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Network Rail makes ballast cleaning investment

27 Feb 15 Network Rail has ordered a new £50m ballast cleaning machine and is bringing 500 contracting staff in house.

High output ballast cleaning machine
High output ballast cleaning machine

Next month (March 2015) more than 500 contractor staff working for Amey Colas will transfer to become direct employees of Network Rail in the high output track renewals team. This will be the largest people transfer into Network Rail since the phased insource of maintenance activities began in 2005.

The high output track renewals team keeps the ballast, under the track, clean of debris and oil. The ballast is renewed regularly as part of routine maintenance.

High output project director Ben Brooks said: “The move will give us greater opportunity to drive continuous improvement in both safety and performance on site. It is fundamental to delivering our cost efficiencies and also allows longer term investment in training and development for the high output workforce, our fleet and maintenance facilities.”

The new ballast cleaning train is scheduled to be delivered by manufacturer Plasser & Theurer in 2016. It will be the fifth ballast cleaning system in the Network Rail fleet, and so is named BCS5 (ballast cleaning system five).

The £50m machine will incorporate measures to reduce workforce exposure to ballast dust, including mist-based suppression systems. In a UK first, the new cleaner will be built for ‘third-rail’ operation, allowing the conductor rail to remain in place throughout the cleaning process.

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BCS5 consists of:

  • RM900 high output ballast cleaner
  • New ballast power wagon
  • Spoil power wagon
  • Consolidation machine (in-train tamping with double bank dynamic action).
  • 44 MFS conveyor spoil / new ballast wagons

Plus support plant comprising of:

  • Two 09-3X dynamic tamper – track stabiliser machines
  • One ‘third rail’ compatible 09-2X dynamic tamper – track stabiliser machine
  • One USP5000 ballast regulator machine
  • One first of type third rail ballast regulator machine

Mr Brooks added: “With the purchase of the new ballast cleaner and the insourcing of 500 staff who previously contracted for us, Network Rail is taking more direct control of its high output ballast cleaning and track relaying operations; activities core to its day-to-day business.

“Network Rail is leading the world, completing mechanised track renewals overnight in short duration access and handing back the railway at higher speeds than attainable with conventional methods. The new equipment allows us to add the third rail DC electrified network to our programme so passengers south of London can start to see the benefits of high output track renewals too.”

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