Occupying a site of approximately 50 hectares, the Singapore Rail Test Centre (SRTC) plays a pivotal role in Singapore’s efforts to renew, upgrade and expand its rail network. The facility is a dedicated railway testing hub that supports transport authorities and rail operators to perform robust integrated rail systems testing for new and existing mass rapid transit (MRT) trains and systems.

GS Engineering & Construction Corporation engaged our firm as their design consultant to deliver multidisciplinary detailed design services for the facility. Our approach drew from technical expertise and deep collaboration to create an integrated rail solution. We designed the centre’s administration building, operation control centre building, maintenance and refurbishment workshop and three specialised test tracks for the evaluation of rail performance.

The centre makes round-the-clock testing of integrated rail systems possible in a controlled environment, without disrupting passenger services or maintenance on operational lines. With local capabilities now in place, Singapore is no longer dependent on overseas testing facilities, enhancing efforts to maintain rail reliability. SRTC will also serve as a hub for research and innovation, supporting the growth of railway skills enhancements for the rail industry.

Designing structural solutions for rail test tracks

We designed three specialised tracks for the evaluation of various aspects of rail performance:

  1. Endurance test track (outer loop) runs trains non-stop for several days to test their durability.
  2. Performance and integration test track (inner loop) tests complex geometries with tight curves and turns.
  3. High-speed test track tests trains operating at high speeds.

Part of the endurance and performance and integration test tracks are on a viaduct with a section of the endurance test track running above the Tengeh Reservoir.

A different approach to viaduct design

We delivered the full detailed design for two viaducts, which carry the endurance and performance and integration test tracks. Spanning 1.6 kilometres and 1.1 kilometres respectively, the viaducts comprise interconnected continuous deck modules each 160 metres long, monolithically connected to the supporting columns. We designed a multi-frame structural system, which allowed for slender columns, reduced the number of bearings required, and eliminated the need for rail expansion joints.

Due to the higher train loading defined in the project specification and tight in-plane rail alignment, we adopted a novel design for the post-tensioned concrete deck. Instead of relying solely on internal prestressing-steel tendons, we introduced a hybrid system using both internal and external tendons.

Our design prioritises long-term maintainability. The external tendons, positioned outside the concrete, enable a more efficient deck design and allow for easier inspection and maintenance. We incorporated inspection pits, working platforms and internal access routes to facilitate safe and efficient inspection and maintenance of critical components. These components include bearings, movement joints and drainage gullies and can be accessed without disrupting train operations. Our design allows for additional tendons to be installed in the future, enhancing the long-term robustness and reliability of the viaducts.

This approach reduced the amount of concrete required for the columns and substructure, leading to cost and carbon savings.

Rail tracks for testing trains and buildings for operations and maintenance

The Singapore Rail Test Centre © LTA

Rows of solar panels on roof of large building

Solar panels are installed on all roofs © Quite Frankly

Inside a large workshop for train maintenance

The maintenance and refurbishment workshop © Quite Frankly

A building and an elevated rail track for testing trains

One of the elevated sections of the test track © Quite Frankly

Improving the viaduct design for underwater conditions

For the section of the viaduct spanning the Tengeh Reservoir, we enhanced the reference design by replacing fully submerged pile caps with floating pile caps. This solution significantly reduced environmental impact, particularly the risk of water contamination during construction. It also improved construction safety and enabled faster foundation erection within the waterbody.

The site’s challenging ground conditions, characterised by lateral movements due to consolidation of soft marine clay, required innovative foundation design. We introduced a unique system using steel sleeves around the piles, effectively isolating them from ground movement and anchoring them in deeper, more stable strata. This eliminated the need for costly and time-consuming ground improvement works, while ensuring long-term structural stability.

Sustainable building design saves energy

The centre’s main building consists of three blocks: administration building, operations control centre building and the workshop where trains are parked during maintenance and testing.

We designed a metal roof with clerestory windows to optimise daylight penetration into the workshop. This design reduces reliance on artificial lighting, promoting the wellbeing of the workers. To enhance natural ventilation while minimising the risk of wind-driven rain, we conducted extensive computational fluid dynamics simulations. Part of our solution was implementing double-bank louvres to keep rain out and let air in.

To harness renewable energy, we installed large solar panels on the roofs of all three buildings. The energy generated is sufficient to power 570 four-room flats in Singapore for a year. This solar energy can offset 26 per cent of the centre’s annual energy consumption.

We adopted energy-efficient solutions, including LED lighting, high-efficiency fans and chiller plants, resulting in a 35 per cent reduction in overall energy consumption. Additionally, we used structural systems which have lower embodied carbon, such as concrete which has been certified low carbon by the Singapore Green Building Council.

This centre achieved the Building and Construction Authority’s Green Mark Platinum certification.