Contracts awarded for track and systems works on CRL

Two contracts have been awarded for the delivery of works for Auckland’s City Rail Link.

Known as C5 and C7, the contracts have been awarded to delivery consortium Link Alliance and are within the existing project budget.

C5 primarily involves the connection between the new line from Britomart, via Aotea and Karangahape, to the existing line at Mt Eden. Where the CRL meets the North Auckland Line at Mt Eden, the twin track split into two branches, eastbound and westbound, said Francois Dudouit, project director for the Link Alliance.

“This requires changing the vertical alignment of the NAL tracks and partially the horizontal alignment, meaning replacement of tracks and overhead line equipment (OHLE) on more than 1km of the North Auckland line,” he said.

“It also requires retaining walls to transition from the existing NAL track level to the CRL line – a 3.5 per cent slope. More than 1,000 piles, diaphragm and sheet pile walls will be needed to build these retaining structures and the two cross-over structures to connect to the NAL upmain.”

Road and pedestrian bridges at a number of level crossings will also be built, including at Normanby Road, Fenton Street, and Porters Avenue, to improve cyclist and pedestrian safety.

The C7 contract covers the Systems Integration, Testing and Commissioning components of the CRL project. These include trackslab, track, overhead line, signalling, control systems, communications systems, control room fit-out and building work, and trackside auxiliaries. Work also includes integrating the new line and systems with the legacy systems on the Auckland rail network.

Dudouit said that work to connect the various components of the project is already occurring.

“Integration of the C5 and C7 teams into the Link Alliance is well underway across multiple workstreams including civils, programme and cost control. Early works such as utility relocations and establishing single-line running are already taking place as part of an integrated programme to deliver the City Rail Link to Aucklanders in 2024.”

As these elements of the project require involvement from various stakeholder from the current network, such as the transport authority, Auckland Transport, close working relationships have been established.

“KiwiRail and Auckland Transport, and their supply partners, are formally engaged for the City Rail Link project through stakeholder partnership agreements. On a day-to-day basis, staff from both Auckland Transport and KiwiRail work in the Link Alliance offices to maximise collaboration opportunities, as part of an established interface and relationship management programme,” said Dudoit.

Canberra COVID

Election results keep rail on track in ACT and NZ

Election results over the weekend have reconfirmed the pipeline of rail projects on both sides of the Tasman.

In the ACT, where the Labor-Greens coalition government was returned with a likely increased number of representatives in the legislative assembly, future progress on the Canberra light rail is confirmed.

Prior to the election the opposition Liberals had cast doubt over the second stage of the project, suggesting that a connection to Belconnen should be built instead of the currently planned extension to Woden. ACT Labor has said that once the extension to Woden is complete, work will begin on a line from Belconnen to the Airport.

Public Transport Association of Canberra chair Ryan Hemsley said that light rail was a key election issue in the capital.

“Saturday’s election results have re-confirmed the trends we saw four years ago, with strong swings towards the government in Murrumbidgee and Brindabella cementing light rail as a vote-winner,” said Hemsley.

“In contrast to the pro-light rail policies offered by Labor and the Greens, the Canberra Liberals offered half-hearted and at times inconsistent support for the extension of light rail to Woden.”

Light rail also made an appearance in the New Zealand election which saw the Labour Party returned with a parliamentary majority. The party, which had previously governed in a coalition with the Green Party and NZ First, has committed to progressing the Auckland light rail project from the city centre to Māngere and the Auckland Airport.

The party has committed to continue investing in KiwiRail, which has received large cash injections in recent budgets to improve New Zealand’s rail infrastructure and freight services. Upgrades to Wellington’s commuter rail network are also part of the party’s platform.

Under investment in Auckland’s rail network was revealed earlier this year and led to a city-wide restriction on services. The most recent works have seen a 10-minute frequency returned to the Eastern Line and improvements between Otahuhu and Newmarket on the Southern line. Further work on the Southern Line between Homai and Pukekohe will continue for the next three weeks.

KiwiRail chief operating officer Todd Moyle said works have been completed efficiently and on schedule.

“During the first closure on the Eastern Line the teams met their target of replacing 20 km of rail and more than 3500 sleepers on the 10km between Panmure and the city centre,” he said.

“We are continuing to work with Auckland Transport to review our progress and plan the way ahead. We have agreed a programme of rolling line closures across the network is the best and most efficient way to progress this work over the coming months. For the next month our focus will remain on the Southern Line.”

Further network closures are planned for the Christmas period when patronage decreases.

construction

A new look at rail construction: Martinus’ plant department

Martinus’ in-house approach is de-risking rail construction.

Having stepped up from a product supply business into a rail construction outfit, the young upstart of the Australian rail construction industry decided three years ago to head out on its own with the purchase of major multi-million-dollar pieces of machinery.

“The business has only been delivering construction projects for around eight years,” said Martinus chief operating officer Ryan Baden. “For the first part of five years, we would be relying on other people’s plant and equipment to do the final piece, mainly tampers, regulators, and flash butt welders. We had grown to a position where it was only the large, tier one contractors that had these pieces of equipment and we were now competing with them.”

To de-risk construction projects it was working on, Martinus made the decision to purchase the plant, machinery, and equipment and recruit their own team to overhaul and maintain the growing fleet.

“It’s essentially about de-risking project delivery and overall business risk ,” said Baden. “We control all the pieces of the puzzle; we recruit all of our own labourers, engineers, and supervisors, plus our strong financial position and current project pipeline means we can significantly invest in our own plant and machinery.

“Our next goal was to purchase our own ballast trains – that has really changed everything for us, it solidified our end vision of having the largest fleet of specialised rail equipment in Australia, all the while ensuring we were well equipped to deliver upcoming projects and maintain full control of logistics and maintenance.”

For any major rail construction project, having a few pieces of bright yellow kit is not enough by itself, there needs to be a level of logistical and rail safety knowhow to ensure that the kit is fully operational, at the right place, and at the right time.

“In the past, particularly for the product supply side of the business, we were using freight forwarders and received good service, but the plan for some time has been to bring it all inhouse.”

As the fleet grew, so did the team. Martinus hired logistics manager Jason Gibson who has previously worked for a large mining company. The vertical integration of Martinus’ supply chain has worked before and is now even more enhanced by their inhouse experts.

The value of these investments was realised straightaway, said David Van Hoos, national plant and asset manager for Martinus.

“The first tamper we secured was mobilised as part of the Gold Coast light rail project Stage 2. We were able to quickly bring it up to site specification and employ our own operators and fitters, we gained flexibility to adapt to program changes and minimise any potential interruptions or delays that may have occurred relying on external suppliers.”

With the successful implementation of the first piece of major plant and several large- scale projects in the pipeline, it made good business sense to create a standalone plant department dedicated to servicing their own rail projects. This has also increased Martinus’ capacity and capability to become a consistent and reliable interface on major rail and civil construction projects.

“What we’ve found is clients are looking to de-risk themselves around interfaces on sites,” said Baden. “In the past, clients would bring us in to deliver the track, someone else to complete the overhead wiring, and another contractor for signalling – that’s three different interfaces for them to manage. With extensive rail knowledge and strong project management skills, the next step to further add value for our clients was bringing in subject matter experts to handle the overhead wiring, signalling and comms as part of the Martinus team.”

Martinus’s The continuous track laying machine has been built locally.

THE DEVELOPMENT OF A RAIL-DEDICATED PLANT DEPARTMENT
Having established the plant department, the team under Van Hoos’ leadership has grown to include a maintenance team of 15 fitters, project managers, engineers and support staff.

“Our fitters are key to the success of the plant department, we’ve selected them based on their industry experience, but to build on that experience we’ve also recruited electrical and mechanical apprentices to build a diverse and well-rounded team for the future,” said Van Hoos. “It’s great to be able to invest in the younger generation and teach them everything we know about rail.”

Rather than swelling in size for each individual project, the team at Martinus are employed full-time to ensure that the business can deliver on any of the major projects it is engaged on. Being solely focused on rail has contributed to the energy and enthusiasm in the workshop, said Van Hoos.

Supplementing the skilled tradespeople are local suppliers, when needed. Currently, Martinus is constructing the Carmichael Rail Network (CRN), in Central Queensland, and has just engaged a local Mackay business in a $1 million contract to fabricate the metal framework for the supply consist behind Martinus’ tracklaying machine. Staying in touch with locals has also come in handy as border restrictions have limited the movement of people across Australia and New Zealand. Martinus have engaged Harsco to build two continuous track lifters (CTL), who are local to Martinus’ main plant department in Brisbane. The CTLs are being fabricated and manufactured locally.

“The border restrictions have also forced us to look outside of the rail industry to build our team,” said Van Hoos. “We have employed members from the military, electricians from the automotive industry, and fitters from the mining sector all led by experienced industry leaders – this diverse mix adds another level of knowledge and bring a unique set of skills to our team.”

“With travel restrictions in place, it’s been a great advantage to have Harsco close by as we’ve been able to have regular progress visits and factory acceptance testing at Harsco’s workshop. Any issues can be resolved very quickly, and seeing the production in the workshop first-hand has also been a bonus.”

Not only has Martinus invested in machinery, but also the people needed to operate and maintain it.

MULTIGAUGE AS STANDARD

While the CRN and another project that Martinus is currently working on, the Forrestfield Airport Link are narrow gauge, the team are mindful that having dedicated narrow gauge plant and equipment will limit where it can work in Australia, New Zealand, and internationally.

“We operate an international rail business that works across three different gauges and probably about 20 different railway networks. Van Hoos and the in-house rollingstock engineers work closely to ensure that our build specification enable us to move the machinery around safely, quickly and efficiently,” said Baden.

In terms of the equipment that Martinus has purchased, which in addition to ballast wagons and the continuous track lifting machine also includes a sleeper laying machine, a track laying machine, four tampers and four ballast regulators, six flash butt welders among other pieces of plant, all are designed to be used across multiple projects.

“When purchasing plant, be it new or second-hand, we have been focused on gauge convertible plant which ensures the flexibility from one project to the next,” said Van Hoos.

Being able to move between standard and narrow also allows Martinus to work on shorter jobs on metropolitan networks.

“Soon, we will be taking delivery of 40 ballast wagons, two continuous track, six flash butt welders on hi-rail trucks – all brand new, gauge convertible equipment ready to go,” said Van Hoos.

This fleet is complimented with six locomotives that Martinus purchased from KiwiRail.

“It was perfect timing for Martinus that KiwiRail were renewing their current locomotive fleet. The gauge and specifications of the locos were aligned to our requirements for CRN” said Van Hoos. “These locomotives will be used for construction only to haul our ballast and sleeper wagons.”

While the fleet sets Martinus up for any number of projects around Australia and New Zealand, as the past year has shown, there are any number of unpredictable events that could occur in the meantime and require new thinking to ensure projects get over the line. In New Zealand, where Martinus has a contract to provide flash butt welding services to its Woburn depot and around the network. Of course, getting people there has not been possible so Van Hoos has come up with a unique fix.

“We’ve come up with a solution to train a local operator via video link under the supervision of our project team in New Zealand. One of our Australian based operator/fitters has been providing non- stop online training for carefully selected Martinus fitters and operators in New Zealand. This initiative has allowed us to continue on despite travel restrictions and resulted in minimal delays to KiwiRail’s re-railing projects.”

Martinus is ready to look at rail construction in a different way.

Government funding supports up to 100 KiwiRail apprentices

KiwiRail will employ 100 new apprentices, thanks to government funding from the Regional Apprenticeship Initiative.

The New Zealand infrastructure manager and rail operator will receive $4 million to support the employment of up to 100 apprentices who will have a pathway into employment in the rail industry.

Apprenticeships will involve areas such as mechanical engineering, electrical engineering, electricity supply, rail operations, building/structures, and track infrastructure. Job roles will include signals and electrical specialists, train drivers, and track staff.

To facilite the training component, KiwiRail will also establish four new apprenticeship qualifications, taking the total number of qualifications to six.

KiwiRail group chief executive Greg Miller said the apprenticeships would not only ensure the trainees’ future, but the longevity of the company.

“The new qualifications will make rail more than just a job – they will make it a rewarding career – and help ensure KiwiRail has the new blood and skills it needs for a strong future,” he said.

With the funding support from the government, which KiwiRail will match with in-kind and cash contributions, will expand the depth of the rail industry workforce.

“This government support for apprenticeships will help us attract more young people into rail, including through a school gateway programme, and it will allow us to create a clear, sustainable pathway for them to learn skills and progress in the businesses,” said Miller.

Apprentices will be employed in the regions, however applications are open to anyone. Some apprenticeships will be offered to existing staff for upskilling, but most will be delivered to new staff.

“There is a wealth of experience and knowledge among KiwiRail’s staff and I want to see that passed down to the next generation,” said Miller.

“KiwiRail is committed to delivering an efficient and effective rail system for New Zealand – that can help take trucks off our roads and reduce our carbon emissions – but that can’t be done without people.”

Apprentices who are employed by KiwiRail will have a workforce development adviser assigned to them to provide pastoral care and ongoing support to enable the apprenticeship to be successfully maintained.

Extended shutdown period to allow for major repairs in Auckland

KiwiRail has extended a shutdown of the Eastern Line between Quay Park and Westfield for another two weeks to enable urgent upgrades to the Auckland railway network.

The Eastern Line will now remain closed until September 21.

KiwiRail is conducting repairs across the Auckland network after testing revealed that 100km of rail needs repairing or replacing. The entire Auckland network is restricted to speeds of 40km/h.

KiwiRail chief operating officer Todd Moyle said that significant work had already been done.

“We have made a good start on the Eastern Line with 1,000 sleepers replaced and close to 6km of new rail laid so far.”

To meet the targeted amount of work completed, teams are working at all times.

“Allowing KiwiRail around the clock access to the track over a four-week period is an efficient and productive way of working and enables our teams to keep momentum and get through a larger amount of work,” said Moyle.

The replacement of significant amounts of rail began in August after testing found that the rail was in a worse condition than previously thought.

However, New Zealand media have reported that a consultant’s report in December 2019 identified $200 million of work was required due to inadequate maintenance and underinvestment in rail infrastructure.

Up to a quarter of all rail on the 190km network will need to be replaced, with grinding required elsewhere.

A shortage of locally based track-welders has also contributed to the maintenance backlog.

While maintenance and repairs are conducted, Auckland Transport is providing commuters with replacement buses. Auckland Transport executive general manager integrated networks Mark Lambert said the repairs were essential.

“This work by KiwiRail is urgently needed and we will continue to support our customers with bus replacement services and other support for as long as we need to.”

The New Zealand government has made major commitments to rail, including a NZ$1bn upgrade package for the Auckland rail network. Prior to 2019, however, investment in the rail network nationally was limited to the minimum needed to keep the network operating. The investment that was made was reactive, rather than planning for the network’s future needs.

NZ rail continues during lockdown

Rail services have continued in New Zealand despite the reimposition of lockdown measures to control the spread of new cases of COVID-19.

Auckland is now in level 3 restrictions while the rest of the country is under level 2 restrictions after cases of COVID-19 were confirmed on Tuesday, August 11 with no known source of transmission.

In Auckland, rail services are continuing during the lockdown to their existing timetable for those who need to access local services and businesses and travel to work and school when that cannot be done at home. Physical distancing of two metres must be maintained on public transport.

Auckland Mayor Phil Goff advised commuters to follow health guidelines.

“Maintain physical distancing, wear a mask when in public and follow good hygiene practices and we will get through this together.”

Auckland Transport will be cleaning trains regularly and will be making changes to timetables as needed.

KiwiRail chief executive Greg Miller shared Goff’s advice to wear face masks when using public transport.

“The health and safety of our staff, and the public, is the company’s main priority as we maintain essential services, just as we did successfully earlier this year.”

KiwiRail has suspended the TranzAlpine service that was to run over the weekend of August 15-16. The Capital Connection service between Wellington and Palmerston North will run as normal.

Freight services will continue with appropriate precautions instituted.

In Wellington, which is under level 2 restrictions, public transport is also continuing as normal.

General manager of Wellington transport operator Metlink Scott Gallacher emphasised the need for passengers to take care when travelling.

“We’re asking passengers to keep a 1-metre distance on board trains, buses and ferries and keep a 2-metres distance while waiting at bus stops, train stations and ferry wharfs,” he said.

“The government has made it clear that people should wear face masks where physical distancing is difficult and we encourage passengers to follow this advice on public transport. These measures will help keep passengers safe across the whole network.”

Metlink will accept cash payment, however Auckland Transport is only accepting payments via the AT HOP card.

Rail track. Photo: Shutterstock

Urgent track upgrades lead to Auckland-wide speed restriction

Urgent upgrades to track around Auckland have led to KiwiRail imposing a 40km/h speed restriction across the entire network for the next six months.

Testing conducted on the network found that track wear was more widespread than previously understood, leading KiwiRail to bring forward repair work, said KiwiRail group chief executive Greg Miller.

“Following our testing we are accelerating our programme of replacing the most worn sections of rail and resurfacing less damaged sections.”

The speed restriction and need to access the track will disrupt commuter services, with services running every 20 minutes during the day instead of every 10 minutes during the morning and afternoon peak. Journey times will also increase, said Mark Lambert, executive general manager of integrated networks at Auckland Transport.

“We hope to add some extra services at peak times to ensure that we can meet passenger demand, but this speed restriction will unfortunately mean longer journey times for all our customers of up to 50 per cent for this temporary period.”

The works will involve replacing 100 kilometres of track and are expected to take six months. Miller said that KiwiRail had the local capacity to complete the upgrade.

“We are equipped and ready to resolve the issue with the necessary rail already in the country and staff available to lay it. Specialist rail grinding equipment, which will be used to remediate some of the rail, will arrive from Australia shortly.”

While the track upgrade work was anticipated, the move to level three restrictions in Auckland due to cases of COVID-19 has provided an opportunity for KiwiRail to begin sooner.

“We are working closely with Auckland Transport to arrange optimum access to the track so we can get to work as quickly as possible while managing operation of services,” said Miller.

“The faster this work can be completed, the sooner the network can be back to operating safely at full speed as we continue our work to deliver a resilient and reliable rail network for Auckland.”

The works form part of the NZ$1 billion upgrade package for Auckland’s rail network, which includes electrification from Papakura to Pukekohe.

“This is part of the critical upgrade of the rail track infrastructure in Auckland as we plan and prepare for significant increase in services when the City Rail Link is open, and dramatically reducing travel times across the region,” said Lambert. “We are working closely with KiwiRail to ensure the track infrastructure is ready for the future demands that will be placed on it that will continue the transformational journey of rail in Auckland with the opening of the City Rail Link.”

Work begins on $1.1bn Auckland rail upgrade

Construction has begun on major upgrades to the Auckland rail network, with improvements between Wiri and Quay Park, south of Auckland, the first works to kick off.

The work is part of the New Zealand Upgrade Programme’s NZ$1.1 billion ($1.02bn) rail package, which in Auckland will include electrification of Papakura to Pukekohe, and new train stations at Drury. Once complete in 2024, the upgrades will enable greater capacity for the City Rail Link (CRL) in central Auckland and a commuter service from Hamilton to Auckland.

Transport Minister Phil Twyford said the work complemented each other.

“Building the third main rail line will remove a key bottleneck for freight and commuter services, as well as give more capacity for the increased services expected once the CRL is completed. The CRL along with the other upgrades will shave off up to an hour of the daily commute for thousands of people,” said Twyford.

The work will also improve the movement of freight through the urban area.

“Auckland is already the busiest rail freight corridor in New Zealand, with around six million tonnes coming to, from or across the city each year – the equivalent of 400,000 truck trips. This work will make freight services more reliable and make our roads safer by taking trucks off them and moving more freight to rail,” said Twyford.

State-owned operator KiwiRail announced that Downer NZ won the contract for the third main rail line between Wiri and Quay Park. Electrification works will be completed by eTRACS, a consortium of McConnell Dowell and John Holland. KiwiRail will lead on track and signals for both projects.

KiwiRail group chief executive Greg Miller said that it was good to see work beginning.

“This is a major investment in Auckland’s metro network, and we’re excited to be getting these projects underway,” he said.

“In the years ahead, rail will continue to play an increasingly important role in helping reduce New Zealand’s emissions for transport. KiwiRail also wants rail to be the mode of choice for freight movers, commuters and tourism opportunities. All those are underpinned by a modern, resilient network and that’s what this work will deliver.”

Deputy Prime Minister Winston Peters said there would be clear local benefits.

“Hundreds of local contractors will be needed for this work and there will be spin-off benefits for local businesses, from lunch bars to local hardware stores. The vast majority of the materials used will be coming from the Auckland region – that’s creating work for quarries, concrete suppliers, steel fabricators and drainage companies.”

In addition to the new works, renewal around the network is also part of the transport upgrade program. This includes replacing 60km of track, tens of thousands of sleepers, and more than a hundred thousand tonnes of trackbed.