-
We specialize incomplex tasks and challengesProject report
VDE 8.1 ABS/NBS Hallstadt - Ebensfeld - Erfurt, BA 2400 Zapfendorf
PROJECT DESCRIPTION
The Project Zapfendorf is part of the infrastructure project German Unity Rail N° 8 upgrade/new construction line Nuremberg - Erfurt - Leipzig/Halle - Berlin. The existing double track line is extended to four tracks between Hallstadt and Zapfendorf. The building section is almost 9 km long and is part of the upgraded line beginning in Nuremberg and an important part of the connection of the new line to Erfurt.
LEONHARD WEISS was awarded the construction and planning of the project by DB AG in 2015 and executes it with the business divisions road construction, engineering, track construction as well as railway technology (general contractor network construction).
The particularity of the large project is, that over 70 percent of the entire construction performance had to be carried out during the eight months‘ complete shutdown of the line from 11/01/2016 until 04/09/2016. In addition to the numerous buildings and construction performances cited below, a 430 m bridge construction had to be erected in this short period of time. The so-called flying junction, as well as the support of the “Hölzla“ slope in danger of sliding on a length of 600 m by means of large bored piles (6,500 drilling metres with a diameter of 1.8 m). Furthermore, the course of the river Main had to be relocated at a bottleneck of the motorway BAB A 73 on a stretch of approx. one kilometre.
FACTS AND FIGURES
- Customer: Deutsche Bahn AG, Erfurt
- Construction period: January 2016 – November 2017, complete shutdown 11/01/2016 – 04/09/2016
- Length of project section: approx. 9 km
- Noise protection wall length: approx. 9.7 km
- Noise protection wall height: 2-6 m
- New construction of track upgraded line/new line: approx. 32 km track and 7 points
- Superstructure: ballast superstructure
- Design speed upgraded line: 160 km/h
- Design speed new line: 200 km/230 km/h
- New construction of overhead line facility incl. foundations: approx. 17.5 km
- Cable duct 17,500 m
- New construction railway crossings: 8 pcs.
- New construction flying junction: 1 pc.
- New construction road overpasses (national and county roads): 6 pcs.
- New construction road overpasses of the motorway BAB A73: 1 pc.
- Support walls within city limits: approx. 1.8 km
- Support wall for securing of slope: approx. 0.6 km
- Auxiliary road bridges: 3 pcs. over the route, 2 pcs. over the river Main
- Auxiliary pedestrian bridges: 1 pc. over the route
- New construction platforms: stop station Breitengüßbach, stop station Ebing, stop station Zapfendorf
- Earthworks in the area of the route: over 500,000 m³ - in the area of the bend of the river Main (relocation of the course of the river): approx. 200,000 m³
- Formation protection layer: 64,500 m³
- Drainage: approx. 14 km
- Passages: 13 pcs.
- Road construction: 76,000 m² asphalt superstructure
- Construction roads: approx. 10 km
- During the complete shutdown approximately 500-600 employees
ASSIGNED STAFF
ENGINEERING CONSTRUCTION
SERVICES
- 6 road bridges partly with preassembled supports, width over 30 m
- 1 tunnel in cut-and-cover method, length 200 m with avalanche screen areas, length 100 m
- 5 auxiliary road bridges / auxiliary pedestrian bridges for temporary public traffic and for construction site logistics
- 10 support walls, total length approx. 1,950 m with foundation made of bored piles, diameter of bored piles up to 1.80 m, lengths of piles up to 30 m
- 4 railway crossings, framework passages for pedestrian and bicycle paths and for crossings of water bodies
- 3 stop stations, handicapped accessible framework buildings
- 1 basement waterproofing, length 220 m as road underpass under the railway and under the district road
- 1 railway bridge, flying junction total length 430 m, composed of 5 separate pre-stressed continuous beams over a total of 16 sections
EQUIPMENT USED
- 37 stationary construction cranes
- 12 mobile cranes
- Wheel loader and excavators for supply and handling of materials
- Excavator
- 10 large drilling units for the production of bored piles
- Up to 8 concrete pumps simultaneously for installation performances of over 1000 m³
ASSIGNED STAFF
- 220 Industrial workers
- 12 Employees
IMPRESSIONS
CIVIL ENGINEERING
SERVICES
- New construction deep drain 14,000 m incl. 330 manholes (DN 600 – DN 1500)
- 13 passages (DN 400 – DN 1800)
- 7 drainage crossings
- Cavities/trenches 11,000 m
- Water retention measures at the buildings during the construction period
- Earthworks 500,000 m³
- Earthworks in the area of the bend of the river Main 200,000 m³
- 450 m bank reinforcement of the river Main
- Installation of formation protection layer 64,500 m³
- Asphalt roads 76,000 m²
- Farm roads 2.3 km
- Construction roads 10 km
- Motorway BAB A 73 1 km
- 3 retention basins
- Demolition of bridges 4 pcs.
- Demolition of halls/buildings/houses 10 pcs.
- Demolition of passages 15 pcs.
- Disposal of contaminated soil
- Measures resulting from environmental care plans
- Forest clearance
- Construction of 8 km protective fence
- 24 building site equipment areas along the line
- Area of potential archaeological concern 7 ha
- Warfare material sounding 100,000 m²
Other services
EQUIPMENT USED
- 10 bulldozers
- 28 chain dredgers
- 1 long excavator, 15 wheel excavators
- 3 graders – 2 finishers – 23 earth compactors
- Soil stabilisation – 5 rotary hoes and gritters
- 6 high pressure road sweepers, 50 trucks on construction site
- 30 tractors on construction site
- 2 trench cutting machines
ASSIGNED STAFF
- 80 industrial workers
- 12 employees
IMPRESSIONS
TRACK CONSTRUCTION
SERVICES
- Dismantling of track: 20,200 m
- Dismantling of points: 26 pcs.
- New construction of points: 2 pcs. EW 60-2500 + 5 pcs. EW 60-500
- Ballast: 64,000 t
- Concrete sleepers: 54,900 pcs.
- Rails 60E2: 65,000 m
- New construction tracks: 32,500 m
- Ballast for backfilling: 57,000 t
- Welding joints: 570 pcs.
EQUIPMENT USED
- 3 road rail excavators
- 4 trucks and tractors
- 1 graders
- 1 single drum roller
- 1 chain dredger with hydr. sleeper laying device
- 1 EMD rail unloading system for unloading long welded rails (180m)
- 1 point tamping machine 09-4X4-4S
- 1 track tamping machine 09-3X
- 1 ballast levelling machine SSP 110
- 1 EM Sat (rail test car)
- 1 Gedo (measuring of tracks and points)
- 1 welding truck for flash butt welding joint (RA)
- 3 railway locomotive
- 32 industrial workers
- 3 technical employees
ASSIGNED STAFF
IMPRESSIONS
TECHNICAL EQUIPMENT AND NOISE PROTECTION
SERVICES
- 9,700 m length
- 39,200 m² surface
- Approx. 2,000 bore foundations
- Underground cable engineering
- 2,300 m demolition channel
- 17,500 m new construction channel
- 75 cable ducts
- 17.5 km dismantling overhead line facility
- 290 pcs. dismantling overhead line masts
- 17.5 km new construction overhead line facility
- 360 pcs. new construction overhead line masts
- 32 driven pipe foundations for signal points
- Construction of a signal bracket
- Demolition of 4 concrete railway control centres, 6 km wire transmission and approx. 44 km cable
- Foundation of concrete railway control centres (emergency power supply, point heating, control centres)
- 8,500m temporary cable duct for temporary telecommunications cable incl. construction, relocation during construction period and dismantling
- Laying of 34km fibre optic cable as well as 21km copper cable
- 4x new construction of platform with a length of 210 m each (conventional)
Noise protection walls
Technical equipment
Platforms
EQUIPMENT USED
- 7 drilling units
- 6 mobile excavators
- 4 road rail excavators
- 4 2.5t - 5t chain dredges
- 8 wheel loaders
ASSIGNED STAFF
- 45 industrial workers
- 7 technical employees
IMPRESSIONS
