As part of the project to operate BYA Wagons in France, it was necessary to provide evidence to the French Approval Authority that the wagon complied with the brake requirements of UIC leaflet 544-1.

Although the wagon complied with UK brake requirements it was theoretically under-braked for the more onerous requirements of UIC 544-1 and a minor modification to the brake system was required which necessitated confirmation by actual slip brake test results - where the wagon is remotely unhitched from the back of a moving train and the distance it takes to brake to a stop is measured.

A Swiss testing body (Prose) were selected to take the test measurements, however, access to a suitable test track proved very difficult as not only is it necessary to ensure the track is level and straight but also the test must be conducted within a full track possession. As a result of this it was decided to test on a private railway, the Great Central Railway (GCR) situated between Loughborough and Leicester. The GCR has a suitable section of track where 100 kph brake testing can be undertaken, however, the only downside is that the GCR is rail-locked so the BYA had to be delivered by road.

GCR provided a Class 45 Locomotive for the test and Prose installed the measuring equipment inside the BYA wagon (in between the coils of steel), a wireless link provided real-time data transfer of speed, distance and brake pressure to a recording laptop located in the back cab of the locomotive.

ESG project managed the operation, procured necessary resources and produced the test specification, the project team included:

• The test track, motive power, driver and ground staff were provided by GCR
• Wagon haulage (to and from Toton) was provided by Moveright International
• Wagon was provided by EWS Industrial (loaded at EWS Wolverhampton Steel Terminal)
• Wagon modification (Toton and Quorn) undertaken by EWS Wagon Repair Dept
• Slip coupling was provided and operated by Network rail
• Test measurements were taken by Prose

The tests were conducted on 23 & 25 October 2007

The GCR is rail-locked so the BYA had to be delivered by road:

Prose test engineers fitting measuring equipment inside the BYA at Quorn Station Sidings:

Remotely controlled, pneumatically operated, Slip Coupling in place, this also included a separate valve that closed the loco brake pipe and applied the brakes on the BYA before separation of the vehicles:

Video clip of actual slip brake test (1 of 36 slip test runs) taken from back cab of the Class 45 on approach to Quorn Station between mp 96¾ and mp 95¼:
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The BYA was modified to give maximum brake cylinder pressure (BCP) at 90 tonnes load (on rail) as opposed to the UK standard of 102 tonnes. The slip test results showed that the modification was successful, satisfyingly close to predicted values, and more importantly, met the requirements of UIC 544-1.

• Cost effective Slip brake testing
• Brake modification to meet performance targets
• High-requirement test specification

• Multiple resource management
• Application of international standards
• On site project control and staff safety
• Brake system design