BALLAST UNDERCUTTERS....Our ballast undercutting bar and spoil removal wheel can transit spoil from under the track, through the conveyor system and onto a rail wagon at a production

Stobart Rail & Civils Ballast Undercutter 1

BALLAST UNDERCUTTERS.Our ballast undercutter and the process in which they are used has been developed and improved so that ballast can be excavated and replenished without the requirement to remove the track from the infrastructure.

Stobart Rail

@stobartrailltd

Stobart Rail [email protected]

2 Stobart Rail & Civils Ballast Undercutter

Ballast UndercutterOur machines working alongside road rail excavators (RRVs) and a team of highly qualifies operators, can effectively remove ballast from underneath the following;

• Plain line• Single line• Switched and crossing (S&C)• Third and fourth rail

In addition to this the machine can also carry out;

• Track lowering• Wet beds• Removal of contaminated ballast• Apply cross fall to the formation• Improvement of drainage

Being capable of removing spoil at 70m2 per hour and at a depth of up to 350mm below the bottom of the sleeper, this method has proven to be a cost-effective way of improving the infrastructure without the need for major disruption.

To enhance the procedure, our ballast undercutters can be delivered to remote accesses using our own specialised road transport where they can be on track using level crossings or approved RRAP’s thus removing the complex planning to get Plant to site via the rail infrastructure.


Driver comfort and controlMK2 has been designed with the drivers’ comfort and machine control being paramount. The operator can select every machine command from a seated position and can view the full operation from the cab.

Conveyor systemA complex conveyor system can discharge the spoil throughout a 110-degree swathe either into a train onto the cess or into a Unimog towing trailers and spoil boxes. The swing conveyor on the end of the main unit reduces spillage of spoil during the transition between rail wagons.


Spoil removal wheelOur ballast undercutting bar and spoil removal wheel can transit spoil from under the track, through the conveyor system and onto a rail wagon at a production rate of approx. 15-20 meters an hour depending on ground conditions.

Removing spoil and ballastThe spoil/ballast can be removed from below the track up to 350mm below the sleeper base. The machines also have the facility of putting a cross fall on the formation to assist drainage and excavation on canted rail.

As the ballast is removed from under the sleepers with the cutter bar, the formation is left perfectly level to allow if required, a membrane to be placed in situ prior to the ballast being replaced.


SupportOur support team and Plant that work with the ballast undercutter includes the following;

• RRV trenching in front of the ballast undercutter

• RRV with large clam shell following the undercutter to replace ballast

• RRV fitted with a tamping bank to compact the ballast prior to a main line tamper following through

• We have experienced operators both on the machines and on ground to ensure the track geometry is maintained whilst the work is in progress

SafetyThe safety features on our machines include the facility of setting up a trip wire, protected exclusion zone and multiple emergency stops to protect operatives from the cutter bar and other moving parts.

Specialist transportStobart Rail & Civils has its own fleet of specialist transport that is capable of transporting the ballast undercutters to site by road, adapter rails allow the machine to on/off track at RRAPs and level crossings.


MK3 Ballast Undercutter

Our latest ballast undercutter (MK3) is the third major iteration of the technology that it has been perfecting for over ten years. This machine incorporates a rubber-tracked undercarriage to increase on and off tracking capabilities – it can move under its own power from a lineside position and onto the track using only a temporary RRAP. It also has both front and rear tilting axles, which allow the cross-fall of the cutter bar to be set from the safety of the cab.

MK3 is equipped with Stobart Rail & Civils’ bespoke integrated operating system, with a 12-inch touchscreen in the cab connected to its head office using a GPS/GSM modem with CAN (Controller Area Network) interface. This provides a continuous live data feed of the machine’s operating parameters, from pre-start checks through to completion of operations, to allow the engineering team to access the system remotely for performance monitoring and to aid in diagnostics.

Advantages of the ballast undercutter

• A quick, efficient and cost-effective way to re-ballast S&C and Plain Line track

• Re-ballasting can be carried out without removing any track components reducing risk and increasing possession working times, increasing efficiency and value

• Can be quickly and easily transported to the site on our own fleet of specialist low loaders that can transport the undercutters to site by road. The machines can be on/off tracked by remote control or via adapter rails and can require as little as a temporary RRAP

• Increased efficiency and reduced cost when compared to other ballast renewal methods, with a reliable and consistent output and finish

• Health & safety has been improved: Safety features include state of the art object recognition camera’s, warning the operator and showing anyone in his exclusion zone. The facility of setting up a trip wire, protected exclusion zone and multiple emergency stops to protect operatives from the cutter bar and other moving parts and all-round vision for the operator

• Greener – the new MK3 ballast undercutter is built with the industry leading Perkins 1204F Tier 4 Final Engine boasting reductions in CO2 emissions and increasing fuel economy

• Rapid results/high output - working in conjunction with our highly experienced team of operatives and the company’s extensive road-rail capability, the undercutters can achieve exceptionally fast rates of ballast renewal

• Operates on all track categories - the units are deployable for work on any track category including third and fourth rail, overhead lines and through S&C

• No train required. Stobart Rail & Civils award winning Plant can provide a “train-free” solution to the entire process of ballast renewal


Technical data

Mk1 Mk2 Mk3

Weight 1550kg 18500kg 24100kg

Max Height Stowed - Rail 3200mm 3400mm 3400mm

Max Length Stowed - Rail 11600mm 12200mm 11300mm

Max Axle Weight - Front 7350kg 6650kg 7120kg

Max Axle Weight - Rear 8140kg 11820kg 16980kg

Wheel Base 3530mm 3530mm 3469mm

Rail Wheel Diameter 508mm 508mm 500mm

Rail Wheel Profile P1 P1 P1

Brakes Four Wheel Pnuematic

Four Wheel Pnuematic

Hydrostatic Brake Packs

Service Brake Pressure (Air) 4-8 bar 4-8 bar 4-8 bar

Maximum Travelling Speed 12mph 12mph 10mph

Maximum Working Speed 3mph 3mph 3mph

Maximum Travelling Speed through S&C

3mph 3mph 1mph

Minimum Travel Radius 80m 80m 80m

Minimum Work Radius 80m 80m 80m

Maximum Rail Cant - Travelling 200mm 200mm 150mm

Maximum Rail Cant - Working 150mm 150mm 150mm

Maximum Rail Cant - On/Off Tracking

0-50mm 0-50mm 150mm

Maximum Rail Gradient - Working 1:29 1:25 1:25

Engine GM Heavy Duty Diesel Engine. Model 4-71

GM Heavy Duty Diesel Engine. Model 4-72

Perkins 1204F Tier 4 Final

Horsepower 160bhp @ 2250rpm 160bhp @ 2250rpm 147bhp

Cooling Water Cooled Water Cooled Water Cooled

Transmission Three Speed Transmission (Forward/Reverse). Infinately Variable Hydrostatic Drive

Three Speed Transmission (Forward/Reverse). Infinately Variable Hydrostatic Drive

Fully Hydrostatic Axles - 4 Wheel Drive

Fuel 208ltr 350ltr 200ltr


Technical data continued

Hydraulic Oil 291ltr 475ltr 350ltr

Dust Supression Fitted No Yes Yes

Digging Wheel Drive Hydraulic Hydraulic Hydraulic

Under Cutter Bar Drive Hydraulic Hydraulic Hydraulic

Conveyor Width 508mm 508mm 410mm

Conveyor Length - Digging Wheel 2000mm 2000mm 2356mm

Conveyor Length - Intermediate 1500mm 1500mm N/A

Conveyor Length - Delivery 6200mm 6200mm 6200mm

Conveyor Length - Swing N/A 1500mm 4806mm

Digging Wheel Diameter 2800mm 2800mm 2700mm

Digging Wheel Width 310mm 310mm 250mm

Maximum Undercutting Depth350mm from bottom of sleeper

350mm from bottom of sleeper


Minimum Cutting Depth150mm from bottom of sleeper



Trench Width 900mm 900mm 900mm

Under Cutting Speed0.5 - 1.0 MPM depending on ballast condition

0.5 - 1.0 MPM depending on ballast condition

0.5 - 1.0 MPM depending on ballast condition

Under Cutting Width - Plain Line 3050mm 3050mm 3050mm

Under Cutting Width - Switches & Crossings

3660mm 3660mm 3660mm

Single Line Cutting CapabilityOnly if Spoil can be Disposed onto Cess or Trackside

Yes Yes

S & C Cutting Yes Yes Yes

Capable of Cutting from Cess Yes Yes Yes

Capable of Cutting from 6’ Yes Yes Yes

Turn Table Fitted Yes Yes No

360deg Slew Capability No No Yes

Full Remote Control Operation No No Yes

Documents

BALLAST UNDERCUTTERS....Our ballast undercutting bar and spoil removal wheel can transit spoil from under the track, through the conveyor system and onto a rail wagon at a production