Reducing Delays and Future-Proofing Urban Rail Infrastructure

Customer challenge

Hankyu Railways operates approximately 3,300 trains per weekday across a network of 90 stations, connecting the Osaka, Kobe, and Kyoto areas and carrying around 1.7 million passengers each day.

The Hankyu Awaji Station Continuous Grade Separation Project is an urban infrastructure scheme involving the elevation of a 7.1 km  section around Awaji Station , where the Kyoto Line and Senri Line intersect at grade. The project involves the removal of 17 level crossings, many of which were classified as 'never opening' crossings, with barrier down times exceeding 40 minutes per hour during peak periods, resulting in significant road congestion.

At Awaji Station itself, the at-grade crossing between the two lines had long been a source of operational conflict. This meant trains using one line could block or delay movements on the other, resulting in frequent service delays and safety risks associated with flat junctions. Elevating the track via viaduct addresses all of these issues while also reconnecting communities previously divided by the railway, therefore supporting urban revitalisation across the area. The double-decked elevated section of track will run from Sozenji to Kami-Shinjo on the Kyoto Line and from Kunijima to Shimo-Shinjo on the Senri Line.

Central to the project's success was the specification of a rail fastening system capable of delivering sufficient toe load for elevated track applications, accommodating gauge adjustment and offering the long-term durability and low maintenance profile that a project of this scale demands. Pandrol was well placed to meet every one of these requirements.

Pandrol solution

Pandrol's FastClip FC1101, a rubber-booted sleeper system, was specified for its ability to deliver a consistent toe load without the need for manual adjustment - a key factor in minimising long-term maintenance requirements.

The system's under-sleeper pads play an equally important role, significantly reducing vibration transmission to help limit the impact on surrounding residents and the wider environment. Crucially, the pads can be replaced with alternatives of different stiffness if environmental requirements change in the future, giving Hankyu Railways a degree of adaptability that a fixed system could not provide.

A further practical advantage of FastClip FC1101 is that the clips and insulators can be pre-assembled to the sleepers prior to delivery, reducing the volume of on-site installation work and associated labour requirements. This type of clip has a well-established track record in Japan, having been used on the Tohoku Shinkansen for more than 20 years.

Results

Pandrol met every construction milestone across the project, including the delivery of all fasteners to site according to a rigorous supply schedule.

The project has a lengthy history, with planning beginning in the 1980s and final approval granted under the Railway Business Act in 2008, when construction commenced. Although there have been changes to the project schedule over time, the elevated track is currently scheduled to open in 2028, at which point it will carry more than 900 trains per day.

This project is part of a long-standing relationship between Pandrol and the Japanese rail market. The company has supplied FastClip assemblies to a wide range of projects across Japan over the past 20 years.