New approach to embedded track renewal trialled on Croydon tram network
VolkerRail has completed essential embedded track renewal works on the Croydon tram network, using a new track maintenance solution developed by Sika.
The works were delivered during a fifteen day blockade, and included the renewal of a key crossover and 500 metres of embedded rail, all completed within a constrained possession window, in a busy urban environment.
As part of the works, VolkerRail partnered with Sika to trial its Icosit® KC 350/45 polymer rail grout, to support improved efficiency during construction and long‑term performance of the asset.
Icosit® KC 350/45 is a flexible, two-part polyurethane polymer resin grout that is used across European light rail systems.
This is the first time Sika’s Icosit® KC 350/45 polymer rail grout has been used in the UK, and offers significant improvements in vibration absorption and long-term rail maintenance. The grout cures up to six times faster than traditional methods, helping to shorten track closure times, and can be applied using an innovative new machine, creating further labour, cost and environmental savings.
This was also the first site in the world to use the innovative machine to apply Sika’s Icosit® KC 350/45 polymer rail grout, moving embedded track renewal away from traditional hand installation.
Jamie Kelly, VolkerRail’s programme manager, said: “The renewal of this important crossover and embedded rail was delivered on time and to the client’s satisfaction. With over one hundred people on site each day, the professionalism, drive, and commitment shown by the team was exemplary. Thanks also to Sika, who supported the introduction of a new application method that helped improve efficiency and remove the need for more labour‑intensive activities.”
David Collins, national business development manager at Sika, said: “This is the first time Sika Icosit® KC 350/45 polymer has been installed by machine anywhere in the world. By combining faster curing with controlled application, we have demonstrated a more efficient way to deliver embedded rail renewals, and our solution provides a clear example of how rail replacement can be delivered more efficiently with improved performance, less waste and reduced disruption. The benefits extend beyond installation, and its elastic properties reduce vibration ensuring improved ride quality and greater long-term durability too.”
The life extension works took place between 11 and 26 February, near Addiscombe Road and on the East Croydon to Wimbledon line, and were planned to coincide with the school holiday period to help reduce disruption for customers using the network.
VolkerRail has been replacing sections of embedded track across the Croydon tram network for London Trams since 2012. This latest programme of work forms part of the Embedded Track Replacement Framework, which was originally awarded to VolkerRail in 2022 and later extended following continued delivery across the network.
Croydon’s tram network runs for up to 19 hours a day and carries around 18 million passengers annually. It spans 28 kilometres and includes 39 tram stops, providing a modern and environmentally friendly public transport system serving Croydon and the surrounding areas of south London.
