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Replacing the main rail-mounted brake 2

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Kijfhoek Yard

Date

25 May 2021

Expertise

Rail Construction

At the Kijfhoek classification yard the freight cars coming from the port of Rotterdam are assembled into trains with many destinations throughout the Netherlands and the European hinterland. The trains are assembled using a hump process. A locomotive pushes the trains to the top of a hill after which they are sorted using an automated system. Kijfhoek has a double-track hill with branches leading to 43 classification tracks. Each year the yard processes tens of thousands of trains and the Kijfhoek tracks are subjected to highly intensive use. The hump system, which was put into use at the end of the nineties, is long overdue for renovation. Replacing the main rail-mounted brake 2 – or master retarder 2 – was a very special job. Strukton Rail carried out this work from May 1 to 11, inclusive, under contract to ProRail. With success. The hump track was put back into operation with time to spare.

Unique approach: “I don’t believe in silos”

A unique project demands a unique approach.

Willem Franken, Project Manager at ProRail, looks back on the collaboration with Strukton Rail with a great deal of satisfaction.

“ProRail, as well as Strukton, had the highly specific knowledge required to do the work. They were able to connect together. One was unable to do without the other; I don’t believe in silos. You have to bring everything together and then carry out the work.” Willem Franken, Project Manager at ProRail
“This meant, for example, that the knowledge of the civil works construction supervisor and the ProRail inspector was pooled. The structural component, such as the frame and the retarder, was jointly evaluated. Joint conclusions were also drawn from the test results. The knowledge gained during the renovation of master retarder 1 in November of last year proved to be invaluable. Both organisations have a high learning capacity.”

Joint interest

This team also stood out due to the fact that ProRail’s people, at the inspector’s level, were not afraid to get their hands dirty. Everyone rolled up their sleeves.

“While the client – contractor role was clearly there, it was really invisible. A construction team had been assembled that acted and tackled problems together. I am a proponent of this approach. The financial aspect then takes on less of a leading role because you both have the same interest: to ensure the project succeeds.” Massimo Parisi, Project Manager at Strukton Rail,

Confidence

Joint responsibility was not only evident in the work itself, but also in the project’s leadership. I told Massimo that whenever I was absent he would be in charge. Confidence in one another’s ability is very valuable. Using everyone’s strengths in terms of their skills or the technology they have mastered. Confidence also means that you can express yourself openly towards one another about things that are not working as smoothly. This will get you even further.

Challenge

“The biggest challenge for me was to have everything back in service on time. Are we capable of working together at the same level of energy for eleven days in spite of the inevitable setbacks or poor weather conditions? Eleven days of effort, dedication and resilience… There was a lot riding on this, but now I know what I can expect from everyone and what everyone is capable of. I would not hesitate to take on another similar project with this team and that possibility is not all that farfetched. Pursuant to recommendations and models there is the possibility that the frames of six group retarders will need to be refurbished at the beginning of next year.” Willem Franken, Project Manager at ProRail

 

Working on the main rail brake

The tamping machine at work

Working on the main rail brake

Only with this Obelix the main rail brake could be lifted

Our craftsmen at work

Strukton rail civil engineering

The main rail brake is lifted into two parts and then taken apart

Welding

Replacing the main rail brake with the Obelix

Frequently asked questions

Find answers to frequently asked questions here.

What are the main challenges of railway construction in densely populated European urban areas

Railway construction in European urban areas faces several challenges, including limited space, strict environmental regulations and the need to manage noise and vibration in line with European rail standards. Complex public transport networks, high population density and the demand for uninterrupted urban mobility add further constraints.

What factors influence the cost of building a new railway line?

The cost of constructing a new railway line in Europe depends on several key factors, including route length, local geography, environmental requirements and the complexity of the surrounding rail infrastructure. Prices can range from several million to hundreds of millions of euros, depending on whether the project involves urban environments, tunnels, bridges or upgrades to existing public transport networks.

Strukton delivers tailored railway engineering solutions and provides expert advice on cost optimisation through smart design, efficient project planning and sustainable construction techniques. By applying innovative technologies and meeting European rail standards, we help clients reduce lifecycle costs while ensuring reliable, future‑proof transport connections.

How long does a typical railway construction project take?

The duration of a railway construction project in Europe varies widely, depending on the project’s scale, location and the complexity of the surrounding rail infrastructure. Smaller upgrades or maintenance works may take only a few months, while major infrastructure projects — such as new rail lines, station upgrades or urban mobility improvements — can take several years to deliver due to engineering challenges, environmental requirements and European rail standards.

Strukton ensures efficient project delivery through precise planning, integrated railway engineering and smart construction methods. By coordinating with local transport authorities and applying techniques that minimise disruption for passengers and communities, we help keep Europe’s rail networks reliable, accessible and future‑ready throughout the entire construction process.

What safety measures are required during railway construction projects?

Safety is a top priority in all railway construction projects across Europe. Construction teams must comply with strict rail safety standards, European regulations and national guidelines to ensure a safe worksite and a reliable rail infrastructure. Measures typically include the use of personal protective equipment, designated worksite barriers, controlled access zones and continuous digital safety monitoring to reduce risks around active rail lines.

At Strukton, safety is embedded in our railway engineering expertise. We apply advanced monitoring technologies, rigorous training programmes and proactive risk management to safeguard our people, our partners and the travelling public. By integrating safety into every phase of a project, we help deliver secure, future‑proof rail infrastructure throughout Europe.

What is the difference between railway construction and railway maintenance?

Railway construction involves building new rail lines, stations and other assets that expand or upgrade Europe’s rail infrastructure. This includes activities such as track installation, civil engineering works, signalling systems and the development of new corridors to support sustainable transport and growing mobility needs across European rail networks.

Railway maintenance, on the other hand, focuses on keeping existing infrastructure safe, reliable and efficient. This includes inspections, repairs, asset renewals and preventative maintenance to ensure smooth operations and compliance with European safety and performance standards.

Strukton provides both railway construction and rail maintenance services, combining advanced engineering, digital monitoring technologies and lifecycle‑based asset management. This integrated approach helps keep rail networks across Europe in optimal condition while supporting future‑proof mobility solutions.

What materials are used in modern railway construction?

Modern railway construction in Europe relies on high‑performance and durable materials that meet strict European rail standards for safety, sustainability and long‑term performance. Typical components include high‑grade steel rails, reinforced concrete sleepers, copper contact wires for overhead line systems and high‑quality, sustainably sourced ballast for track stability.

To support Europe’s shift towards sustainable and circular rail infrastructure, Strukton prioritises low‑maintenance, recyclable and long‑life materials. By applying circular construction principles and selecting components that minimise material consumption and maintenance needs, we help extend the lifespan of railway assets and reduce the environmental footprint of rail infrastructure projects across Europe.

Which machines are used in rail construction?

In rail construction, highly specialised machinery ensures that work is carried out safely, efficiently and with minimal disruption. Typical equipment includes track‑laying trains, tamping machines, rail welding units, road‑rail excavators and ballast profiling systems, each designed to build or restore track structures with precision. These machines support both large‑scale track installation and daily maintenance operations. Innovations in automation and robotics are increasingly enhancing productivity and safety, helping infrastructure managers deliver consistent quality in a growing European rail network.

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