Robust Cable Management for Railways

National Specification Manager for Marshall-Tufflex, Barry Roberts, highlights the cable management solutions that have been applied to the Stansted Tunnel upgrade project

With a reputation for leading the way in research and development, UK manufacturer and supplier of cable management systems Marshall-Tufflex has built a wide portfolio of solutions specifically engineered for the rail sector and is registered with the Railway Industry Supplier Qualification Scheme (RISQS).

Since 1942, Marshall-Tufflex has been at the forefront of cable management and plastic extrusion in the UK and today delivers high-quality, durable cable management solutions for a variety of sectors. The company’s expertise and commitment to providing products that meet the highest standards and levels of compliance has earned the British manufacturer accreditation from the RISQS Railway Industry Supplier Qualification Scheme to supply its products for Network Rail, LUL/Transport for London, DLR, train operators and other product and services providers within the rail industry.

The company uses a range of materials in its manufacturing, with each product designed to suit specific or on-site installation needs, particularly where hazards or harsh environments require a specialised solution. For the rail sector, this includes:

Glass Reinforced Polyester (GRP) Cable Management Systems

GRP is effective at temperatures between -80°C to +130°C, with low conductivity, is self-extinguishing in the event of fire and utilises zero halogen material which is classified as ‘low smoke’. The material also offers high corrosion resistance making Marshall-Tufflex’s GRP products ideal for challenging rail environments such as tunnels, bridges and environments where extreme weather, high temperatures or water ingress is likely.

MT Supertube LS0H Conduit

MT Supertube FR was a key component in the upgrade of London Underground’s Victoria Line OPO CCTV camera system, with more than five miles (8,100 metres) of this conduit installed. This LS0H, three-layer heavy gauge conduit comprises polyethylene internal and external layers over a continuous aluminium tube that provides additional mechanical strength. The product has excellent EMI screening performance and is a practical and cost-saving alternative to standard galvanised conduits. Moreover, it is available in continuous lengths of up to 100 metres, meaning fewer fittings per installation, reduced waste, and no water ingress.

System 170 and System 130 Steel Trunking

Robust and durable, these pre-galvanised steel dado and skirting trunking systems offer a reliable, practical system for public areas where there is a high footfall, thanks to the resilient white powder-coat finish that helps to prevent smearing and marking.

Aluminium Trunking

Aluminium perimeter trunking systems provide the specifier, contractor and enduser with elegant, stream-lined containment that offers the practical advantages of inherent LS0H and screening properties making it ideal for industrial environments. It is also lightweight with a mechanical strength and impact resistance that is superior to steel.

Marshall-Tufflex installed at Stansted Tunnel

A notable project where Marshall-Tufflex products have been used for a rail project is the Stansted Tunnel upgrade, where the entire lighting, lighting support systems and power supplies of the tunnel are being replaced between January 2022 and January 2023.

Despite ad-hoc repairs and replacements, 30 years of water ingress and general wear and tear meant that was it no longer possible to cost-effectively sustain the lighting by simply replacing the degraded or life expired parts. As such, J Murphy & Sons was awarded the contract to replace the entire lighting, lighting support systems and power supplies for the tunnel.

The upgrade project involves the installation of a new GRP handrail with integral lighting running along the tunnel wall and the steel walkway, emergency lighting and supporting electrical supplies and a GRP cable management system. The cable trays had to meet Class 1 fire rating in order to maintain a certain level of fire resistance while still maintaining the integrity of the cabling. In addition, the systems needed to have a minimum design life of 25 years.

Furthermore, J Murphy & Sons was also constrained by a strict schedule to ensure the project could be completed by the financial year end 2022/2023. J Murphy & Sons found the nominated supplier for this project had long lead times on its products and therefore couldn’t meet the allocated possession dates in January 2022. After going back to the market and contacting a number of other manufacturers to source a perforated GRP tray that met the stringent standards for the rail environment, RISQS registered manufacturer Marshall-Tufflex was the only company able to supply GRP cable management products with the right specification and meet the tight installation deadlines.

Craig Anger, Contacts Engineering Manager at J Murphy & Sons, said: ‘Barry Roberts provided us with all the datasheets including fire test documentation which was a big bonus as Network Rail could see that the products have undergone all the relevant tests. The team at Marshall-Tufflex provided excellent support and ensured all the products were delivered to site to meet our strict schedule. This has helped us to keep on track to complete the final cabling installation and commissioning during our January 2023 possession.’ field of railway construction with a range of cable management solutions to ensure cabling remains safe, operational and secure. The manufacturer’s priority is to re-invest for the future and to continue to produce new and effective solutions with quality and customer service at its heart. manufacturer that moves with you For 80 years Marshall-Tufflex has refined its portfolio to meet the fast paced and evolving

The lighting upgrade project of Stansted Tunnel is due for completion in January 2023, by which time, J Murphy & Sons will have installed 1,800 metres of MarshallTufflex’s GRP cable management system to house the cabling for the new handrail with integral lighting – all during limited weekend possessions in January 2022 and January 2023.

Marshall-Tufflex’s project specialists and specification team are on hand to work closely with electrical consultants, contractors and clients in order to ensure the most suitable products are specified to meet any project brief.

To find out more about how MarshallTufflex can help with your transport project, visit: www.marshall-tufflex.com/ transport or get in touch via the contact information below.

Tel: 01424 856600

Email: sales@marshall-tufflex.com Visit: www.marshall-tufflex.com