Burdens

Against a backdrop of increasing demands placed on the railway network, Burdens Rail provides a sustainable supply chain to support this key part of our nation’s infrastructure. The starting point is over 80 years experience in providing products and services to benefit construction programmes and the environment. Furthermore, the company’s product range is uniquely configured to the needs of our industry, offering solutions in permanent way, embankments and structures, stations and car parks, maintenance and safety, logistics and environmental.

Understanding the challenges of both the civil engineering and physical requirements of railway construction are central to Burdens Rail’s unique approach. The supply chain operates throughout the life cycle of our infrastructure - from design and construction to operation and maintenance - and is further supported by 50 strategically located distribution depots. 

Over the years, our long-term business within rail has grown as a result of working in partnership with Network Rail track engineers, consultants and contractors to provide the permanent way with what’s needed, when it’s needed and where it’s needed. In recent years, the company has become established as the major supplier of geosynthetics and drainage materials - ‘geosynthetics’ being the general term for all synthetic layers included in the trackbed either to enhance the properties of, or replace, a granular layer. The term covers geotextiles, geomembranes, geocomposites, geogrids and geosands.

Then and now

It is important to understand that the use of geosynthetics in rail construction, and geotextiles in particular, has been a practice for over 25 years. Terram 4000, now PW1, began life in the early days of British Rail and was used nationally as a filter/separator between ballast and subgrade. Over this period, opinions varied on the effectiveness of a separator at both ends of the performance scale.

At the time, little attention was paid to ground investigation and soils and, with little geotextile choice, T4000 was most commonly used. Over a fine subgrade soil with cohesive content, the apparent pore size of Terram 4000 is 0.085mm and the clay particle size could be anything down to 0.002mm so that the fines would freely pump up through the geotextile into the ballast, suggesting correctly that the geotextile had failed. But where it was used over granular subsoil with particle sizes >0.85mm, it performed effectively as a separator and prolonged the life of the trackbed. It is therefore not surprising that there was a varied response to early geotextile effectiveness.

Today, the ground investigation element provides the main criterion along with other data such as GRP information to determine the selection of suitable trackbed formation treatments in accordance with NR/SP/TRK/9039 and associated components including geosynthetics. And, working alongside track engineers, manufacturers have become more in tune with progressive track geometry and created new geosynthetic solutions.

Development and innovation are areas continually referred to as unnecessary evils, generally because of their drain on resources and funds. However they are easily some of the most important areas as they are the catalyst for taking track engineering forward and providing longevity in maintenance and track life. Burdens Rail is heavily involved in a number of development programmes to make track life more cost-effective.

GEOSAND has recently been developed to allow a consistent yet thinner layer of blanketing sand to be contained within its structure in a roll form, providing a way of creating an effective pumping barrier layer over any undulating surface. Following extensive testing at universities and on the operational railway, the product has been approved for use across the UK network and has been installed at more than 50 sites.

The importance of innovation

Over the past year, Network Rail has also trialled a new ditch-lining material suggested by Burdens Rail. Originally designed to protect soldiers in Afghanistan, ‘concrete cloth’ has since been used on a number of track drainage projects with more planned. Supplied in rolls, it behaves like a thick carpet and can be unrolled in lengths up to 200m. When sprayed with water, it sets rapidly and hardens to 80% strength within 24 hours, becoming a robust, durable, waterproof concrete surface with a design life of over 25 years. Quick to install in all weathers on any surface or slope, it is economical because of its ease to use, time saved and long-lasting high wear resistance.

Innovation is critically important across all areas and drainage is no exception. Burdens Drainage Catch Pit system uses the STAKKAbox™ Ultima access chamber, a system that is strong, structural and easily meets manual handling requirements. 

Approved by Network Rail in clear opening sizes of 1200x600mm and 1160x380mm, they have been designed for use in the sixfoot and other restricted parts of the track. The system offers significant economies in money and time - for example, a twoman team unfamiliar with the product installed a catch pit in 18 minutes. Shorter possessions are required and there is no need for any specialist labour or equipment. Each component section weighs less than 25kg, meeting UK manualhandling requirements.

The STAKKAbox™ Ultima’s sidewall and vertical loading capability is equivalent to concrete and the AX-S Composite Cover is certified to take a load of 12.5 tonnes. Once installed, the cover is non-conductive, nonslip and non-corrosive whilst the phenolic grating option is also non-slip. 

Embankment products

Over the past few years, Network Rail has been tackling the legacy of Victorian and neglected embankments. Burdens, through its sister companies WTB Geotechnics and Enviromesh, has played a key part in this challenge.

WTB Geotechnics offers a range of geosyntheic solutions including -

• Azweb - a lightweight expandable cellular confinement system that creates an erosion barrier or structural foundation.

• Tensarmat/Trintermat - typically used on slopes up to 40°, providing a three-dimensional structure for the confinement of soils.

• Biodegradeable erosion control - a range of biodegradeable products to provide long-term protection and permanent turf reinforcement. They are available seeded or unseeded and can also be supplied fire-retardant.

• Gabions and mattresses - welded or woven, these are available in a range of standard and bespoke unit sizes to suit applications from mass gravity retaining walls to free-standing acoustic barriers. All are BBA-certified and backed by a free in-house desktop design service.

• Enviromesh block wall - this is an innovative concrete block facing with textured finish that is secured externally to the gabion face, giving the appearance of a natural rock face with no visible mesh wires.

• Rockfall protection - a hexagonal woven wire mesh that can follow the contours of the embankment/rock face.

• Rabbit/badger netting - this offers a low-cost and effective solution to the destruction of embankments, preventing damage and economic loss.

Extensive catalogue - (get yours here)

The challenges of today’s rail construction projects are not limited to the permanent way alone and require integration with other modes of travel. Adequate parking arrangements for those starting their journey by car, storage for those travelling by bicycle as well as links with buses and other forms of public transport are critical to the effectiveness of the rail network. 

Large car parking areas create issues of surfacing and dealing with water run-off. Burdens Rail offers sustainable modular drainage systems using permeable concrete block-paved surfaces together with high void-ratio storage and infiltration blocks - proven systems that also incorporate Hydrobrake devices to control flows from storage into outlets. 

Pedestrian safety and customer satisfaction are enhanced through a range of environmental street furniture that includes seating, litter bins, tree grilles, signage, exterior lighting, cycle racks and bollards. These are all part of solutions that also include platform copings, edge warning paving and oversail blocks. In addition, there is a comprehensive range of access units, pole chambers and ducting systems that provide access to lighting and the all-important communications cable networks.

With over 3.3 million passengers using our railways everyday, safety and on-going maintenance are major issues. Burdens supports health and safety demands internally within the business and delivers the same service to Network Rail sites, ensuring that all current safety legislation is met. High visibility workwear that meets industry specifications, along with appropriate footwear and PPE, is stocked as are high quality track tools for areas with live electrical systems. Permanent, temporary and hazard warning fencing are also available from stock, along with a wide range of hand and power tools, surveying and measuring equipment.

Burdens’ rail catalogue includes construction chemicals to assist in problems associated with waterproofing, curing, coatings, levelling, dustproofing and sealing. Lubricants and adhesives form part of the range too, for use with plate/slide chair mechanisms, clamp lock point mechanisms, and in-track and rail lubrication.

Care for the environment

The wide-ranging experience of Burdens Rail in environmental issues associated with water, energy and waste provides an extensive problem-solving support network for the construction of buildings, employing natural insulation materials that perform in harmony with nature and are unaffected by moisture, breathable and simple to install. There are also lime mortars and heritage rainwater systems to protect and enhance the legacy of the existing infrastructure.

Creating new buildings allows a ‘greening’ of locations, minimising surface water runoff and urban overheating by means of green walling and green roof solutions that complement the already comprehensive sustainable drainage products on offer. Large areas of surface water collection provide an opportunity for capturing and reusing this valuable resource through a range of commercial rainwater harvesting systems.

Burdens Rail is committed to the minimisation of waste in all of its activities and actions. Indeed, the company strives to be the industry leader in providing materials and services for the three areas of infrastructure, construction and the environment. These efforts, innovation and resources are now focussed across all sectors of the industry and have been assembled in an 84-page brochure entitled ‘Rail products and services’, providing more details and useful information to help all involved in our industry. 

Kevin Hancock is Geosand’s corporate development director.

The tenth Railtex exhibition of railway technology, equipment and services takes place at Earls Court, London, from 14 to 16 June 2011. Railtex is the UK showcase for technological innovation in the rail industry across all sectors of the supply market. This year there will be over 350 exhibitors, with a comprehensive programme of technical seminars & briefings from some of the biggest names in the industry.  As well as discussing their latest products and services there will be a questions and answer session after each presentation. Areas covered include; Rolling Stock, Track and Infrastructure,  IT Systems Signalling and Communications, Security Systems, and Electrification.

Burdens Rail will be on stand E71 in partnership with Terram, launching the second edition of the industry standard brochure of Rail Products and Services. Offering a comprehensive range covering Permanent Way geosynthetics, and drainage, materials for embankments and structures, & stations and car parks, as well as the civils and maintenance products which Burdens have been market leaders in for eighty years.

There will be a focus on the revolutionary concrete cloth material a flexible cement impregnated fabric that hardens on hydration to form a thin, durable water proof and fire proof concrete layer.

>> View Concrete Cloth Video <<

To register for Railtex visit www.railtex.co.uk

Burdens Rail will also be exhibiting at the premier technical seminars  Railway Engineering: 11th International Conference and Exhibition held on 29 - 30 June 2011 at University of Westminster, London. This year the theme will be “High Speed Rail, Maintenance & Renewal of Permanent Way, Points, Power & Signalling, Structures & Earthworks”. There will be 80 papers read from the leading authorities in Rail Engineering

For more information or to register as a delegate www.railwayengineering.com

Crossrail will become the largest construction project in Europe following on from the Olympics, with a contract value of
over £16bn. It has several sections of work underway already and we are supplying all of these sites with a wide range of products. The stations and tunnelling starts this year and Burdens Rail are ideally positioned to become a major supply chain partner to this prestigous project. 

London Underground is undergoing a major upgrading programme and requires specialist products and services together with a flexible approach to logistics and innovative product solutions. Often very complex and tight programme schedules need positive and trusted response from a supplier and Burdens are at the forefront of this market.

There are several London Overground lines in operation and a number of improvements and extensions are in progress or have capital funding. The first section of the East London line for example has recently opened where Burdens sold £1.5m of products and the second phase is due to start shortly, so our knowledge and experience in servicing large rail projects is continually growing.

Network Rail has 670 stations in the South East Region and over 2000 nationally. The government recognises the importance of a world-class efficient railway system and have approved record levels of investment nationwide.   New projects, together with all the infrastructure work associated with the stations, car parks, tunnels and maintenance will provide continuity of work for the long term.

Burdens Rail is uniquely aligned to assist network rail and their approved contractors with projects  such as Crossrail by our tailored Burdens Rail catalogue, logistics solution and innovation through our flexile and specialised approach.

We look forward to updating you with our progress and reporting on the exciting challenges and new developments to come.

The Burdens Rail product catalogue has over 80 pages of products and solutions for the rail industry for stations and car parks, embankments and structures and rail track applications.

> > Request a copy  <<

Did you know that?

To keep you up to speed with the global rail market we've listed some interesting rail travel statistics below:

• The world’s busiest station is Shinjuku station in Tokyo.  An average of 3.6 million people per day uses the station The largest station in area is Beijing, covering 510,000 square metres.

• The station with the largest number of platforms is Grand Central Station, New York with 44.

• The busiest station in Europe is the Gard du Nord in Paris with 180 million passenge rs per year and has 42 platforms.

• Clapham Junction has the largest throughput of trains with an average of 1 every 13 seconds at peak times.

• The fastest train and track combination is the Magler line in Shanghai - designed for consistent speeds of 431km/hr.

• Rail transport uses on average 7 times less CO2 emissions than road transport and is 3 times more energy efficient.

• Completed in 1890, Scotland’s Forth Rail Bridge has the second longest cantilever span in the world measuring 521 metres - Quebec Bridge in Canada has the longest.

• The longest railway line in the world is the Trans-Siberian Railway, at 9297 km. The line crosses 7 time zones and takes over 7 days to complete.

Burdens Rail is not only up to speed with it's rail travel statistics, importantly we provide a sustainable supply chain to support the expanding rail network. This builds on over 80 years of Burdens’ experience and its market-leading position in supporting the civil engineering and utility industries with the supply of materials and on the Group’s already extensive rail experience and expertise.

The unique Burdens co-ownership business model ensures its own sustainability and offers a ‘better way to do business’ for the industry. Contact us for more information.

The government is committed to funding the railways, and the demand for materials has remained steady. Against this background, Burdens – already a major and increasingly relevant supplier to the railway infrastructure for at least half of its 80+ years of service to the civil engineering and construction industries – formalised its activities by setting up the Rail Division (Burdens Rail).

Over the years, Burdens’ long-term business within rail has grown as a result of working in partnership with Network Rail track engineers, consultants and contractors to supply the permanent way with what’s needed, when it’s needed and where it’s needed. More particularly, for example, the company has become established as the major supplier of geosynthetics and drainage materials to the rail infrastructure. 

Complex mix
Burdens Rail has developed a complex mix of specialist and innovative products together with a flexible approach to logistical solutions to meet the requirements of Network Rail, London Underground and Crossrail.
Understanding the challenging demands of both the civil engineering and physical requirements of the railway construction programme, from design and construction to operation and maintenance, is central to the company’s unique approach. The range of products and services offered is diverse and 50 strategically located distribution depots means that products can be delivered in a timely and economical manner. In addition, Burdens’ technical expertise and close connections with its suppliers allows them to find product solutions for the more unusual or complicated applications.

Timesaver
For example, the company is currently working with Saint Gobain on various product and application solutions for tunnelling contracts. The cast-iron Timesaver pipework system is used extensively for drainage applications in tunnels and on bridges. This range contains a wide assortment of black-coated fittings including chambers, gully traps, gully inlets, raising pieces and garage gullies. All the items are extra-thick for strength while their non-combustible properties make them for a wide range of uses.
One early application for the Timesaver system was on a bridge in Dumfriesshire. Eleven wrought-iron spans carried the Glasgow and South-West Scotland line over the River Nith. Built in 1875, they badly needed replacing. Carillion Rail, working with designer Scott Wilson, came up with a new design which both realigned the railway and has a spectacular 90 metre curved truss as its central span. Burdens assisted with a Timesaver design for on-bridge drainage and supplied all the components to help the contractors finish the project on time, to budget and without disruption to the railway.

Tunnels

Another close trading partner provided an advanced drainage system solution for the Bramhope tunnel in Yorkshire. This 3441 metre long tunnel was opened in 1849 and runs under the ridge that separates Airedale from Wharfdale. The Victorian box-culvert drainage system has an average daily outflow of one and a half million gallons a day from intercepted water courses and water coming through the roof. A modern alternative was required which could be installed quickly and didn’t need too much heavy plant to install, keeping disruption to the minimum. Once again, Burdens supplied a complete system from their local depot.
Delivering to rail sites regularly poses logistical problems. London and the south east has various major rail schemes under way or starting shortly. Restricted access sometimes involves delivering material at night or weekends. This is not always an ideal situation  but, with road closures not always possible and possession times limited, night deliveries may be the only solution.

Barges
Central London poses its own problems, but deliveries to the Thameslink improvement programme at Blackfriars station were made easier by using barges on the Thames – a logical approach that is estimated to have saved 300 lorry movements.
Development and innovation are increasingly important in taking track engineering forward. Burdens Rail is heavily involved in a number of development programmes to make track life more cost-effective. To combat pumping erosion, GEOSAND has recently been developed to allow a consistent yet thinner layer of blanketing sand to be contained within its structure in a roll form, providing a way of creating an effective pumping barrier layer over any undulating surface. Following extensive testing at universities and main-line installation trials, the product has been approved for use across the UK network and has been installed at more than 50 sites.

Concrete carpet?

drainage projects around the UK with more installations planned. Supplied in rolls, Conrete Canvas behaves like a thick carpet and can be unrolled in lengths of up to 200m. Once unrolled and sprayed with water, it sets rapidly and hardens to 80% strength within 24 hours, becoming a robust, durable, waterproof concrete surface with a design life of over 25 years. Easy and quick to install on any surface or slope in all weathers, Concrete Canvas is economical because of its ease of use, the time saved and the finished product’s long-lasting high wear resistance.

Burdens Rail provides products and services for the rail industry. To find out more you can request a catalogue or contact us.A selection of Burdens Rail’s innovative new products were on display to visitors to the recent Railtex exhibition. They focussed on seven main areas of application: permanent way, embankments & structures, car parks, stations, infrastructure, maintenance & safety and green technologies. It will be interesting to see how they are applied to future projects.

It has long been recognised that the provision of drainage in permanent way work is a vital factor in ensuring the effectiveness and life span of ballast and it would be fair to say that designers have put a greater emphasis on drainage design in the last few years. This has resulted in product development to ensure that not only is any railway drainage system guaranteed to perform its primary function but that it offers advantages in terms of speed and safety of installation.

Having been involved in railway drainage since the company was founded in the 1920s, Burdens Rail is today a leading supplier of the many products involved. For example, the company is Network Rail-approved for the supply of structured wall pipes and is currently working with Simona in relation to heavy-duty solid-wall PE pipe for use in pressure zones.

A good example of the application of these pipes was seen recently at Lake Thun in the Bernese Oberland, Switzerland. Here, BLS Netz AG operates a rail network spanning more than 900 km. Direct proximity to Lake Thun and Lake Brienz as well as minuscule differences in altitude regularly cause the groundwater level to rise and penetrate the track bed. After more than 30 years of service, it was decided to renew the railway line. In parallel with permanent-way renewal, the existing drainage system – made of concrete pipes in an open drain trench along the railway line – and the cross drainage to a navigational canal also had to be modernised. According to the requirements of RTE 21110 (Railway Technical Code of Practice) railway drainage in the roadbed and ballast has to meet the figures specified by the operator, e.g. a clear water inlet opening of at least 100cm and a minimum slot width of 6mm. To ensure reliable operation of such a drainage system over a period of decades, demanding static, dynamic and mechanical requirements also have to be met. The gradient requirements are 0.65 to 11.05 per mil.

This construction project was realised with Simodrain® drainage pipes with an OD of 250mm, SDR 21, and 10mm slotting, specially developed for traffic route drainage. These extruded smooth-wall pipes meet the requirements of such a system, and with their large water inlet area they are capable of handling the specified 100cm. Using a special slot geometry and slot arrangement, and with the excellent hydraulic properties of the PE material, the drainage provided by the system is ‘best in class’ and designed for the long term. End-milled slotting avoids undercuts, and hence deposits and incrustations. In addition, the pipes are easy to rinse out, making them the perfect solution for the railway operator BLS Netz AG.

When it comes to railway cathchpits, Burdens offers standard concrete frames, circular HDPE systems, and traditional GRP chambers. In addition, in recognition of the need for fast installation as well as performance, the company is working closely with Cubis in promoting their STAKKAbox Ultima access chamber, which is claimed to have numerous advantages over existing systems, particularly as regards speed of installation. Indeed, because the chamber comes complete to site, they can be installed in as little as 18 minutes. Other advantages are a loading strength of 12.5 tonnes, high chemical resistance, and design flexibility. Manufactured from recycled materials, the chambers offer a high level of safety in installation and use, all of which makes the product very cost-effective.

Another innovative product is so-called concrete canvas (CC), which is a flexible cement-impregnated fabric that hardens when hydrated. It comes in a roll format with a PVC waterproof backing and has been used on several Network Rail contracts where a traditional concrete pour would have been difficult. This flexible, strong and durable material is also easy to lay, allowing around 400m of ditch to be installed in one day with minimal staff. Concrete canvas has achieved a Euroclass B-sl fire rating.

In September 2009, a 140m section of ditch was lined using Concrete Canvas by Amalgamated Construction (AMCO). The project was commissioned by Network Rail to provide drainage at the top of a railway embankment in Chipping Sodbury, Gloucestershire. This was the first time AMCO had used CC for ditch lining and the project was heralded as a major success. CC proved significantly quicker and easier to install than conventional concrete slab construction, reducing the project cost and time on site. The cloth was supplied in a portable rolls for ease of use on a site with limited access. Andrew Gurd, construction manager for contractor Amalgamated Construction Ltd, said “Concrete canvas is incredibly quick and easy to use. It allowed us to line over 100m of ditch in less than 8 hours, with the minimum of manpower and plant.”

Installation begins with digging a V-shaped ditch with smooth, flat sides. Concrete Canvas can be supplied either in man portable-lengths (8 linear metres weighs 105kg) or in large rolls (120m, 1400kg) if the necessary plant is available. Once unrolled and positioned, CC is hydrated by controlled spraying with water - even sea water may be used – with care being taken to avoid washout. An excess of water should be used as CC cannot be over-hydrated. Once hydrated, it remains workable for about two hours, though warm climates may reduce working time. It hardens to 80% of its 28-day strength in 24 hours and is ready for use.

The extent of Burdens Rail’s commitment to the industry can be gathered from the company’s 104 page brochure entitled Rail Products and Services, which includes products for Permanent Way, embankments and structures, car parks, stations, infrastructure, construction, maintenance and safety as well as semi-permanent buildings and green technologies.

For further information on the company’s products and services or to request a copy of the catalogue, please contact our rail office on 0845 6043060, email us on rail@burdens.co.uk or visit the Burdens Rail website.

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Against a backdrop of increasing demands placed on the railway network, Burdens Rail provides a sustainable supply chain to support this key part of our nation’s infrastructure.

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