • Preparatory investigation and surveying including:
    • A detailed review of as-built records
    • Reviewing and assessing of current designs
    • Correlation of the RCM installation
  • Design works which covers:
    • Collation of survey data to determine the scope
    • Civils design
    • E&P design
  • Installation works:
    • Civil Engineering works
      • Installation of TX Bases
    • Electrical works
      • Cabling, Jointing and termination works
    • PHCC/RCM Remedial works and commissioning
      • Removal and replacement of CT boards
      • Mechanical fixing and installation of new CT’s
      • Installation of new Aerials
      • Installation of new circuitry (MCB’s, CT’s, Terminals, Labels)
      • Installation of DCU 390 PH – Data Loggers
      • Environmental testing (Hot & Cold Probes)
    • Commissioning, configuration checking and final testing
  • The provision of as-built information including O&M data

The 6-week design and survey period commenced this month, with the remainder of the contract works being completed by late September 2020. Installation works will be undertaken during a standard 5-day working week and activities will be worked concurrently in order to meet the required project milestones.

Mechanical & electrical services provided by Global Rail Construction are constantly upgraded through training and development and are consistently delivered to the highest specification.

Design and project management of these specialist services are deployed on projects such as sub-station refurbishment and new build, station refurbishment and new build, signalling equipment room fit-outs, station platforms and car park lighting.

Ericsson 5G Upgrade Projects Success for GRA Networks

GRA Networks has been awarded a framework agreement with Ericsson to install 5G Technology on both Optus and Telstra Networks, including the upgrade of existing communication towers to support the new 5G technology.

GRA Networks scope covers the upgrade of headframes to accommodate extra equipment inclusive of new fibre trunk cables and also internal power upgrades.

Specific project deliverables include:

  • Removal and installation of new headframes
  • New RRUs
  • Installation of trunk cables, internal DC and patching equipment
  • New baseband units for 5G
  • New iDCDP for RRU power
  • Power system unit upgrades
  • Site integration and test calling

GRA Networks are delighted to be delivering this framework for Ericsson as an approved supplier and look forward to being able to develop this relationship over the next few years.