FFU Synthetic Sleeper. Patrick Childs UK Sales Manager Sekisui Chemical

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1 FFU Synthetic Sleeper Patrick Childs UK Sales Manager Sekisui Chemical

2 FFU synthetic sleeper

3 Annual Turnover SEKISUI Chemical Co. Ltd. [billions ] 70 years leading manufacturer of synthetic products Worldwide more than 200 subsidiaries Approx employees 2014 SEKISUI Chemical Co., Ltd.

4 High Performance Plastics Housing Urban Infrastructure and Environmental Business Units

1 2 Glass fiber supply Impregnation, Spray

Inspection Long glass fiber glass fiber before

Pultrusion process ISO 9001 Management System

5 1 2 Glass fiber supply Impregnation, Spray Molding Cooling Pulling Cutting Finishing & Inspection Long glass fiber glass fiber before adding polyol molding pulling Foamed Urethane Pultrusion process ISO 9001 Management System Certificate ISO Environmental Management certificate Continuous glass-fibre and Polyurethane FFU sleepers are manufactured by Pultrusion. Glass fibers are soaked in polyurethane and the linkage is then hardened at a raised temperature Fibre reinforced Foamed Urethane

Milling and Drilling FFU will be milled to adjust

Bonding of basic sleeper Possible dimensions: Up to

6 Milling and Drilling FFU will be milled to adjust height very precisely (mm). Holes will be drilled according to the drawings from the customer. Bonding of basic sleeper Possible dimensions: Up to 10 m length, Up to 600 mm width, height according request. basic sleepers after pultrusion Fabrication of FFU sleeper

7 Bridges Steel and Ballast Switches Slim tie Switches Bridges Specials

8 Direct Fixation Slab track Ballast track Any kind of track

1980 Railway Technical Research Institute (RTRI) adopted FFU after laboratorial approval in Japan and started the following field tests: Miomotegawa Bridge of Uetsu Line Kanmon Tunnel of Sanyo Line

Application of FFU by private and municipal railways.

9 1980 Railway Technical Research Institute (RTRI) adopted FFU after laboratorial approval in Japan and started the following field tests: Miomotegawa Bridge of Uetsu Line Kanmon Tunnel of Sanyo Line 1985 very good results of field tests FFU sleeper became a approved standard product of JNR 1991 RTRI reported the results of 10 years field tests, which showed almost no deterioration. Application of FFU by private and municipal railways RTRI reported the results of 15 years field tests, which indicated that the strength deterioration of 15 year old wooden sleepers will be equal to the strength deterioration of 50 year old FFU sleepers Japanese Industrial Standard JIS RTRI tested FFU sleeper installed in 1980 positive announced further use for the next 20 years positive to JR Historical development - 35 years in service

2004 Austria: First FFU Railway project in Europe, Metro bridge in Vienna 2008 Germany: 16 cm FFU sleeper positive tested by TU Munich First switch on FFU in Germany Chempark Leverkusen Austria: LCC

10 2004 Austria: First FFU Railway project in Europe, Metro bridge in Vienna 2008 Germany: 16 cm FFU sleeper positive tested by TU Munich First switch on FFU in Germany Chempark Leverkusen Austria: LCC Analysis TU Graz - FFU is more economical than wood at bridges 2009 Germany: Approval of FFU by EBA for German Railway Infrastructure 2011 Germany: Deutsche Bahn first Bridge with FFU sleepers and low height sleepers 2012 Germany: Deutsche Bahn two switches 70,000 t/day & sleepers & bridges Netherland: Pro Rail installed 3 bridges 2013 Austria: Wiener Linien installed 78 switches with FFU Germany: 12 cm slim tie positive tested by TU Munich - 22,5 t axel load 200 km/h 2014 Switzerland:BAV approval for FFU sleepers starting by 12 cm height RHB - bridges plus slim ties 12 cm BLS - switches UK: Network Rail longitudinal (40/40/750cm) and regular bridge sleepers World: ISO Standard for synthetic sleepers enters into force 2015 Belgium: Infrabel: first bridge project France: Tisseo Toulouse: two switches in slab track Switzerland: SBB first switch project UK: Network Rail longitudinal sleepers in a curve 2016 France: Keolis 2 switches in slab track RATP uses FFU 100 for switches at slab track Norway: Jernbaneverket first bridge project UK: LU first bridge project Germany: TU Munich tested FFU 100 positive and lateral resistance test positive 2017 Germany: April final approval from EBA UK: November 2017 final certification for all bridge types Sweden: SL: Stockholm center bridge with 5 tracks Ireland: Irish Rail: bridge in Limerick Historical development Europe since 2004

Worldwide approximately 90.000 FFU Synthetic Sleepers are installed annually Accumulated installation amount until 2015 has become more than [1000pcs. ] 120 2,2 million sleepers 1.

11 Worldwide approximately FFU Synthetic Sleepers are installed annually Accumulated installation amount until 2015 has become more than [1000pcs. ] 120 2,2 million sleepers km of track 2, Thousand sleepers 230/140/2200mm ,000 1,500 1, FFU sleepers installed since 1980

property unit beech FFU synthe1c wood new new 10 years 15 years 30 years standard density [kg/m 3 ] 750 740 740 740 740 JIS Z 2101 flexural strength [kn/cm 2 ] 8 14,2 12,5 13,1 11,7 JIS Z 2101 elashc

12 property unit beech FFU synthe1c wood new new 10 years 15 years 30 years standard density [kg/m 3 ] JIS Z 2101 flexural strength [kn/cm 2 ] 8 14,2 12,5 13,1 11,7 JIS Z 2101 elashc modulus [kn/cm 2 ] JIS Z 2101 Compressive strength [kn/cm 2 ] 4,0 5,8 6,6 6,3 6,0 JIS Z 2101 Shear strength [kn/cm 2 ] 1,2 1,0 0,95 0,96 0,93 JIS Z 2101 hardness [kn/cm 2 ] 1,7 2,8 2,5 2,7 2,4 JIS Z 2101 Impact flexural strength + 20 C [J/cm 2 ] JIS Z C [J/cm 2 ] JIS Z 2101 Water absorphon [mg/cm 2 ] 137 3, JIS Z 2101 InsulaHon resistance dry [Ω] 6,6x10 7 1,6x ,1x ,6x ,2x10 11 JIS K 6852 wet [Ω] 5,9x10 4 1,4x10 8 5,9x ,9x JIS K 6852 Pull-out force dog nail [kn] RTRI Pull-out force screw [kn] RTRI Technical properties

EBA (German Railway Authority), research of: The impact of vertical and horizontal loads during the effect of repeated

Bedding in ballast track DIN-EN 13481-3 Tightening torque tests: determine tensile strength of sleeper screws depending on

(concrete sleeper) Impact tests to simulate derailment Electrical resistance in accordance with DIN EN 13146-5

13 EBA (German Railway Authority), research of: The impact of vertical and horizontal loads during the effect of repeated loading. Bedding in ballast track DIN-EN Tightening torque tests: determine tensile strength of sleeper screws depending on torque moment. Sleeper screw extraction tests DIN EN (concrete sleeper) Impact tests to simulate derailment Electrical resistance in accordance with DIN EN Static/dynamic tests according DIN EN (concrete sleeper) Static Tests at Sleeper Centre Up to a load of 240 kn, corresponding to a tensile bending strength of 74 N/mm² on the bottom of the sleeper, no crack was detected within the bending area where flexural tension was applied. TU Munich September 2008

Static Pressure Test Up to a load of 150 kn no plastic deformation was detected Thus, a load of 300 kn

Generally the support force for an axle load of 250 kn is 150 kn under the most severe conditions.

T=-20 C for two days. The average testing temperature is T = -10 C.

A comparison of deformation results does not show any significant differences.

14 Static Pressure Test Up to a load of 150 kn no plastic deformation was detected Thus, a load of 300 kn (supporting force) below the rib plate shows a plastic deformation of a maximum of 0.8 mm. Generally the support force for an axle load of 250 kn is 150 kn under the most severe conditions. Static Bending at T = RT and T = -10 C FFU sleepers were stored in a climate-controlled environment at T=-20 C for two days. The average testing temperature is T = -10 C. The sleeper shows no signs of embrittlement at low temperatures. A comparison of deformation results does not show any significant differences. Test of temperature dependency of sleeper deformation behavior showed no significant bending differences at T=RT and T=10 C. At T= -10 C there is no noticeable brittleness due to temperature variation. Deformation is predominately purely elastic. TU Munich September 2008 Coefficient of thermal extension For FFU 74 sleepers is 0,79 x 10-5 / K = 0, m/ K Delta T = 50 C leads to 1 mm extension for a 2,600 mm long sleeper

15 Lateral resistance of FFU synthetic sleepers comparing with wood 45 sleepers from each type have been installed in ballasted track. 15 sleeper of each type have been tested. The unconsolidated test happened after the installation Consolidated test happened after 1 year and around 23 million load tonnes were running over it Lateral resistance test October 2016

Approvals in Europe 2017 Europe: 2017 - EC Certificate Germany:

speed up to 230 km/h Switzerland: 2018 final approval starting

railway use United Kingd: 2017 certification for all bridge

16 Approvals in Europe 2017 Europe: EC Certificate Germany: final Approval for FFU starting by 10 cm height and for a speed up to 230 km/h Switzerland: 2018 final approval starting by 12 cm height sleeper Netherland: 2015 certification for railway use United Kingd: 2017 certification for all bridge applications Approvals in Europe 2017 Details of final EBA approval for Germany

17 Easy repair For example: Fastening position may be readjusted by filling nail holes Optimize your solutions with FFU

FFU Joint sleeper for Switches On site is it realizing high

almost everywhere Bending strength at the connecting part of the FFU

18 FFU Joint sleeper for Switches On site is it realizing high tolerances with all FFU materials Advantages: No short circuit Shorter working time ( approx.1.5 hours/pcs/5persons for connection) Possible to attach base plates almost everywhere Bending strength at the connecting part of the FFU joint sleeper is lower than that of regular sleeper - as you can see on the diagram. But it has sufficiently high bending strength, wider elastic area and the same young s modulus as regular sleeper, therefore, it can be used in track safely Joint sleeper - Switches

19 Manufacturing of FFU

20 Customized production

21 Drilling, sawing, chiselling Handling at the project

22 Bridges open steel constructions concrete Projects in Japan since 1980

23 Switches ballasted track - slab track Projects in Japan since 1980

24 Bridge, Switches, 38 t Axel load Projects in Australia since 2011

25 Bridges & switches Projects in Austria since 2004

26 Ballast, bridge, switches, slim tie Projects in Germany since 2008

27 Switches Projects in Russia since 2008

28 Bridges Projects in Netherland since 2012

29 Bridges & switches Projects in Switzerland since 2014 Since km track

30 Longitudinal baulks, cross sleepers and run on and off Projects in the United Kingdom since 2014

31 Longitudinal baulks frame London Underground Projects in the United Kingdom since 2014

32 Bridge Projects in Belgium since 2015

33 Switches Projects in France since 2015 Since km track

34 Bridge Projects in Norway since 2016

35 Bridge Projects in Ireland since 2017

36 Bridges Projects in Sweden since 2017

37 Track crossings

38 Recycling SEKISUI CHEMICAL CO., LTD. has been selected for the fourth year in a row (starhng 2012) by the "World Index" of the "Dow Jones Sustainability Indices (DJSI)" K-FFU, R-FFU Recycling 100% & Sustainability

39 Customized sleepers mm exactly optimizing of design & profile Form retentive always good bearing on construction Easy & fast installation minimizes: installation costs / track closing time Easy care/repair minimizes: installation time/sleeper amount Chemical/oil resistance application in special areas Ecological 100% recyclable Maintenance very little; minimizes maintenance costs/time High availability of track maximizing possible trains on the track Workability/weight like wood, 740 kg/m 3 Long life time reduces total cost of track and saves money for further project investments LCC Analysis bridges, TU Graz, Prof. Veit and Dr. Maschnig, 2008 in order of ÖBB, life time of bridge longer than 15 years FFU more economical than wooden sleepers switches, SBB, Dölf Egloff, , 7 10% more economical than wood (50 years) up to 15% more economical than concrete sleepers if the substructure has to be improved Experienced Advantages

40 SEKISUI CHEMICAL GMBH Königsallee Düsseldorf Germany TEL: +49-(0) FAX: +49-(0)

41 Q&A FFU Synthetic Sleeper Patrick Childs UK Sales Manager Sekisui Chemical

FFU synthetic sleepers Composite Slim tie and longitudinal baulks

FFU synthetic sleepers Composite Slim tie and longitudinal baulks Continuous glass-fibre and Polyurethane durability of plastics light weight and workability like wood Pultrusion process FFU sleepers are