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Vivarail’s first Class 230 in service

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Date

26 April 2019

Expertise

Sustainability

West Midlands Trains’ first Class 230 DMU train has entered passenger service on the Marston Vale line on 23 April.

 

Unit 230004 is now in service on the route between Bletchley and Bedford, which forms part of its London Northwestern Railway business unit. The train, which has been developed by Vivarail, will provide extra capacity and improved customer experience for passengers on the line. Strukton Rail developed the traction and auxiliary systems. These systems control the power from the genset to the right voltage for the motors, batteries and auxiliary systems. West Midlands Trains ordered the three two-car units from Vivarail. The remaining two sets are expected to enter service in the coming weeks.

Traction Electronics

The traction system is able to power DC and AC motors while assuring smooth acceleration and higher travelling comfort for passengers. These trains are currently powered by fuel efficient diesel generators. With minor changes, this traction system is also suitable for battery hybrid operation. Later this year, five hybrid three-car trains will be delivered to KeolisAmey for the Wales and Borders franchise.

Low fuel

The fuel consumption is roughly half that of a Class 14X Pacer diesel multiple-unit. This is supported by the use of stop-start technology, which sees the engines shut down when not needed, such as at stations or when stabled, although one engine will remain operational for battery charging. The designers say that having four separate engine modules would enable a train to operate at near full power even if one engine should fail. The design of the traction package allows the trains to be maintained locally, rather than needing to return to a depot. Individual engine modules can be exchanged in 10 min with just three operations: disconnecting the fuel and air hoses; unhooking the safety catches and lifting out the module using a pallet truck. Current estimates are that a full engine change would only be needed every 250 000 to 300 000 km.

 

Next generation traction systems

 

In order to support Vivarail’s innovative plans, Strukton is developing a next generation traction system. This will enable full battery operation with the opportunity of charging at stationary stops as well as hydrogen fuel cell operation. This will make Vivarail one of the first long-distance, zero-emission train manufacturers worldwide. The traction system is expected to be ready before 2020.

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Frequently asked questions

Find answers to frequently asked questions here.

What does sustainability mean in the rail and civil infrastructure sector?

Sustainability in rail and civil engineering focuses on reducing environmental impact across the entire lifecycle of infrastructure. This includes using emission‑free equipment, circular and recycled materials, and designing assets with a longer lifespan and lower maintenance requirements. Reusing structural components—such as circular viaduct beams or recycled copper contact wires for overhead lines—significantly reduces CO₂ emissions while conserving valuable raw materials.

How can CO₂ emissions be reduced in infrastructure projects?

CO₂‑reduction is achieved through a combination of clean construction methods and material innovation. Key strategies include:

  • Deploying zero‑emission machinery such as electric cranes, electric rail‑road vehicles (Krols), electric vans and battery‑powered locomotives.
  • Integrating circular concrete, geopolymer concrete, and recycled materials to lower embodied carbon.
  • Collaborating across the supply chain — from client to contractor to materials supplier — to scale circular and low‑carbon solutions.

These measures not only reduce carbon emissions but help create more resilient, future‑proof infrastructure.

Which sustainable innovations are being used in modern rail and civil engineering projects?

Infrastructure projects increasingly rely on advanced sustainable technologies, such as:

  • 100% recycled copper contact wire, reducing CO₂ emissions by up to 92%.
  • Geopolymer concrete, offering 50–80% CO₂ savings compared to traditional mixes.
  • Electric and battery‑powered locomotives for maintenance and logistics.
  • Circular overhead‑line foundations and poles made from low‑impact concrete.
  • The Energy Bank, an innovative click‑and‑go substation that captures and reuses regenerative braking energy.
  • Circular viaduct and bridge concepts, enabling reuse instead of demolition.

These innovations drive measurable environmental benefits throughout the asset lifecycle.

What is zero‑emission equipment in infrastructure construction?

Zero‑emission equipment refers to machinery that operates without producing exhaust gases, typically powered by electricity or batteries. Examples include:

  • Electric locomotives and battery locomotives
  • Electric cranes and rail‑road (Krol) vehicles
  • Electric vans and support vehicles

This equipment eliminates local emissions, improves air quality around work sites, reduces noise pollution and helps clients comply with increasingly strict sustainability requirements.

What does the future of sustainability in infrastructure look like?

By 2050, the infrastructure sector aims to be fully climate‑neutral. This future includes:

  • A robust, climate‑resilient infrastructure network designed for extreme weather.
  • A fully emission‑free construction fleet.
  • Circular material chains where components are reused at scale.
  • Rail as a leading sustainable mobility system, supported by smart energy management and low‑carbon construction methods.
  • Infrastructure that integrates nature, supports biodiversity and ensures safe mobility for everyone.

The transition is already underway, driven by innovation, collaboration and long‑term thinking.

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