DLR CITY AIRPORT EXT

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

2PWI Ashford Section Mtg – Colin Burnikell | Feb 2021

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

PWI Ashford Section Mtg – Colin Burnikell | Feb 2021

SITE OPERATION – CONSTRUCTING THE VIADUCT


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.


THAMES WHARF VIADUCT


TRANSITION SLAB


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TRACK BED PREPERATION


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.


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.


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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• Working in a controlled fashion although a manual process a template was used.



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• Working in a controlled fashion although a manual process a template was used.


TRACKWORK PREPARATION

Component parts laid out.On both the curved track & straight.


TRACKWORK PREPARATION

Track geometryTrackwork set up to represent the initial layout.


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


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.



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).



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.


TRACKWORK – INTERNAL/INDEPENDENT ANCHOR TESTING

Test Reports.

Internal (Schaan)• 3m cycles.

External• TUM submitted.• Joseff Eisenmann.


TRACKWORK – HOLE CLEANING

Anchor hole cleaningEssential for when using chemical anchors.


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DRILLING TRIALS


TRACKWORK – DRILLING TRIALS

Options for drilling holes for holding down bolts.• Diamond drilling (DD150 & DD200).

• Percussive (TE80).


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.


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


TRACKWORK – VIBRATION TESTING

Testing set up.• Wired up to rig.• Vibration measured over several trials.• Results ave. 7ms2.


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TRACKWORK INSTALLATION


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.


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


TRACKWORK – S. & C. COMPONENTRY

S. & C. Baseplate• Cologne Egg 4-hole baseplate was specified.• Installed with Hilti RE500 injectable resin.


TRACKWORK – ADDITIONAL COMPONENTRY


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


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


DOCKLANDS LIGHT RAILWAY – CITY AIRPORT EXTENSION (DEC 2005)

Station ConstructionSilver Town & Pontoon Dock

Presentation title | Month 202x 41

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SUMMARY


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


PWI Ashford Section Mtg – Colin Burnikell | Feb 2021 44

THANK YOUContactColin BurnikellStrategic Key A/c Manager - Rail

Hilti GB Limited1 Trafford Wharf RoadTrafford Park, Manchester, M17 1BY

Tel: 07801 913 [email protected]

Documents

DLR CITY AIRPORT EXT