Recall Due To Flaws in Construction
On March 12, 2004, Siemens admitted to problems concerning the stability of the car bodies and, as a precautionary measure, instructed all public transportation services to take all Combinos with a service distance of more than 120,000 kilometres (74,565 mi) out of service. Torsion forces generated in S-curves were much higher than anticipated, leading to cracks around the articulations between the car modules. Subsequently, hairline cracks were found in the joints of the aluminium bodies, which could cause the roof to collapse in the case of an accident.
The problem was acute in Combino cars that had run more 150,000 km. Cracks were reported on the connections between the sidewalls and the roof girders such that the safety of passengers in the wheel-less modules could not be assured in the event of a severe collision. These flaws were reported in many cities that had adopted the Siemens-Combinos, such as Dusseldorf, Freiburg, Augsburg, Erfurt, Hiroshima, Nordhausen, Basel, Potsdam, Bern, Amsterdam and Melbourne. In March 2004 Siemens Transport Systems confirmed that body-shell problems were emerging at high mileages and it advised all operators to take out about 400 Combino’s that had run more than 120,000 km .
Siemens launched a three stage process of rebuilding the 454 modules affected. Under this process the Combino modules were reinforced to give an expected 30-year life. The cost of the rebuild programme was put at €400m.
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