Ankara High-Speed Train Maintenance Plant

Project Introduction

The Ankara High-Speed Train Maintenance Plant is the first high-speed train maintenance plant of Turkey. Before it, the service maintenance of CAF high-speed trains used to be done in the TCDD conventional depot of Ankara area, with limited material and room, which were insufficient to realize properly the maintenance operations of all high-speed train sets. Therefore with the arrival of SIEMENS trains, TCDD decided to plan the project of a depot only for high-speed trains with material to do all maintenance tasks from A to Z, including all heavy maintenance operations. The realization of this project took place between July 2013 and June 2017, with an initial budget of 153.000.000,00 €.

Project Design & Consultancy

In partnership with ITALFERR company, for the project of the Ankara High-Speed Train Maintenance Plant we acted as a consultant on the design and the maintenance systems needed for the maintenance of high-speed trains. The Sugar Factory field area was decided to be appropriate for the realization of the project due to its large potential expandable area and the high-speed line passing just behind the field. The whole project includes 15 buildings, 109 different workshop equipment, and 373 equipment in total.

Building A: Bogie Workshop

The Building A: Bogie Workshop is where the heavy maintenance of bogies is realized. All parts of the bogie such as frame, wheelsets, axles, wheels and smaller components are assemble/disassembled, tested, modified and/or replaced in order to have a fully operational bogie at the end of the maitnenance. This building is the most furnished of the plant in term of number of machinery with 118 workshop equipment and of number of different machinery with 61 different workshop equipment.

Building B: Car Workshop

The Building B: Car Workshop is where the heavy maintenance of cars is realized. The works in this building are done on a whole car after the high-speed train cars have been separated from each others in the Building M. Operations such as car lifting, roof control, bogie changes, renewal of external painting, battery charging, etc… take place there. This building and its sub workshops contain 81 workshop equipment and 27 different workshop equipment.

Building C: Service Workshop

The Building C: Service Workshop is where the service operations of the trains take place. This is where the duration of the work operations are the most important as trains come and stay only a short time during the day. Operations such as inside car cleaning, sand filling, bogie changes, wheelset changes, etc… take place there. This building and its sub workshops contain 104 workshop equipment and 35 different workshop equipment.

Building H: Under-Floor Wheel Lathe

The Building H: Under-Floor Wheel Lathe is where the wheels of the train are cut. The whole train enters the building tracked by a Rail/Road Shunter, and the CNC Tandem Under-Floor Wheel Lathe can work on one full bogie (4 wheels) at the same time. Each wheel profile is measured, and the operator decides values to be applied for the cutting of the wheel. A dedicated building is necessary for the proper functioning of this machine. That’s why this building contains only 2 different workshop equipment.

Building M: Train Lifting Building

The Building M: Train Lifting Building is where the whole train is lifted synchronously. It is used for dismantling the train’s cars from each others, as well as to replace bogies. After leaving this building, a bogie is sent to Building A or a car is sent to Building B through a Locomotive Transport for heavy maintenance works. This building contains only 1 Lifting Jacks System and 2 Bogie Turntables for Bogies coming from the Bogie Drop Pit.


Building T: Dynamic Inspection

The Building T: Dynamic Inspection is used for the dynamic control and measurement of each wheel/axle/bogie of a passing train. The laser system allows to have precise measurements and determine if any wheel has any issue and should be either changed or reprofiled at the Building H. A dedicated building is necessary for the proper functioning of this machine. That’s why this building contains only the Automatic Train Dynamic Inspection Station.

Building W: Washing Plant

The Building W: Washing Plant is where the trains are washed. The whole train enters the building tracked by a Rail/Road Shunter, and the Automatic Train External Body Washing takes care of washing in details the train. A dedicated building is necessary for the proper functioning of this machine, and the temperature of the building should be controlled to avoid the water in tanks to become ice and damage the piping system. That’s why this building contains only 2 different workshop equipment.