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TECHNICAL ARTICLE
AS PUBLISHED IN
The PWI Journal
January 2020
VOLUME 138 PART 1
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Ballarat line upgrade
Regional rail revival in Australia
AUTHOR
INTRODUCTION Freight was also a monopoly government provider
of the state’s rail freight services. Since 2004, V/ Phil Kirkland
The Ballarat V/Line rail service is a regional Line Pty Ltd, the main operating rail company, CEng MICE, FPWI P
passenger rail service operated by V/Line in has been owned by the V/Line Corporation, a WI Vice President
Victoria, Australia. It serves passengers between Victorian State Government statutory authority. England (North)
the state capital Melbourne and the regional city In 2016, V/Line Corporation became a subsidiary
of Ballarat. Beyond Ballarat, two routes continue agency of Transport for Victoria, very much like Phil is an experienced
west; the Ararat line and the Maryborough line. NECA (North East Combined Authority), Nexus Railway Engineer of
Track construction varies, being 1600 mm (5 and Metro here on the Tyne and Wear Metro in 47 years continuous
ft 3 in) gauge, a mix of flat bottom rail weights the UK. service, beginning in
with a mix of jointed and CWR on both timber 1973 with British Rail in Newcastle and more
and concrete sleepers. All track renewals now Since the mid-1990s, Melbourne has maintained recently retiring as Head of Maintenance
comprise flat bottom rail on concrete sleeper significant population and employment growth. Delivery at Nexus Metro (Tyne and Wear
assemblies. Track gauge is 1600 mm (5 ft 3 in), There has been substantial international PTE).
known in Australia as ‘Broad gauge’. At Ararat investment in the city’s industries and property
and Maryborough, the existing broad gauge market. Melbourne has sustained the highest Phil has worked in the rail industry worldwide,
systems are connected with standard gauge population increase and economic growth rate of specifically in the areas of track inspection,
railways (see image 1). any Australian capital city and these factors have maintenance, renewal, mechanised
led to population growth and further suburban maintenance, high output systems, railway
V/Line, the government-owned corporation, expansion through the 2000s.The spread of rules, regulations, policies, processes and all
operates regional passenger train and coach urbanisation has been significant and rapid. safety matters.
services in Victoria, Australia. V/Line provides After the release of ‘Melbourne 2030’ in 2002,
passenger train services on five commuter lines planning policies have encouraged medium-
and eight long-distance routes from its major hub density and high-density development in existing
at Southern Cross railway station in Melbourne, areas with greater access to public transport and
as well as bus services across Victoria and other services. As a result, Melbourne’s middle
into New South Wales, the Australian Capital and outer-ring suburbs have seen significant
Territory and South Australia. In addition, V/Line brownfields redevelopment.
is responsible for the maintenance of much of
the Victorian freight and passenger rail network, From 2006, the growth extended beyond the city’s
outside of the areas managed by Metro Trains urban growth boundary. Predictions of the city’s
Melbourne and ARTC (Australian Rail Track population reaching five million people pushed the
Corporation). state government to review the growth boundary
in 2008 as part of its ‘Melbourne @ Five Million’
The V/Line brand was introduced after the strategy. In 2009, more new jobs were created
breakup of VicRail in 1983 and has been used by in Melbourne than any other Australian city and
all successive government and private operators Melbourne’s property market remained highly
of the state’s regional public transport. Until 1999, priced, resulting in historically high property
when its freight operations were privatised, V/Line prices and widespread rent increases.
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All of this has led to population increases in the outlying towns to the To alleviate capacity constraints on the single track section, one Ballarat
west and north west of the city, making commuting an attractive and to Melbourne service in the evening peak was provided by a road coach.
viable option. V/Line operates passenger trains on the Ararat line to and from Southern
Cross station in Melbourne, as well as three road coach services
V/Line’s operations, particularly those on long-distance routes however, connecting with buses at Ballarat. Roughly half the number of services
remain heavily subsidised by the Victorian Government. The Ballarat run towards Maryborough. Beyond Ballarat, the line is classified by V/
service is the second busiest service in the state of Victoria (behind Line as an Intercity service, and many services run as limited express
Geelong). V/Line operates on average, half-hourly passenger services services between Ballarat and Melbourne (see image 2).
along the line. Half terminate at Bacchus Marsh with every second one
continuing through to Wendouree; four of these also extending to Ararat Several rail stations such as Gordon and Warrenheip were closed in
station and two to Maryborough. Services are operated primarily by October 1981. In 1994, all services beyond Ballarat were withdrawn.
V/Line VLocity DMUs, while peak-hour trains to Bacchus Marsh are In 1995 the routes beyond Ararat to Maryborough were completely
operated by Sprinter DMUs and locomotive-hauled trains. re-gauged to standard gauge 1425 mm (4 ft 8 1/2 in) at the same time
as the main line from Melbourne to Adelaide. The broad-gauge line
between Ballarat and Ararat was closed to all traffic, with the broad-
gauge passenger service from Ballarat to Ararat not reinstated until
2004.
Rail system map, Victoria, Australia (image free-issue: Wikimedia Image 1: Existing (typical) track conditions Geelong to Ballarat line, 1600
permissions). mm / 5 ft 3 in gauge (photo: WCCMW).
Image 2: 17 Feb 2018 the first revenue freight train to run on the re-
gauged Ararat to Maryborough line, an empty grain train on its way to
load at Birchip (photo: Sean McGarraghy).
Image 3: Martinus Rail Plasser 07-275 tamper engaged upon track
refurbishment works (photo: WCCMR).
Image 4: New Pan concrete sleepers laid out on graded formation ready
for rail installation (photo: WCCJB).
Image 6: The impact of thermal stresses in CWR. Here the weak point
in the new works appears to be where the new concrete sleepered track
Image 5: MartinusRail Plasser 09-32 CAT on the newly re-laid standard adjoins existing timber / spiked track. Thermal stresses have overcome
gauge Maryborough line (image: WCCMR). the weaker track fixings (image: WCC).
53
Image 7: 2015 derailed grain train at Ouyen, Victoria due to excessive CWR compression and rail creep at a fixed level crossing (photo: Transport
Safety (Vic)).
Image 8: Melbourne to Ballarat, Ararat and Maryborough Route upgrades Image 9. Installation of concrete bearer switch and crossing units with flat
(image: RPV (Rail Projects Victoria)). bottom rail and Pandrol fastenings (image: RPV (Rail Projects Victoria)).
In December 2007, work began on upgrading of line between Ballarat and Maryborough. As of any geotextile on to the prepared formation.
the essential freight only line between can be seen from the image 4, the construction Perhaps an alternative is to consider laying
Gheringhap (on the Geelong–Ballarat line and strategy (summarised) was to: up to 200 mm of bottom ballast first, ahead of
Mildura, at a cost of $73 million. This involved sleeper laying, or if this is not practicable, run a
one in every two sleepers being replaced, • Remove the old track mechanical lifting unit to complete the big lifts,
followed by ballast, tamping and CWR • Regrade the formation ahead of the tamping machine (see image 5).
stressing and lifting maximum train speeds to • Relay and assemble new track directly on
80 km/h. Current speeds are restricted to 50 to the new formation Author: Learning Point -The issue should be
km/h on one-third of the track and are as low • Tip ballast the subject of further discussion/research
as 30 km/h in some sections. The main freight • Lift, tamp and align new track by apprentices and students, and serves to
traffic on the line is grain and containerised • Weld and stress CWR underline the real value of considering ‘how
wine, grapes, citrus, dried fruit and juice for others do it’
export, totalling around 1.5 million tonnes per As many Permanent Way engineers will
year (see image 3). know, the conundrum and risk here is that The grain season in Victoria is highly
the tamper will potentially punch holes in the dependent upon reliable rail transportation
In April 2008 it was announced that the newly compacted formation if sufficient lift isn’t and in recent years following such as the
Mildura–Yelta section of the line would also applied before the tamping tines are lowered. Maryborough and Ararat lines upgrades,
be similarly upgraded, as part of the Victorian this had not proved to be the case. High
core grain network in a $23.7 million package Generally tamping tines will penetrate up temperatures during the harvesting season
with six other lines. to 75 mm below sleeper bottom. Usually, provided for multiple track buckles and
significant lifts are necessary in multiple derailments during the season, bringing
In 2010, as part of upgrades for the return of passes to establish final design profiles. All of activities to a halt.
Maryborough passenger services, the crossing which puts excessive strain on the machine
loops at Sulky, Tourello and Talbot stations chassis and frame, tamping banks, hydraulic This caused furore amongst the local farming
would be removed, resulting in only one train systems and limit switches etc. Obviously this and business communities, shippers and
at a time being able to use the 60 kilometres methodology does not facilitate the installation customers. In the eight days to Boxing Day
54
2016, 137 freight services were affected by The $1.75 billion Regional Rail Revival is a Passing loops at Ballan and Millbrook will
heat speed restrictions, including 77 which joint initiative of the Australian and Victorian provide more operational flexibility enabling
were not permitted to run between midday and governments which will fund the upgrade of the trains to pass each other. The upgrades
8 pm or 10 pm. stations, signalling and track on every regional at Wendouree station will also allow trains
passenger train line in the state of Victoria and to pass each other here for the first time,
Relaying track and managing the subsequent in addition will create in excess of 1000 new so passengers on delayed services from
post-project operational railway in areas where railway jobs. Of interest to many involved in Melbourne won’t have to be transferred onto
ambient air temperatures reached 47°C proved urban and suburban rail upgrade schemes are traditional replacement coaches at Ballarat.
to be a significant challenge to the engineers, the partnerships and funding models/sources (A lesson in future-proofing investment for all
and one which attracted widespread state being used in this project. The $1.75 billion here).
press coverage and public criticism (see Regional Rail Revival will provide for much
image 6). New temperature restrictions had needed transportation and reliable rail links’ The new station at Toolern will cater to the
been applied to rail operators, requiring both peak and off peak, to service the rapidly region’s growing population. Rockbank station
some major lines to close on 33°C (air temp) expanding communities in Melbourne’s outer will be completely rebuilt, with Ballan and
days. Similar operating requirements were west areas including existing rail-served towns Bacchus Marsh stations receiving subtle
implemented for freight trains on the Swan such as Bacchus Marsh, Ballan and Balllarat. upgrades. The project is being specifically
Hill, Echuca, Shepparton, Murrayville, Mildura designed to allow for the future electrification
and Dimboola-Yaapeet, requiring lines to be Like any major rail project, the Ballarat Line of the line from Melbourne right through to
closed during the day when air temperatures Upgrade is being delivered in stages to spread Melton. (Again a lesson learned here and a
reached 33°C. Freight on the Manangatang the workload, minimise disruptions and allow determined policy in Victoria that passenger
and Sea Lake lines was stopped at 36°C air robust budgetary planning and forecasting, rail electrification is the way forward) (see
temperature. It’s understood the restrictions whilst at the same time facilitating timely image 9).
were introduced after two grain trains derailed procurement and accurate resource sourcing
in Victoria the previous summer, when air for the multiple worksites and activities wholly Author: Learning point – Apprentices and
temperatures above 40°C were the norm (see coordinated within the overall route corridor students to further research the subject of
image 7). (see image 8). structure / vehicle gauging to determine what
considerations may need to be made for future
The bumper grain crop actually meant more STAGE ONE: route electrification schemes.
freight movements were needed and hurried
consultations were required with farmers and • 18 km of new twin tracking between Deer The Ballarat Line Upgrade is being
freight operators to help best meet their needs. Park West and Melton delivered by Rail Projects Victoria (RPV),
Author: Learning point – apprentices and • A new station at Toolern, between on behalf of the Victorian Government. The
students should be encouraged to research Rockbank and Melton, (separately funded construction contractor for the Ballarat Line
CRT (Critical Rail Temperature) and the by the Victorian Government’s Growth Upgrade comprises a consortium made up
associated criteria which direct the imposition Area Infrastructure Contribution) of Lendlease, Coleman Rail and SMEC, in
of safety speed restrictions or blockages of the • Rockbank station rebuild, including partnership with RPV and V/Line; V/Line being
line. platform extensions, pedestrian link and a the existing TOC – (Train Operating Company).
new car park
• In 2008, as part of the Victorian Transport • A new platform and pedestrian link at Construction started on the Ballarat Line
Plan, the State Government announced Bacchus Marsh, Ballan and Wendouree Upgrade in October 2017. Mobilisation works
passenger rail services to Maryborough stations would see site preparation and safety fence
would resume, with services commencing • An additional track at Wendouree station installation to facilitate off track construction
July 2010. • Track twinning at Bacchus Marsh works, primarily by the civils teams and
• In 2009, Wendouree station to the west of • Relocation of rolling stock existing those engaged on earthworks and structure
Ballarat station opened. stabling facilities from Bacchus Marsh to constructions and reconstructions. Station
• In 2009, a total of 48,000 passengers, an Maddingley upgrades and track works also commenced
average of 1,000 per week were using the • Provision of new passing loop tracks at and continued to progress throughout 2018.
line between Ballarat and Ararat. Ballan and Millbrook The intention is that the upgrade project will be
• In 2010, with the upgrade of the • Signalling system upgrades and completed in late 2019 (see images 10 and 11).
line completed, passenger services track refurbishments to existing
were reintroduced from Ballarat to infrastructure (ballast, tamp, lift, geometry One significant activity forming part of the
Maryborough. improvements and CWR stressing, S&C project was public consultation and notification.
• In 2017, the new Caroline Springs station, overhauls). Specialist project media and communication
between Deer Park and Rockbank teams were assembled in order to constantly
stations opened. STAGE TWO: notify the community of any disruptions with
• In 2018, the Australian and Victorian information sessions, letter box drops, emails,
governments began upgrading the • Signalling systems and lineside asset website updates, advertising, social media
route. The Ballarat Line Upgrade would upgrades and station pop-ups. Undoubtedly, this high
enable much-needed extra capacity to • Further track improvements level of public and stakeholder engagement
give passengers more frequent services • Further rolling stock stabling facilities at through this well-thought out programme of
during peak times, meaning trains every Ararat. engagement, has contributed positively to the
40 minutes. project success.
Image 10: New station platforms and footbridge Image 11: Bridge replacement
55
Since 2015, with the ever expanding from Saturday 9 November to Sunday 1 Revivals here in the UK? Case in point,
urbanisation west of Melbourne, more than 100 December 2019, coaches will replace trains the Borders Railway has proven to be an
new rail services have been added for Ballarat, during the full route closure between Ballarat/ outstanding success.
Melton and Bacchus Marsh. Extra train Wendouree and Melbourne.
carriages have been added to the Ballarat line, Once again, I sincerely hope you have enjoyed
boosting capacity on many services. This will allow completion of the duplicated this informal insight into another world rail
track between Deer Park West and Melton project, simply seen through the eyes of an
To cope, car parks have already been and the final upgrading of key stations and outside observer. The author is not responsible
extended at Deer Park, Melton and Bacchus completion of ‘wheels–free’ critical signalling for any detail errors or omissions.You may have
Marsh, allowing more passengers the option commissioning.” After completion of the Blitz, noticed some study challenges set for PWI
to park and ride. Again, lessons learned here; there will be a staged commissioning phase, apprentices and students, I hope you all enjoy
how much UK railway property such as goods including critical safety testing and driver researching them, and I hope your seniors
yards and station depots have been disposed training, prior to new services being introduced enjoy explaining and supporting you in those
of at too early an opportunity in the past?. early in 2020. studies. The extended paper might also be
The State of Victoria Government has also available for presentation at future PWI section
separately invested $18 million to improve It is interesting to compare the timelines of the meetings to support that learning if desired;
mobile phone coverage for regional rail current UK GRIP process for similar projects. (but Section Secretaries don’t all rush at once
passengers along the route with new mobile In Victoria, the Maryborough line upgrade was please!).
towers and in-train, Wi-Fi capability (see image announced in 2008 and physically completed
12). by 2010. The Ballarat line upgrade was Finally, thanks must go to all my Australian
announced circa 2015 and is on target for railway / non railway colleagues and friends
During a planned 23-day Ballarat Line Upgrade completion 2020, including new rolling stock who have both provided and supported the
works ‘BLITZ’ (note the Aussie descriptor, as and signalling. Are we missing something assembly of this presentation, Good on yer
opposed to our ‘Possession’ or ‘Blockade’) here? Will we see post-Brexit Regional Rail mates!
Image 12: Ballarat station 2019 (image: WCCMBGN). Image 13: Regional Rail Revival, Bombardier V/Locity trains at Southern
Cross station, Melbourne (image: V/Line).
PWI TECHNICAL SEMINAR
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safe for the people who use it, work on it and interact
a safer with it will always be a paramount responsibility. This
seminar will provide delegates and speakers with
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important aspects of railway safety, helping them to
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The seminar will include topics such as:
20 MAY 2020 • Worker safety and the current actions and
programmes in place to ensure people go home
12:00 - 17:00 safe everyday.
• Particular safety considerations within the
REGISTRATION railway environment, for instance: electrification
FROM 11:30 systems, working with plant.
• The importance of reporting and building safety
into everyone’s behaviour.
• Reviewing significant historical railway accidents
to understand root causes and reinforce the
lessons learnt.
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