EDILON Level Crossing Systems (LC)

Transcription

1 EDILON Level Crossing Systems (LC) edilon)(sedra bv Nijverheidsweg 23 NL-2031 CN Haarlem P.O.Box 1000 NL-2003 RZ Haarlem T +31 / (0) F +31 / (0) mail@edilonsedra.com Solutions that won t shake the world...

2 EDILON LC introduction the history For over 130 years tracks for mainline rail traffi c and urban mass rapid transit systems were based almost exclusively on track panels and cross sleepers supported on stone ballast. During the 1960 s, increasing train loads, higher speeds and the demand for more cost effective track installation methods, resulted in the development of ballastless track or slab track systems. Since the introduction of slab track systems edilon)(sedra evolved as a specialist in this field. Based on 40 years of experience edilon)(sedra developed specially for road rail intersections a range of EDILON Level Crossing Systems, called EDILON LC. EDILON LC have given assurance and comfort for more than 30 years, for both rail and road traffi c. The weight and stiffness of the EDILON LC enables a good distribution of forces, which guarantees both a durable as well as a settlement free system. In addition the EDILON Corkelast Embedded Rail System (ERS) also provides signifi cant noise and vibration reduction opportunities, more and more important these days in densely populated areas. The EDILON LC range consists of the following types: EDILON LC-H, known as the Dutch Harmelen level crossing, installed since 1976 EDILON LC-1, known as the German Stelfundo level crossing, installed since 1997 EDILON LC-L installed since 2002 Naturally edilon)(sedra is ISO 9001 certified. In EDILON LC the use of mechanical fastening systems, such as clips, anchors and baseplates, for both the crossing as well as the rail are made completely redundant because of EDILON Corkelast ERS. By using EDILON Corkelast ERS, the rails are connected to the EDILON LC concrete slab in a fl exible yet extremely durable way. Continuous elastic rail support means that horizontal and vertical forces are more evenly distributed. Furthermore, the chance of rail breaks compared to traditional level crossing systems based on ballast track, is signifi cantly reduced and rail corrugation is effectively eliminated. EDILON Corkelast ERS also offers maximum electrical insulation. GENERAL ADVANTAGES Proven minimal costs-of-ownership Durable long life structure Proven technology resulting in a range of technical approvals One structural monolithic unit Continuous elastic rail support Smooth transition between rail and road EDILON LC track elasticity matches elasticity of adjacent track Excellent electrical insulation of the track COST EFFECTIVENESS Simple and fast installation EDILON LC service life more than 30 years Reduction of rail wear and rail corrugation Maintenance free Low lifecycle costs (LCC) 2 3

3 Application areas where a road meets rails EDILON LC types EDILON LC is applied in all possible kinds of intersections where road meets rail. There are almost no restrictions. EDILON LC offers a unique solution, which combines in an ideal way the track ballast bed, rail fastening and the paved road into one structural monolithic unit. By combining EDILON LC concrete slabs, level crossings from 6 to 50 meters length can be installed in a period of 8 hours, including the removal of the old crossing as well! Quality and installation speed are both very important. Depending on the condition of the subsoil and the function of the level crossing in e.g. continuous welded track a choice can be made between EDILON LC-H and EDILON LC-L or EDILON LC-1. All EDILON LC systems meet the various requirements for heavy rail and high-speed rail. EDILON LC systems all meet the requirements of UIC load model 71 as specifi ed in UIC code 702. The extremely durable longwearing surface meets the highest road load class standard of load class 60. Certain EDILON LC systems are applicable in heavy loaded level crossings with train axle loads up to 37 tons and heavy traffi c axle loads up to 90 tons The top surface of EDILON LC slabs can be prepared in such a way that high skid resistance values (SRV) can be obtained. SRV of more than 45 up to 70, are possible with special concrete mixtures of the top surface. EDILON LC-H EDILON LC-H is especially designed for continuous welded track where the high weight of the slabs is of major importance to prevent track movement. Because of the thickness of the EDILON LC-H concrete slabs, the structural stiffness is high, which allows application in areas with a subsoil with low foundation coeffi cient, ks = 20 MN/m³, which is equivalent to a subsoil modulus, Ev2 = 35 MN/m². The installation of EDILON LC-H is done with a top-down approach: the slabs are levelled at the proper Top of Rail position by using hydraulic jacks and an injection grout is used to fix the correct slab position. In this way the forces of the slab are evenly distributed over the supporting subsoil. The rail channels are protected and strengthened by strong steel edge profiles. EDILON LC-1 and EDILON LC-L EDILON LC-1 and EDILON LC-L are both EDILON LC systems that offer an optimized slab design which still meets all rail and road requirements with a slab thickness of 400 mm. The installation of EDILON LC-L and EDILON LC-1 is carried out with a bottom-up approach were the slabs are placed on a smooth and levelled split bed with the appropriate subsoil foundation stiffness. Application of these slabs is possible in subsoil areas with a foundation coeffi cient, ks = 70 MN/m³, which is equivalent to a subsoil modulus, Ev2 = 120 MN/m². Protection and strengthening of the rail channels is also possible. Depending on the channel design all vignole and grooved rails are accommodated. The fi elds of application of EDILON LC main roads with high density of traffi c industrial areas with intensive heavy traffi c rural routes in city track crossing with angles up to S-shaped roads and horizontal turn movements Embedded Rail Characteristics All EDILON LC systems include the EDILON Corkelast Embedded Rail System (ERS) and offer the following ERS characteristics: Continuous rail support Track stiffness tunable following for instance UIC LM71 Excellent electrical insulation Top-down rail alignment and levelling 4 5

4 EDILON LC-H type Harmelen edilon)(sedra obtained its Dutch product approval for EDILON LC-H concrete level crossing slabs type Harmelen in September 2007 but the principle of the heavy EDILON LC-H system was developed already in 1974 in close co-operation with Netherlands Railways NS. Since 1976, more than 1250 level crossings of this type have been installed. The EDILON LC-H level crossing is available in two standard slab lengths. Concrete Slab length Slab width Slab height Weight Radius Vmax slab type [mm] [mm] [mm] [kg] [m] [km/h] Features Used in heavily loaded road-rail combinations Standard asphalt road approach Suitable for roads crossing at angles up to and even exceeding 45 degrees Suitable for curved track sections with super elevation Intensive heavy road traffi c will not move nor damage EDILON LC-H Standard level crossing drainage solutions Approvals ProRail Infrabel SNCF MAV Ontario Northland RENFE / ADIF Netherlands Belgium France Hungary Canada Spain LC-H LC-H Depending on track curvature and rail type the EDILON LC-H slabs can be tapered or wider channels or curved channels can be applied. EDILON LC-H track curvature slab range LC-H6 LC-H9 Standard slab type R 1000m R 1500m Tapered slab with straight channels 225m R 1000m 500m R 1500m Tapered slab with curved channels R < 225m R < 500m EDILON LC-H system characteristics Maximum train speed V 200 km/h Slab characteristics Minimal slab settlement and optimal distribution of forces Maintenance free Ability to connect slabs to form longer crossings Road surface is extremely durable (special dressings and treatments) Edges and channels protected with strong steel profi les Rails fastened securely using EDILON Corkelast ERS Reduced rail corrugation Optimized reinforcement design with C45/55 concrete Seamless connection to the road surface Rapid installation method maximizes the track availability Motorbike, bicycle and wheelchair friendly REFER EP Portugal Rail traffi c load classes - 150, 250 and 270 kn Road traffi c load class - Load class 60 Maximum superelevation/track cant D 75 mm Maximum cant defi ciency I 40 mm Maximum cant excess E 40 mm Rail inclination - 0 or 1:40 or 1:20 or as required High skid resistance value SRV 70 (typical) Stray current insulation and electrical insulation in compliance with EN / EN requirements 6 Prefab Embedded - Harmelen LC 7

5 EDILON LC-1 type Stelfundo edilon)(sedra obtained its approval for EDILON LC-1 concrete level crossing slabs type Stelfundo from the German Federal Bureau of Railways already in September EDILON LC-1 is a logical addition to EDILON LC-H. Developed in the mid 1980 s, these crossings have also enjoyed worldwide acceptance. Although of lower weight, the reinforcement, surface treatments and various colours make the slabs also suitable for a wide range of applications. EDILON LC-1 slabs are installed on a layer of well compacted levelled grit. Crossings of, for instance, 50m length can be installed in track possessions of only eight hours. Again, steel profi les can be used on the edges of the channels to increase slab durability. It is possible to couple individual slabs to prevent problems caused by subsoil settlements. EDILON LC-1 is available in the following slab lengths: EDILON LC-1 system characteristics Maximum train speed V 160 km/h Rail traffi c load classes - 150, 250 and 270 kn Road traffi c load class - Load class 60 Rail inclination - 0 or 1:40 or 1:20 High skid resistance value SRV 45 (typical) Stray current insulation and electrical insulation in compliance with EN / EN requirements Features Approvals Suitable for all rail and road traffi c EBA Germany Used in all types of road crossings Suitable for road crossing angles up to 45 degrees DB Netz AG Germany Ideal for curved and inclined track ÖBB Austria Concrete Slab length Slab width Slab height Weight Radius Vmax slab type [mm] [mm] [mm] [kg] [m] [km/h] Slab Characteristics Minimal settlement and optimal distribution of forces Various slab lengths available (L codes) Available for curves (R codes) Highly durable surfacing Maintenance free; no rutting, reduced rail corrugation C45/55 concrete with optimized reinforcement design Increased safety for cyclists, motorbike and wheel chairs riders Minimal installation times Slabs can be connected to longer crossings Re-adjustability after installation possible SBB Switserland 8 9

6 EDILON LC-L edilon)(sedra obtained approvals for EDILON LC-L concrete level crossing in several countries i.e. Poland and France. The principle of EDILON LC-L is based on the proven concept of EDILON LC-H and EDILON LC-1. The EDILON LC-L slab design gives freedom to apply virtually all rail profi les and install track with different gauge widths. EDILON LC-L slabs are installed on a well compacted subgrade with a fine split bed top layer. Steel profi les can be used on the edges of the channels to increase the slab durability. EDILON LC-L is available in the following range of slab lengths: Concrete Slab length Slab width Slab height Weight Radius Vmax slab type [mm] [mm] [mm] [kg] [m] [km/h] LC-L1, Features Used in highly loaded road-rail combinations Standard asphalt road approach Suitable for roads crossing at angles up to 45 degrees Standard level crossing drainage solutions Approvals SNCF RATP PKP Banverket France France Poland Sweden LC-L LC-L LC-L LC-L EDILON LC-L system characteristics Maximum train speed V 160 km/h Rail traffi c load classes - 150, 250 and 270 kn Road traffi c load class - Load class 60 Rail inclination - 0 or 1:40 or 1:20 or as required High skid resistance value SRV 45 (typical) Slab characteristics Minimal slab settlement and optimal distribution of forces Maintenance free Ability to connect slabs to longer crossings Durable road surface, special dressings and treatments possible Edges and channels protected with steel profiles Rails fastened securely using EDILON Corkelast ERS Optimized reinforcement design with C45/55 concrete Seamless connection to the road surfacing Rapid installation method maximizes the track availability DSB MAV SNCF ENR APTA MTRC GVB Denmark Hungary France Egypt Alexandria Hong Kong Amsterdam Stray current insulation and electrical insulation in compliance with EN / EN requirements 10 11

7 EDILON LC system design and installation method edilon)(sedra offers a range of EDILON LC systems optimized for supporting the forces from both rail as well as road traffi c. A distinction is made in strength and defl ection behaviour between different EDILON LC slabs. A common characteristic is that the slabs must be installed on stabilized ground. The ground support stiffness plays an important role in the choice between the different types of EDILON LC systems. Design on rail and channel The forces arising from rail and road traffi c on the slab are most critical around the rail. To understand this, extensive modelling and laboratory tests are performed to analyze and optimize the system. Rail profi le and mechanical properties, channel dimensions, materials and building tolerances are all included in the process of fi nding the most durable EDILON LC system possible. Depending on its application and the type of EDILON LC a range of standardized channel designs have been developed which gives freedom to apply each possible rail profi le and will also meet the requirements set by road and rail authorities. System features The use of slabs means that provisions for cables for signalling, water drainage and a protection against loose train couplings, must be made. Standard solutions are available and can be included in the system design. In EDILON Corkelast ERS, multi functional plastic tubes are applied. These tubes offer the opportunity to: align the rails in the channels and to adjust the width of the gauge reduce the amount of Corkelast and so the material costs pull cables for signalling through the tubes On both ends of the crossing, a steel protection plate is mounted to protect the concrete and/or the drainage system from impact forces caused by loose couplings, hanging from passing trains Geotextile mats are preferred to be applied adjacent to EDILON LC to provide a long lasting stable ballasted track. The concrete slab reinforcement is optimized and together with the applied concrete the electrical insulation of the slabs is durably secured. Track facilities EDILON LC systems are compatible with all international train control systems. EDILON LC systems have been in service in a wide range of light rail, high-speed and heavy rail applications over a period of many years. EDILON LC installation method For all EDILON LC systems a well consolidated subgrade is essential. The excavation profi le depends on the type of installation. In case of a level crossing replacement the excavation depth can be kept limited, whereas the bottom of the excavation should be disturbed as little as possible. EDILON LC-H allows for a top-down approach were the slabs are levelled with hydraulic jacks and an injection grout is used to fi x the correct slab position. Because of the high structural stiffness of EDILON LC-H, a low ground support stiffness is permitted. EDILON LC-1 and EDILON LC-L have a reduced slab thickness, which requires a reduced excavation depth. The installation of both EDILON LC-1 and EDILON LC-L is done with a bottom-up approach were the slabs are placed on a compacted smooth and levelled split bed with the appropriate ground support stiffness. In all cases the forces of the EDILON LC slabs are evenly distributed over the supporting subsoil. Special attention must be paid to the adjacent ballasted track, which must be sound and stable. EDILON Corkelast ERS installation materials EDILON Corkelast EDILON Primer 21 Rail fastening system EDILON Primer U90WB EDILON Corkelast Embedded Rail Systems (ERS) EDILON Resilient ERS Strip offers many advantages because of its continuous rail EDILON Dex -G support. Track stiffness can be tuned by choosing the EDILON Fillerblocks and tubes appropriate resilient ERS components. edilon)(sedra is EDILON Nylon spacers able to perform stiffness analysis using fi nite element EDILON Polymer wedges methods (FEM) and is able to test new system designs in EDILON Polymer (inclination) shims 12 its own laboratory. 13

8 EDILON LC mainten ance and recycling Track with EDILON LC is designed to work exactly how our clients want it to work. Should, for any reason, the track no longer meets these expectations, either maintenance or rail replacement may be necessary. Height corrections of EDILON LC concrete slabs can be carried out easily by high pressure injecting a special mortar underneath the slabs and lift them in this way. Rail replacement of EDILON Corkelast ERS is only necessary when rail wear or rail fatigue limits are exceeding the regulations, or in the exceptional case that a rail break did occur. EDILON Corkelast ERS can be removed completely from both channels and after cleaning the channels new EDILON Corkelast ERS can be installed. EDILON Corkelast ERS installation can be done in very tight track possession periods. recycling and environment All components used in EDILON LC systems are fully recyclable. Cured embedding and pouring compounds can be disposed as domestic waste, in accordance with the European Waste Catalogue. partnership edilon)(sedra supplies EDILON LC as a complete track system, from initial contacts to system delivery, and from commissioning to removal. We work with our clients on questions and advice. EDILON LC delivers the benefi ts of prefab element quality and rapid installation, and combines our specialists knowledge of track, concrete and civil engineering. rail wear It is well known that a well supported rail as well as one of good quality will have positive influences on the life of the rail. EDILON LC ensures a well supported rail through various aspects: the support of the slab, the weight of the slab, the tight tolerances of the slab, the alignment of the slab and the exceptionally accurate alignment of the rail on the slab. Connecting the slabs together also ensures for better slab support over a longer period of time. Furthermore, a well documented advantage of EDILON Corkelast ERS is a reduction of rail wear. With EDILON Corkelast ERS rigid points are omitted. This results in an improved spreading of the forces and signifi cantly reducion of high dynamic forces in the rails. logistics and supply The logistic process for EDILON LC track follows a detailed and accurate planning. Each part, from initial discussions, channel design, production, transport, installation and commissioning, are all included in the planning. All materials supplied are subject to constant quality control