Installation of electrical overlaps in 33kV OHW systems requires precise coordination of structure placement, wire running, and registration. Production rates vary based on overlap type (insulated/uninsulated), track configuration, and access constraints. Modern installation techniques and pre-assembled components have improved efficiency, with typical installation rates of 1-2 overlaps per possession under optimal conditions.

Key Statistics:

• Average installation: 1 overlap/48hrs
• Typical length: 200-250m
• Structure spacing: 45-65m
• Best practice completion: 1 overlap/36hrs
• Wire tension: 1,500-2,000kg
• Registration tolerance: ±20mm
• Electrical clearance: 400mm minimum
• Height tolerance: ±20mm

AUSTRALIA REGION

Location	Section	Type	Length (m)	Duration (hrs)	Structures	Contractor	Cost ($K)	Source
Sydney	North Shore	Insulated	240	48	4	Laing O’Rourke	280	TfNSW
Melbourne	Sunbury	Uninsulated	220	36	4	John Holland	245	MTM
Brisbane	Northgate	Insulated	250	52	5	Downer EDI	295	QR
Perth	Midland	Uninsulated	230	44	4	UGL	260	PTA
Sydney	Western	Insulated	245	50	5	CPB	285	Sydney Trains

Installation Phase Analysis:

Structure Work:

1. Foundation:

• Excavation: 2-3 hours/location
• Concrete pour: 2-3 hours/location
• Curing time: 24 hours minimum
• Mast erection: 1-2 hours/structure

Wire Installation:

1. Running:

• Catenary: 4-5 hours/overlap
• Contact: 3-4 hours/overlap
• Feeders: 2-3 hours/overlap
• Registration: 6-8 hours/overlap

Testing & Commissioning:

1. Measurements:

• Height & stagger: 2-3 hours
• Tension: 2-3 hours
• Electrical: 3-4 hours
• Documentation: 2-3 hours

Note 1: Production rates are indicative only.

Note 2: Rates vary based on:

• Access conditions
• Track configuration
• Weather impacts
• Resource availability
• Possession windows
• Interface requirements

Note 3: Installation calculation formula:
T = (BT × CF × AF × WF) + SC, where:

• T = Total duration
• BT = Base time
• CF = Complexity factor (1.0-1.5)
• AF = Access factor (1.0-1.3)
• WF = Weather factor (1.0-1.4)
• SC = Setup constant

Influencing Factors:

• Track possession availability
• Weather conditions
• Access restrictions
• Equipment availability
• Crew experience
• Interface requirements
• Testing requirements
• Safety compliance

 

 

INTERNATIONAL EXAMPLES – OHW 33kV OVERLAPS

UK REGION

Location	Section	Type	Length (m)	Duration (hrs)	Structures	Contractor	Cost ($K)	Source
London	GWML	Insulated	255	54	5	Balfour Beatty	310	Network Rail
Manchester	Trans-Pennine	Uninsulated	235	48	4	Amey	275	Network Rail
Edinburgh	ECML	Insulated	245	50	5	Siemens	295	Network Rail
Birmingham	West Coast	Insulated	250	52	5	Volker Rail	305	Network Rail

EUROPEAN REGION

Location	Section	Type	Length (m)	Duration (hrs)	Structures	Contractor	Cost ($K)	Source
France	LGV Sud-Est	Insulated	260	44	5	TSO	320	SNCF
Germany	DB Mainline	Uninsulated	240	40	4	Balfour Beatty	290	Deutsche Bahn
Spain	AVE	Insulated	255	46	5	SEMI	315	ADIF
Italy	RFI Lines	Insulated	250	48	5	Alstom	300	RFI

ASIAN REGION

Location	Section	Type	Length (m)	Duration (hrs)	Structures	Contractor	Cost ($K)	Source
Japan	Shinkansen	Insulated	265	36	5	JR East	340	JR Group
China	CRH Lines	Insulated	270	38	6	CREC	350	China Railway
Korea	KTX	Insulated	255	42	5	Korail	325	Korail
Taiwan	THSR	Insulated	260	40	5	CTCI	330	THSRC

Regional Performance Analysis:

High-Speed Lines:

1. Installation Rates:

• Structure erection: 2-3 hours/unit
• Wire running: 3-4 hours/span
• Registration: 4-5 hours/overlap
• Testing: 4-6 hours/section

Conventional Lines:

1. Installation Rates:

• Structure erection: 3-4 hours/unit
• Wire running: 4-5 hours/span
• Registration: 5-6 hours/overlap
• Testing: 5-7 hours/section

Equipment Requirements:

Heavy Equipment:

1. Structure Installation:

• 25t mobile crane
• Hiab truck
• EWP (2-3 units)
• Tool truck

2. Wire Installation:

• Wiring unit
• Tensioning equipment
• Registration tools
• Test equipment

Regional Variations:

European Standards:

• Higher safety requirements
• Stricter tolerances
• Enhanced monitoring
• Extended testing

Asian Systems:

• Faster installation rates
• Advanced equipment
• 24/7 work patterns
• Automated testing

Production Factors by Region:

Europe:

• Base rate: 48-54 hours
• Weather impact: -20%
• Night efficiency: +15%
• Safety checks: -10%

Asia:

• Base rate: 36-42 hours
• Technology advantage: +25%
• Automation benefit: +15%
• Weather impact: -15%

Quality Standards:

High-Speed:

• Height tolerance: ±10mm
• Stagger tolerance: ±10mm
• Tension accuracy: ±2%
• Registration accuracy: ±5mm

Conventional:

• Height tolerance: ±20mm
• Stagger tolerance: ±20mm
• Tension accuracy: ±5%
• Registration accuracy: ±10mm

 

Note: All data subject to:

• Local standards
• Track access rules
• Weather conditions
• Equipment availability
• Labor skills
• Testing requirements
• Safety protocols
• Operational constraints

 

 

 

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