ORR release report into Hitachi train cracks

• The industry should conduct further work to identify the reasons for the higher levels of fatigue loading experienced by rolling stock. Since the Hitachi Rail design complied with the applicable industry standards, the industry as a whole should evaluate whether the applicable standards take into account the loads arising from operation on the rail network in Great Britain. This industry collaboration will require the involvement of those parties responsible for design, manufacture and maintenance of rolling stock including, but not limited to, Hitachi Rail.
• Hitachi Rail should carry out a formal review of the effectiveness of their processes for welding when the component geometry is more challenging, which should include consideration of whether the existing approach adequately mitigates the risks of a weld with insufficient fusion being accepted.
• Designers of rolling stock should understand the risk posed by stress corrosion cracking and give it specific consideration when proposing the use of 7000 series aluminium components. This does not mean that the specific type of aluminium should not be used in future, or that the aluminium used in the current trains compromises safety; but when used, steps should be taken to ensure protection of structures.
• The industry should consider whether a standard for mitigating SCC risk should be developed, as no dedicated standard currently exists.
• The industry should develop a process for responding to similar future cross-industry crisis events and appoint a strong, independent chair who can maintain pace, focus and ensure all voices are heard.

ORR’s HM Chief Inspector of Railways Ian Prosser CBE said: “With our oversight, Hitachi Rail and operators have put in place robust plans to make sure the right safety issues are being managed following the initial discovery of cracks on the trains, which have allowed trains to re-enter service.

“Safety remains the number one priority. Our review provides a clearer picture of the issue and we will continue our oversight to ensure work moves forward to agree the permanent solution and our recommendations are acted on.

“It is important that the whole industry works together to learn lessons from what has happened and our recommendations will help with that.”