Crowded trains may be a sign of the times but the new units to be rolled out on the Tyne and Wear Metro system have been undergoing special tests to ensure they perform at their best when they are at full customer capacity.

A series of crush-laden testing checks are designed to confirm that, when carriages are full, they run correctly. In order to undertake the tests, one of the new Stadler-built units was loaded with 39 tonnes of ballast – a similar weight experienced when the maximum number of passengers are aboard the carriage. Once the carriages had been loaded with the required number of containers full of sand, the train was put through its paces on a series of night-time trial runs across the network.

The Swiss-based train manufacturer has been working closely with Nexus, the public body when manages Metro, and said the tests went well, which means that the new fleet is a step closer to entering full passenger service.

Now, the next phase of the £362m programme to replace the old trains can begin. Known as testing and commissioning, every single component on each new train will be tested to make sure that everything is in perfect working order before the trains enter service. This includes everything from seats and windscreen wipers, as well as such vital components as wheels, brakes, doors, power supply and the CCTV system.

In all, 480 members of staff will be trained up to use the new fleet, which will require 19,000 hours of training time.  The fleet of 46 trains will need to complete 37,000km of fault-free running to ensure they run safely through the Metro’s 60 stations and 77km of track. Not only that, but the necessary boxes relating to 22,000 standards and clauses have be meticulously ticked off.

Head of Fleet and Depot Replacement Programme at Nexus, Michael Richardson, said: “Crush load testing is a critical part of getting the first new Metro trains ready for our customers. The test ensures that the train can perform safely and correctly when it is full. This was replicated by loading the carriage up with almost 40 tonnes of ballast cartons and then putting it through its paces on the system.

“We checked how it performed under braking and on the curves when its full capacity was replicated.  I am pleased to say all the crush laden tests went well and the new train performed as exactly we expected it to.  Testing the new Metro fleet is a really detailed process. We are going through around 90,000 different checks and are leaving no stone unturned as we get the first train ready to welcome customers next year.

“The Stadler trains are going to be transformative, and we are really excited to get them into service. They have been shaped by customers, employees, trade unions and specialist user groups. We believe this to have been the most far-reaching consultation yet staged into a new train design. Over 23,000 customer responses have helped to shape the design.”