09/2012 English

Report on Rhomberg Sersa Rail Activities

rhomberg and sersa: together we make a difference

Rhomberg Rail and the Sersa Group merge to become Rhomberg Sersa Rail Group

This merger of Europe‘s two leading rail engineering companies, Rhomberg Rail and Sersa Group, in September 2012 sets the course for Europe‘s most comprehensive railway technology company. „We are confident that we have taken the right step with this merger to ensure the long-term alignment of both companies,“ said Konrad Schnyder, CEO and owner of the Sersa Group, who is putting his group in a joint holding. Market penetration

The joint venture will considerably expand his market presence as a full service provider in the railway engineering area at the company‘s locations in Austria, Switzerland, Germany, the UK, Turkey, the Netherlands, Canada and Australia. „This merger is a logical step as part of our efforts to align our railway engineering sector even more internationally. The Sersa Group is a family-owned company and, as such, has a very similar culture to our own, also due to the geographical proximity,“ said Hubert Rhomberg, CEO of the Rhomberg Group, based in Bregenz, Austria.

After the merger, about 1,500 employees will be looking after the customers‘ needs – no matter whether these needs are in the areas of commercial and mechanical railway construction with renovation and maintenance, project business that includes the planning, construction and renovation of high performance railways and railway tunnels, especially slab tracks, electrotechnical equipment, providing measuring and track alignment systems or technical consulting. The Rhomberg Sersa Rail Group has many experts and well trained employees with many years of experience in railway engineering. brand recognition

By retaining the two successful brand names, Rhomberg and Sersa, nothing will change for the customers and partners of the two companies as regards project processing – the Rhomberg Sersa Rail Group will continue to stand for high quality, keeping costs under control and on-time delivery.

rhomberg sersa rail group Headquarters Bregenz, Austria Management Hubert Rhomberg, Konrad Schnyder, Ernst Thurnher, Jürg Braunschweiler Employees approx. 1,500 Locations Austria, Switzerland, Germany, the UK, the Netherlands, Turkey, Canada, Australia Services Technical consulting; planning and project management; planning, construction and maintenance of high-performance railways, especially in the area of slab tracks; commercial and mechanical railway construction of normal and meter gauge track; leading edge machinery; provision of systems (patented track alignment and measuring systems); track welding, milling and grinding; renovation of railway tunnels; electro-technical equipment; transport, rolling stock; logistics services and provision of temporary staff

Projects

Projects

Alptransit Brenner reaches milestone Final handover of basic infrastructure for the northern Brenner approach line to Austrian Federal Railways (ÖBB)

„MUNGG“* sighted in the tunnel Line renewal Bernina-Line in the Charnadüra Tunnel II

The ARGE Alptransit Brenner consortium, consisting of Rhomberg Bahntechnik GmbH and Alpine Bau GmbH, achieved its objective: after three and a half years of intensive work on site, Contract A1 – the basic infrastructure for the Kundl/Radfeld Baumkirchen railway line – the largest railway technology contract in the history of ÖBB – was successfully completed. The final handover took place as planned, on time and to the complete satisfaction of the client.

The Bernina Line of the Rhaetian Railway (RhB) begins in St. Moritz and crosses the Inn river on the Inn viaduct directly behind the station. This is followed a few metres later by the Charnadüra Tunnel II, the Bernina Line then continues through Celerina Staz, Pontresina, the Bernina Pass and Val Poschiavo to Tirano (Italy). The Charnadüra Tunnel II was originally put into operation in 1904 and, at 689 metres, is the longest tunnel on the Bernina Line. From 11 June to 10 July 2012 Sersa Maschineller Gleisbau AG renewed this section of the line. Directly behind the Inn viaduct, 990 metres of track on the open section and the track in the entire Charnadüra Tunnel II were renewed. The line renewal was completed with no delays and was handed over to RhB on schedule.

This final handover represents another important milestone for the Lower Inn Valley railway line as all the systems on the Kundl/ Radfeld – Baumkirchen section are now up and running. ÖBB are due to commission the complete section by 9th of December, 2012, after which commercial operations can commence on the Lower Inn Valley line. „We are proud that we have fulfilled this challenging contract on time and to our customary high standards of quality, while making our contribution to this state-of-theart transportation project. We would like to express our thanks to all those who played a part – first and foremost to the whole team for their excellent hard work,“ says Dirk Diederich, who manages the project for the ARGE consortium and Rhomberg Bahntechnik. „However,“ he adds, „our work has not yet ended. By December 2012, we will have carried out the inspection and maintenance of all the systems – while the final work is progressing on the signalling, telecommunications as well as the

energy supply and distribution systems in Contract A2.“ Impressive figures

Some considerable construction work was involved over the three and a half years to complete the 41 kilometre section, which is a key component of the future Munich – Verona rail route. For example, about 260,000 cubic metres of concrete were poured. The length of slab track is 71 kilometres, incorporating a total of 142 kilometres of rail. Approximately 1,100

kilometres of cables and cable ducts were installed. To preserve the quality of life of the local population, about 27,000 square metres of noise protection walls were erected along the line. 43 service buildings, 44 ventilation systems, 14 pumping stations as well as a fire-fighting water supply with 35 kilometres of DN 200 pipes, three wells and 17 monitoring and control stations have also been installed over the three and a half years.

In 18 night shifts the old track was removed in 60-metre segments using the MUNGG gantry crane. Following this, the earthworks were carried out by the AVW 1 excavator, BSW 3 feeder wagons and old ballast wagons from RhB. In the tunnel the floor had to be lowered with the UAM 1 rock excavation system, as the old steel sleepers were replaced by new wooden sleepers as part of the line renewal. A total of 1,880 cubic metres of excavated material were removed and disposed of. The new sleepers and rails were laid on the excavated base before the ballast could be put in place with

RhB ballast wagons. The R 7 ballast plough created the ballast profile and the B40UM-4 universal tamping machine packed the track ballast in three passes. Work in the tunnel was a great challenge for the workers and the machines. RhB‘s tunnel ventilation system effectively reduced the amount of dust and exhaust gases. The confined space demanded extreme concentration and precision

from the workers. Each morning during the construction phase the line had to be released for day-to-day operations. According to RhB, a complete blockage of the section was inconceivable because the Bernina Line has to be available at all times as a significant attraction for domestic and foreign tourists. * MUNGG is not only the crane used for this project, in Swiss German it is also a marmot.

facts Name Access Brenner North, Lot A1 Client ÖBB Infrastruktur AG, Innsbruck Contractor ARGE Alptransit Brenner Rhomberg Bahntechnik GmbH Alpine Bau GmbH Contract value EUR 260 Mio. Project time 01/2009 - 07/2012 Name Access Brenner North, Lot A2 Client ÖBB Infrastruktur AG, Innsbruck Contractor ARGE Alptransit Brenner Rhomberg Bahntechnik GmbH Deutsche Bahnbau GmbH Contract value EUR 40 Mio. Project time 12/2009 - 06/2012

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Projects contracts in derry Construction contracts won once again in Northern Ireland Northern Ireland Railways have issued two major contracts on the Coleraine to Derry line to renew and refurbish the complete section of track between Castlerock and Derry. The “Track Safety Improvement Works” contract has been awarded to McLaughlin and Harvey, while the “BAM McCann Joint Venture” has been awarded the Derry renewal contract. Both contracts have to be completed within a nine-month blockade, which started on the 30th July 2012. Derry Track Safety Improvement Works

Sersa UK Ltd. will deliver the rail infrastructure elements of the project to its longstanding partners McLaughlin & Harvey, who will undertake all of the civil engineering works and project management. The core work of the entire project involves replacing the rails along a 29 km section of the Belfast to Derry route. During fifty shifts, Sersa UK Ltd. will remove, replace and weld approximately 3,250 x 18 m rails, using the SERSTAR Mobile Flash Butt Welding system to complete the welding. In addition to the rail replacement other works will include the installation of forty “Benkler mechanical insulated joints”, rail stressing and the signal disconnections and reconnections. Support for the welding operation will be provided by Lloyd Sersa IE Ltd., a specialised joint venture company between the Sersa Group and Lloyd Rail IE Ltd. The Lloyd Sersa IE Ltd. team

will undertake the profile grinding, weld inspection and thermic welding for the entire project. Derry Renewal

Sersa UK Ltd. has also been awarded the contract to undertake various items of work by the “BAM - McCann Joint Venture”. The scope of works includes the welding of 2,220 rails, the stressing of the constructed track, as well as the installation of the insulated block joints (IBJs) and thermic welding during the months of November and December 2012. Sersa UK Ltd. will also play a major role in the installation of four switches and crossings (turnouts) and one crossover in the Coleraine area. Once again, the colleagues from SWT Sersa Welding Team GmbH will provide the SERSTAR Mobile Flash Butt Welding System to undertake the flash welding, while Lloyd Sersa IE Ltd. will supply the welding teams to complete the final profile grinding and weld inspection of the flash welds, as well as the thermic welding.

Rhomberg rail with successful track record in Germany for over a year Electrical engineering/equipment will be expanded The Oberhausen branch of Rhomberg Bahntechnik has been successfully operating on the German market for more than 12 months. Continuous growth in terms of personnel and turnover, and constant expansion in the service spectrum are clear indications of the company‘s solid structure. The company‘s range of services now include the construction of power supply systems, point heating systems, planning, engineering, project management, installation and commissioning of medium and low voltage switchgear. The services also cover earthing systems, lighting and signalling and safety lighting. Within the scope of the now completed public economic stimulus plans, several railway stations and stops were renovated and converted in terms of lighting, distribution boards and underground cabling. Rhomberg Bahntechnik GmbH in Oberhausen always strives to achieve the best result for everyone involved in the construction work with unconventional proposals/approaches. The subsidiary looks ahead into a positive future with the firm belief that all further projects will be executed to the clients’ fullest satisfaction.

references

• C  ologne Fair/Deutz station: Renewal of lighting, distribution boards, 50 Hz • Cologne Deutzerfeld: Construction of a transformer station • Essen-West station: Installation of media channels, distribution boards, 50 Hz • Gelsenkirchen Bismarck: Installation of a point heating system • Dortmund-Hörde station: Lighting, distribution boards, earthing systems • Düsseldorf central station: Installation of LCD advertising systems in the entrance hall • 7 stops in Düsseldorf/Cologne: Renewal of lighting, distribution boards, 50 Hz • Wuppertal Steinbeck: Construction of a new transformer station • Wanne-Eickel: Installation of track field lighting • Several renewal and conversion projects for DB Netz and DB Energie • Media separations for DB Energie

pending projects

• B  ad Honnef (4 stations): Installation of lighting systems and cable infrastructure • Rheinfelden (3 stations): Distribution boards, cable installation, lighting • Duisburg Walsum: Construction of transformer station • Einbeck station: Renewal of lighting and associated work • Deuten station: Lighting and energy supply • Several deployments on short notice for DB Netz and DB Energie

versinus - pre-survey system The third track measurement system from the RTE development team has attracted a lot of interest RTE has once again become a talking point with its trend-setting new system: The new development of the VERSINUS tamping surveying system has been a focal point of the rail technology experts in Salzburg since summer 2011. With the input from staff at Bahnbau Wels, the measurement system, which provides correction data directly before the tamping begins, was initially designed for three measurement modes with a strong focus on practical applications. The standard variant is what is known as a two-vehicle mode in which one measuring vehicle represents each of the end points of a chord that the measurements relate to. Intermediate points on the chord can be

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Projects

measured at any chosen interval, optionally in stop&go mode or in a continuous motion. In the one-vehicle solution the total station mounted on the vehicle measures two neighbouring reference points and determines the exact track position in terms of direction and height as well as gauge and camber at its position.

undergo thorough testing on the VERSINUS and HERGIE systems as well as on the PLASMA chord measuring system. The first results already exceed expectations.

The total station can also be mounted conventionally on a tripod and record a measurement vehicle from outside at the intended intervals.

VERSINUS has attracted a lot of interest from ÖBB, from US partners and from Rhomberg Rail Australia. Demand for innovations such as this has led to an increase in development work in RTE, which is also reflected in the increase in the number of team members.

To ensure the highest possible degree of reliability of all RTE systems a cooperation with Innsbruck University was established to

Another variant of the VERSINUS is planned that can be used on tracks with no known axis or reference points.

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Projects

Projects

CELEBRATION OF ONE YEAR MAINTENANCE CONTRACT WITH PACIFIC NATIONAL Australia‘s largest private rail freight company trusts Rhomberg Rail Australia‘s expertise

After the Sersa Group completed a range of different projects in France to its clients’ fullest satisfaction in 2011, it has now won the international tender for the complete refurbishment of the “Le Blanc-Argent” metre-gauge railway line, as part of a syndicate including Colas Rail and Technifer (both Bouygues Group subsidiaries). The client is RFF (Réseau Ferré de France). This substantial order is being funded by RFF, the regional authority and by various municipalities along the line.

Pacific National (PN) is Australia‘s largest private rail freight company and operates in all states, including the Northern Territory. PN sees itself as a leading provider of transport services, which it will continue to develop through long-term investments, innovation and growth. In New South Wales and in the north of Victoria PN has responsibility for 38 railway yards covering an area of more than 800,000 km², which form part of the maintenance agreement with Rhomberg Rail Australia. The services include periodic inspections, a 24/7 on-call service in case of emergencies and planned preventative maintenance, engineering support and yard upgrade works. Within the first year of contract, a significant amount of time was invested to identify the current asset condition and to jointly develop a 10 years rolling asset strategy with PN. In this context, the PLASMA system was introduced – an in-house development of RTE Rhomberg. The system records the track geometries, which which can be used

in PN’s Asset Management System for further data analysis and reporting. RRA’s in-house design team developed a number of yard optimisation solutions that were implemented seamlessly by RRA‘s construction team.

Furthermore RRA has provided professional services to PN on the main lines when Rhomberg professionals were called to support in derailment investigations as PN’s preferred rail contractor.

RK safetec achieves numerous successes System is ideally suited for flexible and extendible use in projects and on construction sites. RK safetec GmbH, the most recent subsidiary of Rhomberg Bahntechnik, was founded as a result of the successful handling of the temporary works during construction of the new Lower Inn Valley line in 2011. Since then RK safetec has been providing temporary works during the construction of various large and smaller tunnel construction sites and for industrial applications. A special milestone was the development of the ZOKA system, which combines access, positioning, communication and

alarm functions and runs on an IP-based data network. ZOKA is ideally suited for flexible and extendible use in projects and on construction sites. RK safetec can look back on many successes since its foundation in 2011: • During the temporary works project within the scope of work on the Lower Inn Valley line, the company already entered into discussions about the Brenner Base Tunnel (BBT) project. Even before RK safetec was founded, it had an order for exploration/drainage/access galleries

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Le Blanc-Argent Railway Line Sersa Group demonstrates its metre-gauge skills in France once again.

for the two tunnel sections Sill Gorge and Ahrental. RK safetec received a third order - for the Ampass access gallery - in the beginning of 2012 A power plant gallery with an access control system was installed in Zillertal in 2011 (contractor TIWAG). Currently, a rescue gallery for the existing Reutherberg road tunnel (BadenWürttemberg, D) is being equipped with the complete ZOKA system. At the start of July 2012, a WLAN-based construction communication system with personal identification system was put into operation in the Zurich CrossCity Link (CH). RK safetec equipped the complete Weinberg Tunnel (4.8 km), including the parallel rescue tunnel, with a WLAN system - (monitoring five access/ exit points with an RFID system) During renovation work in the Simplon Tunnel between Italy and Switzerland a manual, web-based access and positioning program is used, which RK safetec programmed and implemented. Interesting extension - CCTV monitoring of solar fields: In the Emilia-Romagna region and in the Province of Parma three solar fields (photovoltaic) were fitted with CCTV monitoring systems. If there is any movement in the fields, images are e-mailed and the alarm system is activated.

The complete refurbishment of the SalbrisValençay line (56 km) in the Centre region (south of Orléans), which is intended to increase speed on the line from 40 km/h to 70 km/h, involves replacing track and sleepers and to some extent laying a new ballast bed. Most of the track currently lies on a sand bed, which results in poor track positioning. The line was already closed in April 2012 to enable construction work to begin. Construction is due to be completed and the line is scheduled to be reopened in September 2012 – although this date could be postponed if additional work needs to be carried out – to enable passengers (particularly schoolchildren and commuters) to travel quickly and in comfort through the scenic countryside. The acute construction phase is now well underway. This challenging work is being performed by Sersa Group AG (Schweiz) and Sersa UK employees in partnership with colleagues from Colas Rail and Technifer. Assistance is provided in the form of tamping machines supplied by

our subsidiary, metrico, the pan-European specialist for narrow-gauge tamping machines. Logistics also pose a major challenge – tens of thousands of wooden sleepers and approximately 35,000 tonnes of railway ballast (environmentally compatible delivery of railway ballast in

block trains to nearby interim storage facilities) have to be delivered on time to the construction site.

Railway Line Characteristics

• C  urrent length: 56 km  sections of the line (original length: 67 km) were closed or converted to standard-gauge or heritage lines • Line opened in 1902 • Route: Salbris - Valençay • Infrastructure owner: RFF (Réseau Ferré de France) • Operator: Kéolis (pan-European operator of bus, rail and tram services, an SNCF subsidiary) • Passengers carried: 350,000 p.a. • Train type: TER Service centre (line is only used for passenger traffic)

main deliverables

• R  eplacement of approx. 30 km of track (UIC 60 and UIC 33)  used rails • Replacement (partial) of sleepers along approx. 50 km of track • Ballasting along approx. 39 km of track • Tamping work along the entire line 7

„we want to shape the future together“

An interview with Hubert Rhomberg and Konrad Schnyder about the merger of their two railway engineering companies You both run successful companies and have been able to increase your turnover consistently over the past years in spite of the financial crisis. Why did you decide to merge? Schnyder: Market trends will pose great challenges for the railway engineering industry in the future. We are facing these changes in the market and, by merging with the Rhomberg Group, see an opportunity to achieve a stronger position in the market. This will also enable us to promote innovations and to produce more economically. We want to profit from the economies of scale. Rhomberg: Of course, the merger makes us more efficient and powerful. Our joint strategy envisages that we will offer our customers even more quality with our time-proven speed and flexibility. In other words, we can continue to be completely agile like a medium-sized company from our local sites – but, as a group, we can think on a larger scale.

Konrad Schnyder

Are there plans to amalgamate the two brands Rhomberg and Sersa? What name do you want to operate under? Rhomberg: We will retain our strong brand names Sersa and Rhomberg in the respective markets – but they will be integrated in a strong, joint umbrella brand: The Rhomberg Sersa Rail Group. Schnyder: This umbrella brand is absolutely necessary for us to show our customers and also our employees that we want to shape the future together. A merger such as this involves many new features – what can customers expect? Schnyder: Customers can look forward to a company that is able to offer even more services from one source as a result of the merger, because both groups complement each other perfectly. Rhomberg: Essentially, our customers will have the same contacts and can expect the same quality of service – but

Hubert Rhomberg

with a much larger range of products and services. The group in the background also means security. What does this decision mean for your employees? Rhomberg: The broader range of activities with the additional markets will offer our employees many more and many different development opportunities – especially international. The merger of two strong companies into one group also increases job security. Do you plan to cut jobs? Schnyder: I can definitely say NO to this, since no jobs are at risk because of the merger. In fact, we plan to expand our existing markets and open up new markets. In other words, the opposite is true – we are more liable to create new jobs. Where will the Rhomberg Sersa Rail Group be in ten years? Schnyder: In ten years we want to be a railway engineering company that can satisfy our customers even more through our wide range of services from one source, through our innovation and through our internationality. Rhomberg: We don‘t want to grow at any price but rather become even better at what we already do well. Research and development is a very important area for us: The merger will especially allow us to bundle our strengths in this field. We are also aiming to become leaders in what we do – whether it is slab track, alignment and measuring systems or product business.

EDITORIAL | Published by, photos and responsible for the content: Rhomberg Sersa Rail Holding GmbH Mariahilfstraße 29, 6900 Bregenz/Austria Tel. +43 5574 403 0, Fax +43 5574 403 309 [email protected], www.rhombergrail.com www.sersa-group.com