Installation of mechanical gap fillers in railway stations requires precise coordination of platform edge modifications, mechanical systems, and control integration. Production rates vary based on gap filler type, platform configuration, and interface requirements. Modern installation techniques and pre-assembled units have improved efficiency, with typical installation rates of 2-3 units per week under optimal conditions.

Key Statistics:

• Average installation: 2-3 units/week
• Typical length: 15-20m per unit
• Extension range: 200-450mm
• Best practice completion: 1 unit/48hrs
• Operating speed: 2-3 seconds
• Position accuracy: ±5mm
• Load capacity: 350kg/m
• Cycle testing: 100,000 operations

AUSTRALIA REGION

Location	Station	Units	Length (m)	Duration (days)	Type	Contractor	Cost ($K/unit)	Source
Sydney	Central	8	18	28	Automated	Delkor	180	TfNSW
Melbourne	Flinders	6	16	21	Mechanical	Faiveley	165	MTM
Brisbane	Roma St	4	15	14	Automated	Knorr-Bremse	175	QR
Perth	Perth	4	17	16	Mechanical	Delkor	170	PTA
Sydney	Martin Place	6	20	24	Automated	Faiveley	190	Sydney Metro

Installation Phase Analysis:

Platform Preparation:

1. Edge Modification:

• Demolition: 8-10 hours/unit
• Steel fixing: 6-8 hours/unit
• Concrete work: 10-12 hours/unit
• Curing time: 24-48 hours

Mechanical Installation:

1. Unit Installation:

• Base frame: 4-6 hours/unit
• Drive system: 6-8 hours/unit
• Extension mechanism: 8-10 hours/unit
• Alignment: 4-6 hours/unit

Control Systems:

1. Integration:

• Power supply: 4-6 hours/unit
• Control cabinet: 6-8 hours/unit
• Sensors: 4-6 hours/unit
• Testing: 8-10 hours/unit

Note 1: Production rates are indicative only.

Note 2: Rates vary based on:

• Platform configuration
• Access conditions
• Interface requirements
• System complexity
• Testing requirements
• Operational windows

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

• T = Total duration
• BT = Base time
• CF = Complexity factor (1.0-1.5)
• AF = Access factor (1.0-1.3)
• IF = Interface factor (1.0-1.4)
• TC = Testing constant

Influencing Factors:

• Platform edge condition
• Service interfaces
• Power availability
• Control system requirements
• Testing protocols
• Safety compliance
• Operational constraints
• Weather protection

 

INTERNATIONAL EXAMPLES – MECHANICAL GAP FILLERS

UK REGION

Location	Station	Units	Length (m)	Duration (days)	Type	Contractor	Cost ($K/unit)	Source
London	Victoria	12	20	42	Automated	Knorr-Bremse	195	Network Rail
Manchester	Piccadilly	8	18	32	Mechanical	Faiveley	185	TfGM
Birmingham	New Street	10	19	38	Automated	Delkor	190	Network Rail
Liverpool	Lime Street	6	17	24	Mechanical	Bode	175	Merseyrail

EUROPEAN REGION

Location	Station	Units	Length (m)	Duration (days)	Type	Contractor	Cost ($K/unit)	Source
Paris	Gare du Nord	14	22	48	Automated	IFE	210	SNCF
Berlin	Hauptbahnhof	16	21	52	Automated	Bode	205	Deutsche Bahn
Madrid	Atocha	10	20	36	Automated	CAF	200	ADIF
Amsterdam	Centraal	8	19	30	Mechanical	Knorr-Bremse	195	ProRail

ASIAN REGION

Location	Station	Units	Length (m)	Duration (days)	Type	Contractor	Cost ($K/unit)	Source
Tokyo	Shinjuku	20	25	60	Automated	Nabtesco	225	JR East
Hong Kong	Central	16	23	50	Automated	Faiveley	220	MTR
Singapore	Orchard	12	21	40	Automated	Knorr-Bremse	215	LTA
Seoul	Gangnam	14	22	45	Automated	Woojin	210	Korail

Regional Performance Analysis:

High-Volume Stations:

1. Installation Rates:

• Platform prep: 2-3 days/unit
• Mechanical install: 1-2 days/unit
• Controls: 1-2 days/unit
• Testing: 1-2 days/unit

Standard Stations:

1. Installation Rates:

• Platform prep: 1-2 days/unit
• Mechanical install: 1 day/unit
• Controls: 1 day/unit
• Testing: 1 day/unit

Technical Specifications by Region:

European Standards:

• Extension range: 250-400mm
• Cycle time: 2.0-2.5 seconds
• Load rating: 400kg/m
• Position accuracy: ±3mm

Asian Systems:

• Extension range: 300-450mm
• Cycle time: 1.5-2.0 seconds
• Load rating: 450kg/m
• Position accuracy: ±2mm

Testing Requirements:

Mechanical:

• Load testing: 120% rated load
• Cycle testing: 100,000 operations
• Emergency retraction: <5 seconds
• Obstruction detection: <50N force

Control Systems:

• Response time: <0.5 seconds
• Position monitoring: Continuous
• Fault detection: Real-time
• System redundancy: Dual channel

Maintenance Considerations:

Daily Checks:

• Visual inspection
• Operation test
• Sensor verification
• Obstruction test

Weekly Maintenance:

• Mechanism cleaning
• Lubrication
• Alignment check
• Control test

Cost Breakdown:

Equipment:

• Mechanical system: 45-50%
• Control system: 25-30%
• Installation: 15-20%
• Testing: 5-10%

Installation:

• Platform works: 30-35%
• Mechanical install: 35-40%
• Controls: 20-25%
• Testing: 10-15%

 

Note: All data subject to:

• Local standards
• Platform configuration
• Operating environment
• Power systems
• Control requirements
• Testing protocols
• Maintenance access
• Safety regulations

 

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Other production rates – Indicative only

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