World leading cable seal manufacturer Roxtec is exhibiting at stand number D34 at the May 2018 Infrarail trade show at London’s Excel Arena – the UK’s definitive railway infrastructure exhibition. Roxtec has developed a niche in the rail and rolling stock markets where it delivers specialist cable, pipe and conduit seals. The key benefit it offers customers is one simple sealing solution protecting against multiple and complex hazards. Roxtec UK managing director Clive Sharp explains how Roxtec’s certified seals cover all requirements for rail facilities and systems within electrification, signalling and communication and how its expertise is being put into effect by London Underground and Network Rail.
Roxtec was founded in Sweden in 1990 and is today active in more than 80 geographical markets. Roxtec’s products are used to protect people and equipment from multiple hazards including lightning, gas, fire, dust, flood, humidity, rodents, electro-magnetic disturbances and explosion. While traditional sealing systems only tend to protect against one particular hazard, Roxtec’s solutions are designed to withstand a plethora of dangers.
Roxtec is building a strong track record in the rail sector offering complete design and engineering services through to installation training and inspection support. Our clients are able to standardise with superior solutions to ensure safe, reliable and cost-effective operations. Our solutions make it possible to route multiple cables and conduits of different sizes through each opening in your buildings and equipment as well as to add cables at a later stage – without making new holes.
There are a multitude of applications which benefit from Roxtec’s solutions including traction power, signalling and rail control, communications, tunnels and bridges, railway stations and rail yards. Within the rolling stock arena, we offer cable management solutions for converters, inverters, flooring, HVAC systems, junction boxes, pantograph, partition walls, retention systems and roof-tops. Roxtec’s pre-configured solutions are tested and certified according to standards such as EN 45545:3 up to E60, EN 45545:2 HL3 and NFPA 130 in order to guarantee long-term protection against multiple risks. We can also create tailor-made transits according to specific needs and requirements.
London Underground multi-cable transit system
A recent project saw Roxtec’s innovative modular cable seal system tested and approved by London Underground. Following a rigorous process designed to challenge every aspect of our multi-cable transit system, the product is now the first of its kind cleared for use on London’s Tube network. More than £5.5bn is being invested in upgrading the capital’s underground transport network leading to increased train frequency and efficiency. Roxtec’s sealing system will play a key role in that modernisation programme, allowing cables to pass between separate areas while protecting people and infrastructure against a range of hazards. It represents the largest improvement to be carried out in 60 years.
The multi-cable transit system offers robust protection. If a fire breaks out, it is able to maintain its integrity and continue to provide insulation for at least an hour. It can also shield an area against smoke, gas, humidity and dust. Meanwhile water ingress and rodent protection are also assured. Further protection is provided against vibration, electromagnetic pulse/interference and risk of explosion. The seals will also offer resistance if an attempt is made to forcefully remove the cables.
The Roxtec system can be used in a wide variety of locations across the Tube network, including trackside in relocatable equipment buildings, junction boxes, control cabinets and substations. Up to six units (cable transit frames) measuring 0.5m x 0.3m each can be used in station areas, while one unit of the same size has been cleared for use in tunnels. London Underground approval is considered to be the global rail industry’s gold standard, as it requires products to meet a higher level than either current GB or EU certification. The process took 18 months to complete, during which every Roxtec fire certificate was read and interpreted at a specialist testing facility. Further tests were carried out for smoke density in line with London Underground standards. Having prior approval also means less paperwork for clients installing our cable transit systems.
Network Rail Thameslink Programme
Another high-profile rail project involved the design and manufacture of heavy-duty cable seal solutions for Network Rail’s London Bridge railway station substation. The bespoke frames, at 218kg each, are the heaviest products Roxtec has ever produced for the UK. Together with the Roxtec sealing modules and compression units they protect against the threat of water ingress, condensation, fire and rodents.
The rail substation project, part of the multi-billion pound Thameslink Programme, required all of Roxtec’s engineering experience and expertise. Network Rail commissioned us to seal cables entering the substation from ground level inside a trackside riser above a switch room. We had to ensure that the cables feeding from the switchgear substation to the tracks were properly sealed and protected against multiple hazards. To achieve this, we designed and manufactured customised frames to seal the high voltage cables. The frames, which had to both protect the 53mm diameter cables and provide ultra-rigidity for the tight radius bend, were then cast into poured concrete because of their weight. As a risk of condensation was also identified, each frame was sealed at both ends.
The frames measured 1.5m in depth and were designed with puddle flanges and a special arch shaped flange to match the curvature of the existing substation roof. Roxtec’s cable seal solutions provide water ingress protection, a one-hour fire rating and vibration and pull-out resistance. Crucially for the rail industry, they also have a long-life expectancy of up to 30 years. Network Rail needed multiple cables to be sealed, of differing diameters, and because of the sheer weight of the cables a mastic or foam alternative simply would not have worked. This job required a mechanically engineered solution and Roxtec’s strong track record in designing and building bespoke cable seal solutions was a key factor in us winning the contract. Our engineers were heavily involved during the design phase of the project and provided full technical support throughout. We also provided installation training ahead of the work and then sent a Roxtec representative to oversee the weekend installation. As ever with Roxtec solutions, we ensured that space was created to enable future cable upgrades can be made with the minimum of disruption.
Roxtec provides a free technical CPD seminar for the rail industry and we were able to win the Network Rail contract after showcasing a high-level of expertise during one of these sessions. The CPD covers protection of assets and ensuring reliable operation with certified cable sealing systems and we encourage any industry professionals wanting to learn more to get in touch.
For more information contact Roxtec at Waterfold Business Park, Bury Tel: 0161 761 5280 Email info@uk.roxtec.com or go online at: www.roxtec.com