Installation of new OHW structures involves complex coordination of foundations, mast erection, and wire installation. Production rates vary based on access, ground conditions, and system specifications. Modern installation methods and prefabricated components have improved efficiency, with some projects achieving up to 20-25 structures per week under optimal conditions.

Key Statistics:

• Average installation: 12-15 structures/week
• Typical span: 45-65m
• Foundation depth: 2.5-4m
• Mast height: 6-8m
• Best practice completion: 20-25/week
• Average cost: $40K-60K per structure
• Design life: 50 years
• System voltage: 1500V DC/25kV AC

AUSTRALIA REGION

Location	Section	Structures	Type	Duration (weeks)	Rate (units/week)	Contractor	Cost ($M/km)	Source
Sydney	North Shore	180	Portal/STS	16	12-15	Laing O’Rourke	2.2	TfNSW
Melbourne	Sunbury	220	Cantilever	18	14-16	John Holland	2.0	MTM
Brisbane	Redcliffe	160	STS/Portal	14	12-14	CPB	1.8	QR
Perth	Forrestfield	140	Cantilever	12	13-15	Coleman Rail	1.9	PTA
Adelaide	Gawler	120	STS	10	12-14	Downer	1.7	DPTI

Installation Phase Analysis:

1. Foundation Works:

• Site preparation: 1 day/location
• Boring: 2-3 hours/foundation
• Reinforcement: 2-4 hours
• Concrete pour: 2-3 hours
• Curing: 7 days

2. Mast Installation:

• Assembly: 2-3 hours/mast
• Erection: 1-2 hours/mast
• Alignment: 1 hour/mast
• Bolting: 1-2 hours/mast

3. Wire Installation:

• Registration arm: 2-3 hours
• Catenary: 4-5 hours/span
• Contact wire: 3-4 hours/span
• Tensioning: 2-3 hours/span

Equipment Requirements:

1. Foundation Works:

• Piling rig
• Concrete trucks
• Excavators
• Cranes (20-25T)

2. Structure Installation:

• Mobile cranes (50-80T)
• EWPs
• Tool trucks
• Wire tensioning equipment

 

Note 1: Installation rates are indicative only.

Note 2: Rates vary based on:

• Access conditions
• Ground conditions
• Structure type
• System design
• Resource availability

Note 3: Cost calculation formula:
C = (BS × TF × CF × LF) + IC, where:

• BS = Base structure cost
• TF = Type factor
• CF = Complexity factor
• LF = Location factor
• IC = Installation constant

Influencing Factors:

• Track possession
• Ground conditions
• Access restrictions
• Weather impacts
• Material delivery
• Testing requirements
• Safety compliance
• Integration needs

 

INTERNATIONAL OHW STRUCTURE INSTALLATION EXAMPLES

UK REGION

Location	Section	Structures	Type	Duration (weeks)	Rate (units/week)	Contractor	Cost ($M/km)	Source
GWML	Reading-Newbury	280	Series 1	20	14-16	Amey/Balfour	2.8	Network Rail
ECML	Peterborough	240	Series 2	18	13-15	Siemens	2.6	Network Rail
MML	Bedford	200	Portal	16	12-14	VolkerRail	2.5	Network Rail
Crossrail	West	320	Series 1	24	15-18	Alstom	3.0	Crossrail Ltd

EUROPEAN REGION

Location	Section	Structures	Type	Duration (weeks)	Rate (units/week)	Contractor	Cost ($M/km)	Source
France	LGV Sud-Est	400	V350	24	18-20	TSO	3.2	SNCF
Germany	Stuttgart-Ulm	350	Re330	20	17-19	DB Bahnbau	3.0	Deutsche Bahn
Spain	Madrid-Valencia	380	C350	22	16-18	ADIF	2.8	ADIF
Italy	Milan-Bologna	360	FS-H3	21	17-19	RFI	2.9	RFI

ASIAN REGION

Location	Section	Structures	Type	Duration (weeks)	Rate (units/week)	Contractor	Cost ($M/km)	Source
Japan	Chuo Line	450	Type T	25	20-22	JR East	3.5	JR East
China	Beijing-Shanghai	600	CR-HT	30	22-24	China Railway	3.2	CRC
Korea	Gyeongbu Line	320	KR-350	18	18-20	Korail	3.0	Korail
Taiwan	THSR	280	THSR-H	16	17-19	THSRC	2.8	THSRC

Regional Technical Specifications:

High-Speed Lines (250-350 km/h):

1. Structure Requirements:

• Deflection limit: <10mm
• Wind loading: up to 35m/s
• Temperature range: -20°C to +80°C
• Contact wire height: 5.3m ±20mm

2. Installation Tolerances:

• Mast verticality: ±0.5°
• Registration arm: ±20mm
• Contact wire height: ±10mm
• Stagger: ±10mm

Conventional Lines:

1. Structure Requirements:

• Deflection limit: <15mm
• Wind loading: up to 30m/s
• Temperature range: -15°C to +70°C
• Contact wire height: 4.7m ±30mm

Production Rate Analysis by Region:

Europe (High-Speed):

• Base rate: 16-18 units/week
• Foundation work: 8-10/day
• Mast erection: 6-8/day
• Wire installation: 400-500m/day

Asia (High-Speed):

• Base rate: 20-22 units/week
• Foundation work: 10-12/day
• Mast erection: 8-10/day
• Wire installation: 500-600m/day

Cost Breakdown by Region:

Europe:

• Materials: 45-50%
• Installation: 30-35%
• Testing: 10-15%
• Design: 5-10%

Asia:

• Materials: 40-45%
• Installation: 35-40%
• Testing: 10-15%
• Design: 5-10%

Quality Control Standards:

High-Speed Systems:

• Structure alignment: ±2mm
• Wire height: ±5mm
• Tension: ±5%
• Stagger: ±5mm

Conventional Systems:

• Structure alignment: ±5mm
• Wire height: ±10mm
• Tension: ±7%
• Stagger: ±10mm

Installation Equipment:

Heavy Duty:

1. Foundation:

• Rotary boring rigs
• Concrete pumps
• Reinforcement cages
• Survey equipment

2. Structure Installation:

• 100T mobile cranes
• 25m EWPs
• Wire running equipment
• Testing instruments

 

Note: All data subject to:

• Design specifications
• Local standards
• Site conditions
• Access restrictions
• Weather impacts
• Material availability
• Labor skills
• Testing requirements

Additional Considerations:

• EMC compliance
• Earthing systems
• Lightning protection
• Maintenance access
• Asset monitoring
• Environmental controls
• Interface management
• Safety systems

 

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Other production rates – Indicative only

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