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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

ASSIGNED STAFF

During the complete shutdown approximately 500-600 employees
 

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
 
 

Other services

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

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

ASSIGNED STAFF

32 industrial workers
3 technical employees

IMPRESSIONS

TECHNICAL EQUIPMENT AND NOISE PROTECTION

SERVICES

Noise protection walls

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

 

Technical equipment

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

 

Platforms

4x new construction of platform with a length of 210 m each (conventional)

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