Railway Track Manual Part 1

July 9, 2017 | Author: Sima Viorel | Category: Track (Rail Transport), Track Gauge, Rail Transport, Screw, Civil Engineering
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Description

Content

Preliminary remark

Preface for the second edition

Page: 000-01

Preface for second edition The Railway Track manual is now available, the second edition of it was first published in December 2004. Completely revised and expanded, this comprehensive reference book provides up-to-date information about the railway track. A compendium of the practice for the practice. It focuses on the application and provides empirical knowledge on types of track systems and materials, especially about • Rails, • Barriers, • Turnouts, • Fasteners as well as • Other accessories As a Q1-supplier of the Deutschen Bahn AG and as a system provider with a decades of gathered experience, we hereby put all our expertise on the complete railway track. We are therefore confident to provide you with Railway Track Manual valuable services for your work.

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Date of issue 08/10

Content

Preliminary remark

Instructions for use

Page: 000-02

Instructions for use The department of Planning and Development of ThyssenKrupp GfT Gleistechnik GmbH has created a manual for you, which represents the current state of engineering. All content has been reviewed by our colleague for accuracy and timeliness. However they do not replace the critical review done by an experienced expert. Therefore we do not take any responsibility for the issue. In case you come across with something on our Railway Track Manual that requires correction or amendment, please contact us. Your contact person at ThyssenKrupp GfT Gleistechnik GmbH, Dr.-Ing. Siear Qaimi gladly welcomes your suggestions and contrary comments. Contact: Dr.-Ing. Siear Qaimi Tel.: +49 234 9114-541 Fax: +49 234 9114-316 E-Mail: [email protected] We look forward to working with you.

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Date of issue 08/10

Content

Preliminary remark

Addresses, sales offices and engineering

Page: 000-03

SALES Regional office

Location of sales

North Vahrenwalder Str. 205 D-30165 Hannover Phone: +49 511 6703-25 Fax: +49 511 6703-37

Waidmannstraße 26 D-22769 Hamburg Phone: +49 40 85340-700 Fax: +49 40 85340-701

West Hollestr. 7a D-45127 Essen Phone: +49 201 844-563745 Fax: +49 201 844-563750 East Rotherstr. 7 D-10245 Berlin Phone: +49 30 628901-15 Fax: +49 30 628901-20/-21

An der Kreuzkirche 6 D-01067 Dresden Phone: +49 351 4902040 Fax: +49 351 4902480

Humboldtstr. 3 D-04105 Leipzig Phone: +49 341 6017054 Fax: +49 341 6017055

South Fürstenrieder Str. 267 D-81377 München Phone: +49 89 7871-300 Telefax: +49 89 7871-343 South-West Weilimdorfer Str. 74/2 D-70839 Gerlingen Phone: +49 7156 430730 Fax: +49 7156 430740

Dortmunder Str. 2 D-68219 Mannheim Phone: +49 621 8906-120/-121 Fax: +49 621 8906-122

EXPORT SALES MRT Track & Services Co., Inc. 270 Broad Street 07003 Bloomfield • NJ-USA Phone: +1 973 748-8899 Fax: +1 973 748-9243

ThyssenKrupp GfT Polska Sp. z o.o. Al. Slowackiego 66 30-004 Kraków • Poland Phone: +48 12 6204130 Fax: +48 12 2677548

Holzschwellenwerk Am Bahnhof 2 D-29393 Groß Oesingen Phone: +49 5838 9905-0 Fax: +49 5838 9905-79

ThyssenKrupp Weichenbau Obere Stahlindustrie 4 D-44793 Bochum Phone: +49 234 9114-343 Fax: +49 234 9114-557

Betrieb Industrieweichen Am Wasserturm 3b D-06869 Coswig/Anhalt Phone: +49 34903 4741-0 Fax: +49 34903 4741-20

Betrieb Spannmittel Am Wasserturm 3b D-06869 Coswig/Anhalt Phone: +49 34903 4741-0 Fax: +49 34903 4741-24

ThyssenKrupp Langschienen Ladestr. 8 D-39175 Königsborn Phone: +49 39292 6958-17 Fax: +49 39292 6958-20

Export Hollestr. 7a D-45127 Essen Phone: +49 201 844-563764 Fax: +49 201 844-563757 MANUFACTURING PLANT

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Date of issue 08/10

Vertriebsbereich Waggonausrüstung Rotherstr. 7 D-10245 Berlin Phone: +49 30 628901-15 Fax: +49 30 628901-22

Content

Preliminary remark

Information service

Page: 000-04

This information service serves exclusively the function, modifications, amendments and other important informations on the Railway Track manual if required and to transfer to the interested individuals and companies in a defined time. It is not used for sending of advertisements, information sheets or the similar! Of course, your data will be kept confidential and not disclosed to third parties. Data exchange takes place exclusively via e-mail. To participate in the information service please fill in the following fields below and send this page by fax to +49 234 9114-316 or email to [email protected] The required fields are marked with *. Alternatively you may also register under www.tkgftgleistechnik.de and keep yourself updated.

REGISTRATION FOR INFORMATION SERVICE

Company*:

Contact partner*:

Street:

Place:

Tel.No.

E-Mail*:

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Railway Track Manual

Table of contents

Preface, Table of contents, Railway Track terms

000-00

Preliminary remark

000-01 000-02 000-03 000-04

Preface for second edition Instructions for use Addresses of sales office and engineering Information service

000-10

Table of contents

000-11 000-12 000-13 000-14 000-15 000-16 000-17

Preliminary remark, Table of contents, General terms of tracks Types of track systems Vibration-damping rail bedding Slab track / Crane and depot tracks Special constructions / Track materials Turnouts / Crossings / Rail expansion joints Track accessories

000-20

General Railway Track terms

000-21 000-22 000-23 000-24 000-25 000-26 000-27 000-28

Development, Railway Track, Classification Gauge of the track, Gauge widening Track distance Overview of various standards and regulations Overview of various standards and regulations (Continued) Track system abbreviations Track system abbreviations Thanks

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Page: 000-11

Railway Track Manual

Table of contents

Types of track systems

Page: 000-12

100-00

Types of track systems

110-00 110-01

Standard variants Overview

111-00 111-01 111-02

Variant W 3 - Concrete sleepers W 3 - 60E2 made of concrete sleeper W 3 - Width of the rail flange 125 mm made of concrete sleeper B70/B90

112-00 112-01 112-02

Variant W 14 - Concrete sleepers W 14 - 60E2 made of concrete sleeper W 14 - Width of the rail flange 125 mm made of concrete sleeper B70/B90

113-00 113-01

Variant K - Concrete sleeper K - Width of the rail flange 125 mm made of concrete sleeper

114-00 114-01 114-02

Variant K - Wood sleepers K - 60E2 made of wood sleepers K - Width of the rail flange 125 mm made of wood sleeper

115-00 115-01 115-02

Variant KS-H - Wood sleepers KS-H - 60E2 Wood sleeper KS-H - Width of the rail flange 125 mm wood sleeper

116-00 116-01 116-02 116-03 116-04

Variant KS-St - Steel sleepers KS-St - 60E2 made of steel sleeper KS-St - Width of rail flange 125 mm made of steel sleeper KS-St-Iso - 60E2 made of steel sleeper KS-St-Iso - Width of rail flange 125 mm made of steel sleeper

117-00 117-01

Variant Y-Steel sleepers Rail fastening S15 made of Y-Steel sleeper

118-00 118-01 118-02 118-03 118-04 118-05

Variant grooved rails with guardrail Installation views 59R1, 59R2, 60R1, 60R2 Installation views 57R1, 67R1, Ph 37N Guardrail details Material requirement / 15 m Indoor track 57R1 made of situ-concrete plate

119-00 119-01 119-02 119-04 119-06 119-08 119-09 119-10

Variants Vossloh / ThyssenKrupp System W 3 - Standard for Concrete sleepers System W 14 - Standard for Concrete sleepers System E14 / E21 - Highly elastic for Concrete sleepers System 300 - for Slab track System KS - for ribbed base plates System W-Tram - with Wedge angle plates System W97 - for reground concrete sleepers

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Railway Track Manual

Table of contents

120-00

Vibration-damping rail bedding

120-01

Overview of rail bedding

121-00 121-01 121-02 121-03 121-04 121-05 121-06 121-07 121-08 121-09

Continuous rail bedding ThyssenKrupp Railflex ISOLast ThyssenKrupp Flexpoint Whisper rail Railcover VIBRALast Highly elastic grooved rail turnouts Potting material Powerflex ThyssenKrupp Flattrack

122-00 122-01 122-02 122-03 122-04 122-05 122-06 122-07 122-08

Discrete rail bedding Delta stock Krupp ECF-System EASYLast TK 99 / TK 99 S TK07-R TK 04-R Ei-attachment Acoustical Loadmaster

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Vibration-damping rail bedding

Page: 000-13

Railway Track Manual

Table of contents

Slab track Crane and depot tracks

130-00

Slab tracks

131-00 131-01 131-03 131-04

NFF (New slab tracks) General Engineering structure Schematic construction cycle

132-00 132-01 132-02

NBU (Naumburg Bauunion) Introduction Schematic construction cycle

140-00

Crane and depot tracks

141-00 141-01 141-02 141-03 141-04 141-05 141-06 141-07 141-08 141-09 141-10 141-11

Crane runways MX-System MX-System description MX-System screwed MX-System welded MX-System discontinuous rail bedding MXA-System discontinuous rail bedding MX-System continuous rail bedding MXA-System continuous rail bedding MX-Bottom casting Surveying System Railcontrol Crane runway beams

142-00 142-01 142-02 142-03

Railroad depot Rail support point for side track and wash tracks Rail fastening on working pits Rail fastening on steel colum

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Page: 000-14

Railway Track Manual

Table of contents

Special constructions Track materials

150-00

Special constructions

151-01 152-01 153-01

Guardrail Guide rails Rut rails

200-00

Track materials

210-00 211-01 212-01 213-01 214-01 214-02 214-03 215-01 216-01 217-01

Rails Overview of commonly used track types Flange rails Grooved rails Crane rails Form A Crane rail AS 86 Crane rails bevel cuts Special sections Rails for crossings and turnouts Perforation plates Rail perforation

220-00 221-01 222-01 223-01 224-01 225-01

Sleepers Y-Steel sleepers Pre stressed concrete sleepers Wood sleepers Steel sleepers Steel bridge sleepers SBS

230-00 231-01 232-01 232-02 233-03 233-01 233-02 234-01 235-01 236-01

Ironmongery and accessories Fastening clamping plates Fastening rib based plates Rib based plates for guide rails Rib based plates for guide rails and supporting rails Screw sleeper screws Screw hook screws Plastic screw anchor Plastic spacer plate Discs and spring lock washer

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Page: 000-15

Railway Track Manual

Table of contents

Turnouts / crossings / Rail expansion joints

Page: 000-16

300-00

Turnouts and crossings

300-01 300-02

Preface General switch description

310-00 311-01 312-01 313-01 314-01 315-01 316-01 317-01 318-01 319-01

Switch Switch description Types of switches / Split locking plans for Vignol- and Ph 37a Switch Tram railed grooves Tables Layout plan according to VDV track 1435, system of units C Turnout definition Turnout parts Turnout accessories Changeover system

320-00 321-01 322-01

Crossings, EKW, DKW Turnout parts Crossing variant LSH, Linear slidable centrepiece

330-00 331-01 332-01

Rail expansion joints Flange rails Grooved rails

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Railway Track Manual

Table of contents

Track accessories

400-00

Track accessories

411-00 411-00 411-01 411-04 411-06 411-07

De-watering boxes Overview for grooved rail variant "DENA" for grooved rail variant "RIECKEN" for vignol rail variant "DENA" for elastic rail bearings whisper rail

412-00 412-01 412-02 412-03

Track endings General Overview of the variants Buffer stops

413-00 413-01 413-02

Plastic cable channel DRAE - KA AU – KA

414-00 414-01 414-02 414-04 414-05 414-06

Insulated splicing MT-Insulated splicing rail foot width 125 mm MT-Insulated splicing 60E2 MT-Insulated splicing 60E2 increased MT-Insulated splicing rail foot width 125 mm increased Transition 49E5 to 54E4

415-00 415-01 415-03 415-04 415-05 415-06 415-07

Railway plates Other signals Speed limit signal Signal for electrical traction Additional signal at home signal Signal for shunting operation Turnout signal

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Page: 000-17

Content

General Railway Track terms

Development, Railway Track, Classification

Page: 000-21

Formation of rail forms The tracks should take the wheel load and transferred to the sleepers. They should also run the wheel and have a levelled railway. To reach present level, the rail profile has gone through various stages of development.

From the variety of rail forms, the wide foot rail, today called vignol rails consists of head, base and foot. The rail is symmetrically shaped in cross section. The rail cross section is designed due to the extensive experience and detailed considerations on today's valid profiles. The resisting torque and carrying capacity of the rail is determined primarily by their height and weight as an I-beam. It is the rolling friction of the wheels of the vehicle and thus exposed to material wear. The rail should remain only up to a certain degree of wear and tear on the track. Railway track The route for railway vehicle is to be understood under railway track. The Railway track includes: • • •

die tracks, turnouts and crossings, the concrete as well as the sub-structure

Classification of tracks and turnouts The tracks and turnouts are divided according to operational and railway track technical aspects. 1. Operational aspects: Differentiation between the tracks and turnouts according to main and side tracks. Main tracks are scheduled traffic tracks of the trains. Main tracks of the free routes and continued through the stations are known as continued main tracks. All other tracks are side tracks. 2. Railway track technical aspects: The tracks and turnouts are divided in 3 orders according to operating characteristics and specially in 1. Order: strong mode, high travelling speeds and large axle loads 2. Order: moderate strong operation and slower travelling speeds without regard to the axle loads 3. Order: weak operation, slower travelling speeds.

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Content

General Railway Track terms

Gauge of the track , Gauge of the track

Page: 000-22

Gauge of the track The gauge of the track is the smallest distance between inner surfaces of the rail heads in the range of 0-14 mm below rail level. The basic size of the gauge of the track is 1435 mm. Deviations from the basic size of the gauge of the track are allowed. Thus, for example turnouts for non-federal railways (NE-turnouts) can also be prepared with a basic gauge of 1432 mm. The gauge of the track in any case must not be smaller than 1430 mm and - also including curve radius of the required extension -not more than 1465 by main line and 1470 mm by loop lines. The gauge of tracks in rail and turnout curve parts with radius less than 240 m must not fall below the following values: Radius of the rail curve parts (m)

The minimum size of the gauge of track (mm)

under 175 to 150

1435

under 150 to 125

1440

under 125 to 100

1445

Gauge widening A) Federally owned railway capital Radius of the rail curve parts (m)

manufactured gauge of track (mm)

under 175 to 150

1440

under 150 to 125

1445

under 125 to 100

1450

The gauge of the track in turnouts is set in the control drawings (low). Standard turnout 54E4 and 60E2 for railway tracks DB AG have no gauge widening. Turnouts with 49E5 rails and diverging track radius from 150 to 190 m have 6 mm gauge widening. B) Non-federally owned railway capital Radius of the rail curve parts (m)

manufactured gauge of track (mm)

under 190 to 140

1440

under 140 to 100

1445

The gauge widening in rail curve parts is to be produced by impressions of the inner stand in steps of 5 mm. The length of a step in each case is 5 sleeper fields. Before the first stage with a track gauge from 1440 mm, 5 sleepers with a track gauge of 1435 mm.

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Content

General Railway Track terms

Railway Track distance

Page: 000-23

Track distance 1.) Standard gauge railway The usual track distance is according to EBO for new buildings on free routes in curved parts with a radius of ≥ 250 m and in the line of 4, 00 m. This measure applies to speeds > 160 km/h to 200 km/h. The dimension refers to the distance from rail centre to rail centre. In rail curves with radius of ≤ 250 m, the rail distance must be enlarged according to EBO § 10. Curve radius

Increased distance by:

250 m

0 mm

200 m

115 mm

150 m

300 mm

For existing attachments, the track distance at right operation must be even less than 4.00 m. The minimum track distance for existing plants according to EBO § 10(1) is 3.50 m. On diverging track routes, the reverse to be driven in right operation and whose tracks have a distance of 3.50 m, no security space exists for adjacent track. It is just barely a measure for minimum clearance. During structural alteration works, the desirable track distance for these plants is 4.00 m. Should this not be possible for compulsory reasons, exceptionally a distance of 3.75 m and 4.00 m can be permitted. The distance between track pairs or a track pair and a third track should be minimum 4.50 m. For better security of rail staff during maintenance work on the inner tracks and possibly to store building materials on inner tracks, the track distance possible should be 5.40 m. The required track distance apart from over loaded tracks should be at least 4.50 m, with new buildings at least 4.75 m and with intermidiate platform at least 6.00 m. 2.) Track distance from narrow gauge lines of general traffic: A) On the free routes and on loading tracks: Track gauge 600 mm

2,100 mm Track distance

Track gauge 750 mm

2,900 mm Track distance

Track gauge 900 mm

3,100 mm Track distance

Track gauge 1000 mm

3,100 mm Track distance

B) At stations apart from loading tracks: Track gauge 600 mm

3,000 mm Track distance

Track gauge 750 mm

3,800 mm Track distance

Track gauge 900 mm

4,000 mm Track distance

Track gauge 1000 mm

4,000 mm Track distance

For increasing the track distance in curved parts with narrow gauge rails there are special guidelines. The dimensions are given in the appropriate tables.

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Content

General Railway Track terms

Overview of different Standards and regulations

Page: 000-24

Overview of various standards and regulations: DIN / BN / TL / UIC Kodex / DS/RIL

Name

DIN

Lock washer made of steel for Railway track Clamping plates rolled

5906

Crane rails form F

536/2

Crane rails with bottom flange A

536/1

Plastic material for railway tracks Brief description of the railway track systems Tabs for groove less bottom rails Fish bolts with Slotted round head / Oval neck Fish bolts with Square head Railway tracks, basics, General, guidelines

BN/TL

UIC Kodex

918 006

864-3 V

918 025

918 280 820.0101 5902 5903/1 5903/2 820.0101

Rising height in track curves Guide rail; Release planned Standard gauge railways, Railway track recommended practice Rails, Flash butt welded, new and reground Rails, General Rails, bottom rails (old description) Profile S 10, S 14, S 18, S 20, 33E1, 41E1, 49E5 Rails, for turnouts and crossings, in connection with vignol used from 46 kg/m; Release planned

820.3030 EN 13674-3

918 255 820.2120

EN 136741

EN 13674-2 20501

Rails, Bus bars made of steel

17122

Rails, use Rails, Vignol rails 27 kg/m up to under 46 kg/m; Release planned

EN 13674-4

Rails, Vignol rails from 46 kg/m

EN 13674-1

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918 168 820.01

Rails, 30E1 and fish plates Fl 30

Rail expansion joints, arrangement of

DS/Ril

918 254

860 V

820.2121

918 254

860 V 820.0134

Content

General Railway Track terms

Overview of different standards and regulations (Cont.)

Page: 000-25

Overview of various standards and regulations: DIN / BN / TL / UIC Kodex / DS/RIL (continuation) Name

DIN

BN/TL

Rail base plate made of rolled steel

UIC Kodex 864-6 V

Sleepers

820.0105

Sleepers, wood, non-impregnated

918 144

Sleepers, prestressed concrete

918 143

Sleepers, steel

918 123

Sleeper screw Rail clamps, rail nails Clamping yoke Track gauge and rail cant Structure of rails

918 024-1

Steel upper wall screws

918 024-2

Butt plate made of rolled steel Turnouts and crossings, Technical foundation for complete tracks Turnouts, crossings and Crossover made of wood and steel sleepers Turnouts, crossings and Rail expansion joint, Heat treated components Intermediate layers of rubber Driveway Intermediate layers, elastic Intermediate layers, under rails

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DS/Ril

863 V

864-1 V

918 127 820.2110

864-4 V

820.0142

918 120

918 142 918 234 918 235 864-5 V

Content

General Railway Track terms

Railway Track abbreviations

Page: 000-26

Railway track-Abbreviations ABS ATD ATS Az Obv B BN BTD BTS BZA CEN DB AG DIN DKW Dann DS EBA EBO Ei EN EW Fe FF Fl Fsch FSS Fz Grp Gz H HGT HGV Hs ISO Kp KS Ksp LfB LIS MFS N NBS Obv Ri Ril

Upgrade of existing line Asphalt-base course with directly stored sleepers Asphalt-base course Appendix additional provision for railway track specifications Concrete sleeper Railway standard Concrete-base course with directly stored sleepers Concrete base course Central Office of the German Federal Railways of the former German Federal Railways European Committee for Standardisation German National Railway Company German Institute for Standardisation Double-slip diamond crossing Double clamping nail Leaflet German federal railway organisation Railway engineering- and work rules Insulating insert (in turnouts: Arch support - Ei = Anti-creep device) Eurocode Standard turnout Spring lock washer Slab tracks Fish plates Flexible rail switch-turnout Anti-freeze layer Flexible switch-turnout Base plate Pivoted heel-turnout Wood sleeper Hydraulically bound base course High speed traffic Hook screws International organisation for standardisation Clamping plate Crane rail Clamping track plate Country representative for rail road supervision Light industrial sleeper Mass-Spring-System Newton (Measuring unit according to English natural scientist) New upgrade of existing line Railway track specification for standard gauge railway Grooved rail Directive with modules

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Content

General Railway Track terms

Railway Track abbreviations (Continuation)

Page: 000-27

Railway Track Abbreviations (Continued) Rp Rpb Rph Rps Rsw Rus Rz S SbS SBS Sbü Sdü SO SO Sp Ss St TBS TL UIC UIG Uls VDV VOB WA WE Wfp Yno YÜli YÜre Zw Zwp

Ribbed base plate Ribbed base plate for concrete sleepers Ribbed base plate for wood sleepers Ribbed base plate for steel sleepers Ribbed base track plate Weldable ribbed base space plate Control drawing Rail City rail road ties Steel beam bridge sleepers Clamping yoke Sleeper anchor Elastic sole of concrete sleepers Rail level Track adjustment plates Sleeper screw Steel sleeper Tramway sleeper Technical delivery condition Union Internationale de Chemin de Fer (International Union of Railways) Unternehmensinterne Genehmigung (Deutsche Bahn AG) Washer Association of German Transport Companies German Construction Contract Procedures (Before 2002: Contracting rules for award of public works VOB 2000) Start of turnout End of turnout Angular guide plate Y-Normal rail Y-Transition rail left Y-Transition rail right Intermediate level Spacer plate

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Content

Thanks

Page: 000-28

For their assistance and support in creating this manual, we heartly thank:

A. Rawie GmbH & Co KG DENA Stahlbau GmbH & Co Deutsche Bahn AG DW Schwellen GmbH Elektro-Thermit GmbH & Co KG Gebr. Marmetschke GmbH & Co KG Hanning & Kahl GmbH & Co KG Heinrich Krug GmbH & Co KG H.+ R. Riecken Maschinenbau GmbH Leonhard Moll Betonwerke GmbH & Co KG Ortec Gesellschaft für schienentechnische Systeme mbH Rail.ONE GmbH Schilderwerk Beutha GmbH ThyssenKrupp Weichenbau GmbH TSTG Schienen Technik GmbH Vossloh Fastening Systems GmbH Wirthwein AG

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49090 Osnabrück 49086 Osnabrück 60326 Frankfurt am Main 39317 Güsen 06132 Halle 29393 Groß Oesingen 33813 Oerlinghausen 44145 Dortmund 49565 Bramsche 30629 Hannover 50668 Köln 92318 Neumarkt 09366 Stollberg OT Beutha 44793 Bochum 47166 Duisburg 58778 Werdohl 97993 Creglingen

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Steel sleeper

K

K

K

K

Ks

Ks

Ks

Ks

Ks-iso

Ks-iso

S 15

E 14/ E 21 Sytem 300 W-Tram

W-Tram

W 97

113-01

114-01

114-02

114-02

115-01 119-08

115-02 119-08 116-01

116-02

116-03

116-04

117-01

119-03

119-09

119-10

1:40

60E2

Rail foot width 125mm

1:40

without

without

1:40

60E2

59R1 / 60R1 57R1

1:40

60E2

Zw 900180 Zw 900180 Zw 687a*

Zwp104 NT

Zw 692*

Zw E14

Zw 401*

Zw 697*

Zw 697a*

Zw 691*

Zw 664a Zw 686* Zw 690*

Zw 672, Zw 691* Zw 672, Zw 691* Zw 661a Zw 687* Zw 664a Zw 686* Zw 664a Zw 686* Zw 661a Zw 687*

Zw 700*

Kpo 9

Rph 6**

Wfp 3b – 22 Wfp 3b - 28

K-Wfp 14 R /L K-Wfp 14 R /L

Wfp 15a

Wfp E14

Zwp 192**

Rps 8 ia**

Rps 15 ia**

Rps 8**

Rps 15**

Rph 1**

Rph 6**

Rph 1**

Skl 1/97

Skl 14

Skl 14/92v

Skl 14/ Skl 21 Skl 15

Skl 14

Skl 12

Skl 12

Skl 12

Skl 12

Skl 12

Skl 12

Kpo 9

Kpo 6

Kpo 9

Rpb 1

Rph 1**

Kpo 6

Skl 14

Skl 14

Skl 1

Skl 1

Railfastening

Rpb 1

Wfp 14k

Wfp 14k

Wfp 3b

Zw 686a* Zw 700*

Wfp 3b

Zw 687a*

Plate

Hs 32-55

Hs 32-55

Hs 32-55

Hs 32-55

Hs 32-55

Hs 32-55

Hs 26-65

Hs 26-65

Hs 26-65

Hs 26-65

Hs 26-65

Hookscrews

Uls 7

Uls 7

Uls 7

Uls 7

Uls 7

Uls 7

Uls 6

Uls 6

Uls 6

Uls 6

Uls 6

Uls 6

Uls 7

Uls 7

Uls 7

Uls 7

Disc/ washer

Ss 25

Ss 36

Ss 36

Ss 36

Ss 36-220

Ss 34

Ss 8-150

Ss 8-150

Ss 8-150

Ss 8-150

Ss 8-150

Ss 8-150

Ss 8-150

Ss 35

Ss 35

Ss 25

Ss 25

Sleeperscrew

Fe 6

Fe 6

Fe 6

Fe 6

Fe 6

Fe 6

Springlock washer

Sdü 25

Sdü 25

Sdü 26

Sdü 25

Sdü 25

Dü S15a

Sdü 13

Sdü 9a

Sdü 9

Sdü 9

Sdü 9

Sdü 9

Anchor

Overview of Standard variants

Slab track with Upl 180/120 Concrete sleeper Concrete sleeper

1:40

1:40

1:40

Rail foot width 125mm

Rail foot width 125mm 60E2

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

RailIntermediate gradient level

Overview

119-09

Concrete sleeper Slab track

Y-Steel sleeper

Steel sleeper with Iw 16

Steel sleeper with Iw 16

Steel sleeper

Wood sleeper Rail foot width 125mm 60E2

Rail foot width 125mm Rail foot width 125mm 60E2

Wood sleeper

Wood sleeper

Rail foot width 125mm Rail foot width 125mm 60E2

Concrete sleeper Concrete sleeper Wood sleeper

Rail foot width 125mm

60E2

Rail foot width 125mm

60E2

Rail

Standard variant

119-06

Wood sleeper

K

113-01

Concrete sleeper

W 14

112-02

Concrete sleeper

Concrete sleeper Concrete sleeper

Storage

W 14

W3

W3

Railway tracksystem

112-01 119-02

111-01 119-01 111-02

Page

Railway tracks Page: 110-01

Captive gradient 1:40

Railway track systems

Standard variant

W3 – 60E2 Concrete sleeper B70 / B90

Page: 111-01

Tightening torque 200 Nm

6

1

Intermediate level

Zw 687a

5

2

Plastic dowel

Sdü 9

4

2

Angular guide plate

Wfp 3b

3

2

Rail clamps

Skl 1

2

2

Sleeper screws with track

Ss 25 with Uls 7

1

1 Number/Support point

Rail

60E2

Designation

Brief description

Pos.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Standard variant

W3 - Width of rail flange 125 mm / Concrete sleeper

Page: 111-02

Tightening torque 200 Nm

6

1

Intermediate level

Zw 686a

5

2

Plastic dowel

Sdü 9

4

2

Angular guide plate

Wfp 3b

3

2

Rail clamps

Skl 1

2

2

Sleeper screws with track

Ss 25 with Uls 7

1

1 Number/Support point

Rail

49E5 or 54E4

Designation

Brief description

Pos.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Standard variant

W 14 - 60E2 Concrete sleeper B70 / B90

Page: 112-01

Tightening torque 200 Nm

6

1

Intermediate level

Zw 700

5

2

Plastic dowel

Sdü 9

4

2

Angular guide plate

Wfp 14k

3

2

Rail clamps

Skl 14

2

2

Sleeper screws with track

Ss 25 with Uls 7

1

1 Number/Support point

Rail

60E2

Designation

Brief description

Pos.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Standard variant

W14 - Width of rail flange 125 mm / Concrete sleeper

Page: 112-02

Tightening torque 200 Nm

6

1

Intermediate level

Zw 700

5

2

Plastic dowel

Sdü 9

4

2

Angular guide plate

Wfp 14k

3

2

Rail clamps

Skl 14

2

2

Sleeper screws with track

Ss 25 with Uls 7

1

1 Number/Support point

Rail

49E5 or 54E4

Designation

Brief description

Pos.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Standard variant

K - rail flange width 125 mm / Concrete sleeper

Page: 113-01

Tightening torque 180 - 250 Nm

9 8 7

1 2 2

Intermediate level Plastic dowel Hexagonal nut

6

2

Clamping plate

5 4 3 2 1

2 1 4 2 1 Number/Support point

Hook screws Ribbed base plate Spring lock washer Sleeper screws Rail

Zw 672 or Zw 691 Sdü 9a DB M22 Kpo 6 (49E5) Kpo 9 (54E3) Hs 26-65 Rpb 1 Fe 6 Ss 8-150 49E5 or 54E4

Designation

Brief description

Pos.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Standard variant

K - 60E2 made of wood sleeper

Page: 114-01

Tightening torque 180 - 250 Nm

8 7 6 5 4 3 2 1 Pos.

1 2 2 2 1 6 4 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Hexagonal nut Clamping plate Hook screws Ribbed base plate Spring lock washer Sleeper screws Rail

Zw 661a or Zw 687 DB M22 Kpo 9 Hs 26-65 Rpb 6 Fe 6 Ss 8-150 60E2

Designation

Brief description

Railway track systems

Standard variant

K - Width of rail flange 125 mm made of wood sleeper

Page: 114-02

Tightening torque 180 - 250 Nm

8 7

1 2

Intermediate level Hexagonal nut

6

2

Clamping plate

5 4 3 2 1

2 1 6 4 1 Number/Support point

Hook screws Ribbed base plate Spring lock washer Sleeper screws Rail

Zw 664a or Zw 686 DB M22 Kpo 6 (49E5) Kpo 9 (54E3) Hs 26-65 Rpb 1 Fe 6 Ss 8-150 49E5 or 54E4

Designation

Brief description

Pos.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Standard variant

KS - H - 60E2 made of wood sleeper

Page: 115-01

Tightening torque 180 - 250 Nm

9 8 7 6 5 4 3 2 1 Pos.

1 2 2 2 2 1 4 4 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Rail clamps Washer Hexagonal nut Hook screws Ribbed base plate Spring lock washer Sleeper screws Rail

Zw 661a or Zw 687 Skl 12 Uls 6 DB M22 Hs 32-55 Rpb 6 Fe 6 Ss 8-150 60E2

Designation

Brief description

Railway track systems

Standard variant

KS - H - Width of rail flange 125 mm made of wood sleeper

Page: 115-02

Tightening torque 180 - 250 Nm

9 8 7 6 5 4 3 2 1 Pos.

1 2 2 2 2 1 4 4 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Rail clamps Washer Hexagonal nut Hook screws Ribbed base plate Spring lock washer Sleeper screws Rail

Zw 664a or Zw 686 Skl 12 Uls 6 DB M22 Hs 32-55 Rpb 6 Fe 6 Ss 8-150 49E5 or 54E5

Designation

Brief description

Railway track systems

Standard variant

KS - 60E2 made of Y-Steel sleepers

Page: 116-01

Tightening torque 200 Nm

7 6 5 4 3 2 1 Pos.

1 2 2 2 2 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Rail clamps Washer Hexagonal nut Hook screws Ribbed base plate Rail

Zw 690 Skl 12 Uls 6 DB M22 Hs 32-55 Rpb 15 60E2

Designation

Brief description

Railway track systems

Standard variant

KS - Width of rail flange 125 mm made of steel sleepers

Page: 116-02

Tightening torque 180 - 250 Nm

7 6 5 4 3 2 1 Pos.

1 2 2 2 2 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Rail clamps Washer Hexagonal nut Hook screws Ribbed base plate Rail

Zw 691 Skl 12 Uls 6 DB M22 Hs 32-55 Rpb 8 49E5 or 54E4

Designation

Brief description

Railway track systems

Standard variant

KS - St - Iso - 60E2 made of Y-Steel sleepers

Page: 116-03

Tightening torque 180 - 250 Nm

8 7 6 5 4 3 2 1 Pos.

1 2 2 2 2 2 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Insulating insert Rail clamps Washer Hexagonal nut Hook screws Ribbed base plate Rail

Zw 697a Iw 16 Skl 12 Uls 6 DB M22 Hs 32-55 Rpb 15 ia 60E2

Designation

Brief description

Railway track systems

Standard variant

KS -St - Iso - Rail foot width 125 mm made of steel sleeper

Page: 116-04

Tightening torque 180 - 250 Nm

8 7 6 5 4 3 2 1 Pos.

1 2 2 2 2 2 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Insulating insert Rail clamps Washer Hexagonal nut Hook screws Ribbed base plate Rail

Zw 697a Iw 16 Skl 12 Uls 6 DB M22 Hs 32-55 Rpb 8 ia 49E5 or 54E4

Designation

Brief description

Railway track systems

Standard variant

Rail fastening S15 made of Y-Steel sleepers

Page: 117-01

Tightening torque 200 Nm

9 8 7 6 5 4 3 2 1 Pos.

1 2 2 1 1 2 2 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Spacer plate Intermediate level Clamping dowel Guide plate (outside) Guide plate (inside) Rail clamps Washer Sleeper screws Rail

Zwp 192 (or Zwp 193) Zw 401 Dü S 15 Fpa 15 Fpi 15 Skl 14 Uls 7 Ss 34 60E2 (49E5 / 54E4)

Designation

Brief description

Railway track systems

Grooved rail with guardrail

Installation views 59R1 / 59R2 / 60 R1 / 60 R2

Page: 118-01

Track 1435/1000

Correction plates 2 and 3 mm thick

End perforation

Splice joint

Welding joint 750 for 15 and 18 m rails

Without scale/schematic diagram

Date of issue 08/10

Guardrail perforation – oval holes only for steel grade 700

Railway track systems

Grooved rail with guardrail

Installation views 57R1 / 67R1 / Ph 37N

Page: 118-02

Track 1435

Correction plates 2 and 3 mm thick

End perforation

Guardrail perforation – oval holes only for steel grade 700 Splice joint

Welding joint

937.5 for 15 m rails (900 for 18 m rails) H = 75 for 57R1 71 for Ph 37N and 67R1

Without scale/schematic diagram

Date of issue 08/10

h = 65 for 57R1 63 for Ph 37N and 67R1

Railway track systems

Grooved rail with guardrail

Guardrail Details

Page: 118-03

Track

A = Clear width between the bars L = length of guard rail

Correction plates 2 and 3 mm thick

Guard rails Fl. 70 x 10 mm

2 or 3

Profile 59R1 - 59R2 60R1 - 60R2 59R1 - 59R2 60R1 - 60R2 59R1 - 59R2* 60R1 - 60R2* 59R1 - 59R2** 60R1 - 60R2** 57R1 Ph 37N 67R1 * Dresden/ ** Leipzig

Without scale/schematic diagram

Date of issue 08/10

Track 1000 1000 1435 1435 1450 1450 1458 1458 1435 1435 1435

Dimensions / Weights A 1018.5 1018.5 1453.5 1453.5 1468.5 1468.5 1476.5 1476.5 1444 1453.5 1453.5

L 1015 1015 1450 1450 1465 1465 1473 1473 1442 1451 1451

kg / St. 7.233 7.233 9.623 9.623 9.579 9.628 9.628

Railway track systems

Grooved rail with guardrail

Material requirement 15 m

Page: 118-04

Material for a 15 m long track length (without tabs) 59R1 / 59R2 track 1435 2 10 10 10 40

Rails 59R1 / 59R2 N Guard rails Correction plates (2 mm dick) Correction plates (3 mm dick) Guardrail perforation

59R1 / 59R2 track 1000 2 10 10 10 40

Rails 59R1 / 59R2 N Guard rails Correction plates (2 mm dick) Correction plates (3 mm dick) Guardrail perforation

60R1 / 60R2 track 1435 2 10 10 10 40

Rails 60R1 / 60R2 Guard rails Correction plates (2 mm dick) Correction plates (3 mm dick) Guardrail perforation

60R1 / 60R2 track 1000 2 10 10 10 40

Rails 60R1 / 60R2 Guard rails Correction plates (2 mm dick) Correction plates (3 mm dick) Guardrail perforation

57R1 / 67R1 / Ph37 N track 1435 2 8 8 8 32

Rails 57R1 / 67R1 Ph 37N Guard rails Correction plates (2 mm dick) Correction plates (3 mm dick) Guardrail perforation

Without scale/schematic diagram

Date of issue 08/10

lg, mm 15000 1450 M22 x 55

lg, mm 15000 1015 M22 x 55

lg, mm 15000 1450 M22 x 55

lg, mm 15000 1015 M22 x 55

lg, mm 15000 1442 / 1451 1451 M22 x 55

kg / pc. zus. kg 884.55 / 872.10 1769.1 / 1744.2 9.623 96.2 0.135 1.4 0.202 2.0 0.456 18.2 Sum 15 m = 1886.9 / 1862.0

kg / m

kg / pc. zus. kg 884.55 / 872.10 1769.1 / 1744.2 7.233 72.3 0.135 1.4 0.202 2.0 0.456 18.2 Sum 15 m = 1886.9 / 1862.0

kg / m

kg / pc. zus. kg 908.85 / 896.25 1817.7 / 1792.5 9.623 96.2 0.135 1.4 0.202 2.0 0.456 18.2 Sum 15 m = 1935.5 / 1910.3

kg / m

kg / pc. zus. kg 908.85 / 896.25 1817.7 / 1792.5 7.233 72.3 0.135 1.4 0.202 2.0 0.456 18.2 Sum 15 m = 1911.6 / 1886.4

kg / m

kg / pc. zus. kg 847.50 / 1003.65 1695.0 / 2007.3 988.20 1976.4 9.528 / 9.577 76.2 / 76.6 9.577 76.6 0.135 1.4 0.202 2.0 0.456 18.2 Sum 15 m = 1788.5 / 2101.2 2070.3

kg / m

125.8 / 124.1

124.2 / 122.5

129.0 / 127.4

127.4 / 125.8

119.2 / 140.1 138.0

Railway track systems

Grooved rail with guardrail

Indoor track 57R1 made of situ-concrete plate

Page: 118-05

Guard rail with threaded ends M 20 Grooved rail 57R1 / 67R1 Rail grouting MINEY-grout

Indoor track 57R1 / 67R1 made of situ-concrete plate The usual guard rails made of flat steel are for for grooved rails that are embedded in the final state are not recommended. Round bar with threaded ends according to the conventional reinforcement. The site concrete in this case is produced up to 16 cm below SO. For including the width of rail flange, recesses are provided. The grooved rails are installed with track holders to the rails, laid and aligned according to location and height. The rails with MINEX-grout to be grouted in the gaps. Subsequently, the remaining site concrete is introduced, if necessary. with asphalt coating in crossing areas before the halls or special industrial floors in the hall.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Variant Vossloh

System W 3 / standard for concrete sleepers

Page: 119-01

System W 3 for concrete sleepers Extract from the Technical Communication RO 26 / 05 of DB AG from 08.11.2005: Replacement of the rail fastening W 3 on site W 14. According to the Directive RiL 820.2010. The rail fastening W 3 with rail clamp Skl 1 and angular guide plate Wfp 3b is to be installed instead of the previously used rail fastening W 14 k made of concrete sleepers B70 W, B70 W-2.4 and B90. Rail fastening with rail clamp Skl 1 The rail is placed with the elastic intermediate layer on the concrete sleeper. The lateral position of the rail is secured by the angular guide plate Wfp 3. The Wfp is made of steel (with insulating insert) or glass fibre reinforced plastic. They transfer the lateral forces on the concrete body, without claiming the screw to bend and without effecting adversely for the track gauge formation. The resultant of vertical force and screw clamping force is directed obliquely. The angular guide plate and the support in the concrete sleeper are shaped in such a way, so that a tight fit is ensured even with loosened tie screws. The insulating insert between steel angular guide plate and concrete allows a complete attachment and an electrical insulation. The rail clamp Skl 1 is supplied with a permanent rust preventive coating. The non-positive bracing between rails and sleepers is achieved by using the listed parts. Advantages • • • • •

Exact track gauge even by heavy load operation and in curved parts. High creep distance and torque resistance to prevent fracture gap openings. High frame rigidity to secure the position of the track. Low maintenance, no rework after installation. No route blocking on suspended sleeper screws (stress equalisation). Captive pre-assembly in the sleeper factory. After installation of the rails, and intermediate layers, the sleeper screw is loosened, the rail clamp is rotated around 180° and the screw tightened with a torque of approx. 200 Nm. The correct mounting poition is to be identified so that the intermediate loop touches the angular guide plate. The clamping force of the spring arm is then approx. 11.5 kN at a deflection of 14.5 mm. There is an air space of about 1.5 mm between rail clamps intermediate loop and rail flange. The lifting or tilting of the rail is executed by the intermediate loop and thus excluded overexpanding of the spring arms.

installed

6 5 4 3 2 1 Pos.

1 2 2 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

pre-installed

Intermediate level Plastic dowel Angular guide plate Rail clamps Sleeper screws with track Rail

Zw 686a / Zw 687a Sdü 9 Wfp 3b Skl 1 Ss 25 with Uls 7 49E5 / 54E4 / 60E2

Designation

Brief description

Railway track systems

Variant Vossloh

System W 14 / standard for concrete sleepers

Page: 119-02

System W 14 for concrete sleepers Characteristics: Different rail profile on the the same sleeper On the same sleeper in same track gauge, the rail profiles 60E2, 54E1 and 49E5 can be used by simply changing the angular guide plates. Gauge widening A gauge widening of +/-10 mm in levels of 2.5 mm is available by default. Tilting table Lifting or tilting the track during the way maintenance or while passing through the narrow track curves is braced after overcoming the small air gap (between intermediate loop of the rail clamp and rail flange) with an intermediate loop. Thus a permanent deformation of the outer spring arms is excluded. Track maintenance The Vossloh rail fastening system requires no regular maintenance. Rail bracing and creep distance The rails consistently braced non-positively through the free spring arms in a deflection of approx. 13 mm and a retaining force of approx. 2 x 10 kN. This will require the high creep resistance of the rail, which prevents dangerous gap openings in welded rails, as well as a sufficient frame rigidity of the track section is achieved. Neutralisation For continuous welding of the rails (CWR), no fastening parts are removed from the sleeper. Only the sleeper screws are loosened but not removed.

installed

6 5 4 3 2 1 Pos.

1 2 2 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

pre-installed

Intermediate level Plastic dowel Angular guide plate Rail clamps Sleeper screws with track Rail

Zw 700 Sdü 9 Wfp 14k Skl 14 Ss 25 with Uls 7 60E2

Designation

Brief description

Railway track systems

Variant Vossloh

System W 14 / standard for concrete sleepers

Page: 119-03

Height adjustment In Vossloh-rail fastening system W 14, a height adjustment of 8 mm is possible by inserting height correction plates. Interchangeability All components are interchangeable. Electrical insulation Since the angular guide plate, the intermediate layer and the anchor screw is made of plastic, the fastening system W 14 is completely electrically insulated. No additional insulated parts are required between the rail flange and rail clamps. Pre-assembly All the fastening parts can be pre-assembled in the sleeper factory manually or automatically. Only the rail is inserted at the installation site. Either during transport or during track construction, the fastening parts are missing. Mounting Simple mechanical installation with standard screw machine. Use of angular guide plates The Wfp 14 K as a standard railway track, the Wfp 14 S, with Ei and 32 is used only in exceptional cases depending on the type of earthing.

Installation instructions Correct

Wrong

The correct installation clamping position is achieved when the intermediate loop touches the rib of angular guide plate by tightening the sleeper screw. (max. permissible air gap: 0.5 mm). A tightening torque of approx. 200 Nm is required.

Intermediate loop does not rest, air gap is too large. Desired clamping force is not reached!

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Variant Vossloh

System 14 / E 21

highly elastic for concrete sleepers

Page: 119-04

System E 14 for concrete sleepers Railway track E 14 with rail clamps Skl 14 is a highly elastic rail fastening system for concrete sleepers in gravel tracks. When upgrading from W 14 to E 14, the sleeper in gravel bed remain stuffed. Features: • • • •

fully compatible to railway track W 14 Improved travelling comfort improved modulus of grade reaction lower gravel erosion

It is achieved with the large elastic intermediate plate with surface pressure distribution plate, similar to the system 300 for slab track, large deflection of the rails. The Skl 14 is also fatigue endurable in these high vertical dynamic rail movements. All fastening parts can be captively installed in sleeper factory on the sleeper. Hence mechanised and fully automatic installation in the track is possible. A possible efficient increase of drive comfort on gravel tracks, equipped with standard railway track W 14, and/or a reduction which takes place under heavy loads gravel destruction can be achieved with compatible rail fastening system E 14. Gravel tracks often have insufficient deflection values when used in high-speed traffic on new tracks. With EVA intermediate layers, the maximum of 0.2 mm compressed under rolling wheel, achieved together with the gravel elasticity of about 0.6 mm on new tracks of the highest values of 0.8 mm. Even the use of so-called "soft" intermediate layers with static spring digits of c = 50 - 70 kN/mm brings an improvement of about 1.0 mm of rail depression.

8 7 6 5 4 3 2 1 Pos.

1 1 1 2 2 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

installed

pre-installed

Intermediate level Base plate Intermediate level Plastic dowel Angular guide plate Rail clamps Sleeper screws with track Rail

Zwp E 14 Grp E 14 Zw E 14 Sdü 25 Wfp E 14 Skl 14 / Skl 21 Ss 36-220 with Uls 7 60E2

Designation

Brief description

Railway track systems

Variant Vossloh

System 14 / E 21

highly elastic for concrete sleepers

Page: 119-05

It was therefore the task of finding possible solution by using standard elements that can be achieved with the desired rail deflection values of 1.5 mm. The railway track E 14 uses the monoblock concrete sleeper B 70 W 60 with the rail flange Skl 14. Thus, this railway track system are both on existing routes as well as on new lines to be built for use. Structure: The E 14 fastening system is a direct high elastic rail fastener for standard concrete sleepers B70 W60 for the slab track. It is analogously built to the rail fastening system 300. Lateral forces are transferred via angular guide plates. The rail is still braced with usual elastic rail flange Skl 14 in ballasted track. The two free spring arms are located on the rail foot. The superior intermediate loop of the rail foot acts as a tilting table. Controllability: The fastening system is designed in such a way that the height adjustments are possible up to 5 mm as in W 14 railway track, without darning. If desired, a gauge widening of up to +/- 10 mm are provided even in levels by changing the angular guide plates, as in systems W 14 and 300.

The System E 14 is available for local public transport under the name 300 UTS with rail flange Skl 21 and adapted intermediate plate. The Sk 21 in this case replaces the Skl 14 with higher vertical and dynamic fatigue strength.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Variant Vossloh

System 300 / for Slab Lane

Page: 119-06

System 300 with rail 60E2 and Skl 15 for the slab track Slab tracks meet all the requirements for combined high-speed and heavy traffic. The pre-assembled rail fastening system 300 is suitable for all types of installation of the slab track. The highly elastic intermediate plate replaces the elasticity of gravel bed. For better load distribution, a steel pressure distribution plate which rests on the customary interposition of a conventional interlayer rail. Laterally the rail is held in position by the plastic angular guide plates. The rail flange Skl 15 is braced non-positively by the long elastic deflection. The slab track rail fastening system 300 with Skl 15 is analogously built of the fastening W 14. The lack of gravel elasticity is replaced with the rail fastening system 300 for the slab track by using the highly elastic intermediate plate. While using a spring constant of 22.5 kN/mm, measured as secant stiffness between 18-68 kN, a depression of rail is achieved from up to 1.5 mm in the standard gauge railway (22.5 t axle load). Construction of the slab track: • • •

Monolithic: Stored Special systems

The fastening can be provided on both the sleepers and for individual bases.

Regulatory options: Height adjustability

Side controllability

Without scale/schematic diagram

Date of issue 08/10

+6 -4 +26 -4 +/- 5

∑10 mm ∑ 30 mm ∑ 10 mm

using intermediate levels using intermediate levels and height balancing plates using angular guide plates

Railway track systems

Variant Vossloh

System 300 / for Slab Lane

Page: 119-07

Rail flange Skl 15 Installation instructions Correct The correct installation clamping position is achieved when the intermediate loop touches the rib of angular guide plate by tightening the sleeper screw. (max. Permissible air gap: 0.5 mm). A tightening torque of approx. ≤ 200 Nm is required.

Wrong Intermediate loop does not rest, air gap is too large. Desired clamping force is not reached!

installed

8 7 6 5 4 3 2 1 Pos.

1 1 1 2 2 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

pre-installed

Intermediate level Base plate Intermediate level Plastic dowel Angular guide plate Rail clamps Sleeper screws with track Rail

Zwp 104 NT Grp 21 Zw 692 Sdü 25 Wfp 15a Skl 15 Ss 36 with Uls 7 60E2

Designation

Brief description

Railway track systems

Variant Vossloh

System KS for rib based plates

Page: 119-08

System KS with rail flange Skl 12 for rib based plates The rail flange Skl 12 was designed for rail fastening on rib based plates with "hard" intermediate layers (c ≥ 200 kN/m). The rail flange Skl 24 is available as an alternate. All fastening parts can be captively installed in sleeper factory on the sleeper. Hence mechanised and fully automatic installation in the track is possible. With the two free spring arms of the rail flange, a permanently non positively braced rail with approx. 13 kN clamping force is achieved with approx. 14.5 mm deflection per rail flange, whereby the fastening do not require any maintenance. The tilting movement of the rail is executed by the intermediate loop of the rail flange. A temperature stress equalisation of the rails is made easier by only loosening the screws. Any necessary rail requirement can be done easily, in which the rail flange while installation is pushed back. Installation instructions 1. Loosen hexagonal nut of the screw-hook (approx. 1-2 revolutions) 2. Bring rail flange in installation position (Spring arms must rest on the rail foot) 3. The installation position is achieved when the interediate loop of the rail flange touches by tightening the screw of the rail foot, or an air gap is up to 2 mm (tightening torque 180-250 Nm).

pre-installed

installed

9 8 7 6 5 4 3 2 1 Pos.

1 2 2 2 2 1 4 4 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Rail clamps Washer Hexagonal nut Hook screws Ribbed base plate Spring lock washer Sleeper screws Rail Designation

Zw 687 Skl 12 Uls 6 DB M22 Hs 32-55 Rph 6 Fe 6 Ss 8-150 60E2

Zw 687 Skl 12 Uls 6 DB M22 Hs 32-55 Rph 1 Fe 6 Ss 8-150 49E5 / 54E4

Brief description

Railway track systems

Variant Vossloh

System W-Tram - with Wedge angle plates

Page: 119-09

Rail fastening system W-Tram with wedge angular guide lates K-Wfp 14 R and L With the wedge angular guide plates with a continuous adjustment, the limited rail foot tolerance related to manufacturing process, above all balanced in grooved rails, and so the track width can be regulated upto +/-10 mm. In the slab track, the use of insulated anchor bolts is possible, alternatively the proven anchor screw combination Sdü 26/Ss 36. The lateral forces of the rail is carried on the angular guide plate and the base plate in the concrete support plate. Does not have the bending or shear forces on the embedded anchorage system. High power dissipation by the profiled bottom of the base plate. The sleeper screw / anchor bolts is only subjected to train. Completely electrically insulated. For laying the rail grooves on concrete sleepers, the system W is used, for slab track the system WTram is used.

Application examples W-Tram on slab track

W made of concrete sleepers

installed

Concretesleeper

Slab track

7 6 5 4 3 2 1

1 2 1 2 2 2 1

Pos.

Number/Support point

Without scale/schematic diagram

Date of issue 08/10

pre-installed

Intermediate level Plastic dowel Base plate Angular guide plate Rail clamps Sleeper screws with track Grooved rail Designation

Zw 900/180 Sdü 26 Upl 180/120 K-Wfp 14 Skl 14 Ss 36 + Uls7

Zw 900/180 Sdü 25 K-Wfp 14 Skl 14 Ss 35 + Uls7

W-Tram W-Sleeper Brief description

Railway track systems

Variant ThyssenKrupp

System W 97 / for 49E5 /

54E4 made of concrete sleepers

Page: 119-10

System W 97 for concrete sleepers Characteristics: The rail fastening W 97 was developed as an adapter solution for using the rails with rail flange width of 125 mm (rails 49E5, 54E4) on concrete sleepers B 70 W-60 that requires the rail flange width of 150 mm. Here, specifically, the use of reclaimed sleepers B 70 W-60 is considered (from the year 1974), as standard equipment of DB. • • •

Tracks with a permissible speed v < 160 km/h Tracks with a traffic density < 30,000 Lt/d Routing and marshalling attachments

Authorisation under: • • •

DBS 918127 DIN EN 13481-2 Creep distance in Rail longitudinal direction Electrical resistance



Tightening torque 200 Nm

F = 10 kN R33 = 7,11 k Ω

(according to 3.0 Mio. load changes) (average)

installed

pre-installed

7 6 5 4 3

1 2 1 1 2

Intermediate level Plastic dowel Angular guide plate Special angular guide plate Rail clamps

2

2

Sleeper screws with track

1

1 Number/Support point

Rail

Zw 686a Sdü 25 (alternatively Sdü 9) Wfp 3b - 22 Wfp 3b - 28 Skl 1 / 97 Ss 25 (alternatively Ss 35) with Uls 7 49E5 / 54E4

Designation

Brief description

Pos.

Without scale/schematic diagram

Date of issue 08/10

Railway track systems

Variant ThyssenKrupp

System W 97 / for 49E5 /

54E4 made of concrete sleepers

Page: 119-11

Resultant track gauge: Depending on the large sick dimension of the sleeper, there is a resulting theoretical track gauge when using of rail fastening W 97. See the below table: resultant track gauges gr. sick dimension 1810 1811 1812 1813 1814 1815 1815.5

Field side

Track gauge

Track gauge

Field side

28

22

22

28

Gauge of the track 1432 1433 1434 1435 1436 1437 1437.5

Economy: Compared to the supply of new concrete sleepers, by using the rail fastener W 97 on reclaimed concrete sleepers B70, W 60 indicates possible savings of about 30%. (Source: DB, TM 2009-030 I.NVT4 (F) 10.02.2010). Mounting / Installation: The following points must be considered in planning and installation: • •

Providing the right Ironmongery (sleeper screws) depending on the used plastic screw anchor (Sdü 9 / 20 or Sdü 25). Installing two different angular guide plates on the specified positions

Installation instructions after inserting the rails: 1. Release sleeper screw - approx. 1.5 turns. 2. Rail clamps rotate by 180° → Spring arms are placed on the rail flange 3. Interlocking the rail fastening as per the Directive 824 5050.

Without scale/schematic diagram

Date of issue 08/10

Elastic rail bedding

Overview

Road cross section

Operational area (Axle load) Tram (up to 100 kN)

Continuous rail bedding

Discrete rail bedding

Without scale/schematic diagram

Date of issue 08/10

Page: 120-01

City railway (up to 135 kN)

Metro (up to 160 kN)

Rail cover

Standard gauge railway (up to 250 kN)

constructive possible deflection (in mm) up to 1.5

Railflex

up to 1.5

ISOLast

up to 1.5

Flexpoint

up to 1.5

Whisper rail

up to 10

VIBRALast Highly elastic grooved rail turnouts Powerflex

up to 2

variable

Flattrack

up to 1.5

Delta stock

between 2-8

TK 07-R

up to 1.5

up to 4

TK 04-R

up to 5

TK 99

up to 3

EASYLast

up to 3

Krupp ECF-System

up to 3

Ei-attachment

up to 3

Acoustical Loadmaster

up to 4

Elastic Rail bedding

Continuous Rail bedding

ThyssenKrupp Railflex

Page: 121-01

The system RAILFLEX is a continuous elastic rail bending system for city rails and trams. It consists of the main elastic components, electrically insulating base element, electrical chamber element for inner and outer side, elastic and electrical insulating coatings for the track holder, rail fastening and installation base plate. The rail bedding is continuously horizontally and vertically adjustable. Application for all tracks with asphalt, concrete, paved areas, surface as well as for crossings. No track geometry limitations, use on bridges and in tunnels. High damping effect for air-borne and structure-borne sound. Application with all known grooved rails and vignol rail profile. Operational info systems sice 1993 with approx. 180,000 m rail and 80 crossings.

8 7 6 5 4 3 2 1 Pos.

1 1 1 2 1 2 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Foot coating profile Chamber element inside Chamber element outside Adjustable foot Support plate with adjusting anchor Insulation barrel Hexagon head bolt Rail

59R1 / 59R2 / 60R1 / 60R2

Designation

Brief description

Elastic Rail bedding

Continuous Rail bedding

ISOLast

Page: 121-02

ISOLast stores grooves and vignol rails continuously and elastically, and significantly reduces shocks and vibrations in railway vehicles by degenerating the entire track of this type (slab track, pavement, and plantation) from the environment. Due to the installation situation a deflection of more than 1.5 mm is recommendable. The chamber filling profiles are waterproof. The track should be laid on a situ-concrete plate and encapsulated with low-shrinkage cement mortar for height adjustment. The width of the chamber filling profiles is recessed during construction of the surface and later encapsulated to the rail level with highly elastic compound based on bitumen (Ortec.ESV). Applications for all tracks and crossings with roofing: • • • •

Asphalt Concrete / Asphalt Concrete / Natural stone paving Crossings 9 8 7 6 5 4 3 2 1

Pos.

2 2 1 1 2 2 1 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Clamping plate Hexagonal nut Base coat profile Base plate Lock-nut Thread block DIN 976 - M24 Chamber filling profiles outside Chamber filling profiles inside Rail

IL-3062-04-A4 DIN 985 - M24 GP-1215-00-A3 IL-3135-00-A3 DIN 7967 - M24 IL-3126-00-A4 IL-2029-03-A1 IL-2028-02-A1 59R1 / 59R2 / 60R1 / 60R2

Designation

Brief description

Elastic Rail bedding

Continuous Rail bedding

ThyssenKrupp Flexpoint

Page: 121-03

The system FLEXPOINT is a discontinuous elastic rail bending system on the basis of rail support point TK07-R, which is is so provided with an integral elastomer element so that no dynamic gauge widening is possible under the vehicle. It further consists of both sided elastic chamber elements, the cover cap on the rail fastenings and the insulating base profile between rail support points. Application for all tracks with asphalt, concrete, paved areas, crossings. No track geometry limitations, use on bridges and in tunnels possible. Application with all known grooved rails and vignol rail profile.

10 9 8 7 6 5 4 3 2 1 Pos.

1 2 2 1 1 1 2 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Chamber element Anchor Baseplate with ribbing Elastic base plate Support plate Rail clamps Washer Sleeper screws Rail

Skl 1 Uls 7 Ss 25 59R1 / 59R2 / 60R1 / 60R2

Designation

Brief description

Elastic Rail bedding

Continuous Rail bedding

Whisper rail

Page: 121-04

The whisper rail offers the possibility of deflections to reach up to 10 mm due to their construction. Rail car sound and vibrations are reduced up to 90% in densely built areas especially in trams. The enclosure profile decouples the inner movement of the rail from the environment. The rail flooring is not affected by the movement. For open cross-sections, like gravel bed, the whisper rail can be constructed as a header rail, whereby to stop the enclosure profile below the rail head. Applications for all tracks and crossings with roofing: • • • •

Asphalt Concrete / Asphalt Concrete / Natural stone paving Crossings 12 11 10 9 8 7 6 5 4 3 2 1

Pos.

1 1 2 2 2 1 2 1 1 1 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Hexagonal nut Hexagon head bolt Lock-nut Hexagonal nut Thread block Base plate Clamping plate Base coat profile Elastomer profile head Elastomer profile groove Enclosure profile Rail

DIN 980 - M20 ISO 4014 - M20 x 160 DIN 7967 - M24 DIN 985 - M24 DIN 976 - M24x240 RI-2754-00-A3 KS-2210-00-A4 GP-1122-03-A3 GP-1160-04-A3 GP-1158-08-A3 RI-2334-01-A3 49E5 / 54E4

Designation

Brief description

Elastic Rail bedding

Continuous Rail bedding

Rail cover

Blatt: 121-05

Primarily the system railcover provides the protection against stray current corrosion. For this reason, the rail is coated with a profile made of plastic. The system design permits a deflection of up to 1.5 mm. The plastic profile is connected on Th rail with a special adhesive. Within the profiles, under the rail foot, an elastic intermediate layer is inlaid to achieve the desired deflection. The system is attached to underground guard rail with MX-guide rail clamps. Thus a wheel truing of +/- 8 mm can be set. Applications for all tracks and crossings with roofing: • • • •

Asphalt Concrete / Asphalt Concrete / Natural stone paving Crossings 10 9 8 7 6 5 4 3 2 1

Pos.

2 2 2 1 2 2 2 1 1 1 Number/Support point

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Date of issue 08/10

Washer Hexagonal nut Hexagon head bolt Underfloor steering track rod Hexagon head bolt Hexagonal nut MX-fasteing Base coat profile Rail bedding Rail

ISO 7090-20 ISO 4032 - M16 ISO 4017 - M16 x 120 ER-1001-00-A3 ISO 4017 - M20 x 65 ISO 4032 - M20 MX 2424 GP-1262-03-A3 GP-1269-02-A3 59R1 / 59R2 / 60R1 / 60R2

Designation

Brief description

Elastic Rail bedding

Continuous Rail bedding

VIBRALast

Page: 121-06

The system VIBRALast is a channel system that is used with a 2-component material based on polyurethane. The system can be loaded with grooved rails and also with vignol rails. The rail foot is furnished with a base coat profile to achieve required deflection of up to 2 mm. All parts are prefabricated, delivered on the installation site, whereby significantly reducing the installation time. Applications for all tracks and crossings with roofing: • • • •

Asphalt Concrete / Asphalt Concrete / Natural stone paving Crossings 7 6 5 4 3 2

1 1 1 1 1 1

Hexagonal nut Threaded rod Tightener Base coat profile Chamber filling profiles outside Chamber filling profiles inside

1

1

Rail

Pos.

Number/Support point

Designation

Without scale/schematic diagram

Date of issue 08/10

ISO 4032 - M24 DIN 975 - M24x600 DIN 1480 SP - M24x255 GP-1215-00-A3 IL-2029-03-A1 IL-2028-02-A1 59R1 / 59R2 / 60R1 / 60R2 49E5 / 54E4 Brief description

Elastic Rail bedding

Continuous Rail bedding

Highly elastic Soft grooves

Page: 121-07

standard cross-section

For using within the rail turnouts, system VIBRALast is expanded in view of the deflection. It consists of the similar components as in VIBRALast, only within the rail foot, modified elastomer elements are arranged to brace the different rigidity within the crossings and to achieve a uniform deflection of up to 4 mm. The system is suitable for road-aligned cross-sections. Applications for all tracks and crossings with roofing: • • • •

Asphalt Concrete / Asphalt Concrete / Natural stone paving Crossings 6 5 4 3 2

1 1 1 1 1

Steel cable coating Elastomer pad Foam carpet Chamber filling profiles outside Chamber filling profiles inside

1

1

Rail

Pos.

Number/Support point

Designation

Without scale/schematic diagram

Date of issue 08/10

EWL-1025-00-A3 GP-1297-00-A3 EWL-1028-00-A3 IL-2029-03-A1 IL-2028-02-A1 59R1 / 59R2 / 60R1 / 60R2 49E5 / 54E4 Brief description

Elastic Rail bedding

Continuous Rail bedding

Potting material Powerflex

Page: 121-08

Our durable elastic product Powerflex can be used individually in order to grout grooved rails. The material which sets rapidly after casting can be introduced manually or mechanically. The latter is suitable for larger projects. The deflection can be varied depending on customer requirements, but they must not be more than 2 mm. No big actions must be taken for processing; disposal after decommissioning is possible without any special effort. Applications for all tracks and crossings with roofing: • • • •

Asphalt Concrete / Asphalt Concrete / Natural stone paving Crossings 4 3 2

1 1 1

Base coat Chamber filling profiles outside Chamber filling profiles inside

1

1

Rail

Pos.

Number/Support point

Designation

Without scale/schematic diagram

Date of issue 08/10

GP-1148-03-A3 IL-2029-03-A1 IL-2028-02-A1 59R1 / 59R2 / 60R1 / 60R2 49E5 / 54E4 Brief description

Elastic Rail bedding

Continuous Rail bedding

ThyssenKrupp Flattrack

Page: 121-09

Joint sealing

The system FLATTRACK is a continuous elastic rail bending system on the basis of the new grooved rail FLAT RAIL, with the rail height of 100 mm enables a miimum construction height. It further consists of the elastic; electrically insulating base element, electrical chamber element and rail fastening and installation support point, so that the rails can be set continuously horizontal and vertical. By using the adapter elements on the long side of the chamber elemnt, an optial joint design is possible. The FAT RAIL is possible with an advantageous wide rail head, the big rail depth und extended head thickness of an extended service compared to conventional rail service.

9 8 7 6 5 4 3 2 1 Pos.

1 1 2 2 2 1 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

elastic foot element Chamber element Cover cap Clamping plate Adjustable foot Support plate with anchor Eccentric Hexagon head bolt Rail

Flat Rail ( Ri58N)

Designation

Brief description

Elastic Rail bedding

Discrete Rail bedding

Delta-Stock

Page: 122-01

The Delta-Lager can be designed in such a way for all local traffic loads, so that a vertical deflection of 2-8 mm is achieved. The maximum horizontal deflection is < 2 mm. The system is suitable for concrete sleepers with W-fastening. When using an additional base plate, the load can be used on concrete or wooden sleepers. Therefore the Delta-Lager is ideal for slab track. 12 11 10 9 8 7 6 5 4 3 2 1 Pos.

4 4 4 2 2 1 1 2 1 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Lock-nut Hexagonal nut Thread block Spring washer Hexagon head bolt Base plate Polyamide plate Insulating insert Intermediate level Spring element Console Rail

DIN 7967 - M24 DIN 985 - M24 DIN 976 - M24 x 240 DIN 6796-24 ISO 4017 - M24 x 55 DL-1071-00-A2 DZ-2187-00-A4 DZ-2123-03-A3 DZ-2126-01-A4 GP-1093-11-A3 DL-1104-01-A3 49E5 / 54E4 / 60E2

Designation

Brief description

Elastic Rail bedding

Discrete Rail bedding

Krupp ECG-System

Page: 122-02

Alternatively: Screw stay

The developed Krupp ECF-system for the slab track from ThyssenKrupp Gleistechnik is a height and side adjustable rail support which meets the catalogue of requirements of Deutsche Bahn. Within the construction, the ribbed base plate has a large hole for eccentric insulating cases, which is inserted by ribbed base and damping plates and enables a continuous lateral adjustability from 10 mm. By using slotted correction plates of appropriate thickness, height adjustability from +26 to -4 mm "under operation" is possible. The Krupp ECF-system is used in precast slabs, concrete sleepers for slab track and in continuous concrete beam.

11 10 9 8 7 6 5 4 3 2 1 Pos.

1 1 1 2 2 2 2 2/4 2/4 2/4 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Ribbed base plate Spacer plate Washer Hook screws Rail clamps Hexagonal nut Spring lock washer Insulated collar brushing Hexagon head bolt Rail

ZW 686 / Zw 687 ERp 1 / ERP 2 Zwp 194 - 125/150 Uls 6 Hs 32-55 Skl 12 DB M22 Fe 31 Fbu 8 ISO 4014 - M22 x 230 49E5 / 54E4 / 60E2

Designation

Brief description

Elastic Rail bedding

Discrete Rail bedding

EASYLast

Page: 122-03

The electrically insulating system EASYLast provides a flexible solution for the storage of vignol and grooved rails. Using the elastic intermediate plate, it also provides an efficient protection from vibrations, whereby the deflection should be limited to 3 mm. The system consists of a ribbed base plate, which in addition has an intermediate layer under the rail foot and also an elastic intermediate plate. The rail fastening is supplied with conventional rail clamps. While fastening the rib based plate, the pressure springs are arranged to prevent lifting of the rib based plate. Below the pressure spring, the plastic collar brushes are arranged, which provides the electrical insulation. The necessary height compensation should be prepared with non-shrinking cement mortar.

14 13 12 11 10 9 8 7 6 5 4 3 2 1 Pos.

2 1 2 2 2 2 2 2 2 2 1 1 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Protecting cover Base plate Thread block Hexagonal nut Pressure spring Washer Collar brushing Washer Hexagonal screw with nut Rail clamps Intermediate level Ribbed base plate Elastic base Rail

DZ-2259-00-A4 DZ-2172-00-A4 DIN 976 - M24 x 240 DIN 985 - M24 DZ-2238-01-A4 DZ-2257-00-A4 EA-2033-02-A4 Uls 6 Hs 32 x55 Skl 12 ZW 677 EA-2025-01-A1 DZ-1015-05-A1 49E5 / 54E4

Designation

Brief description

Elastic Rail bedding

Discrete Rail bedding

ThyssenKrupp TK 99 / TK 99 S

Page: 122-04

The TK 99 is an elastic rail support with 2 or 4 anchor bolts with proven construction design of the system 314 / 336 of the Deutsche Bahn. The elastic deflection is adjustable up to 3 mm. The optimised sub-structure leads to the improvement of technology and function. In TK 99 S system, the load around the fastening of guard rail was extended. The system is constructed as a composite structure made of cast steel for whisper rail and guard rail and is suitable for all rail profiles. The elastic deflection is adjustable to the complete system. 13 12 11 10 9 8 7 6 5 4 3 2 1 Pos.

1 1 1 1 2 2 2 2 2/4 2/4 2/4 2/4 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Support plate Elastomer base Ribbed base plate Rail clamps Washer Hexagonal nut Hook screws Collar brushing Helical spring Hexagonal nut Anchor bolts Rail

Skl 12 Uls 6 DB M22 Hs 32 x 55 DIN 985 - M24 54E1

Designation

Brief description

Elastic Rail bedding

Discrete Rail bedding

ThyssenKrupp TK 07-R

Page: 122-05

The TK 07 is a supporting base that has been developed specially for the system Flexpoint. It consists of 100% plastic and is approved for the use of Metro and tram. The deflection is between 1 and 1.5 mm. The base is available in two versions. The system is not adjustable in TK 07, in TK 07-R, the horizontal position can be changed even later via wedge adjustment. The system is height adjustable and optimised with a special base plate for the use on a site-concrete construction - also with minimal thicness. 9 8 7 6 5 4 3 2 1 Pos.

1 2 1 1 1 2 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Anchor Baseplate with ribbing Elastic base plate Support plate Rail clamps Washer Sleeper screws Rail

Skl 1 Uls 7 Ss 25 59R1 / 59R2 / 60R1 / 60R2

Designation

Brief description

Elastic Rail bedding

Discrete Rail bedding

ThyssenKrupp TK 04-R

Page: 122-06

with alternative anchoring

A standard solution developed for Metro and tram rails, the elastic rail support TK 04-R. An innovation with many technical options. The elastic deflection up to 5 mm ensures driving comfort and low noise emission. In addition TK 04-R provides a height adjustment between -3 and +10 mm as well as a lateral adjustment between -10 and +10 mm. Through extensive use of plastic, the rail is electrically insulated against the concrete construction optimally. The low dead weight and the possibility of sub-assembly minimise substantially the installation time on-site. 11 10 9 8 7 6 5 4 3 2 1 Pos.

1 2 1 1 1 1 2 2 2 2 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Sliding wedge Base plate Elastic base Spacer plate Support plate Rail clamps Disc/washer Hexagonal nut Anchor bolts Rail

Skl 15 Ø44 / 25x4 M24 49E5 / 54E4

Designation

Brief description

Elastic Rail bedding

Discrete Rail bedding

Ei-attachment

Page: 122-07

The Ei-attachment - the name comes from the characteristic oval shape - was originally designed to reduce the impact sound. Because of the construction, consisting of the ribbed base plate and the frame, the deflection should be not more than 3 mm. The rail is mounted on the rib based plate using rail flange or E-clips. The outer side on the frame, the ears cast integrally, that are provided with bolts for fastening with anchor bolts. Between the rib based plate and frame, there is a tilted vulcanized elastomer ring, which provides a pressure-/ superimposed power intake. This results in the excellent acoustical effectiveness of the Ei-attachment. Besides the track gauge is reliably maintained because of construction. When overloaded, the rib based plate lowers maximum up to the dead end on the concrete. The elastomer ring dampens not only the vibrations, but also offers excellent electrical insulation. 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Pos.

11 10 9 8 7 2 2 2 6 5 4 1 1 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Lock-nut Hexagonal nut Spring lock washer Thread block Cog plate Washer Hexagonal nut Hook screws Rail clamps Polyamide plate Intermediate level Ribbed base plate Elastomer ring Frame Rail

DIN 7967 - M22 DIN 985 - M22 Fe 7 DIN 976 - M22 x 240 EI-0007-00-A1 Uls 6 DB M22 Hs 32 x 55 Skl 12 DZ-2254-00-A3 Ei-0009-00-A3 EI-0008-00-A1 vulcanised EI-0002-00-A0 49E5 / 54E4

Designation

Brief description

Elastic Rail bedding

Discrete Rail bedding

Acoustical Loadmaster

Page: 122-08

The Acoustical LoadMaster has been developed in order to achieve low stiffness in the rail. Depending on the axle load, the deflection of the rib based plate as per the construction is designed up to 4 mm. The system consists of a ribbed base plate and a frame which are connected through a vulcanised elastomer with each other. As per the requirements, the ribbed base plate are manufactured straight or inclined (1:20 / 1:40). The frame is so shaped that the ends of the ribbed base plate protrude. The gap is also filled with an elastomer and provides an elastic lift lock. On the frame of the load, the fastening points up to 4 are appropriate, which ensures an adequate lateral adjustability. 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Pos.

1 1 2 2 2 2 2 2 2 2 2 1 1 1 1 Number/Support point

Without scale/schematic diagram

Date of issue 08/10

Intermediate level Polyamide plate Cog plate Lock-nut Spring lock washer Hexagonal nut Thread block Washer Hexagonal nut Hook screws Rail clamps Ribbed base plate Elastomer Frame Rail

LM-1016-02-A4 DIN 7967 - M24 Fe 7 DIN 985 - M24 DIN 976 - M24 x 240 Uls 6 DM M22 Hs 32 x 55 Skl 12 DZ-2200-00-A1 LM-1015-02-A0 DZ-1114-00-A2 60E2

Designation

Brief description

Fixed Slab track

NFF

General

Page: 131-01

General Information Gravel construction and conventional fixed slab track as e.g. the system NBU differ in the interface of base / railway track. Hydraulically Bound Base course (HGT) instead Sub Structure (PSS) and Concrete Base course (BTS) instead gravel. Gravel roads can be repaired in limits by considering height and position, in FF-systems, these ratios are possible in limits in rail fastenings. The gravel roads requires more maintenance and has a shorter life until the complete reconstruction, FF systems have a long life and requires less maintenance but a more elaborate preparation of the base (soil stabilisation, compaction, exchange etc.). The ThyssenKrupp GfT Gleistechnik GmbH comes with two different slab track (FF)-Systems: • System FF NBU • New slab track NFF New slab track - NFF In poor soils, the cost for this soil stabilisation increases enormously. Here begins the operational area of NFF. It accounts to all base course work, that the system NFF loads from the dead weight and rail traffic over deep foundation (bore piles, micro piles, etc.) directly initiates the bearing capacity of base course The necessary pickets and associated pile lengths are determined by a ground survey, so that only minimum setting can be done. Thus, the advantages of the conventional slab tracks (low maintenance cost, long life) are connected to safe load transfer through deep foundations (small settlements, no complex substructure etc.) the system NFF. The system "New slab track" (NFF) is looked from a structural point of view as a bridge-like construction with a railway track part. Chamber (cross-fall) +100mm

Longitudinal support unit Chamber (cross-fall) +100mm

Cross bar



Drilling or micro piles.

Fig. 1: Schematic representation of NFF, here with each 6 pickets per CROSS BAR

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Date of issue 08/10

Fixed Slab track

NFF

General

Page: 131-02

The NFF consists of the rails, the rail fastening of longitudinal support unit (e.g. rail fastening system Krupp ECF), cross fall and the deep foundation consisting of drilling or micro-piles. The LTE is stored as a two-span beam on the cross bar which in turn supports the piles.

Fig. 2: NFF longitudinal support unit in track curves with the chamber Diameter, length, number and inclination of the pickets can be adjusted to the ground conditions, the reduction requirements and the rail characteristics. The inclination of the pickets in the ground can absorb both vertical and horizontal forces. The cross bar is advisable on the pickets. The cross bar in turn serves as a support for LTE. LTE and cross bar consists of precast concrete element, which are produced under optimal conditions and can be delivered with consistent quality. Only the connection of the cross bar with the pickets is on the installation site.

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Date of issue 08/10

Fixed Slab track

NFF

Constructive construction cycle

Page: 131-03

Constructive construction The following are the individual modules of the NFF are briefly represented in the real building process. Deep foundation The deep foundation serves the load transfer in subsoil and is therefore dependant on load and soil conditions. The kind of pickets, lengths and diameters can be selected for each individual case. The dimensioning and design is carried out according to the picket loads of tested statics and soil properties per geological survey. Cross bar The cross bars are pre-cast reinforced concrete dimensioned and reinforced according to the tested statics. The 108 m long traversing length at the company Rheinkalk built in Wülfrath, cross bars have a length of (in the direction of the track) 1.5 m, a width of 3.0 m and a height of 0.5 m. Longitudinal support units (LTE) The LTE are composite sections made of steel sections and concrete, which is produced as pre-cast elements. They consist of two longitudinal sleepers, which are connected like a ladder at the ends and in the middle. The dimensioning and reinforcement of steel-concrete-composite sections takes place after tested statistics. The device on the LTE test track has a length of 10.78 m (dimension between centre lines = 10.80 m), a total width of 2.165 m and a height of 650 mm plus 38 mm bump for the rail fastenings. The LTE is constructed (dimension between centre lines = 5.40 m) as a two-span beam and lie on an authorised rubber mat on the cross bar. The LTE are already factory provided equipped with rail fastenings KRUPP ECF.

Fig. 3: NFF longitudinal beam showing the pickets

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Fixed Slab track

NFF

Schematic construction cycle

Page: 131-04

Schematic construction cycle In figure a) is a track section to toughen up, still shown in its original state.

a) a track section to toughen up figure b) shows track section after setting The deep foundation 1. The track still remains boundless for use or drivable

b) Track section after settling the deep foundation figure c) shows the state of track section after the dismantling of the old tracks and sleepers. The cross bars are already set and fixed.

c) Track section with cross bars

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Fixed Slab track

NFF

Schematic construction cycle

Page: 131-05

After the cross bars are set and fixed, the laying of LTE can be started (see Figure d and e).

d) Longitudinal support unit LTE is set

e) further LTE's are set

In figure f), the complete and approved tracks are presented. The "voids" of LTE are filled with gravel. The stopper is completely eliminated!

f) complete gravel work and approved tracks

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Date of issue 08/10

Fixed Slab track

NFF

Schematic construction cycle

An overview of the relevant modules is shown in figure g).

g) NFF Track section showing the three component groups

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Date of issue 08/10

Page: 131-06

Fixed Slab track

NBU

Introduction

Page: 132-01

The slab track "system NBU" is a sleeper free and so monolithic design with individual support on a concrete base (BTS). The "System NBU“ is for application area • Ground construction • Bridges and tunnel (also in trough structures) applicable without restrictions to gauge railways and mass transit systems In 2008, the road network of DB AG (route 2600 - Aachen - German border with Belgium), a trial track was successfully tested and approved for continuous operation. The railway track construction consisting of the rails, rail fastening system, the concrete base (BTS) "system NBU" and the hydraulically bound base (HGT) is defined in its deflection and damping state. It requires a low-deformation support on ground construction, on bridges and in tunnels. The parameters are defined in rule for bridges and in tunnel.

Introduction System cross-sectional slab track "System NBU"

Longitudinal groove fusible joint tape

Rail 60E2 Rail fastening

Asphalt Covering

Gravel

Fig. 1: Cross-section "system NBU"

The structural design of the overall system allows unrestricted use up to speeds of 300 km/h.

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Fixed Slab track

NBU

Schematic construction cycle

Page: 132-02

In the slab track "system NBU", using a slip form paver, a continuously reinforced concrete layer (BTS) manufactured with longitudinal grooves for receiving the anchor bolts of a rail fastening. The pre-installed rails with the rail fastening system Krupp ECF (or similar system) are fixed in longitudinal grooves of the BTS in precise length and lateral position. Subsequently the anchor bolts of the rail fastening is grouted and straightened in the longitudinal grooves of BTS.

Schematic construction cycle Manufacturing of HGT (hydraulically bound base). The HGT is a part of railway track and is the lower bound base. Its quality is equal to the concrete C 12/15 (B 15). Their installation is done single or multi layered depending on the thickness.

Fig. 2: HGT before the production of concrete base

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Fixed Slab track

NBU

Schematic construction cycle

Page: 132-03

The BTS is the upper bound base of the railway track. It is reinforced throughout, and will initially concreted seamlessly. The reinforced concrete body is made with a C 30/37 (B 35). The seamless BTS is reinforced longitudinally throughout with 20 pieces Ø 20 mm (construction steel BSt 500 S). At a distance of 20 cm, in the transverse, construction steel of Ø 14 mm is arranged. Thus the reinforcement content is provided as 0.84%.

Fig. 3: BTS S with reinforcing elements of BST 500 M or BST 500 S

The picture below shows the applied concrete base with integrated longitudinal grooves by a modified slip-form. Their installation is done single or multi layered depending on the thickness.

Fig. 4: Modified slip-form paver

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Fixed Slab track

NBU

Schematic construction cycle

Page: 132-04

Finishing, installation and completion of the route "system NBU" This is then followed by concealed joint by chamfering (minimum depth 120 mm), whereby ensuring the overall design of a crack width limit of < 0.5 mm (controlled cracking).

Fig. 5: BTS with introduced grooves

Concrete base with attached rails.

Fig. 6: BTS with rails and rail fastening system

Without scale/schematic diagram

Date of issue 08/10

Fixed Slab track

NBU

Schematic construction cycle

Page: 132-05

Completed track section. The longitudinal grooves are grouted by measurement and fixing the rail position with the grout.

Fig. 7: Completed and freed track section of the slab track "system NBU"

Without scale/schematic diagram

Date of issue 08/10

Crane- & Depot track

Crane runways

MX-System

Page: 141-01

Rail supports for conveyor vehicle, e.g. cranes are not common trains they should resist high loads and low speeds and horizontal forces abrade largely on the frictional resistance of the bearing. Selecting the suitable rail bedding is to be determined in advance, which loads are acting on the rail system. In comparison to the continuous storage cheaper discontinuous rail bedding leads to high stresses on the attachment and is only partially recommended. The continuous rail support is the long term economic solution in most applications. Continuous rail bedding

Discontinuous rail bedding

For the storage of rails on a concrete foundation, the MX-rail bedding has been designed with the MX-rail fastening. The MX-rail fastening system is defined by the new VDI-guideline 3576, a guidance system, i.e. the rail foot is not clamped, but is run free from backlash. Linear expansion, e.g. with the effect of temperature, does not lead to deflection of terminal screws or ground anchors, but is not effective in the MX-system. The MX-rail bedding, continuously or discontinuously includes the entire rail bedding including the grouting. • • • • • • • •

Crane rails Prefabrication of crane rails (planing, milling, drilling, bevel cuts). MX-crane rail fastening system Elastic MX-intermediate layer made of special material to prevent the incorporation of rail foot in the bedding, insulation of driving noise and reduction of stress peaks. Steel rail bedding MX-anchoring and fastening material Precision casting material MINEX Grout and MINEX EP Grout End delimiter

In addition, we also offer the surveying of your crane rail with automatic crane rail surveying system railcontrol.

Without scale/schematic diagram

Date of issue 08/10

Crane- & Depot track

Crane runways

MX-system description

Page: 141-02

The crane rail fastening system from ThyssemKrupp is available as a powerful screw system (MX) and as welding system (MXA), as simple or highly resilient, dual system. The outstanding advantage of a designed system by a structural engineer from Hamburg lies in the principle of the rail guide - the rail is held sideways, but not clamped from the top. The fastening material is the (shear) loading due to temperature changes and not exposing the braking of vehicle. The closed, flat design protects it from dirt. The draw-lead connector is a secure screw; the eccentric allows a step less lateral adjustability. The system designation comprises of: • •

the letters MX (screw system) or MXA (welding system) of 4 or 5 numbers.

The first two digits represent the system height (rail foot thickness + intermediate layer thickness + minimal air gap). The last two letters stands for the diameter of a bolt (M16, M20 or M24). The middle number stands for simple or dual system. For historical reasons, this is not implemented consequently in the simple screwing system. - these are named only with four numbers. Example MX1820: Simple screw system with screw bolts M20 for rails 60E2: MX: Screw system 18: 12.5 mm thicker rail foot + 5 mm thick intermediate layer + 0.5 mm air gap. 20: Screw M20

max. plus position

neutral position

max. minus position

Rail foot thickness

MX-Intermediate layer thickness MX-Guide height

Without scale/schematic diagram

Date of issue 08/10

Crane- & Depot track

Crane runways

Version 1 with screw head on the top

Version 2 with the screw on the top

MX-System screwed

Page: 141-03

Version 3 with medium high Nut

Version 4 with counter sunk screw V60 / V90

Double system Simple system

Name MX1316 MX13216 MX1516 MX15216 MX1520 MX15220 MX1820 MX18220 MX1524 MX15224 MX1524-20 MX15224-20 MX1824 MX18224 MX1824-20 MX18224-20 MX2124 MX21224 MX2124-20 MX21224-20 MX2424 MX24224 MX2424-20 MX24224-20 MX2624 MX26224 MX2624-20 MX26224-20

e [mm]

+/- 5

+/- 6.5 +/- 8 +/- 10 +/- 8 +/- 10 +/- 8 +/- 10 +/- 8 +/- 10 +/- 8 +/- 10

Without scale/schematic diagram

Date of issue 08/10

S [mm] 13 15 15 18

L [mm] 60 60 61 62 65.5

15

93

18

93

21

93

24

93

26

93

System overview B [mm] H1 H2 [mm] [mm] 44 95 27 39.5 44 95 56 110 32 44.5 56 110 70 140 36 50.5 70 140 70 140 36 50.5 70 140 70 140 36 50.5 70 140 70 140 36 50.5 70 140 70 140 36 50.5 70 140

H3 [mm] 34.5

39.5

H4 [mm] 20 22 23 26

35.5

23

35.5

26

35.5

29

35.5

32

35.5

34

max horizontal Load [kN] 38 76 38 76 75 150 75 150 125 250 75 150 125 250 75 150 125 250 75 150 125 250 75 150 125 250 75 150

Crane- & Depot track

Name MXA13116 MXA13216 MXA13120 MXA13220 MXA15116 MXA15216 MXA15120 MXA15220 MXA18116 MXA18216 MXA18120 MXA18220 MXA21116 MXA21216 MXA21120 MXA21220 MXA24116 MXA24216 MXA24120 MXA24220

Crane runways

MX-System welded

Page: 141-04

Version 1 standard

Version 2 with medium high nut

simple system

double system

S [mm] 13

15

18

21

24

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Date of issue 08/10

e [mm]

L [mm]

+/- 5

79

+/- 7.5

95

+/- 5

79

+/- 7.5

95

+/- 5

79

+/- 7.5

95

+/- 5

79

+/- 7.5

95

+/- 5

79

+/- 7.5

95

System overview B [mm] H1 [mm] 85 46 150 105 54 185 85 46 150 105 54 185 85 46 150 105 54 185 85 46 150 105 54 185 85 46 150 105 54 185

H2 [mm] 41 49 41 49 41 49 41 49 41 49

max horizontal Load [kN] 55 140 125 200 55 140 125 200 55 140 125 200 55 140 125 200 55 140 125 200

Crane- & Depot track

Crane runways

Discontinued Storage with MXA-System

Page: 141-05

Version 1 2 Ground anchor

Version 2 4 Ground anchor

9 8 7 6 5 4 3 2 1 Pos.

1 1 4 6 2 4 2 2 2 2 2 2 1 1 1 1 1 1 Version 1 Version 2 Number / Rail bedding

Without scale/schematic diagram

Date of issue 08/10

MINEX Grout / EP Grout Plastic impact cap MX-ground anchor with nut and washer Screw system with nut and washer Pressure plate Guide plate MX-intermediate layer MX-rail bedding Vignol rail Designation

Crane- & Depot track

Crane runways

Discontinued Storage with MXA-System

Page: 141-06

Version 1 2 Ground anchor

Version 2 4 Ground anchor

10 9 8 7 6 5 4 3 2 1 Pos.

1 1 4 6 2 4 2 2 2 2 2 2 2 2 1 1 1 1 1 1 Version 1 Version 2 Number / Rail bedding

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Date of issue 08/10

MINEX Grout / EP Grout Plastic impact cap MX-ground anchor with nut and washer Screw system with nut and washer Base plate Pressure plate Guide plate MX-intermediate layer MX-rail bedding Vignol rail Designation

Crane- & Depot track

Crane runways

Continued Storage with MXA-System

Page: 141-07

* The adjusting screw are detached according to the height adjustment.

10 9 8 7 6 5 4 3 2 1 Pos.

6 1 20 10 10 10 10 1 1 1 Number / Rail bedding

Without scale/schematic diagram

Date of issue 08/10

Adjustable screws * MINEX Grout / EP Grout Plastic impact cap MX-ground anchor with nut and washer Screw system with nut and washer Pressure plate Guide plate MX-intermediate layer MX-rail bedding Crane rail

Designation

Crane- & Depot track

Crane runways

Continued Storage with MXA-System

Page: 141-08

* The adjusting screw are detached according to the height adjustment.

11 10 9 8 7 6 5 4 3 2 1 Pos.

6 1 20 10 10 10 10 10 1 1 1 Number / Rail bedding

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Date of issue 08/10

Adjustable screws * MINEX Grout / EP Grout Plastic impact cap MX-ground anchor with nut and washer Screw system with nut and washer

Base plate Pressure plate Guide plate MX-intermediate layer MX-rail bedding Crane rail

Designation

Crane- & Depot track

Crane runways

MX-bottom casting

Page: 141-09

ThyssenKrupp MX Precision casting materials Our decades of experience have shown that the bottom casting of steel rail support on concrete and its processing quality is crucial to the longevity of the crane runway. It plays a role especially at a discontinuous storage, because by the continuous stress, by edge pressure, the material is stressed. Why to use a bottom casting at all? Due to constant stress to operational and environmental influences, the steel rail support must be grouted to the entire surface. Is not the case that voids are present and movement is possible? This leads to a progressive destruction of the lower casting. The result is a cost associated with downtime and restoration. To avoid this, ThyssenKrupp MX precession casting materials are avaiable for complete surface grouting. Concrete is not recommended as a cast - the structure is not suitable and cause additional voids by shrinking. For no more cross sectional steel profiles, we recommend the elastic MX PUR 880-6.

Designation

Graining [mm]

Barrel

min. pressure resistance [N/mm²] 2h

MX Grout 1 MX Grout 5 MX Grout 16 MX Grout S 1 MX Grout S 5 MX Grout S 16 MX Grout 16 reinforced

min. bending tensile strength [N/mm²]

Bottom casting height [mm]

1d

7d

28 d

28 d

0 -1

40

60

80

10

10 - 25

0 -5

40

70

83

10

20 - 100

0-8

40

70

85

10

50 - 200

0-1 0-5

25 kg Sacks

0-8

0-8

MX EP Grout

MX PUR 880-6

Without scale/schematic diagram

Date of issue 08/10

15 kg Combined metal sheet bucket

2 kg

15

30

75

9

10 - 25

15

30

80

9

20 - 100

15

30

85

9

50 - 200

Note

Precision grout

Very high Early strength; recommended for winter construction sites With steel fibres At scheduling high pressure, flexural and shear loads

45

75

81

11

50 - 200

40

70

90

45

20 - 80

2-component Reactionplastic grout

30

to balance of not more scatter cross-section Steel beams

Shore hardness = 85-95 at 20° to 7d mechanically fully resilient after 24h

Crane- & Depot track

Crane runways

Surveying system Railcontrol

Page: 141-10

Automatic crane rail surveying system RailControl Whatever (rail) profile, regardless of inclination your crane runway has, we can measure them threedimensionally - quickly and competently. The system RailControl was designed for automated surveys for crane runways (Crane lifts, gantry crane lifts, sloped runways, etc.). With a vehicle, travelling along the rail on its own, a continuous and fast measurement of rails (e.g. crane rails, vignol rails, rectangular profiles) is possible. Measuring with an engineering tachymeter, you get an exact size, highest accuracy and special software: • • • • • •

Gauge of the track Position of a rail Height of the track Max. run out tolerance Inclination of a rail 3D Data

millimetre accurate All the figures are according to VDI 3576, and ISO 12488-1. The position will be automatically registered in close succession and then evaluated. Furthermore, there is a possibility to hang test coach on the crane (crawl operation) and perform a measurement with heavily loaded crane runway. In the analysis it can be determined how the crane runway acts as compared to the unloaded state. Possible reasons and advantages for the measurement of RailControl: • • • • • • • • •

Short downtime of your system / crane runway Before commissioning new cranes on existing runways To document the location and height of new runways Damage analysis / damage assessment As part of predictive maintenance Assessment of the utilization of a hall construction Quality assurance / minimising of abrasion Health and safety / occupational safety The usual scaffolding not applicable in crane lifts.

We measure for you - quickly and competently. In Germany and world wide.

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Date of issue 08/10

Crane- & Depot track

Crane runways

Crane runwy beams

Page: 141-11

The ThyssenKrupp crane runway beams is a precast concrete element, which is laid on flat foundation and results a monolithic slab track for gantry cranes. It was designed for the requirements of settling areas, as they can be found for example in port areas. The crane runway beams boasts outstanding economy over the entire service life (Life Cycle) and enormously rapid laying compatibility. Through the latter it is particularly suitable for the modernisation (retrofit) of container terminals, which will be converted to automatic operation. To react to the settlements, there is a possibility to correct the entire slab track in position and height. In height they are at least 30 cm! The system is completely free in its dimensioning and can be adapted to the local conditions and loading images. ThyssenKrupp GfT Gleistechnik has designed this innovative product in collaboration with the HHLA CT civil engineering and comes world wide for the first time in use on the automatic container terminal Burchardkai in Hamburg.

MX-fastening

Without scale/schematic diagram

Date of issue 08/10

Crane & Depot tracks

Depot tracks

Rail supports

Storage track- and wash tracks

Page: 142-01

Support points on utility and laundry tracks have special requirements on the electrical insulation. Furthermore, at times highly aggressive special attention should be paid to the corrosion resistance. The present design meets all these requirements. It is completely insulated electrically coupled with optimum corrosion resistance. Self understood, that the production of large cross-falls of the track surface is used to drain the used fluids and use of common rail profiles is readily available. 7 6 5 4 3 2 1 Pos.

Without scale/schematic diagram

2 2 2 1 2 1 1 Number / Rail bedding

Date of issue 08/10

Protective cap Spring washer Anchors with screws Support plate Rail clamps Intermediate level Rail Designation

Crane & Depot tracks

Depot tracks

Rail fastening Working pits

Page: 142-02

For optimal functionality of working pits as few distractions in the work area are required. With the represented construction, maximum internal diameters for all gauges and thus minimum disturbing elements can be achieved. The rail fastening has a small width and allows - if necessary - to insulate the rail electricity. The execution is possible with each rail section. 8 7 6 5 4 3 2 1 Pos.

Without scale/schematic diagram

1 2 2 2 1 2 1 1 Number / Rail bedding

Date of issue 08/10

Chamber filling Countersunk screw Sleeper screws Anchor Hooked tie plate Rail clamps Insulating sheath rail Rail Designation

Crane & Depot tracks

Depot tracks

Rail fastening Steel supports

Page: 142-03

The illustrated rail fastening on a steel support is infinitely adjustable for height and elevation. Here, too, if necessary, the rail can be electrically insulated. The execution is possible with each rail profile. 7 6 5 4 3 2 1 Pos.

Without scale/schematic diagram

2 2 2 2 1 1 1 Number / Rail bedding

Date of issue 08/10

Pipe supports Hexagonal nut Fastening screw MX-fastening, laterally adjustable Support plate Insulating sheath rail Rail Designation

Specialconstructions

Guard rails

Guard rail tracks R = 100 m mit RL 1-60

Page: 151-01

Guard rail track with running rail 54E4 and guard rail Rl1-60 to support analog Rp 71/241, Level surface SO, groove width 60 mm.

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Date of issue 08/10

Specialconstructions

Guide rails

Krupp ECF 49E5 / 54E4 Concrete with TK-DENA

Page: 152-01

The vibration damping rail bedding Krupp ECF is laid on the concrete slab, designed, powered and sealed with MINEX-Grout. The groove width of the guide is set according to on-site requirements and considered in the construction and arrangement of the support. The accuracy of the concrete slab is standard for the construction and design of the system.

Special grout MINEX-grout

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Date of issue 08/10

Base plate

Specialconstructions

Guide rails

60E2 made of concrete (B 355 W60M-S)

Page: 152-02

Guide rail layout on dual-block sleeper B 355 W60M-S track system Krupp GfT – DENA

Dual block sleepers B 355 W60M-S

7 6 5 4 3 2 1 Pos.

1 2 1 1 1 1 1 Number / Support point

Without scale/schematic diagram

Date of issue 08/10

Sealing plug

GPN 300 F 37

Bolt connection

-

Hexagonal nut

M24

Hexagon head bolt

M24 x 60

Spacer plate

Zwp 80 - Stp F

Baffle mounting plate

100 x 50

Guide support point Designation

Stp F355 Brief description

Specialconstructions

Guide rails

60E2 made of concrete (B 93)

Page: 152-03

Guide rail layout on concrete sleeper B 93 track system Krupp GfT – DENA

* rail fastening is represented according lowa 10,0018 * applies for rail fastening according to lowa 10,0012: 195 mm Concrete sleeper B 93

7 6 5 4 3 2 1 Pos.

1 2 1 1 1 1 1 Number / Support point

Without scale/schematic diagram

Date of issue 08/10

Sealing plug

GPN 300 F 37

Bolt connection

-

Hexagonal nut

M24

Hexagon head bolt

M24 x 60

Spacer plate

Zwp 80 - Stp F 93

Baffle mounting plate

100 x 50

Guide support point

Stp F93 Brief description

Designation

Specialconstructions

Rail grooves tracks

Heinrich Krug - Form 49 for 49E5 / 54E4 / 60E2

Page: 153-01

The rut rails are suitable as asphalt, concrete and plaster protected for vignol rails ranging from depots, assembly halls and road crossings. Through processing or use of adapters, the combination with the most vignol rails is possible. Rail 60E2

Dual washer Fe6 Rut rail screws

Rail 49E5

Rail 54E4

Dual washer Fe6 Rut rail screws

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Date of issue 08/10

Rut rail screws

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Date of issue 08/10

Page: 211-01

Special forms of crane rails

Overview of commonly used rail types

Crane rails

Rails

Grooved rails

Vignol tracks

Track materials

Track materials

Rails

European standards DIN EN 13674-1:2008-01

Page: 211-02

The European standard DIN EN 13674-1 existing since year 2003. The following changes to the basic standard UIC-Kodex 860 V have been made: a. b. c. d. e. f.

g. h. i. k.

Rail designations from e.g. UIC 60 in 60E1. Rail designations "Vignol rails" instead "flange rail“. Rails affiliated only from 46 kg/m. All types of steel designations have been changed, wherein serves as a scale basis no longer the tensile strength, but the minimum hardness of the runway. The steel grade R0550 (1.0422) is removed. In a slightly different chemical composition steel grade was maintained: f.1. 700 (1.0521) - replaced by the grade R200 f.2. 900A (1.0623) - replaced by the grade R260 f.3. 900B (1.0624) - replaced by R260Mn (variant of the grade R260 with lower C-content higher Mn-content) f.4. 1100 (1.0915) - replaced by grade R320Cr f.5. 1200 (1.0631) - replaced by R350HT Additionally the steel grades affiliated were R220 (tensile strength 770 MPa) and R350LHT Determining the mechanical properties and identification of heat treated rails. Qualification tests for the manufacturer's approval were determined. Extensive illustrations intended to sampling and testing, on rail profiles and gauges.

The document DIN EN 13674-1:2008-01 was designed by a technical committee CEN/TC256 "Railway track engineering products" and supports requirements of EU directives. According to the national standards bodies, the decisions are kept to implement this European standard. The European standard DI EN 13674 covers for railway applications - railway track - rails the following parts: Part 1: Vignol rails from 46 kg/m Part 2: Rails for turnouts and crossings, which are used in connection with vignol rails from 46 kg/m Part 3: Check rails Part 4: Vignol rails with a linear mass between 27 kg/m and under 46 kg/m Parts 2, 3 and 4 have validity since August 2006. The Standard for grooved rails and associated construction section (DIN EN 14811) was adopted in October 2006. The DIN EN 13674-1 refers to the European quality management standard DIN EN ISO 9001 and includes amongst others: 1. Qualification test 2. Specification test

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Date of issue 08/10

Track materials

Rails

Differences

UIC-K 860 E - DIN EN 13674-1

Page: 211-03

Difference between UIC-Kodex 860 E and DIN EN 13674-1:2008-01 The European Standard 13674-1 •

includes the following qualification tests for steel rails: - Fracture toughness (KIc), Paragraph 8.2 - Assessment of crack growth rate, Paragraph 8.3 - Dynamic fatigue test, Paragraph 8.4 - Determination of the residual stresses in the rail foot, Paragraph 8.5 - Profile of the surface hardness on the runway at HH - rails, Paragraph 8.6 - Determination of tensile strength and elongation using a regression formula, Paragraph 8.7



regulates the hydrogen and oxygen content and also the accompanying elements such as amongst Al, V, N, Cu, Sn etc.- Table 4, Paragraph 9.1.2



regulates surface decarburisation - Table 4, Paragraph 9.1.4



regulates efficiency of the rails - Table 4, Paragraph 9.1.5



contains sulphur prints, Paragraph 9.1.6 (Appendix D)



allows tensile test only once every 2000 t under the condition of a regression formula



refer to the rails after the minimum hardness, such as R260, instead of its minimum strength, such as 9000A according to UIC-Kodex 860 E



refer the new rail sections (60E1 instead UIC 60), Appendix A, Page 43



includes the profile drawings (which were earlier included in UIC 861)



allows two profile classes (X,Y) and two straightness classes (A,B) and on the contrary defines UIC-Kodex 860 E also the straightness between the ends, paragraph 9.2



defines the criteria for testing gauge as well as the methods of measurement, Paragraph 9.3



defines the test criteria for Us-audit, Paragraph 9.4.1



specifies criteria/tolerances and surface finish, paragraph 9.4.2



regulates the procedure for interoperability 󲐀 EU-Directives, Paragraph ZA



is a pure material and testing standards



no more includes the impact test (see Paragraph 2.6, UIC-Kodex 860 E)

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Date of issue 08/10

Track materials

Rails

Old and new Rail designations

Page: 211-04

Overview of old and new rail designations

Vignol and grooved rails Vignol rails according to DIN EN 13674-4:2008-01 new old 30E1 S 30 33E1 S 33 40E1 S41 R14 41E1 S41 R10 Vignol rails according to DIN EN 13674-1:2006-08 new old 49E1 S 49 49E5 50E4 UIC 50 54E3 S 54 54E4 54E1 UIC 54 60E1 UIC 60 60E2 60E2-40 -

grooved rails, RI-special section according to DIN EN 14811:2006-10/12 new old 53R1 Ri 53N Ri 55N 59R1 Ri 59 59R2 Ri 59N 60R1 Ri 60 60R2 Ri 60N 57R1 Ph 37 67R1 Ph 37a Ph 37N 52R1 Ri Ir 56R1 Ri Ic 75C1 BA 75 76C1 VK Ri 60 105C1 D 180/105 310C1 BL180/260

Rails for crossings and turnouts Switch rail according to DIN EN 13674-2:2006-08 new old 49E1A1 Zu 2-49 54E1A2 Zu 1-54 54E1A1 ZuUIC54B 60E1A1 Zu 1-60 Zu60E2-40 Check rail according to DIN EN 13674-3:2006-08

new

old

36C1 48C1 33C1

RL1-49 RL1-54 RL1-60

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Date of issue 08/10

Full-web rails according to DIN EN 13674-2:2006-08

new

old

49E1F1 54E3F1 54E1F1 Vo60E2-40 60E1F1 60E2A2 60E2A3

Vo1-49 Vo1-54 Vo1-UIC54 Vo1-60 Zu60E2-40 60E2A1-20

Track materials

Rail steels

Rails

Chem. composition and mechanical values

Chemical composition % C

Si

Mn

0.15 0.58 0.20 0.60 0.15 0.58 0.15 0.60 0.50 1.10 0.15 0.58 0.15 0.58

0.70 1.20 1.00 1.25 0.70 1.20 1.30 1.70 0.80 1.20 0.70 1.20 0.70 1.20

Cr

V

Tensile strength Rm MPa and N/mm2

≤ 0.15

≤ 0.030

≥ 680

≥ 14

200 - 240

≤ 0.15

≤ 0.030

≥ 770

≥ 12

220 - 260

≤ 0.15

≤ 0.030

≥ 880

≥ 10

260 - 300

≤ 0.15

≤ 0.030

≥ 880

≥ 10

260 - 300

0.80 1.20

≤ 0.18

≥ 1080

≥9

320 - 360

≤ 0.15

≤ 0.030

≥ 1175

≥9

350 - 390

≤ 0.30

≤ 0.030

≥ 1175

≥9

350 - 390

1)

P

S

Page: 211-05

Stretching A5 %

Hardness HBW

Steel grades 2) according to DIN EN 13674-1 R200 R220 R260 R260Mn R320CR R350HT R350LHT

0.40 0.60 0.50 0.60 0.62 0.80 0.55 0.75 0.60 0.80 0.72 0.80 0.72 0.80

≤ 0.035 ≤ 0.025 ≤ 0.025 ≤ 0.025 ≤ 0.020 ≤ 0.020 ≤ 0.020

3

0.008 0.035 0.008 0.025 0.008 0.025 0.008 0.025 0.008 0.025 0.008 0.025 0.008 0.025

according to UIC-Kodex 860 E (2008-01) ) 700 900 A 900 B 1100

0.40 0.60 0.60 0.80 0.55 0.75 0.60 0.82

according to AREMA (2009) Standard steel 0.74 0.86 grades 5 according BS 11 (1985) ) normal A B

0.45 0.60 0.65 0.80 0.55 0.75

4)

0.05 0.35 0.10 0.50 0.10 0.50 0.30 0.90

0.80 1.25 0.80 1.30 1.30 1.70 0.80 1.30

0.10 0.60

0.75 1.25

0.05 0.35 0.10 0.50 0.10 0.50

0.95 1.25 0.80 1.30 1.30 1.70

≤ 0.050

≤ 0.050

680 - 830

≥ 14

≤ 0.040

≤ 0.040

880 - 1030

≥ 10

≤ 0.040

≤ 0.040

880 - 1030

≥ 10

≤ 0.030

≤ 0.030

≥ 1080

≥9

≤ 0.020

≤ 0.020

≥ 980

≥ 10

≤ 0.040

≤ 0.040

≥ 710

≥9

≤ 0.040

≤ 0.040

≥ 880

≥8

≤ 0.040

≤ 0.040

≥ 880

≥8

Steel grades for grooved rails and Ri-special section (DIN EN 14811) R200 R220G1 R260 R260GHT R290GHT R340GHT

0.40 0.60 0.50 0.65 0.62 0.80 0.40 0.60 0.50 0.65 0.62 0.80

0.15 0.58 0.15 0.58 0.15 0.58 0.15 0.58 0.15 0.58 0.15 0.58

0.70 1.20 1.00 1.25 0.70 1.20 0.70 1.20 1.00 1.25 0.70 1.20

0.80 1.30

≤ 0.20

6)

≤ 0.035

≤ 0.035

≥ 680

≥ 14

200 - 240

≤ 0.025

≤ 0.025

≥ 780

≥ 12

220 - 260

≤ 0.025

≤ 0.025

≥ 880

≥ 10

260 - 300

≤ 0.035

≤ 0.035

≥ 880

≥ 12

260 - 300

≤ 0.025

≤ 0.025

≥ 960

≥ 10

290 - 330

≤ 0.025

≤ 0.025

≥ 1175

≥9

340 - 390

1) Check analysis deviant 2) Delivery specifications of the European Committee for Standardisation 3) Delivery specifications of the Internal Union of Railways 4) Delivery specifications of the American Railway Engineering Association and Maintenance-of-Way Association 5) Delivery specifications of the British Standards Institution 6) Delivery specifications of the European Committee for Standardisation

Without scale/schematic diagram

Date of issue 08/10

≥ 310

Track materials

Rails

Mechanical and electrical properties

Page: 211-06

Yield point (Rp0,2) [N/mm2]

Yield ratio for different rail grades

Tensile strength [N/mm2]

The electrical conductivity is dependent on the chemical compositions of the rail steels, in particular the Si-content. In the rail steels R200, R220, R260, R260Mn and R320Cr, the following values for the electrical conductivity can be observed: R200 R220 R260/Mn R320 Cr

4.6 - 4.8 Sm/mm² 4.4 - 4.7 Sm/mm² 4.3 - 4.6 Sm/mm² 3.0 - 3.3 Sm/mm²

Continuous welded rail: Rails were formerly connected with tabs. There must be an expansion gap considered for the thermal expansion. Today, modern rail track systems are welded. They are called completely welded rails. The forces generated by the thermal expansion are taken up by the rail fastening and discharged over the threshold into the gravel track. Change in rail length ΔL due to temperature change: ΔL = L0 x ΔT x α

L0 ΔT α

= Rail length in mm = Temperature change in °C = Expansion coefficient for steel: approx. 0.000012 [-]

Example: L0 = 120,000 mm ΔT = 60 °C ΔL = 120,000 x 60 x 0.000012 = 86.4 mm

Without scale/schematic diagram

Date of issue 08/10

Track materials

Rails

Bearing marks according to DIN EN 13674-1

Page: 211-07

The European Standard DIN EN 13674-1:2008-01 determines the labelling of rails. The bearing marks are raised on a rail side at a distance of more than 4 m to roll on. The bearing marks must be clearly readable on the rails and have a font size of 20 mm to 25 mm and raised to 0.6 mm to 1.3 mm. The distinguishing bearing marks of the steel grades must have a length of 50 mm for the long labelling line and from 25 mm for the short labelling line. The bearing mark must contain the following information: • • • •

Features of a manufacturer steel grades the last digits of the year of manufacture Designation of the rail section

Steel grades Description

Type of bearing marks

R200 R220

Hardness range HBW 200 to 240 220 to 260

Carbon-manganese (C-Mn)-steel Carbon-manganese (C-Mn)-steel

without bearing marks

R260

260 to 300

Carbon-manganese (C-Mn)-steel

R260Mn

260 to 300

Carbon-manganese (C-Mn)-steel

R320Cr

320 to 360

alloy steel (1% Cr)

R350HT

350 to 390

R350LHT

350 to 390

steel grades

Carbon-manganese (C-Mn)-steel thermally annealed Low-alloy steel, thermally annealed

Example for a bearing mark:

In addition to the bearing mark, each rail must be characterised with a numeric and/or alphabetical code, which is on the opposite side of the bearing mark of the base, continuously inculcate at least once every 5 meters. In line with the current version of the standard, the distance of 10 m has been set.

Without scale/schematic diagram

Date of issue 08/10

Track materials

Rails

Bearing marks according to UIC-Kodex 860 E

Page: 211-08

The UIC-Kodex 860 E still exist parallel to the EN 13674-1 and is described in Paragraph 1.3 of the identification of rails. The bearing marks are raised on a rail side, according to the choice of manufacturer between 20 and 30 mm, to be rolled with a relief height of minimum 0.8 mm. The bearing mark must contain the following information: • • • •

features of a manufacturer the last digits of the year of manufacture designation of the rail section steel grades

Steel grades

Symbol for the melting process

Quality

Type of bearing marks

Method

700 900 A 900 B

without bearing marks

On the basis of open hearth process

1100

Example for a bearing mark:

Without scale/schematic diagram

Date of issue 08/10

Electric process Basic oxygen steelmaking

Sign

Track materials

Rails

Profile tolerances and Rectitude for vignol rails

Page: 211-09

Profile limit deviations (tolerances) and straightness for vignol rails from 46 kg/m The profile classes X and Y define according to DIN EN 13674:2008-01 the profile limit deviations. As per the requirements of high-speed rail line (> 160 km/h) refers to the profile class X, while the class Y is tangent to the normal rail lines.

Rail height

< 165 mm ≥ 165 mm

Width of the rail head Rail symmetry Web thickness Width of rail foot Rail foot thickness Concavity on the rail foot

Profile class (measurement in mm) X Y ± 0.5 + 0.5 / - 1.0 ± 0.6 + 0.6 / -1.1 ± 0.5 + 0.6 / - 0.5 ± 1.2 ± 1.2 + 1.0/ - 0.5 + 1.0 / - 0.5 ± 1.0 + 1.5 / - 1.0 + 0.75/ - 0.5 + 0.75/ - 0.5 max. 0.3 max. 0.3

For straightness the classes A and B are fixed. A for the high-speed rail lines (> 160 km/h), B for the normal rail lines. Then the straightness of the rail body (between the ends) is for the classes A to 0.3 mm < 3 m, for class B to 0.4 mm < 3 m.

Perpendicularity of the rail ends (0.6 mm in all directions)

Length tolerance of the rails Length drilled on both sides

L ≤ 24 m L > 24 m L ≤ 40 m

± 3 mm ± 4 mm ± 4 mm

For other lengths (without holes) or with holes at one end of ± 1 mm/m rail (max. ± 30 mm on the rail length). The limit deviations in rails are for particular applications without holes up to 24 m long ± 6 mm, in rails greater than 24 m length ± 10 mm. The specified rail lengths apply to +15 °C. If measurements are performed at different temperatures, expansions or contractions are to be considered by corrections.

Without scale/schematic diagram

Date of issue 08/10

Track materials

Rails

Rail lengths

Page: 211-10

Rail lengths Guideline 820.2120 Para. 3 (1) Fundamentals of tracks, design of tracks and turnouts; rails; here: Rail lengths. With the known guideline the use of rail lengths is provided as follows: •

Complete tracks - basically rails > 100 m length (the theme bearing length and so the delivery here is not tangent; only the installation length is provided).



v > 230 km/h - exclusive tracks of bearing lengths > 100 m



200 ≤ v ≤ 230 km/h - means already at v > 160 km/h exclusive tracks of bearing lengths ≥ 60 m lengths

The current status of the particular welding technique (see "Influence of different welding processes") allows the following rule (put into effect 31.07.2002): •

for the range of v > 230 km/h an opening for the use of factory-welded 60 m rails



for the range up to 200 km/h an opening for the use of factory-welded 30 m rails



With reference to an increasing freedom at the planning and execution of a site, an opening for use of rail lengths under 100 m (overall length, not bearing length).

Depending on the area of application, however at the same time, to provide additional requirements on the geometric quality compared to the previously approved additional welds / rail ends. Influence of different welding processes: The quality of welds is influenced by applying next welding process, i.e.: •

stationary flash butt welds as factory welds (qualitative high quality welding);



mobile flash butt welds as construction welding (metallurgical similar to the stationary welding; however smears with reference to geometric quality, similar to aluminothermy welds)



aluminothermy construction welding (standard welding construction sites, which has reached in terms of welding portions and process technology a standard of quality that approaches the flash butt welding.)



Manual metal arc welds are not considered as not relevant here.

Without scale/schematic diagram

Date of issue 08/10

Track materials

Rails

New rules for the use of rail lengths

Page: 211-11

New regulations for the use of rail lengths Bearing length 30 m V max

RA(5) (Factory)

≤ 160 km/h 160 < v ≤ 200 km/h 200 < v ≤ 230 km/h v > 230 km/h

Yes

Bearing length 60 m

RA(5) (Installation

AS(6)

location) Yes

No

(Factory) Yes

RA(5) (Installation

AS(6)

location) Yes

(1)

No

RA(5) (Factory)

RA(5) (Installation

AS(6)

location)

Yes

Yes

Yes

No

No

Yes

(2)

Yes

(4)

No

(1)

Yes

Yes

Yes

No

No

No

Yes

(2)

Yes

(4)

No

(1)

Yes

Yes

Yes

No

No

No

Yes

(3)

No

Yes

Yes

Yes

(2)

(1)

RA(5)

Bearing length 120 m

No

No (except SS)

Explanations: 1) Opening against the previous default of Ril. 820,2120, 3 (1): "For complete tracks, rails usually in lengths > 100 m to deliver on the site." The values below "d" are to be observed in the entire range of 3 m in front and behind the weld! 2) News of rail ends and weld joint in the production with the following requirements: vertical flatness*: horizontal flatness*:

d ≤ 0,4 mm at L = 3.0 m and d ≤ 0.3 mm at L = 1.0 m d ≤ 0,6 mm at L = 1.5 m

3) News of rail ends and weld joint in the production with the following requirements: vertical flatness*: horizontal flatness*:

d ≤ 0,3 mm at L = 3.0 m and d ≤ 0.2 mm at L = 1.0 m d ≤ 0,45 mm at L = 1.5 m

4) News of rail ends and weld joint in the production with the following requirements on the construction site: vertical flatness*: horizontal flatness*:

d ≤ 0,4 mm at L = 3.0 m and d ≤ 0.3 mm at L = 1.0 m d ≤ 0,6 mm at L = 1.5 m

(5) RA = Flash butt welding (6) AS = aluminothermy welds * matched to the design CEN - Standard Pr 13674-1 Table 9 Significant changes

Without scale/schematic diagram

Date of issue 08/10

Track materials

Rails

Minimum length of rails High support the Welds

Page: 211-12

Rails minimum lengths and maximum numbers of welds according to Ril. 820.0120 (new rails)

1

Rail lengths

2

≤ 80 5

m ≤ 30 > 30 to 60 > 60 to 90 > 90 to 120 > 120 to 180

4 8 12 16 24

3

4 5 Rails All rails Conductor speed (km/h) ≤ 120 ≤ 160 ≤ 230 Rails minimum lengths (m) 10 12 15 Maximum number of welds (piece) 2 1 1 5 2 2 7 4 3 9 6 4 14 9 6

6

≤ 300 30 0 0 1 1 2

Minimum rail lengths may not exist at the end of the finished rail. For the minimum lengths replacement, pass, transition connecting bars apply Ril 820 01 04 and Ril 820 03 18. For high-speed rail lines (v > 160 km/h) only welded rails which are removed according to DBS 918 254-1 These tracks are labelled from the manufacturing factory marked on the bearing side at each rail end, the brush stroke in green oil paint about 20 cm long and 3 cm wide. Approved only for installation in NBS according to Ril 820 01 04. • •

New rails with bearing lengths ≥ 100 m or 180 m long units, to be welded for 60 m long new rails.

Without scale/schematic diagram

Date of issue 08/10

Date of issue 08/10

Without scale/schematic diagram

[mm]

108.00

134.00

138.00

138.00

149.00

154.00

152.00

159.00

172.00

33E1 (S 33)

41E1 (S41 R10)

40E1 (S41 R14)

49E1 (S 49)

54E4 (S 54)

50E4 (UIC 50)

54E1 (UIC 54)

60E1 (UIC 60)

150.00

140.00

125.00

72.00

70.00

70.00

67.00

67.00

67.00

67.00

58.00

60.30

[mm]

Head width

C1

74.30

72.20

72.20

70.00

70.00

67.00

67.00

58.00

60.30

[mm]

Head width below

C2

16.50

16.00

15.00

16.00

14.00

12.00

12.00

11.00

12.30

[mm]

Base thicknes

S

51.00

49.40

49.40

55.00

51.50

43.00

43.00

39.00

31.00

[mm]

Head height in total

K

11.50

11.00

10.00

12.00

10.50

9.48

9.48

9.50

7.04

[mm]

Foot thicknes

D

2

7670.00

6977.00

6428.00

6948.00

6292.00

5217.00

5253.00

4264.00

3839.00

[mm ]

Cross section

A

60.21

54.77

50.46

54.54

49.39

40.95

41.24

33.47

30.13

[kg/m]

Weight

G

4

3038.30

2337.90

1934.00

2074.00

1816.00

1366.90

1382.10

1040.30

608.20

[cm ]

Inertia moment

JX

3

333.60

278.70

252.30

262.70

240.30

195.90

199.30

156.00

108.50

[cm ]

Resistance moment

Wx

Vignol rails

125.00

125.00

125.00

125.00

105.00

108.00

[mm]

Foot width

Rail height

30E1 (S 30)

Rail forms

B

Rails

H

Railway track bearing sections vignol rails

Track materials Page: 212-01

Date of issue 08/10

Without scale/schematic diagram

[mm] 50.00 58.00 70.00 82.00 82.00 90.00

65.00 70.00 80.00 93.00 100.00 115.00

S7

S 10

S 14

S 18

S 20

S 24

Foot width

Rail height

[mm]

Rail forms

B

53.00

44.00

43.00

10.00

10.00

10.00

9.00

6.00

5.00

[mm]

Base thicknes

S

30.50

27.00

25.40

22.00

21.30

15.60

[mm]

Head height in total

K

7.00

6.00

5.00

4.80

4.00

3.20

[mm]

Foot thicknes

D

2

3110.00

2520.00

2330.00

1780.00

1270.00

859.41

[mm ]

Cross section

A

24.43

19.80

18.30

14.00

10.00

6.75

[kg/m]

Weight

G

4

569.00

346.00

278.00

154.00

85.70

51.60

[cm ]

Inertia moment

JX

3

97.30

66.80

58.10

36.90

24.40

15.20

[cm ]

Resistance moment

Wx

Vignol rails Narrow-gauge railways

38.00

32.00

25.00

[mm]

Head width

C

Rails

H

Railway track bearing sections vignol rails Light rails / light rail profiles

Track materials Page: 212-02

Date of issue 08/10

Without scale/schematic diagram

150.00 180.00 180.00 180.00 180.00 180.00

150.00

180.00

180.00

180.00

180.00

180.00

Ri 55N

59R1 (Ri 59)

59R2 (Ri 59N)

60R1 (Ri 60)

60R2 (Ri 60N)

Ri 60 N/L

150.00 180.00 180.00

182.00

180.00

180.00

57R1 (Ph 37)

67R1 (Ph 37A)

Ph 37N

133.75

135.00

127.00

60.02

60.00

51.92

56.00

55.83

113.00 113.00

56.00

55.83

113.00 113.00

56.00

56.00

113.00 113.00

55.83

[mm]

Driving head width

C2

113.00

[mm]

Head width total

C1

58.21

60.60

60.46

36.00

36.34

36.00

42.52

42.00

36.00

36.34

Grooved width

C3

13.00

13.00

11.00

12.00

12.00

12.00

12.00

12.00

12.00

12.00

[mm]

Base thickness

S

43.85

43.85

43.50

41.15

41.15

41.15

41.15

41.15

41.15

41.15

[mm]

Head height in total

K

9.00

9.00

8.50

8.00

8.00

8.00

8.00

8.00

9.50

9.50

[mm]

Foot thickness

D

8392.00

8524.00

7202.00

7725.00

7611.00

7719.00

7407.00

7512.00

7064.00

6748.00

[mm2]

Cross section

A

65.88

66.91

56.54

60.64

59.75

60.59

58.14

58.97

55.45

52.97

[kg/m]

Weight

G

3501.00

3564.00

3030.40

3377.00

3298.10

3352.90

3210.60

3266.80

1976.38

1326.00

[cm4]

Inertia moment

JX

404.00

416.40

363.60

395.40

380.60

391.40

363.10

373.80

248.79

208.30

[cm3]

Resistance moment

Wx

grooved rails

Industry

150.00

[mm]

130.00

[mm]

Foot width

53R1 (Ri 53N)

Rail height

B

Industry - grooved rail

Rails

Transport

Rail forms

H

Transport - grooved rail

Railway track sections grooved rails Track materials Page: 213-01

Date of issue 08/10

Without scale/schematic diagram

[mm] 180.00 180.00 180.00 260.00

180.00

180.00

180.00

184.00

75C1 (BA 75)

76C1 (VK Ri 60)

105C1 (DST 180/105)

310C1 (BL 180/260)

Foot width

Rail height

[mm]

Rail forms

B

-

130.00 260.00

56.00

[mm]

Driving head width

C2

114.00

113.00

[mm]

Head width in total

C1

40.00 12.00 32.00 162.00

-

[mm]

Base thicknes s

S

36.00

Groove d width

C3

56.00

68.25

41.25

41.15

[mm]

Head height in total

K

30.00

9.00

10.00

8.00

[mm]

Foot thickn ess

D

2

39450.00

13405.00

9643.00

9584.00

[mm ]

Cross section

A

309.69

105.23

75.70

75.23

[kg/m]

Weight

G

4

12786.00

4945.00

4237.60

3596.00

[cm ]

Inertia moment

JX

3

1430.00

643.05

546.40

398.30

[cm ]

Resistance moment

Wx

Rails

H

Railway track bearing sections Ri-special section Track materials RI-Special section Page: 213-02

Track materials

Schienen Bridge section

Block grooved rails

Grooved rail B1

Grooved rail B3

Grooved rail LK1

Without scale/schematic diagram

Date of issue 08/10

Page: 213-03

Date of issue 08/10

Without scale/schematic diagram

[mm] 125.00 150.00 175.00 200.00 200.00 220.00 220.00

55.00 65.00 75.00 85.00 95.00 105.00 150.00

A 45

A 55

A 65

A 75

A 100

A 120

A 150

Foot width

Rail height

[mm]

Rail forms

B

150.00

120.00

100.00

75.00

80.00

72.00

60.00

45.00

38.00

31.00

24.00

[mm]

Base thicknes

S

50.00

47.00

40.00

35.00

30.00

25.00

20.00

[mm]

Head height

K

14.00

14.00

12.00

11.00

10.00

9.00

8.00

[mm]

Foot thicknes

D

2

19140.00

12740.00

9470.00

7160.00

5490.00

4050.00

2820.00

[mm ]

Cross section

A

151.60

100.00

74.30

56.20

43.10

31.80

22.10

[kg/m]

Weight

G

4

4373.00

1361.00

856.00

531.00

319.00

178.00

90.00

[cm ]

Inertia moment

JX

3

565.70

235.10

161.80

105.40

71.40

45.60

27.00

[cm ]

Resistance moment

Wx

Crane rails Form A

65.00

55.00

45.00

[mm]

Head width

C

Rails

H

Railway track bearing section crane rails

Track materials Page: 214-01

Track materials

Rails

Crane rails AS 86

Page: 214-02

The crane rails of form MRS used commonly are increasing. Disadvantage of the commercially available crane rails that form the flat tread. The least deviation of the parallelism leads to the direct edge pressure.

Crane wheel

Edge pressure

Crane rail MRS 87A

ThyssenKrupp Gleistechnik has therefore given a change in the tread. The new crane rail AS 86 corresponds in the main dimensions of MRS 86 A, has a similar rounded head as in crane rail A 100. Thus, the wheel force is transferred to the back axle crane rails. The stress on the bearing surface and the wear behaviour is considerably reduced.

Crane wheel

approx. axial loading Crane rail AS 86

Without scale/schematic diagram

Date of issue 08/10

Track materials

Rails

Crane rails Bevel cut

Page: 214-03

Bevel cuts on crane rails are required, if the rails on the components are clamped or riveted. In this antiqued track system, an increased deterioration of the crane rail system pre-programmed. The economic solution is the use of straight-cut rails and welding of the rails on the entire length. Applies for the attachment: not CLAMPING rather OPERATING See page 134-01 ff.: MX-rail support with MX-rail fastening

Example for bevel cut-versions 1. Cut direction Version a Version b Version c

2a. Length information measured in the middle of the head

2b. Length measured from tip to tip

3. Degree setting for the cutting angle

Without scale/schematic diagram

Date of issue 08/10

Date of issue 08/10

Without scale/schematic diagram

120.00

80.00

F120

131.80 131.80 152.40 152.40 152.40 150.00 180.00 220.00

131.80 146.10 152.40 152.40 152.40 152.46 180.00 160.00

MRS 52

MRS 67

MRS 85

MRS 87B

MRS 87A

AS 86

MRS 125

MRS 221 120.00 120.00 80.00

120.00 140.00 105.00

Q 120

R 120

STR 40

35.00 40.00 145.00

101.60 120.00 220.00

18.00

34.93

101.60

80.00

38.10

102.40

80.00

31.75

101.60

80.00

31.80

76.20

120.00

23.80

65.10

120.00

25.40

90.00

120.00 63.50

70.00

100.00

[mm]

Base thicknes

Head width [mm]

S

C

11.80

104.00

91.00

40.00

64.80

50.80

50.80

44.50

50.80

47.60

45.20

38.10

42.00

42.00

[mm]

Head height

K

33.00

24.00

17.00

17.50

21.00

15.40

15.90

12.70

15.60

31.80

10.40

12.20

17.00

17.00

[mm]

Foot thicknes

D

5130.00

15600.00

13080.00

28210.00

16030.00

10940.00

11130.00

11050.00

10850.00

8590.00

6650.00

6640.00

8920.00

40.37

122.40

102.70

221.40

125.00

85.88

86.80

86.80

84.83

66.97

52.09

51.59

70.10

57.50

[kg/m]

[mm2] 7320.00

Weight

G

Cross section

A

626.70

2625.00

1632.00

6862.00

6225.00

2968.00

3068.00

2922.00

3055.00

2105.00

1432.00

1242.00

499.00

414.00

[cm4]

Inertia moment

JX

135.10

364.00

261.50

829.00

681.00

394.00

400.00

344.00

400.00

282.00

203.00

175.00

123.00

101.00

[cm3]

Resistance moment

Wx

Special section

Special forms

127.00

127.00

MRS 51

Thick web rails

100.00

80.00

[mm]

Foot width

F100

[mm]

Rail height

B

Rails

Form F according DIN 536 - 2

Rail forms

H

Railway track bearing section special section Track materials Page: 215-01

Date of issue 08/10

Without scale/schematic diagram

140.00 147.00 140.00

121.00

129.00

134.00

54E1A2 (ZU1-54)

54E1A1 (ZU-UIC54 B)

60E1A1 (ZU1-60)

125.00 140.00 150.00

154.00

159.00

172.00

54E3F1 (Vo1-54)

54E1F1 (Vo1-UIC 54)

60E1F 1 (Vo1-60)

75.00 75.00 40.00

168.00

199.00

93.00

36C1 (Rl1-49)

48C1 (Rl1-54)

33C1 (Rl1-60)

78.50

22.00

19.00

72.00

70.00

67.00

67.00

72.00

70.00

67.00

67.00

[mm]

Head width up

C1

80.00

-

-

76.00

74.00

72.00

70.00

74.50

72.20

70.18

70.20

[mm]

Head width below

C2

20.00

20.00

18.00

76.00

74.00

72.00

85.00

44.00

40.00

40.00

40.00

[mm]

Base thicknes

S

-

-

-

37.50-54.70

54.30

> 50,00

39.80

53.00

49.40

57.50

53.50

[mm]

Head height in total

K

12.00

12.00

10.50

11.50

11.00

12.00

10.50

20.00

20.00

20.00

20.00

[mm]

Foot thickness

D

4202.00

6154.00

4604.00

14171.00

12484.00

11556.00

12300.000

9295.00

8783.00

8385.00

8043.00

[mm2]

Cross section

A

32.99

48.31

36.14

111.24

98.00

90.72

96.55

72.97

68.95

65.82

63.14

[kg/m]

Weight

G

297.00

2330.50

1312.30

3737.30

2818.00

2389.00

2234.00

1726.90

1544.00

1244.30

1098.40

[cm4]

Inertia moment

JX

83.70

218.30

137.60

394.30

385.30

286.10

274.30

229.70

208.40

181.10

165.30

[cm3]

Resistance moment

Wx

Construction rails

Check rails

125.00

149.00

49E1F 1 (Vo1-49)

Complete rails

140.00

116.00

[mm]

Foot width

49E1A1 (ZU2-49)

[mm]

Rail height

B

Rails

Switch rails

Rail forms

H

Railway track section construction rails Track materials Page: 216-01

Date of issue 08/10

Without scale/schematic diagram

Rail perforation

Perforation plates Rail perforation

Flat plate FL 14a, 25,.16 kg / pair

Perforation plates

Flat plate FL 41/49, 17.44 kg / pair

Perforation plates

Rails

Hole diameter 33 mm for rail lengths 30, 45 and 60 m

Rail perforation

Track materials Page: 217-01

Track materials

Rails

Y-Steel Sleeper

Page: 221-01

Y-steel sleepers St 98 Y with rail fastening S 15 Special advantages of Y-railway track • • • • • • • •

Highly economical due to the comparatively low gravel requirement and the low transport weight. Due to the frame stiffness of the system and the high track resistance, the tracks are also at very small radii welded gaps. Long life. Excellent recycling properties. Lower maintenance costs due to long intervals in the elaboration. Applicable for all common rail sections and rail inclinations. Due to the versatile design possibilities of the material steel, an optimum adjustment of the construction of Y-shaped steel sleeper on the individual parameter of infrastructural manager is relatively easy to implement. The used rail support point S 15 ensures the complete electrical insulation of the rail against the sleeper on the Y-shaped steel sleeper.

Fields of application General gravel railway track:

Especially here the major advantages in the field of machine track reconstruction should be mentioned.

High-speed railway tracks

Special sleepers with ra fastening Typ A 8 on asphalt bases with anchor slot.

Cogwheel tracks

Supplement the sleeper construction to hold a cograil, which is welded in any position on the sleeper, can be pinned or screwed. By adjusting the rail clamping grids with the cograil lengths follows a further optimisation of railway tracks.

Multi and broad gauge track

By welding technique facility, all types are feasible.

Railroad crossing

Similar track coverings can be realised on the Y-steel sleeper rail. Furthermore, the installations of LST-systems are unproblematic.

Tracks with safety guard and guiding device

These special solutions on Y-steel sleepers are standard designs of DB AG (180 mm groove width, one and two sided). Deviating from other groove widths already been realized.

Tunnel run

Due to the low height of the sleeper proves that Y-steel sleeper rail currently the reorganisation measures in old stock to be very beneficial. In individual cases a design as a slab track with an overall height of only 440 mm (SO to OK tunnel floor, rail 49E5) is possible.

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Track materials

Rails

Y-Steel Sleeper

Page: 221-02

Y-shaped normal sleeper

Type selection and dimensions Support distance A in mm

B in mm

Weight / Pc. in kg

Track in mm

Comments

Rail 46E1 Y-S15D-No-650-FO

650

1210

122.6

1000

Regular narrow gauge track sleeper

Rail 49E5 Y-FT-No-990-BRB

990

1510

122.1

800

Rail 54E4 Y-S15D-No-600-BAM-SE

600

1160

119.5

1000

Rail 60E2 St98-Y-No-600-60

600

1160

142.3

1435

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Date of issue 08/10

large deflection with cograil and uninsulated support base Base with the possibility of additional track expansion < + 20 mm Control sleeper DB AG

Track materials

Rails

Y-Steel Sleeper

Page: 221-03

Y-Changeover sleeper

Type selection and dimensions Support distance A in mm

B in mm

Weight / Pc. in kg

Track in mm

Comments

Rail 46E1 Y-S15D-Üli-650-FO

210

770

119.2

1000

Regular narrow gauge track sleeper

Rail 49E5 Y-FT-Üli-990-BRB

990 440

1510

169.1

800

Rail 54E4 Y-S15D-Üli-600-BAM-SE

185

745

117.1

1000

Rail 60E2 St98-Y-Üre-600-60 St98-Y-Üli-600-60

185 185

745 745

139.3 139.3

1435

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large deflection with cograil and support base Anchoring possibility Base with the possibility of additional track expansion < + 20 mm Control sleeper DB AG

Track materials

Rails

Y-Steel Sleeper

Page: 221-04

Special section IB 100 S-1 Sleeper body made of steel profile IB-100-S, all around welded to the upper Crossbars (□ 25 x 150) and the lower cross-bars (L 50x50x6) made of material EN10025-2-S235JR+AR. Compound in inert gas welding process, Welding quality as per DIN EN ISO 5817 Kl. C, seam strength 4mm.

Y-axis

Z-Axis

F= G= ly = W y=

26.4 cm2 20.8 kg/m 432.0 cm4 91.0 cm3

iy = lz = W z= iz =

installed

Rail support distance

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Date of issue 08/10

4.04 cm 276.0 cm4 39.5 cm3 3.23 cm

pre-installed

On delivery, the fastening parts are pre-assembled. After inserting the rail, the sleeper screw to be freed for approx. one turn. The rail clamps can be brought in locking position to the rail centre. The screws are tightened until the middle bend of the clamps rest on the guide plate. Torque according to RiL 824.5050 of DB AG: until the distance between middle bend of the clamp and bearing surface of the guide plate is ≤ 0.5 mm, and torque ≤ 200 Nm

Track materials

Rails

Y-Steel Sleeper

Page: 221-05

General product details of the Y-Steel Sleeper Compared to conventional cross sleeper made of wood, concrete or steel, the Y-sleeper has the following key features: The sleeper body made of special rolled steel profile IB 100 S with a low, favourable height of 95 mm. The Y-shaped fork. Three rail supporting points per sleeper. Each base serves the rail a dual bearing. The patented rail support S15 is fully electrically isolated and enables unrestricted use of the Y-steel sleeper in the network of electrified railways. The installation of equipment of control technology and defence electronics is likewise unproblematic.

The rail support S15 The patented rail support S15 enables the rail two bearing surfaces per base. The rail is thus mounted at a distance of 230 mm on elastic intermediate layers and in the middle between these two supports held down by the tension clamp in combination with a threshold, and a screw plug. The corresponding inclination is produced by the intermediate plate, on which the elastic intermediate layers are locked. The guide rail is carried out by the inner and outer guide plate. By pair wise exchange of the guide plates can also be retrofitted on certain types of sleepers also subsequently the track can be adjusted, e.g. at a subsequent desired track extension in tight curves. The guide plates ablate the ensuing horizontal forces on the welded upper crossbar in the emerging body. The lower cross bar from L-sections allow significantly to the high lateral resistance of the Y-steel sleeper track.

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Date of issue 08/10

Track materials

8 7 6 5 4 3 2 1

Pos.

Rails

1 2 2 1 1 2 2 1 Number / Support point

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Y-Steel Sleeper

Spacer plate Intermediate level Clamping dowel Guide plate (outside) Guide plate (inside) Rail clamps Sleeper screws Rail Designation

Page: 221-06

Zwp 192 Zw 401 Dü S 15 Fpa 15 Fpi 15 Skl 14 Ss 34 with Uls 7 60E2 Brief description

Track materials

Rails

Y-Steel Sleeper

Page: 221-07

Sleeper requirement The sleeper requirement for conventional cross sleeper with a rail support distance of 600 mm is 1667 sleepers per 1000 m track.

Y-Steel sleeper requirement

A = Rail support distance

Number of Y-Steel sleepers n =

Length of the track section in meters (Supporting distance in meters + 0.23) * 1.5

Example of supporting distance A = 600 mm and a track section of 1000 m 1000 m (0.6 + 0.23) m * 1.5

= 803 piece per 1000 m rail

Example of a supporting distance from A = 650 mm and a track section of 1000 m 1000 m (0.65 + 0.23) m * 1.5

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Date of issue 08/10

= 758 piece per 1000 m rail

Track materials

Rails

Y-Steel Sleeper

Page: 221-08

Gravel requirement

Safety space according to DS 132

Minimum clearance

Safety space according to DS 132

Edge away

Edge away

1)

Danger zone at v=120 km/h

Gravel requirement of 1.42 m / m³ rail Single line track Elevation 0 mm V max 120 km/h Front and head gravel 30 cm This value is around ~ 30% lower than the comparable railway track with bar sleeper.

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Track materials

Rails

Y-Steel Sleeper

Page: 221-09

Applications and installation criteria in the track network of DB AG

Authorisation document of Federal Railway Authority from 30.12.1997 Certificate No.: 1221/11101/21AZ2/0244/97 Approved area for use according to the approval of former Central Office of the German Federal Railways from 30.12.1993 - VIII.8301 Io: Vmax = ≤ 120 km/h Load: 20,000 Lt/d in continuous main tracks of 2nd rule and ≤ 30,000 Lt/d in other main and side tracks Minimum radius: 190 m Approval of a standard design NEF (0). - Iosb 17.01.2000

Approval series of track detector FSSB construction forum (protective device EbüT 80) for railway track with Y-steel sleepers EBA from 08.04.1995, Approval number 75 025/5

Licence for field test for Y-steel sleeper with rail fastening S 15 ballast substructure for v = 160 km/h EBA 21.61 Iozb (274/98) from 04.01.2000 Identification mark: 1221 / 11101 / 21AZ2 / 8274 / 9

Licence for field test for Y-steel sleeper with rail fastening S 15 heavy duty in ballast substructure EBA 21.61 Iozb (575/00) from 04.01.2000 Identification mark: 1221 / 11101 / 21AZ2 / 0575 / 0

Authorisation for guiding mechanism and safety gear on Y-steel sleepers EBA 21.61 Iozb (575/01) from 04.01.2001 Identification mark: 1221 / 1110 / 21ZEN2 / 0557 / 01 Release as a standard design: TZF 61.Da. K0 20/2003

User declaration of DB AG - TZF63 from 04.03.2002 LeBODAN, System BODAN 2 and BODAN-Y-Platte

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Track materials

Sleepers

Pre stressed concrete sleepers Technical data

Page: 222-01

Pre-stressed concrete sleepers are being produced since beginning of 50s with continuous technical development. While manufacturing, it is differentiated between immediate and delayed stripping. For receiving the rail fastening plastic plugs are required to be fitted in front of the vibrating of the concrete into the form work. On the surface of pre-stressed concrete sleepers is to be placed clearly visible: • • • •

The identifying mark of the manufacturer the last two digits of the year of manufacture the rail foot width in mm the classification mark (e. g. B70)

The sleepers are manufactured of a concrete with high compressive strength ßw 28 of 60 N/mm², i.e. a test cube from the production must have setting time after 28 days of this compressive strength For more information on the nature of the concrete: Compressive strength ßwv Bending tensile strength ßB 7 Cement mortar ßw7 Cement grade CEM 42.5 and CEM 52.5

= 45.0 N/mm² = 6.5 N/mm² = 30.0 N/mm²

Generic information: As a standard railway structure currently the sleeper B 70 W 60 can be considered. The sleeper sole is thus used to reduce the gravel load, especially in elasticity jumps as well as for increasing the railway track elasticity (e.g. bridges and in tunnel areas) and for impact sound reduction. It is used in DB AG currently with UIG under operational tests. For the slab track with the rail fastening system 300-1, pre-stressed concrete sleepers B 301-W 60 and B 302-W 60 are used. Depending on the manufacturer, names may be different. For the gravel crossing / slab tracks, the sleepers B 303-W60ü are used. Classification: e.g.:

Concrete sleeper

Categor

soled

rail 60E2 W-fastening

Requirements for producing pre-stressed concrete sleepers 1. Principles of design, construction and approval procedures 2. Technical specifications of concrete sleepers according to DBS 918 143 3. European Standard EN 13230 1-5, Edition 2009 Railway applications, railway track, track and turnout sleepers made of concrete 4. As VDV railway track guidelines apply OR 13.3, Technical specifications for pre-stressed concrete in each valid copy.

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Edition January 1982 November 2008 valid from 2009

Track materials

Sleepers

Concrete sleepers B70 W60 Immediate limit switch

Page: 222-02

Width of rail foot

Sdü 25 (alternatively Sdü 9)

for 60E2 track gauge 1435 mm

Classification mark Identifying mark

Date Production week

Trough designation Number forms

Axle load Concrete volume Concrete mass incl. concrete reinforcement Attaching part Total weight

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Date of issue 08/10

» 250 kN » 114 L » 280kg » 8kg » 288kg

Track materials

Sleepers

View: B

Dimensions – Rail support 60E2

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Concrete sleepers B70 W60

Immediate limit switch (Details)

A-A

Page:.222-03

Track materials

Sleepers

Concrete sleepers Overview Part 1

Page: 222-04

Nominal gauge 1435 mm

Gravel railway track B70 W54

Nominal gauge 1435 mm

Gravel railway track B70 W-2,4-54

Nominal gauge 1435 mm

Gravel railway track B70 W60

Nominal gauge 1435 mm

Gravel railway track B70 W2,4-69

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Date of issue 08/10

Track materials

Sleepers

Concrete sleepers Overview Part 2

Page: 222-05

Nominal gauge 1435 mm

Gravel railway track B58 W54

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Date of issue 08/10

Track materials

Sleepers

Concrete sleepers Overview Part 3

Page: 222-06

Nominal gauge 1435 mm

Gravel railway track B90 W54

Nominal gauge 1435 mm

Gravel railway track B90 W60

Nominal gauge 1435 mm

Gravel railway track B07 W60

Nominal gauge 1435 mm

Gravel railway track Pre-stressed sleeper

Concrete pre-stressed sleepers are manufactured in each required length The distance of the fastening (L to Z) resulting from the associated pre-stressed design.

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Track materials

Sleepers

Concrete sleepers Overview Part 4

Page: 222-07

Nominal gauge 1435 mm

Gravel railway track ÖPNVW49

Nominal gauge 1435 mm

Gravel railway track ÖPNV W Ri 180

Nominal gauge 1000 mm

Gravel railway track ÖPNVW 41E1

Nominal gauge 1000 mm

Gravel railway track ÖPNVW59R1 / 60R1

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Track materials

Sleepers

Page: 222-08

Concrete sleeper railway track Track system W 3

The construction W 3 (with angled guide plates and Skl 1) is the standard railway track design for concrete sleepers in gravel track.

Position Brief description / Construction W 3 K-60 W 3 K-54

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Date of issue 08/10

1

2

3

4

5

6

Ss 35 Uls 7

Skl 1

Wfp 3b

Sdü 25

Zw 686a

ZW 687a

4 4

4 4

4 4

4 4

2 2

Track materials

Sleepers

Page: 222-09

Concrete sleeper railway track Track system W 14

The construction W 14 (with angled guide plates and Skl 14) for elastic railway track.

Position Brief description / Construction W 14 K-60 W 14 S-60 W 14 K-54 W 14 S-54 W 14 K900-60 on B70 W 14 K900-60 on B 90

1 Ss 35 Uls 7 4 4 4 4

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Date of issue 08/10

2 Skl 14 4 4 4 4

Wfp14 K-12 4

3 Wfp14 S-12

4

5

Ei 31

Ei 32

4

2

2

4

2

2

Wfp14 K900

4

6 Sdü 25 4 4 4 4

7 Zw 700 2 2 2 2

Zw 900

4

4

4

4

2

4

4

4

4

2

Track materials

Sleepers

Concrete sleeper railway track Track system FF 300

Page: 222-10

The railway track design FF 300 (with elastic rail bedding and Skl 15) is the standard-railway track design for the slab track.

pre-installed

installed

Position Brief description / Construction System 300-1

1 Ss 36 Uls 7 4

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Date of issue 08/10

2

3

4

5

6

Skl 15

Wfp 15a

Sdü 26

Zw 692-6

Grp 21

7 Zwp 104 NT c = 22.5 kN/mm

4

4

4

2

2

2

Track materials

Sleepers

Page: 222-11

Concrete sleeper railway track for grooved rails, W 14

The track design W 14 with wedge angular guide plates for gauge widening and Skl 14 is the standard-railway construction for grooved rails with W-fastening.

installed

pre-installed

Concretesleeper

Position Brief description / Construction W 14 with Wedge angle guide plate

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Date of issue 08/10

1

2

3

4

5

6

Ss 35 Uls 9

Skl 14

Wfp 14R

Wfp 14L

Sdü 25

ZW 180

4

4

2

2

4

2

Track materials

Sleepers

Wooden sleepers

Page: 223-01

Wood sleepers For over 150 years, tracks are laid on wooden sleepers. Types of wood, dimension, stacking, planning and drilling, pre-assembly, emerging head sleeper etc. have been explored over decades of work and implemented the research result in production. The wooden track sleepers of the Deutsche Bahn are exclusively made of beech wood. Turnout sleepers exclusively of oak tree. In northern European countries such as Sweden, Norway and Finland, as well as in some German private railways, track and pre-stressed sleepers made of pinewood are used. To avoid that the wood comes from a disputed or illegal logging, a "Programme for Endorsement of Forest Certification Schemes" (German: Certification system for sustainable forest management PEFC) was shortly brought into life PEFC in year 1999. PEFC is an international forest certification system and until today the world's largest independent organization to ensure continuous improvement of sustainable forest management, ensuring environmental, social and economic standards. Wood processing firms can be certified under this standard and ensures their customers that for every felled tree, a new will be replanted and thus causing no harm to the environment. The wooden sleepers are impregnated with the remains of coal tar. This is a very complex mixture of substances, which consists of approximately 10,000 individual compounds. Under the terms of Western European Institute for impregnation - W.E.I. It is classified into two classes, A, B and C according to the content of Benzopyrene. In the meanwhile these W.E.I.-classes have been transferred to the European Standard DIN EN 13991. Today, for wooden sleepers in Deutsche Bahn coal tar oils of W.E.I.-type C are used with a benzopyrene content of < 50 ppm.

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Track materials

Sleepers

Wooden sleepers

Page: 223-02

Requirements of Creosote oil of type A, B and C Parameter

Type A

Type A

Type A

Test procedures

Density at 20 °C (kg/m³)

1.04 to 1.15

1.02 to 1.15

1.03 to 1.17

BS 144:1997, Annexe B

Moisture content in % (m/m)

max. 1

max. 1

max. 1

ISO 760*

Crystallisation temperature (°C)

max. 23

max. 23

max. 50

Annexe A

Moisture extractable phenols in % (m/m)

max. 3

max. 3

max. 3

EN 1014-4

Toluene insoluble in % (m/m)

max. 0.4

max. 0.4

max. 0.4

BS 144:1997, Annexe G Annex B

Boiling curve (Vol.-%) Distillate up to 235 °C

max. 10

max. 20

Distillate up to 300 °C

20 to 40

40 to 60

max. 10

Distillate up to 355 °C

55 to 75

max. 70

max. 65

Benzopyrene content (mg/kg)

max. 500

max. 50

max. 50

EN 1014-3

Burning point (°C)

max. 61

max. 61

max. 61

EN ISO 2719

*Alternatively, the distillation process is used according to ISO 3733.

Comment 1: Type A should be used for the pressure impregnation of wood. Type B is also suitable for pressure impregnation, but has a more defined boiling curve and a more limited residue as Type A. It is particularly suitable for the treatment of masts for power lines and telecommunications where the tar oil constituent parts can be flushed during the use. Type C is suitable for the pressure treatment of wood at temperatures in excess of 100 ° C. In this type, the low-boiling fraction is excluded, which is allowed in the other creosote oil types. Hereby lowering the odour is achieved. Comment 2: All types of creosote oil should not contain more than 3% water. Comment 3: Used creosote oil should not contain more than 3% water. Comment 4: The density is determined at a temperature above the crystallization temperature. For every degree Celsius above 20 °C, a fixed value of 0.7 kg/m³ density to the read is added.

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Track materials

Sleepers

Wooden sleepers

Page: 223-03

Wooden sleepers are impregnated in the pressure process. The impregnating profiles and intakes for wooden sleepers are defined in DIN 68811 and in the DBS 918144. Generally it is to be noted that for a best possible impregnating result, the wooden sleepers must be settled. I.e. for example, beech sleepers must have a gross weight of < 750 kg/m³ and oak sleepers of < 900 kg/m³ before impregnation. The approved shapes of wooden sleepers, dimensions, details on acceptance, manufacturing and acceptance conditions are listed in UIC-Kodex 863 V, the DBS 918144 and in the DIN EN 13145. The impregnation of railway sleepers of wood with coal tar is defined in the DIN 68811 as well as the DBS 918144. Impregnating diagram for beech sleepers

Impregnating diagram for oak sleepers

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Track materials

Sleepers

Wooden sleepers

Page: 223-04

Drying and cracking Wood is a natural material, which is in contrast to synthetic materials not constructed homogeneously. This creates the diversity of appearance, which is particularly appreciated in this ecological material. This inhomogeneity exists both in the structure, as well as in the properties. Wood is a swellable, anisotropic material. Anisotropy means that the behaviour in the three main anatomical directions (longitudinal, radial, and tangential) is not equal. Swelling and shrinkage depends on the moisture change, wherein humilities above the so-called fibre saturation point are of about 28-30% without the influence. Wood changes its moisture content mainly by the relative humidity. As long as the moisture content is above the fibre saturation point, do not change in drying of the freshly cut wood dimensions. With the below this point is where the shrinkage, which results in a change in the output size and the formation of cracks. On the drying ground the rough sleepers are stacked until they mature in an expedient manner. Impregnating is a wood whose cells do not contain "free" water anymore, so that the introduction of the preservative can pass freely by pressure impregnation. External characteristic for these physical processes is a severe weight loss of the sleeper, connection with a natural drying crack growth due to oscillation processes. The cracking is therefore biologically based and therefore inevitable, but also quite desirable. Cracks facilitate impregnation, promote a better distribution of coal tar oil in wood and enable an optimal protection of wood. To request the delivery of crack-free wooden sleepers contradicts the impregnating technical knowledge. Such wooden sleepers are not because of the excessive moisture impregnated properly, would later form drying cracks in the track and so to expose the unprotected wood biological pests with the result of early failure. Excessive cracking is determined by quality control, with frontal cracking can be effectively limited by the prescribed means of security. Cracks, unless they go through the entire threshold not weaken the strength of the wood sleeper.

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Track materials

Sleepers

Wooden sleepers

Page: 223-05

In the European standard DIN EN 13145:2001 the regarding shapes, dimensions and tolerances are specified requirements set below:

Group

I

1 260 2 260 3 260 4 240 5 240 6 240 7 240 8 220 9 250 10 305 11 305 12 250 13 300 14 200 * Minimum size

Dimensions of track sleepers (mm) d* r* e Form E1 Form E2 Form E1+E2 160 160 200 80 150 160 200 80 130 130 170 60 150 160 180 70 160 160 180 80 140 160 180 70 130 130 170 60 130 130 160 50 125 205 230 100 125 255 280 100 150 255 280 125 130 200 225 105 130 250 275 105 120 110 140 40

Dimensions of turnout sleepers (mm) Group I e d* r* 1 300 150 240 120 2 280 140 220 120 3 260 160 200 100 4 260 150 210 120 5 240 150 200 90 6 240 160 160 80 7 240 140 200 80 8 300 130 200 80 * Minimum size

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Track materials

Sleepers

Wooden sleepers

Page: 223-06

Forms: Rail sleepers:

Turnout sleepers:

Dimensions: While ordering, the customer must define the actually required dimensions I, e and d. This also applies to the length. These dimensions are for track and pre-stressed sleepers, ready for use or for impregnation. Tolerances: The following tolerances find applications ready to use or for impregnation in all tracks and pre-stressed sleepers: • • • •

Length: Width: Strength (Height): Cross-section:

± 30 mm; + 10 mm / - 3 mm; + 10 mm / - 3 mm; maximum deviation from right angle is 3".

Note: The length tolerance is limited due to both sided rectangular truncation of tracks and prestressed sleepers. Deviating tolerance for rail and pre-stressed sleepers shall be provided which are installed under specially justified conditions.

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Track materials

Sleepers

Wooden sleepers

Page: 223-07

In UIC-Kodex 863 V respective shapes, dimensions and tolerances specified below are the following guidelines: Track sleepers The shapes of the track sleeper cross-section are shown in the following diagrams (they are also made sharp-edged): Form I:

Form II:

Form III:

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Track materials

Sleepers

Wooden sleepers

Page: 223-08

In addition, the track sleepers are divided into seven group’s accordance to the following in compilation of the dimensions (according to UIC 863 V) listed. The normal track sleeper length is set at 2600 mm. Where tracks with other gauges than 1435 mm, the length of the sleepers in the tendering process is agreed.

Group 1 2 3 4 5 6 7

I (cm) 26 26 26 24 24 24 22

e (cm) 16 15 13 15 14 13 13

d (cm) Form I and III 16 17 13 16 16 13 13

Form II 20 20 17 18 18 17 16

r (cm) Form I and II 8 8 6 7 7 6 5

The dimensions in any case should not exceed from a width of 30 cm and a thickness of 17 cm. The dimensions for d and r are minimum values.

Dimensional deviation: The permissible dimensional deviations are as follows: in the lengths:

+3 cm / -3 cm;

in the widths:

- in the rail support surface: no dimensional deviations towards downwards; - outside this range: -2 cm;

in the thickness:

- This must be exactly equal to 0.5 cm in the two rail supports; - in the rail surface area: no dimensional deviations downwards; - outside this area: -1 cm;

in the ceiling beam

- in the rail surface area: no dimensional deviations downwards.

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Track materials

Sleepers

Wooden sleepers

Page: 223-09

Turnout sleepers The shapes of pre-stressed sleepers given are in the following descriptions Form I:

Form II:

Form IIa:

Form IIb

The pre-stressed sleepers are divided in four groups according to the following compilation transverse dimensions.

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Track materials

Sleepers

Wooden sleepers

Page: 223-10

The expressed dimensions required in cm from a distance of 25 cm to the sleeper ends (according to UIC 863 V) over the entire length. The dimensions for d and r are minimum values.

Group

I (cm)

e (cm)

d (cm)

r (cm)

1. Group

30

15

Form I Form II Form IIa Form IIb

24 21 22 27

12 8 8 12

2. Group

28

14

Form I Form II Form IIa

22 19 20

12 8 8

3. Group

26

16

Form I

20

10

4. Group

26

15

Form I Form II Form IIa Form IIb

21 18 20 23

12 5 5 12

Dimensional deviation: The following dimensional deviations are permitted in the dimensions: in the lengths:

+3 cm / -3 cm

in the widths:

+2 cm / -1 cm for the groups 1 and 2 +1 cm / -0.5 cm for the groups 3 and 4

in the thickness:

- 0.5 cm with all 4 groups, provided the ceiling width around 1 cm is larger than for the group in question.

is required:

- Greatest thickness 17 cm

of the ceiling width:

no dimensional deviations towards lower

level of the lateral processing:

no dimensional deviations towards lower

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Track materials

Sleepers

Steel sleepers

Page: 224-01

Steel sleepers Steel sleepers Sw 82 according to UIC-Codex 865-1 V, 3. Paragraph 1.1.1983, with welded ribbed plates Rps 8 (49E5.54E4 for rail foot 125 mm) or Rps 15 (60 E2 for rail foot 150 mm). Also deliverable in pre-assembled design and insulated one-sided and two-sided. Approach of the accounting measure see detail X

I (e.g. 1674, see table)

Detail X

Spot

Accounting measure Check point

with onesided insulation without insulation

49E5 / 54E4

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Date of issue 08/10

Railway track KS Ioarg 322

without insulation

60E20

Railway track

Railway track KS Ioarg 322

without, with insulation with onesided insulation

Rail

Pre assembly with

track gauge in mm

Measurement in mm +2/-1

Number of Spot

Rps 15 - Iotkp 44 and Rps 15-ia - Iotkp 112U

1450 1445 1440 1435

1689 1684 1679 1674

4 3 2 -

Rps 15 - Iotkp 44

1450 1445 1440 1435

1682 1677 1672 1667

4 3 2 -

Rps 8-Iotkp 47 and Rps 8-ia - Iotkp 12U

1450 1445 1440 1435

1658 1653 1648 1643

4 3 2 -

1450 1445 1440 1435

1651 1646 1641 1636

4 3 2 -

Rps 8 - Iotkp 47 and

Track materials

Sleepers

Steel sleepers

Page: 224-02

Profile

Profile shapes Pr 51 UIC 28 SW 82/54

H Total height in mm 75 90

B Upper width in mm 120 150

C Lower width in mm 232 260

D Ceiling thickness in mm 9 12

F Side thickness in mm 7 7

A Crosssection in mm 2590 3625

100

145

260

9

7

3070

G

20.33 28.46

XH Neutral axis in mm 50.31 63.10

JX Inertia moment 4 in cm 148 277

WX resistance moment 3 in cm 29.4 44

24.10

68.10

313

45.8

Weight in kg/m

X = Axis for torque of inertia Technical values: Cross-section: Stretched length L = 2400 mm: Stretched length L = 2500 mm: Stretched length L = 2600 mm: Weight of SW L = 2400 mm *): Weight of SW L = 2500 mm *): Weight of SW L = 2600 mm *): *) without ribbed plates

F = 30.7 cm² L = 2581.0 mm L = 2681.0 mm L = 2781.0 mm W = 62.20 kg W = 64.61 kg W = 67.02 kg Detail Y - Bearing marks -

SW 82

Profile

Manufacturer

Without scale/schematic diagram

Date of issue 08/10

Mark

04

the last two digits of the year of manufacture

bold font DIN 1451 ≥ 2.5 mm 1-2 mm embossed rolled

Track materials

Sleepers

Steel beam bridge sleeper

Page: 225-01

The SteelBridgeSleeper, developed by ThyssenKrupp GfT Gleistechnik, also known as SBS, is designed for railway bridges with open rail track as an alternative to the traditional wood bridge sleepers. The fatigue test at TU München has been cleared successfully at an elevation of 130 mm, 22.5 t axle load at 3 million load change. In 1999, the steel bridge sleeper was emerging on behalf of DB AG installed on a bridge in Dortmund Wickede for the first time. Up to the current period, the DB AG as well as other transport operators, SBS have been installed in numerous construction projects. The experience gained in the past years, the findings were incorporated into SBS built an established structural standards. The static type meets the requirements of the Directives, thereby eliminates complex individual evidence and the conclusions to be applied for approval by the Federal Railway Authority. Following requirements are met from the steel bridge sleepers: Directive of DB AG 804, 805, 820, 897.02 with DIN EN 50122-1, DBS 918002-2 in connection to DIN EN 10204, DIN 18800, DIN 18800 part 7, DIN FB 101 and 103 DIN 18800 part 7 :2208-11, DIN EN ISO 14555 Technical specialist report of DB Systemtechnik VTZ 115 Functional requirements of DB Systemtechnik etc.

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Date of issue 08/10

Track materials

Sleepers

Steel beam bridge sleeper

Page: 225-02

Nut Spring washer Insulated collar brushing Ribbed base plate Elastic intermediate plates Krupp ECF-correction plates

Zero position (chamfer)

Rail support system: The elastically mounted rail fastening system from ThyssenKrupp ECF, is used as a rail bed. For vibration damping, a 12 mm thick elastomer plate is used as per the dynamic requirements. For ribbed plate fastening weld-on threaded bolts can be used by means of drawn arc or DIN screws by plug connection. A height compensation under Krupp ECF-System is through height compensation plates up to + 26 mm / - 4 mm possible, a side adjustment by the eccentric insulating sleeve of +/- 5 mm.

Impact sound: The steel bridge sleeper in connection with the elastomer plate from Krupp ECF-System reduces the impact sound over wooden bridge sleepers by up to 6 dB.

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Date of issue 08/10

Track materials

Sleepers

Steel beam bridge sleeper

Page: 225-03

Carrier section: For steel bridge sleeper the wide flange beams of the series HEA, HEB and HEM are used in accordance with the DBS 918002-2. The grider depth and weights are derived from the static requirements as well as height requirements of the survey. Coating: The steel bridge sleepers and attachments are coated according to the requirements of ZTV-Ing. and the local corrosivity. The add-on parts, such as cross bars, hooks and front panels get an anti-slip grip coating according to DIN 18800 part 7 and DIN FB 103, quality standard B. Environmental protection: All used construction materials are ecological and completely recyclable. Height structures: The height structures are made according to the individual requirements and specifications, either welded beneath the sheet or conventionally edged with EVA base plate as a site assurance and EVA-height compensation boards. The under welded plates are designed by aligning tracks in elevation as wedges and designed in non-elevated track.

Height between plates

Sleeper shoe

Base plate

Without scale/schematic diagram

Date of issue 08/10

Track materials

Sleepers

Steel beam bridge sleeper

Page: 225-04

Guiding device: In guiding devices on the bridges RIL 820 and 804 may be required, angle brackets are welded on the top flange of SBS. In the locality, an L-corner on the angle brackets are placed, drilled and installed.

L-Corner

Angle bracket

Rail cover: For track cover on SBS GFK-grating, a laminated cover plate to be installed. For securing the position, mounting bracket and bracket from ThyssenKrupp are installed, which are screwed on the welded thread bolts. As a sleeper space cover to protect against falling parts, the edged glass plates or aluminium plates designed by TK are used. Mounting bracket

GFK-cover Sleeper space cover

Mounting bracket

Without scale/schematic diagram

Date of issue 08/10

Track materials

Ironmongery and accessories

Fastenings clamping plates

Page: 231-01

Kpo 6 (49E5) 0.648 kg/Pc.

Kpo 6 i (Steel sleepers) 0.570 kg/Pc.

Kpo 9 (54E4 / 60E2) 0.649 kg/Pc.

Kpo B (for bridges with slipper) approx. 0.53 kg/Pc.

Designation Rail B7 B8 B9 B 10 B 11

60E2 54E4 49E5 49E5 (iso) 60E2 (iso)

Dimension h in mm 7.5 7 8.5 2.5

Inclination

1.5

1:7.8

1:14 1:7.8 1:7.9 1:14

The bridge clamping plates are used in connection with plastic railpad.

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Date of issue 08/10

Track materials

Ironmongery and accessories

Fastenings Rib based plates

Page: 232-01

Inclination

Name

A

La

la

B

LB

lb

F

D1

D2

Inclination

Comment

kg/Pc.

Rph 1 - 150 Rph 1 - 160 Rph 1 - 180 Rph 1 - 210 Rph 6 - 160 Rph 6 - 180 Rph 6 - 210 Rpo 5a-210 Rpo 5 - 160 Rp 01/01 160 Ps 60 - 160 PT 180-160 PT 180-115 Rpb 1 - 110 Rp 16 h Rps 8 Rps 15 Rus 26 a Rp 16 g

345 345 345 345 370 370 370 345 345

285 285 285 285 310 310 310 285 285

30 30 30 30 30 30 30 30 30

150 160 180 210 160 180 210 210 160

90 90 90 90 90 90 90 90 90

30 35 45 60 35 45 60 60 35

127 127 127 127 152 152 152 127 127

13 13 13 13 13 13 13 13 15

15 15 15 15 15 15 15 15 17

1:40 1:40 1:40 1:40 1:40 1:40 1:40 01:20 01:20

49E5 / 54E4, Wooden sleepers

49E5 / 54E4, Wooden sleepers

7.328 7.857 8.950 10.549 8.440 9.500 11.316 11.690 9.540

345

285

30

160

94

33

127

15

15

without

49E5 / 54E4, Wooden sleepers

7.770

375 400 400 345 345 240 265 235 293

310 340 340 285 285

32.5 30 30 30 30

160 160 115 110 160 110 110 110 160

90 94 0 0 90

35 33 57.5 55 35

152 183 183 127 127 127 152 127 127

16 15 15 14 16 7.5 7.5 15 16

16 15 15 14 16 13.5 14.1 15 16

without without without without without 1:40 1:40 without without

60E2, Concrete sleepers

8.800 8.600 6.250 4.836 8.150 3.005 3.390 3.860 7.357

Without scale/schematic diagram

Date of issue 08/10

49E5 / 54E4, Wooden sleepers Bridge sleepers Bridge sleepers 60E2, Wooden sleepers 49E5 / 54E4, Steel sleepers 60E2, Bridge sleepers 49E5 / 54E4, Wooden sleepers

67R1, 59R1, 60R1 67R1, 59R1, 60R1 49E5 / 54E4, Concrete sleepers 49E5 / 54E4, Wooden sleepers 49E5 / 54E4, Steel sleepers 60E2, Steel sleepers 49E5 / 54E4, Steel sleepers 49E5 / 54E4, Steel sleepers

Track materials

Ironmongery and accessories

Rib based plates for guide rails

Page: 232-02

Guide rails, grooved width 180 mm, are used on bridges with more than 50 meters in length. They should keep derailed vehicles as close to the track, so that they can not parallel on bridge piers. Before and after the bridge, gripping device is installed. Here the splice rails converge towards the track axis in such a way, so that the wheels of incoming derailed vehicles driven into the groove. Used ribbed plates Name Rph 11 Ü Rph 12 Ü Rph 13 Ü Rph 14 Ü

Without scale/schematic diagram

Date of issue 08/10

manufactured from Rph 1 / Rpo 5 Rph 1-210 / Rpo 5 Rph 6 / Rph 6 Rph 6-210 / Rph 6 - 160

Width of rail foot 54E4 54E4 60E2 60E2

Weight kg / piece 15.373 17.843 15.268 17.859

Track materials

Ironmongery and accessories

Rib based plates for guide rails and supporting rails

Page: 232-03

Guide rails can be use in curved parts of R < 300m to protect the outside running rail. The groove width is 50 mm, at R < 150m 60 mm. The guard rails are approx. 15 m long, are not welded and are bent at the beginning and at the end to 100 mm, grooved width, 400 mm length. At 60 mm groove width also for ways transitions track type Lindau. Name Rph 7 Ü Rph 8 Ü Rph 9 Ü

Used ribbed plates manufactured from Width of rail foot Rph 6 / Rph 1 60E4 Rph 1 / Rph 1 49 E5 / 54 E4 Rph 1 / Rpo 5 49 E5 / 54 E4

Weight kg / piece 12.727 11.915 13.293

Protection rails are arranged with 80 mm groove width on the inner sides of both the running rails, when a particular reinforcement of the track frame is required; also serve as a derailment. Name Rph 15 Ü Rph 16 Ü

Without scale/schematic diagram

Date of issue 08/10

Used ribbed plates manufactured from Width of rail foot Rph 6 / Rph 1 60E2 Rph 6 – 210 / Rph 6 60E2

Weight kg / piece 1.839 15.321

Track materials

Ironmongery and accessories

Screws sleeper screws

Page: 233-01

Ss 35 with rounded thread

pre-assembled Uls

Name

L

K

R

Ss 8-140 Ss 8-150 Ss 8-160 Ss 23 Ss 25 Ss 30-230 Ss 30-240 Ss 33 Ss 34 Ss 35 Ss 36 Ss 36 Ss 36 Ss 36 Ss 36 Ss 36

132 142 152 152 161 195 205 195 125 161 195 205 215 220 225 235

35 35 35 38 35 35 35 35 35 35 35 35 35 35 35 35

0 0 0 6 0 0 0 0 0 0 0 0 0 0 0 0

Without scale/schematic diagram

Date of issue 08/10

Weight in kg 0.528 0.548 0.568 0.594 0.625 0.703 0.739 0.689 0.530 0.656 0.732 0.769 0.807 0.826 0.844 0.882

Use K-Support, wood and concrete sleeper K-structure K-structure Track system W 14 (replaceable by Ss 35) Track system W 14 with Uls 7 (replaceable by Ss 35) Track system W 300 with Uls 9 (replaceable by Ss 36) Track system W 300 with Uls 9 (replaceable by Ss 36) B 93 with Uls 6 Track system 15 with captive Uls 7 Track system W 14 with captive Uls 7 System 300 with captive Uls 7 System 300 with captive Uls 7 System 300 with captive Uls 7 System 300 with captive Uls 7 System 300 with captive Uls 7 System 300 with captive Uls 7

Track materials

Ironmongery and accessories

Screws Hook screws

Page: 233-02

Name

L

kg

Use

Hs 26-55 Hs 26-65 Hs 32-55 Hs 32-65 Hs 32-75 Hs 32-90

55 65 55 65 75 90

0.45 0.475 0.469 0.503 0.517 0.577

Railway track K Railway track K Railway track KS, turnouts 54E4 / 60E2 Turnouts 49E5 Turnouts 60E2 Turnouts 49E5

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Date of issue 08/10

Track materials

Ironmongery and accessories

Plastic screw anchor

Page: 234-01

The plastic screw anchor always received different forms in their development, which are adapted to the respective used sleeper screw. As an example of Sdü 25 is represented here. Name

L

D1

D2

D3

kg

Use

Sdü 9a Sdü 9b Sdü 25 Sdü 26 Sdü 27

135 155 141 141 141

39 39 36 36 36

25 24 25.5 25.5 25.5

31 31 29 29.4 29.4

0.051 0.062 0.033 0.033 0.037

Concrete sleepers Concrete sleepers Concrete sleepers, gravel Concrete sleepers, slab track Concrete sleepers, slab track

Without scale/schematic diagram

Date of issue 08/10

Track materials

Ironmongery and accessories

Plastic screw intermediate layers

Page: 235-01

Angular deviation
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