Next generation trackform

systems
UK Light Rail conference 19th July 2017

www.precastadvancedtrack.com
 Outlin
e
•PCAT Metro slab

•PCAT Rail slab

•UK Tram Low Impact Competition

•PCAT installation QRTC VIDEO

•Opportunities

•Future R&D
PCAT- Metro (on street slab)
PCAT- Metro (on street slab)
with chamber
 PCAT - Metro slab properties
Design Features
•100% macro synthetic C50/60 advanced
concrete structure > 100 year design life
•No steel rebar hence no stray current to
earth
•High modulus light weight stiff slab
• Distinctive voided slab profile
Foundation
•Designed and constructed to suit site
conditions
•Low strength foundation can be
adopted
•In-situ ground improvement
techniques
•Levels can be restored if settlement
occurs
Construction Benefits
•Rail installation from
single carriageway
•Rapid construction
mechanical process
•Shallow construction
depth
Jointing and Alignments
•Self aligning dry jointing system
•Curved connector bars from surface
easy to install
•Unique ability to decouple , realign
and remove slabs
Conduits and Ducts
•Integrated drainage and service
ducts incorporated in slab
•Secure location for track
communication services avoids
trench excavations
Inbuilt chambers
•Can be located to suit
existing manholes
positions
•Can accommodate
cross connections for
services and drainage
•Many services can
remain undisturbed
Smart technology
•Sensors being developed to
locate tram position
•Speed controls link to vehicle
to increase safety
•Energy harvesting with solar
panels integrated with ducting
Service alterations
•Slabs can be removed if access to services is
needed and replaced quickly
•Slabs can be tunnelled under if required
 PCAT - Rail slab properties
Applicable to new and rehabilitation railway projects - Ultra-Light, Light, Heavy and High Speed rail
- Slabs designed for axle loads 8t to 25t
Design Features Conduits and Ducts
• Distinctive channel beam profile • Integrated drainage and service
• High modulus light weight stiff slab ducts
• Simple and safe mechanised installation. • Secure location for track
• Rapid construction communication services

Surface Water Management

• Surface water outlets
• Efficient dispersal of water away
from track and foundation
• Increases long term ground
stability
Benefits
• Rail wheel noise
reduction
• Train containment
safety upstand
Jointing and Alignments
• Self aligning dry jointing system
• Curved connector bars
• Monolithic structure
• Unique ability to decouple , realign
and remove slabs
Flexibility
• Rail profiles
• Rail fixings
• Space for tools
Concrete Technology
• C50/60 concrete
• Macro synthetic fibre reinforcement
• 120 year design life
• Improved durability and impact resistance
• High quality off site manufacture
Foundation
• Designed and constructed to suit site conditions
• Low strength foundation can be adopted
• In-situ ground improvement techniques
• Long life resilient structure
Funding UKTram Low Impact project
Foundations simple table
 Outcome of UKTram (1)Desk Study

• 70% SAVING IN CONSTRUCTION TIME

• 52% SAVING IN CAPITAL COST

• 38% SAVING IN OPERATING / MAINTENANCE COSTS

• LOW ENVIRONMENTAL IMPACT / CARBON FOOTPRINT

• MINIMUM IMPACT ON SERVICES

• INTEGRAL SECURED DUCTING AND DRAINAGE

• EASILY REMOVED AND REPLACED IF REQUIRED

UKTram Phase 2 – detailed FEM Analysis
UKTram Phase 2 - Laboratory Testing
UKTram Phase 2 – Site Trials
PCAT Demonstrator project
Planing to remove ballast
Reduced levels prior to stabilisation
Fines added to ballast to bulk up grading
Ballast stabilisation
Metro slab rapid installation process
Minimising road-space
Precise 1mm accuracy installation
URETEK geopolymer injection
Smart components
SCT (Smart Component Technologies)
Accommodating cables
Accommodating cables
Time lapse video
Completed rail and metro sections
PCAT collaboration team
 PCAT immediate opportunities

• Colas Rail depot Rugby

• UKTram - gain approval for Light Rail projects
• Discussions WMG for Very Light Rail projects
• UK LA Light Rail metro and light rail projects
• Interest from overseas for projects in Turkey, Denmark
• PCAT – RAPID track upgrading to slab track
PCAT Metro options
PCAT overseas options
 PCAT – R & D

• Produce suite of curved slab track elements

• Network Rail Product Approval process
• Detailed design for S & C
• PCAT – SMART slab for autonomous vehicles
including energy harvesting integrated with ducting
in slabs to locate tram / vehicle position integrated
to speed controls link from vehicle to track and
other vehicles / crossings to increase safety

• PCAT -UTILITIES no dig slab system for utility

cables
 Thanks to
Thanks go to UKTram, Paul Griffiths, Colin Robey, James Hammet,
Professor Felix Schmidt of UoB, KTN, John Ingram, Dave Clarke,
RSSB- Steve Mills, Mark Benton,
Mathew Taylor VIADUCT, Richard Andrews PCAT
Rail Alliance Colin Flack, Robert Hopkin
Mott MacDonald David Hand, and his team at Altringham
AECOM team at Nottingham

Rail Live 2016 “Most Innovative Product Award”