Enhancing Track Performance at Duddeston Junction for the HS2 Program
- May 20, 2026
As part of the wider HS2 program, major infrastructure changes were undertaken at Duddeston Junction in Birmingham—the interface point where the new high-speed railway crosses existing Network Rail infrastructure. To accommodate the HS2 flyover, a section of the conventional network track was relocated and remodeled, resulting in significant modifications to both the Down Derby Goods Line and the Down Saltley Goods Siding Line. The revised layout introduced a reverse curve with tight curvature, with a minimum radius of just 265 m. This inherently increased the risk of rail wear, rail head damage, and surface defects in the area. Previously installed mechanical lubricators also required reinstatement in accordance with Network Rail standards following the remodeling works.
Requirement
L.B. Foster was consulted to define an optimal Friction Management strategy for the location.
Taking into account the tighter geometry and the operational demands of the junction, it was agreed that the legacy mechanical lubricators should be replaced with electric systems to ensure greater reliability, consistency, and coverage.
Three PROTECTOR® IV Gauge Face Lubricators were specified to provide targeted gauge face protection across the critical curve sections.
Although the initial scope did not include Top of Rail treatment, early observations post‑relocation highlighted significant levels of rail head wear. In response, L.B. Foster proposed augmenting the solution with a Top of Rail Friction Management system applying KELTRACK® water‑based friction modifier - a proven technology for mitigating rail head wear and controlling Rolling Contact Fatigue (RCF).
Our Solution
In September 2024, the L.B. Foster Field Engineering Services team installed three 90 kg capacity PROTECTOR® IV Gauge Face Lubricators at the designated positions along the remodeled alignment. These units delivered improved lubricant application consistency across the newly introduced tight‑radius curve.
Following the recommissioning of the track, routine monitoring identified rapid rail head wear and signs of RCF on both the Down Derby Goods Line and the Down Saltley Sidings Line. In response, the L.B. Foster Applications team conducted a detailed on-site assessment. To effectively address the emerging wear patterns, a dual Top of Rail unit was recommended to simultaneously treat both lines.
The dual system—applying KELTRACK® water‑based friction modifier—was installed at the beginning of April 2025. This addition provided a holistic friction management package, complementing the gauge face units and delivering enhanced protection against wear and fatigue across the affected track sections.
AtkinsRéalis Case Study
AtkinsRéalis used Vampire^ to model the track layout of the Down Derby Goods Line, which included taking measurements of the rail profiles. The track model was used with several different vehicle models, representative of current traffic patterns to determine the likely wear patterns and rates. This confirmed that the cause of the high wear rates and RCF was the tight curvature of the re-aligned tracks. The modeling also identified that top-of-rail friction management would reduce the rail wear.
Figure 1 - Vampire track model
^Vampire is an industry-leading railway dynamics simulation package that has been developed and optimised specifically for the railway industry, enabling cost-effective analysis of rail vehicle performance and safety through simulation that is licenced and developed by AtkinsRéalis.
Figure 2 - Measuring rail profiles
AtkinsRéalis revisited the site on three further occasions to take rail profile measurements. This allowed a direct comparison of the wear rates before and after installation of the top-of-rail Friction Management system. The results of the rail profile measurements showed that the predicted rail life had increased by a factor of 4 since the top-of-rail Friction Management system was installed.
The results of AtkinsRéalis rail wear measurements show that L.B. Foster’s top-of-rail Friction Management system has increased the predicted rail life by a factor of 4. Halley Porkess (Halley.Porkess@atkinsrealis.com), Principal Engineer, Dynamics, Gauging & Testing, AtkinsRéalis
Outcome
The upgraded friction management solution has strengthened long-term asset resilience at Duddeston Junction, providing:
Improved protection against gauge face wear on tight-radius curves
Mitigation of rail head wear and RCF, reducing the likelihood of premature rail replacement
Optimized and consistent application through modern electric lubricators
Reduced maintenance intervention compared to legacy mechanical systems
A scalable friction management approach aligned with Network Rail and HS2 interface requirements
The Central Rail Systems Alliance designers completed a 2nd survey on 25th of August as part of their vampire modelling report close out, and it was noted that there was a trend towards lower wear rates, particularly for head wear which indicates that the top-of-rail friction modifier installed in April 2025 is helping to reduce the rail wear rates. Scott Williams, Senior Project Engineer (Track) / DPE, Network Rail
This project demonstrates L.B. Foster’s proactive, engineering‑led approach to supporting major infrastructure programs with reliable and innovative Friction Management solutions.
