SP3 Design and implementation of solutions at test sites WP 3.9 Karlsruhe New installation methods for prefabricated track operator: VBK

Transcription

1 SP3 Design and implementation of solutions at test sites WP 3.9 Karlsruhe New installation methods for prefabricated track operator: VBK presented by Thomas Rupp Verkehrsbetriebe Karlsruhe (VBK), construction department M48 Final Assembly June 25, 2010, Prague

2 Contents Objectives Initial position Description of test site Technical requirements on track modules Description of activities Engineering, technical details Constructing process Final activities Experiences Perspectives Final Conference - June 25, Prague 2

3 Initial position Need of renewing Final Conference - June 25, Prague 3

4 Initial position Superstructure has to be replaced urgently Karlsruhe is constructing a tram tunnel under the pedestrian district, construction has begun in may 2010 Re-Modulix : removable prefabricated track modules Final Conference - June 25, Prague 4

5 Description of test site installation location Final Conference - June 25, Prague 5

6 Description of test site Length: 375 m, double track The chosen section is the track section with the most rail traffic in the entire rail network of the VBK 7 lines of the light rail system (a tram train vehicle crosses every 85 seconds per direction) Extract of network diagram Final Conference - June 25, Prague 6

7 Technical requirements on track modules Surface of red pavement stones like the sand-stone building of the University of Karlsruhe (KIT) Prefabricated concrete pavement stones as integrated parts of the modules Maintenance free surface of the pavement stones Load: trams (11 to axle load) and busses (only at nights) Noise and vibration reduction (slab track!) Stable position and level of the track Integrated rail drainage system Fast construction process Completion of all works on test site within 3 weeks Removable track modules to use elsewhere in the VBK-network Final Conference - June 25, Prague 7

8 Engineering process 18 Re-Modulix out of 42 prefab modules Realisation of all plans for modules and panels Development of embedded hoisting anchors Application of anti-adhering coating allowing future module removal Final Conference - June 25, Prague 8

9 Production and transport Production & transport from Belgium to Karlsruhe

10 Production and transport Delivery of prefabricated slabs in Karlsruhe harbour Final Conference - June 25, Prague 10

11 Technical details Quantity: 247 slab elements ( ) Weight: kg Length: 18 metres Concrete quality: C30/37 Special vehicles for installing (existing catenary!) Final Conference - June 25, Prague 11

12 Construction process Works: Monday, August 10, 2009 until Friday, August 28, 2009 Six days a week (no works on sundays) Daily working time: 6 a.m. to 10. p.m. (two shifts) Detouring diagram for tram lines (3 tram lines replaced by busses) Final Conference - June 25, Prague 12

13 Construction process Production of track modules, transport to test site, cranes, installation: CDM, Brussels (Other) construction works: Heilit+Wörner, Munich Construction supervision: VBK, construction department Removal of superstructure Final Conference - June 25, Prague 13

14 Construction process Module positioning Rail welding Concreting Installation of the great elements within 3 days (average of 2 modules/hour) 750 m of rail Ri 59 N (59 Ri 2) 88 rail welds 210 fill-in panels 400 m³ of concrete (in 4 days) Finishing Panel assembly Final Conference - June 25, Prague 14

15 Constructing process rail underpour with concrete, assembly of small slabs in the centre and in the welding zones Final Conference - June 25, Prague 15

16 Works are finished Final Conference - June 25, Prague 16

17 Experiences: noise & vibration reduction Measurement and analysis by Karlsruhe Institute of Technology (KIT) (former University of Karlsruhe), department for railroading: Maximum amplitude of acceleration lower than before (see below) Amplitude more continuous, but a little stronger before after 4 bogies visible not visible Final Conference - June 25, Prague 17

18 Experiences + stable, quiet track, good visual appearance, fast and successful construction process, track used by trams and busses (bus only at night) +/- expensive (but: long transport distance, long engineering time...) -- Severe damages after only 9 months (!) at several points removal of pavement stones from the prefabricated concrete Joint between elements 7 cm Final Conference - June 25, Prague 18

19 Experiences Reasons (possibly): failure in the production process during the underpooring of the pavement stones: deficient ahesion! Solution (probably): Elastic joints in the pavement level (8 cm) between the elements Close open joints (frost damage!) Fix pavement stones on concrete 5 years of contractual warranty! Consequences: Significant reduction in expected LCC-Savings Final Conference - June 25, Prague 19

20 Perspectives Implementation of Modulix-system in Karlsruhe in the existing form not successful Re-use of Re-Modulix elements because of pavement damages doubtful or: only without pavement stone filling Room for improvement: quality level, tolerances (accuracy) elastic, closed joints adhesion between pavement stones and concrete assembly only with cross beam along the element production near the installation site Good chance for a better quality, durability, price level Competitive system! Final Conference - June 25, Prague 20

21 SP3 Design and implementation of solutions at test sites WP 3.9 Karlsruhe New installation methods for prefabricated track operator: VBK Thank You for attention Final Conference - June 25, Prague 21