Coventry Very Light Rail (CVLR) is an innovative research and development project pioneering an affordable rail-based travel system that can be delivered for less than 50% of the cost and in 50% of the time taken to build conventional light rail systems.
This revolutionary initiative, led by Coventry City Council, set out to research how tram networks could be made financially viable for smaller to medium-sized cities across the UK. The CVLR project will provide residents with an alternative transport option that will improve air quality, reduce congestion and put Coventry at the forefront of the green industrial revolution.
Achieving its goals
The project focused on reducing road excavation levels to just 300mm, which is approximately 50% shallower than conventional light rail tracks. This means installation costs and construction time are both reduced, as essential utilities such as gas pipes, power cables, manhole covers and drainage pipes would require less expensive relocations.
The concept was tested on 220m of city centre track. CVLR track is designed for an urban shared environment, which means it was built to withstand access by buses and HGV loads. The idea is that it would provide a reliable, frequent, environmentally friendly transport system in towns and cities at a lower cost than conventional light rail by allowing the most flexible integration into existing city infrastructure.
The tram developed to run on the track features on onboard battery energy system. This enables simplification of the track by removing the need for stray current insulation, and removes the cost and complexity associated with catenary infrastructure.
It is lighter than other trams, weighs around 11 tonnes and has a capacity for 56 people. It also features an innovative Bogie system, enabling it to handle tighter curves than is typical.
Pandrol was successful in bidding to provide a bespoke cutting-edge rail fastening and welding solution for the Coventry Very Light Rail Project.
The main project requirements were for:
• A rail seat with a moveable and rotational fastening system - that could be secured on site, to allow for the continuously variable alignment typically found in urban environments.
• A rigid, robust fastening system that was proven and tested.
• A welding solution that minimised material under the rail foot.
The project's innovative track design utilises 100mm thick precast panels of ultra-high performance concrete (UHPC), hence enabling minimal excavation while maintaining compatibility with standard grooved rail and fastenings. This approach radically reduces the need for large-scale road modifications and buried utility diversions, reducing material logistics and associated carbon emissions during installation and enabling easier access for future utility maintenance.
The slab design is modular. This allows for edge modification to enable curved track alignment and manhole access cutouts. They have three sets of channels embedded opposite each other, due to the final rail position being unknown. Once the rail is positioned and aligned, the rail fastenings could be placed in the channels alongside the rail and secured.
Pandrol's SD 'Safe Driven' rail fastening system was specifically chosen for its compact, robust design and lower carbon footprint compared to traditional threaded solutions.
On the Coventry Very Light Rail project, Pandrol’s SD fasteners had to sit flat on the slab, so they could be moved on channels to adapt to the angle of the curves. Pandrol recommended an SD1 fastening, which was tested to the relevant standard and proved to be highly effective.
Pre-curved rails were delivered to track and fastened to the Rail slabs with SD fasteners.
A lateral load blocker was positioned behind the fasteners to reinforce the security of the system, where required, for track radius of <150m. The system was fully tested in Pandrol’s laboratory and was compliant to all relevant track standards. The optimised geometry of SD fasteners also enables automatic installation resulting in improved efficiency and cost saving during installation and maintenance. SD is a durable and reliable threaded fastening range that is compatible with SKL-shaped rails seats. SD offers various advantages over traditional screwed systems, which include avoiding ballast entrapment in the fastenings and an improved sealing of the dowel to protect the sleeper. Pandrol worked closely with main contractor Colas Rail UK, which included providing training on installation of the innovative fastening system to ensure best results on this project.
Pandrol was also awarded the contract to supply the rail welding system for the project. The company recommended use of the innovative i+weld aluminothermic welding system, which utilises semi-automated processes that reduces track welding time while maintaining highest quality standards.
Pandrol also provided training to rail contractor RSS on installation of the i+weld aluminothermic welding system.
The requirement was to weld the rails together safely and securely but with a minimum of aluminothermic material remaining outside the rail foot.
Pandrol innovated within its aluminothermic weld system i+weld to create a new low profile weld mould that used less material and left minimum material under the rail foot, to enable it to remain flush with the slab.
• Improved productivity: more welds in less time
• Safer work environment with reduced physical strain on welders
• Reduction in training time
• Stronger, more consistent welds = better long term track performance
• Increases output by allowing one welding manager to oversee multiple assistants
Coventry’s Very Light Rail project has been testing both the prototype vehicle and revolutionary track system over the past years. The latest pilot installation showcased deliverability under real-world conditions.
The result was cost effective track installation with minimum disruption to motorists and residents in Coventry. The 220m single track was installed very quickly. Within 10 weeks, an urban environment street was transformed into an operational tramway which allowed thousands of guests to experience a CVLR ride during a short demo period.
Beyond its immediate application in Coventry, the Very Light Rail concept holds significant potential for transforming urban transport infrastructure. The technology could be applied to both new light railway projects and existing tramway network expansions, making tram systems a viable option for medium-sized cities that previously found such projects financially prohibitive.
The pilot project is now completed and plans are in motion for an 850m double track (1550m of track) of Very Light Rail to be installed in Coventry City Centre, set for completion in 2027.
"This project is a perfect demonstration of how innovative engineering solutions can address some of the UK’s greatest urban transport challenges," said John Booth, Sales Manager EMEA at Pandrol. "Our SD fastening systems and i+weld technology are enabling Coventry City Council to pioneer a more sustainable, cost-effective approach to light rail that could be replicated in cities worldwide.”
Testimonials
“This trial installation demonstrates how innovative rail infrastructure can be delivered in real city environments with minimal disruption”, said Iain Anderson, Managing Director of Colas Rail UK.
“Our teams worked closely with Coventry City Council to adapt to complex site conditions in real time, showing what’s possible when engineering meets digital responsiveness.” (Source www.coventry.gov.uk)
Councillor Jim O’Boyle, cabinet member for jobs, regeneration and climate change said: “Coventry Very Light Rail will be a real game changer in terms of how people move around, especially in smaller towns and cities.
“There is lots of interest from across the UK and further afield so we are really looking forward to showing everyone how the vehicle operates in live traffic. This is a really important step forward and one we are looking forward to as we pioneer this fantastic innovation which can be delivered quickly, affordably and with minimal disruption. It’s an exciting moment for Coventry and brings us significantly closer to a transport network that reflects the ambition and ingenuity of our city.”
Mayor of the West Midlands Richard Parker said: “This revolutionary Very Light Rail technology, in which the West Midlands is leading the way, will slash costs and accelerate construction times for tram networks — allowing us to better deliver on my vision to connect communities with more affordable and accessible public transport.” (Source Colasrail.co.uk)
