North East rail manufacturer Hitachi will have to repairs hundreds of its train carriages over the next six years after an investigation into a cracking issue that led to mass rail cancellations last year.
Services on LNER, TransPennine Express, Great Western Railway and Hull Trains were cancelled last May when cracks were found on the shell of the Class 800 trains made at Hitachi Rail’s plant in Newton Aycliffe, County Durham.
Now an investigation by the Office of Rail and Road (ORR) has pointed to several factors that could have cause the issue, with the regulator making a number of recommendations that aim to rectify the problem that caused severe disruption to passengers.
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The ORR report found that cracking resulted from “trains experiencing greater loads from train movement than allowed for in the original design”, potentially due to “wheel wear and track design”. Cracks were also caused by the use of a particular type of aluminium which was corroded by salt in the air.
But it also found that it was not “known for certain” why the cracking occurred.
As a result, it has called on Hitachi and the wider rail industry to further investigate fatigue levels on rail rolling stock, while Hitachi has committed to a repair programme for 1,247 Class 800 series vehicles, plus nearly 500 other train carriages.
To reduce disruption to the rail network, the programme will take place over six years, with Hitachi prioritising the trains most in need of repair.
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ORR’s HM Chief Inspector of Railways Ian Prosser said: “With our oversight, Hitachi Rail and operators have put in place robust plans to make sure the right safety issues are being managed following the initial discovery of cracks on the trains, which have allowed trains to re-enter service.
“Safety remains the number one priority. Our review provides a clearer picture of the issue and we will continue our oversight to ensure work moves forward to agree the permanent solution and our recommendations are acted on.
“It is important that the whole industry works together to learn lessons from what has happened and our recommendations will help with that.”
A Hitachi Rail spokesperson said: “The ORR’s report identifies that all Hitachi trains meet relevant standards and that we took the appropriate action to prioritise safety and maintain train availability.
“The report also provides a detailed account of the tireless work to simultaneously keep trains running safely, while working towards the long-term solutions.
“The proposed engineering solutions outlined in the report are currently being reviewed by all partners. We are working together to finalise the plan for their implementation, while always prioritising safety and train availability to support consistent passenger services.”
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