The Weight of a Nation’s Freight
The operational ramp-up of the Etihad Rail freight terminal at Dubai Industrial City (DIC) changes the logistics map of the UAE. It connects the port of Jebel Ali to the rest of the GCC via rail.
- Capacity: 50 million tonnes annually across the network.
- Locomotives: 4,500 horsepower beasts.
- The Load: Containerized cargo, aggregates, and petrochemicals.
This is heavy industry. The ground vibrations alone are enough to settle poorly compacted soil. The equipment used to move containers—Reach Stackers and Straddle Carriers—have some of the highest axle loads in existence.
Mass and Reinforcement
In a standard warehouse, a forklift might bump a barrier. In a rail terminal, a loaded Reach Stacker weighing 100 tons slams into barriers.
Standard concrete Jersey barriers snap like chalk under this load.
For rail terminals, we specify our “Port-Grade” barriers.
- Double Reinforcement Cage: To prevent shattering on impact.
- C50 Concrete: 50MPa strength to resist abrasion and crushing.
- Wide Base: To prevent overturning when hit by a massive tire.
We have seen terminals try to save money by using road barriers. Within 6 months, the rebar is exposed, the concrete is spalled, and the site looks derelict. In a safety-critical rail zone, this gets you shut down.
Pavement That Takes a Beating
The terminal floor is where the battle is fought. Between the tracks and the loading bays, the pavement must withstand:
- Static loads from stacked containers.
- Dynamic twisting loads from turning tires.
- Oil and hydraulic fluid spills.
We supply Heavy-Duty Interlocking Pavers specifically designed for this. Our 80mm and 100mm pavers are interlocking, meaning they distribute the load across the surface. Unlike asphalt, which ruts in the summer heat under heavy static loads, concrete pavers remain rigid.
The Separation of Man and Machine
Rail terminals are dangerous. You have trains, cranes, and trucks moving in complex patterns. Separating pedestrians (drivers, inspectors) from this metal chaos is life-or-death.
You cannot rely on painted lines. We advocate for Physical Segregation.
- Walkways: Elevated or separated by Hoarding Blocks.
- Checkpoints: Hardened with blast-proof barriers to protect security staff from runaway trucks.
The Dust and Sand Factor
DIC is in a sandy environment. Rail ballast (the rocks under the tracks) gets contaminated by windblown sand, which destabilizes the track. The perimeter hoarding isn’t just for security; it’s a Sand Shield.
A solid precast wall along the windward side of the terminal can reduce track maintenance costs by blocking the drift of sand onto the rails. Our high-height hoarding systems are engineered for this dual purpose: Security + Environmental Control.
Protecting the Investment
Etihad Rail is a legacy project for the UAE. It is built to last 100 years. The supporting infrastructure must match that lifespan.
If you are a contractor building access roads or storage yards feeding into the rail network, do not spec cheap commercial concrete. Spec for the 100-ton impact.
Impact Is Inevitable
In a busy terminal, accidents happen. It’s not a matter of if, but when.
When a 40-foot container swings low and hits your perimeter wall, will the wall stand firm, or will it collapse onto the tracks and halt the national rail network?
