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Work Packages

The research activity of the project is divided in 9 work packages: WP1 - Study and implement lightweight solutions in cargo wagons, WP2 - Study and implement coating solutions for wagon interior surfaces, WP3 - Design of smart facilities, WP4 - Determine potential actions on the bulk freight that improve the logistic operation, WP5 - Design and construction of a demonstrator wagon, WP6 - Wagon testing and detection of the needs to adequate infrastructure and operation services, WP7 - In-field validation tests, WP8 - Exploitation, dissemination and communication, WP9 - Management.

WP1 - Study and implement lightweight solutions in cargo wagons

The main objective of this WP is to increase load capacity of cargo wagons by reducing the wagon deadweight, to attain weight reductions of 25-30% and to increase in more than 50% the load capacity. To achieve such weight reduction, different design and material topics will be addressed to attain the following objectives :

  • Identify mechanical requirements in wagons.
  • Set the design procedures to get the maximum benefits from AHSS
  • Select and test materials (AHSS, composites) and joining procedures to meet the mechanical

WP2 - Study and implement coating solutions for wagon interior surfaces

The main objective of this WP is to develop a novel coating for the interior surface of cargo wagons. The coating targets are the following:

  • It must permit to reduce the friction coefficient (leading to an increase of bulk discharge speed at terminals), but at the same time, it must show high resistance to abrasion due to potash and vacuum salt.
  • It must be able to be applied by brush and roller duet to both applications, new building and maintenance.
  • It must enable the flexibility intended in the project with regard to the diversification of freights and it must guarantee that it fulfils the needed requirements for contact with food or goods for human consumption.

WP3 - Design of smart facilities

The objective of this WP is to design smart train facilities, with the aim to improve and increase the efficiency of the loading/unloading operations, maintenance processes, and on-line communication with the wagon. The following targets are driven in this WP:

  • Develop a flexible and scalable design of bulk cargo terminals so that they can deal with different types of goods. 
  • Design a novel loading and unloading systems fit for the new wagon to reduce dwelling times.
  • Develop intelligence and communication among facilities and the wagon to get on-line traceability.
  • Add monitorization and processes automation to reduce errors and maintenance costs.
  • Integration of multimodal operations to the proposed facilities.
  • Economic study of the viability of these solutions.

WP4 - Determine potential actions on the bulk freight that improve the logistic operation

The main objective of this WP is to improve the loading and unloading processes, with a focus on the material flow during these operations. This WP particularly aims at:

  • Optimising the material flow at discharging.
  • Minimise wear and stress.
  • Study the effect of wall friction and wear of the coating.
  • Determine the wear distribution in the wagon (using Archard’s law) by calculation of load intensity for different loadings.
  • Determine the influence of the particle size distribution on the unloading flow and the effects of including agents to minimise caking.
  • Build a numerical model that mimics the variations of the bulk material flow behaviour.

The fact that is possible to simulate the behaviour of granular materials in these operations will help to increase wagons flexibility in order to allow a diversification of carried goods, as well as perform an efficient handling of granular materials.

WP5 - Design and construction of a demonstrator wagon

The main objective of this WP is, based on the results of the previous WPs to design, build and test a demonstrator wagon and an unloading station. To achieve such goal the following objectives are set for this WP:

  • Eliminating some important drawbacks of bulk transports on rail for Europe compared to truck transports.
  • Design highly modular wagons that can be adapted to different goods and rail gauges in minutes. Wagons would be suitable for over 90% of Europe’s railroad network.
  • Design wagons with ultra-low tare weight allowing for 50 % higher load capacity per wagon.
  • Modularly scalable unloading capacity.
  • Reduction of dusting at unloading, aimed at broadening the range of granular materials to be bulk transported by rail.

To achieve these goals, a new novel wagon/unloading station design, modern advanced materials and joining techniques will be used. The KIR’s Turn Dumper (TD) system that is already under development seems by far to best suit the overall goals of the project, except it creates more dust at unloading. The goal of the first task of this WP is therefore to create means for dust control. In case this fails, the second alternative is KIR’s Bottom Dumper system (BD).

Some of the above mentioned goals are, however, only valid for the TD system and cannot be reached in the other case. The main foreseen difficulty of TD wagon that may hamper their final development is dust control and minimization. However, based on the previous expertise of KIR in the design of unloading station, and on the expertise of LTU in computer simulation of material flowing, it is expected that a feasible solution to control dust formation can be reached. In the WP description below is assumed that the TD system will be the solution.

WP6 - Wagon testing and detection of the needs to adequate infrastructure and operation services

This WP has a focus on the operation side and has two main objectives: (i) test the wagon demonstrator built in WP5 so that it is safely integrated in WP7 and (ii) determine which are the requirements of the current rail infrastructures so that the new designed wagon in WP5 (UIC gauge and 22,5 t/axle), can be used in the future. In particular, the targets of the WP are summarised below:

  • Testing the wagon in the line Llobregat Anoia, study the dynamic behaviour of the load and dynamic gauge.
  • Explore new opportunities in operation services that may arise with the use of the new designed wagons.
  • Detect what are the needs of the existent infrastructures to enable the increase of load ratio to 22,5 t/axle and allow the use of the new designed wagon.
  • Develop efficient and smart maintenance plans for interoperable wagons.
  • Carry out a comprehensive analysis of the international transport market to identify which are the unsatisfied needs and cope with the advantages (solution solving issues) that the new wagon may fulfil.

WP7 - In-field validation tests

The main objective of this WP is to validate the achievements of the project in real field tests. To attain this aim, in this WP the secondary objectives are:

  • Find the adequacy actions of the existing IBP’s loading and unloading facilities so that the tests can be carried out.
  • Install the unloading station and instrument it following as much as possible WP3 designs and auxiliary systems.
  • Install the unloading station and instrument it according to the designs of WP3.
  • Instrument the loading station and the wagon prototype.
  • Perform field tests with the new loading/unloading stations and the new wagon prototype, and validate the operations according to WP2, WP3 and WP4.
  • Detect if there are aspects that need to be overcome for the future use of the new designed stations and wagon in real
    industrial conditions.

WP8 - Exploitation, dissemination and communication

The objective of this work package is to develop a comprehensive and extensive strategy for exploitation and dissemination of the results and communication of the project. This set of activities in this work package will:

  • Protect the intellectual property generated during the project.
  • Promote and exploit the results of the project.
  • Disseminate activities beyond the consortium to a wider audience. Cover eventual future clustering activities and contribute to Shift2Rail objectives.
  • Promote the action and visibility of EU funding.

These activities are inter-related and will be conceived and implemented in a coherent way, with the overall objective of facilitating exploitation of results.

WP9 - Management

The objectives of this WP are listed below:

  • Efficiently manage the project and the consortium.
  • Review and assess the work being carried out.
  • Ensure that all aspects of the EC requirements for communication and reporting are met.
  • Creating an appropriate management framework linking together all the project components.


H2020 Research Programme

This project has received funding from the European Union’s Horizon 2020 Programme for research, technological development and demonstration under grant agreement no 636520.

Project Coordinator

Dr. Ingrid Picas