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 manufactured by Pultrusion. Glass fibers are soaked in polyurethane and the linkage is then hardened at a raised temperature. Polyurethane Continuous glass-fibre FFU sleeper Form Heat Compression

1 2 Glass fiber supply Impregnation, Spray Molding Cooling Pulling Cutting Finishing & Inspection Major material Polyol is compounded with additives and for curing with Isocyanate before molding. Long glass fiber Polyol Isocyanate Foamed Urethane molding pulling Long glass fibers are impregnated and pulled into the molding. Foaming and curing are done while the materials go through the molding. The continuous pultrusion method allows the production of any length.

Bridges Steel and Ballast Switches Slim tie

1980. RTRI adopted FFU after laboratorial approval in Japan and started the field tests: 1985. very good results of field tests -FFU sleeper became a standard product of JNR 1991. RTRI reported the results of 10 years field tests 1996. RTRI -15 years field test, 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. 2004. Austria: First FFU Railway project in Europe, Metro bridge in Vienna plus ÖBB 2007. Japanese Industrial Standard JIS 1203 2009. Germany: Approval of FFU by EBA for German Railway Infrastructure 2010. Germany: Installation of FFU switch in Germany by Hamburger Hochbahn and MVV Austria: Installation of FFU double slip on Vienna main station by ÖBB 2011. Germany: Deutsche Bahn first Bridge with FFU sleepers on open steel bridge RTRI tested FFU sleeper installed in 1980 positive announced further use for the next 20 years positive to JR 2012 Germany: Deutsche Bahn two switches 70,000 t/day & sleepers & bridges Netherland:Pro Rail installed 3 bridges 2014. Switzerland: approval for FFU sleepers starting by 12 cm height and for tunnels where wooden sleepers are used given by BAV RHB installed bridges and slim ties 12 cm, BLS install switches, double slip and bridge UK: Network Rail installed longitudinal (40/40/750cm) and regular bridge sleepers World: ISO Standard 12856-1 for synthetic sleepers enters into force 2015. Belgium: Infrabel installed first bridge France: SNCF bridge /switch, RATP switches, Metro Toulouse switch Switzerland: SOB first bridge Historical development - 35 years in service

Worldwide approximately 90.000 FFU Synthetic Sleepers are installed annually Accumulated installation amount until 2013 has become more than 2,1 million sleepers 1.300 km of track [1000pcs.] 120.000 3.000.000 90.000 Thousand sleepers 230/140/2200mm 60.000 30.000 2.250.000 1.500.000 750.000 0 0 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13

Direct Fixation Slab track Ballast track

Fatigue test on rail seat height 120 mm A load of 150 kn was selected for the fatigue test. This corresponds to an axle load of 250 kn and a train speed V < 200 km/h. A static load of 1.2 x 150 kn = 180 kn was applied before the fatigue test. After the fatigue test the static load was increased to 2 x 150 kn = 300 kn. No damage to the sleeper could be established during the fatigue test. The ribbed plate was subsequently removed. Plastic deformations of approximately 0.85 mm. Extraction tests on FFU height 120 mm The tests were conducted in line with EN 13481-2 attachment A on 12 sleeper screws Ss 8-140 and synthetic wood sleepers with a height of 120 mm. Sleeper screw Ss-8 diameter 24 mm Hole diameter / drill tool Mean value [kn] 19 mm / steel drill 56.8 20 mm / steel drill 52.7 20 mm / wood drill 49.6 Slim tie with a height of 100 and 120 mm

Static tests in centre of sleeper (sleeper heights 100 mm and 120 mm) The support spacing was 1.5 m and load plate width was 100 mm. The initial test load was set to 10 kn. Subsequently the load was increased in increments of 10 kn, with sleeper bending registered on four dial gauges. Diagram below shows the values of sleeper bending up to a load of 70 kn, corresponding to a torque of 24.5 knm Slim tie with a height of 100 and 120 mm

Drilling, sawing, chiseling

Easy repair For example: Fastening position may be readjusted by filling nail holes 1Removal of rail 2Filling of nail holes with the special filling resin or the plugs 3Tying of rail

Slim tie: switches, ballast, slab, direct fixation

slim tie

Bridge with 12 cm slim tie

Longitudinal baulks W/H/L = 410/370/7500 mm

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