Electrification: Catenary construction
Our experience
A policy of significant investments and acquisitions has enabled GCF to operate in the electrification segment with people, structures and advanced technologies, as well as incorporating and optimising experience gained over the years by sector leaders.
In the railway sector, as well as in urban transport (tram, trolleybus and metro), GCF - Generale Costruzioni Ferroviarie S.p.A. designs and installs, modernises or implements maintenance of:
• Electric traction lines:
construction, modernization and maintenance of conventional systems for slow lines (3 Kv DC) and High-Speed/High Capacity lines (25 Kv AC), with traditional copper cables and/or optical fibre
• Electric sub-stations and cabins:
for power conversion and/or transformation;
• Lighting and drive power systems:
in railway stations and stops, tunnels, pavements, metros.
Our philosophy
The production process starts off with design in our own Technical Office through to final testing of the entire system, providing customers with a single point of contact capable of coordinating all operational stages, from procurement to on-site construction.
Our human resources and operating machines (concrete-mixing train, overhead wiring train, motorised pantograph wagon) the use of innovative processes and products (fixed catenary, omnia railway shelf) means that GCF Electrification is able to manage complex projects and operate on competitive levels.
Our competitive edge
- More than 200 highly specialised operators.
- Our own Technical Design Office.
- Impressive fleet of high-performance machinery.
- Flexible and fast operations.
- Process and product innovations.
video: the construction of the new Electric Traction on the bridge of Venice - Mestre
Some GCF and Group Companies construction sites
Electrification of the Veneto Basin: the Belluno “loops”, Italy
A new green railway loop, promoted by RFI in view of the Cortina 2026 Winter Olympics and delivered by GCF – lead company of the consortium comprising Ineo Scle Ferroviarie Snc and Sirti S.p.A. – with the complete electrification of both the “lower loop” and the “upper loop” of the Belluno railway lines.
A multi-site project focused on sustainability which, in line with the goal of maximizing the environmental benefits of rail transport while minimizing emissions, has delivered along the lower loop of the Belluno lines 6 stations and more than 92 kilometres of fully electrified railway network and, with works ongoing along the upper loop, the electrification of a further 8 stations and 86 kilometres of railway.
Project data
The electrification of the loop, with an overall length of approximately 180 kilometres, required the construction of 4,800 foundations for pole installation and around one hundred portals with MEC-type beams, the installation of 4,000 Omnia-type cantilevers and approximately 800 tubular steel cantilevers.
Around forty “historic” tunnels, often equipped with rigid catenary systems, were involved, along with more than one hundred level crossings and viaducts crossed during the tensioning operations of the overhead contact line (144 km with a 440 mm² section and 34 km with a 320 mm² section), for a total of 300 km of messenger wire and 360 km of contact wire. Three traction substations and five electrical substations were built to serve the loop.
The project marked the end of an era – that of diesel railcars – and enables Belluno and the Dolomites to benefit from a “smart” rail connection, without break of load, both towards Venice via Conegliano and towards Padua via Montebelluna.
Electrification of the Ponte della Libertà Mestre-Venice, Italy
Ten months of construction works and 35,000 hours of night work were required to complete the mission entrusted by RFI to GCF: to rebuild the railway electric traction system on the Ponte della Libertà, strengthening it and making it more resilient to the aggressive phenomena typical of the lagoon environment. The bridge is the historic trans-lagoon link that, since 1845, has connected Venice with the mainland.
The innovative portals adopted and the many solutions implemented - during the design phase, in the selection of materials and in production processes - have contributed not only to better supporting the significant and growing rail traffic, but also to giving the bridge a new skyline, transforming its 2,500 metres into an ideal, sober and modern “rail carpet”, worthy of a city of art, canals and… bridges.
Project features
The works were developed through four operational phases.
A preliminary check-up, including a comprehensive set of experimental investigations, aimed at assessing the overall structural condition of the two parallel railway bridges.
Construction of the foundation blocks, following the replacement of 500 reinforced concrete slabs (800 kg each) connecting the two railway bridges, each consisting of approximately 10 m³ of RCK45 concrete, exposure class XS3.
Installation and testing of the new innovative portals, consisting of 7.60 m high “V”-shaped lattice structures (weighing 1,700 kg) supporting massive 18.60 m beams (1,850 kg each), each equipped with four hangers weighing over 100 kg. Owing to their size, these structures were designed to serve all four tracks with a single large “T” made of 4 tonnes of special steel.
Installation and tensioning of the new overhead lines. Using 216 modern “Omnia” type cantilevers, at the beginning of 2019 the site completed the tensioning of the four new contact lines with a total cross-section of 440 mm² and fully regulated conductors.
Electrification of FER Lines, Emilia-Romagna, Italy
GCF S.p.A.’s intervention in Emilia is part of the investment programme carried out by FER – the second railway infrastructure manager in Italy in terms of network extension – aimed at improving safety, technological standards and passenger comfort across the regional railway network.
More specifically, along the “ecological transition” axis, between 2021 and 2023 Generale Costruzioni Ferroviarie completed the electrification of the three railway lines in the Reggio Emilia area, for a total of 80 kilometres of railway. At the same time, the works included the construction of a traction substation (TE) at Reggio Emilia station, two electrical substations (SSE) at the stations of Guastalla and Dinazzano, as well as the supply and installation of three SCADA diagnostic systems.
Electrification of the Reggio Emilia lines
Three lines were involved in the intervention: the Reggio Emilia - Ciano d’Enza line, consisting of 26 kilometres of single-track railway with 4 stations and 13 stops; the Reggio Emilia - Guastalla line, with 7 stations and 9 stops along 31 kilometres of single-track line; and the Reggio Emilia - Sassuolo line, approximately 23 kilometres of single-track railway, served by 5 stations and 6 stops.
Overall, around 2,200 LSU poles anchored to concrete foundation blocks were installed and equipped with Omnia-type cantilevers.
The Electrification Department of GCF S.p.A. also delivered the works required to supply power to the Reggio Emilia lines: a traction substation (TE) in Reggio Emilia (for the “cantilever supply” of the line to Ciano d’Enza and the “double supply” of the other two lines), and two electrical substations, in Dinazzano and Guastalla, ensuring the power supply of the Reggio Emilia – Sassuolo and Reggio Emilia – Guastalla lines respectively.
Venice-Mestre Station, Italy
In the period January 2006-April 2013, GCF - Generale Costruzioni Ferroviarie carried out for client ITALFERR the executive design and implementation work for electric traction and superstructures, as well as P.R.G. civil works, for Venice-Mestre Station, including the ET cabin and lighting and drive power systems, performed in functional stages linked with the new A.C.S. system.
The project involved expansions and upgrades to the railway track, new piling and contact lines, as well as the construction of a TE cabin and work on lighting and power systems.
Ankara-Sincan line, Turkey
Construction works on a new line on the north side alongside the existing line between Ankara and Sincan (Turkey).
Work was carried out between April 2011 and January 2013 on behalf of TCDD (Turkish Railways) to adapt the line to high speed trains (160 km/h).
Ankara-Sincan: electrification
Electrification work on the new 1x25 kV line, comprising:
- excavation and casting of foundation blocks for about 700 supports;
- subsequent installation and equipping;
- installation of the 107 mm2 single-wire power contact line and a 120 mm2 load-bearing cable.
Ankara-Sincan: superstructures
Construction project for a new line also including infrastructure works (excavations, bridges, underpasses, drainage) and the superstructure (track construction, supply and installation of 59,945 m3 of ballast, installation of 24 points).
Electrification of the Sarajevo–Bradina Line, Bosnia
The construction site was launched in January 2015.
The project concerns the entire Sarajevo–Bradina section, along Corridor V connecting Sarajevo to Mostar, with the aim of enabling rail traffic to reach the 120 km/h standard set by the European Union, overcoming the numerous bottlenecks that previously made it impossible to exceed speeds of 20 km/h.
Sarajevo-Bradina: the project
As regards track works, the detailed design provides, along the 30 km line, for the complete replacement of rails, sleepers and turnouts, as well as the rehabilitation and refurbishment of 19 bridges and 17 underpasses, access ramps and other minor civil structures.
On the electric traction side, the project also includes the complete reconstruction of the OCL (overhead contact line) along the entire section.
Particularly demanding, finally, were the civil and track works along the 3.2 km Ivan Tunnel, a historic stone-built tunnel, only 3.60 m wide and affected by significant water infiltration. These conditions led GCF to opt for the installation of track on a concrete slab.
electrification Kosekoy-Gebze line, Turkey
The project involved the reconstruction and renewal of the double track Kosekoy-Gebze line as an integral and particularly important part of the Ankara-Istanbul high speed corridor.
In addition to complete full renewal of rails, sleepers and crushed stone, the new catenary system was installed, as well as the signalling and telecommunications plant.
Our partner companies - Salini-Impregilo and Kolin - implemented the civil works, infrastructures and drainage projects.
Kosekoy-Gebze: objectives achieved
In this way, the section was upgraded to a speed of 160 km /h - the standard defined by the European Community for trans-European freight networks, thereby consigning a safe and modern line to the Turkish Railways.
Overhead catenary construction: other projects
- Total renewal of Electric Traction Plant on the Brescia-Verona line section
Design and implementation of a new 540 mm2 overhead contact line catenary system for 3 kVdc lines and removal of the old plant. - Modernisation of plant at Verona Porta Nuova Station
Design and installation of the 440 mm2 overhead contact line catenary system on through tracks. - Milan Rogoredo Station
Redevelopment in accordance with planning regulation of Milan Rogoredo Station and the new Milan-Genoa line. - Extension of Milan Metro Line 3
Design, installation of plant and finishing works on the Maciachini-Comasina section of Milan Metro Line 3, including Dergano, Affori Centro, Affori FNM and Comasina stations. - Sambiase Sub-Station
Design, execution of total renewal works and upgrading of Sambiase SSE. - 90 EXPRESS Trolley-Bus
Design and installation of the electric traction plant for the 90 Express trolley bus line, Rome. - Safety work on the Frejus Railway Tunnel
Design, installation of safety lighting plant in the Frejus tunnel, Italian side.