Project Scope:

  • EDC was engaged to investigate and resolve the significant cracking issues on the fleet of CBH aluminium-made wagons, utilising advanced measurements and simulation techniques.


  • As there were a high number of defects or cracks, it was a challenge to develop a test and measurement methodology that accurately represented the cause of the issue.
  • Determine the correlation between the measurement information and the advanced simulations.
  • Providing solutions to resolve the cracking issue.


  • Development of an extensive testing regime utilizing solar panels as the power source for the instrumentation whilst the wagon was in operation for a period of 3 months.
  • Identify the likely main causes of fatigue failures and quantified the loads under normal operations.
  • Provided design modifications to reduce the risk of any future cracking.
  • Post test data showed a significant improvement and verification of the fatigue life estimation with the recommended improvements implemented.