BALLASTLESS TRACK ON EARTHWORKS

Fixed Track Forms for High Speed Lines

PWI/UEEIV 2016 Technical Conference, Manchester, UK

Dieter PICHLER
Johann FLOH 11th October 2016

BALLASTLESS TRACK ON EARTHWORKS

www.vce.at
BALLASTLESS TRACK/ ON
www.porr-group.com
EARTHWORKS www.vce.at / www.porr-group.com
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Content

01 General
02 High-Performance
03 High-Speed
04 Special Solutions
05 Conclusions

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01 General

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01 General
Ballasted Track

Heavy concrete sleeper track Ballasted track

(uniform European track) Elasticity without subsoil

ballast substructure
40%

rail fastening
rail pads
60%

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01 General
Ballastless track system, subsystem and components [prEN 16432-2]

1 Rail/switch and crossing

Fastening system /system for
2
embedded rail
3 Prefabricated element

4 Intermediate layer, boot, fixation

5 Pavement

6 Intermediate layer

7 Substructure

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01 General
Vertical Loading [prEN 16432-2]

Determination of vertical stresses in unbound layers

by distribution of vertical loading

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01 General
The Main Construction Types for Ballastless Track

COMPACT SYSTEMS BASEPLATE SYSTEMS BLOCK SYSTEMS

Monolithic systems e.g. System e.g. Vossloh DFF21, Booted sleeper systems e.g.
Rheda, System Rheda 2000 Pandrol VIPA System Stedef, System LVT

EMBEDDED RAIL SYSTEMS PREFABRICATED SLAB SYSTEMS

e.g. Shinkansen,
PORR Slab Track
System

e.g. Edilon-Sedra EBS,

CDM-Track

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01 General
Features for Ballastless Track Systems

►  Applicability for high-performance and high-speed railway routes with mixed operation
►  Applicability for tunnels, on bridges, in troughs and on earthwork
►  Little space requirements (width, construction height) in particular for tunnel routes
►  High degree of prefabrication
►  Low sensitivity to different assembly conditions (weather etc.)
►  Low noise and vibration radiation
►  Life expectancy > 60 years
►  Great adjustability both in height and in position
►  High achievable alignment quality under real construction conditions
►  Compatibility with all established train control and train protection systems
►  Repair options for rail support or the total system within minimum time slot
►  Overall cost-effectiveness (initial investment costs and life-cycle costs)
►  Carbon footprint and further environmental & sustainability indicators

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01 General
Construction Design – PORR Slab Track System

1 Holes for spindles

2 PORR slab
3 Elastomeric layer
4 Self-compacting concrete SCC)
5 Rail support point
6 Long rail
7 Concrete base

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01 General
Construction Design – PORR slab (elastically supported precast element)

Elasticity without subsoil

ballastless track – elastically supported slab

Coating
10%

rail fastening
rail pads
90%

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01 General
Construction Sequence

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01 General
Methodology – Structural Implementation of PORR Slab Track System: TOP-DOWN

1 2

3 4 5

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01 General
Repair Concept

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01 General
Large Settlement Adjustment

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01 General
Track Quality PORR Slab Track System

►  Distribution of deviations – track geometry in %

⇒ HIGH PRECISION OF TRACK POSITION

Deviation Position Height Cant Gauge Moving chord position Moving chord height
[mm] [%] [%] [%] [%] [mm] [mm]
-4 0.2
[%]
-3.5 0.6 95 %
-3 1.3 32,9
-2.5 4.4
-2 0.2 10.5 29,3 0,1
26,3
-1.5 0.2 18.5 1.1 3,0
-1 9.1 21.9 5.8 45,1 1,1 21,8 10,3
-0.5 46.4 19.9 21.8 19,0 23,3
0 37.5 14.3 32.9 22,7 60,9 30,0
0.5 6.6 5.6 26.3 18,1 19,3
8,6
1 0.2 2.5 8.6 2,8 0,2 5,8 7
1.5 0.2 3.4 7
2 6
2.5 0.2 -1.0 -0.5 0 +0.5 +1.0 [mm]

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01 General
System Comparison

GEOMETRY CONSTRUCTION OPERATION ADDITIONAL Aspects

Long time experience

Space requirements

Maintenance needs

Passibility with cars

Construction height

Noise and vibration

Applicable on open
On site installation

Work accident risk

Adjustment range
Pre-assembling

Repair concept
Quality control

Track quality
SYSTEM

Openings

Error-rate

Life cycle
for shafts

surface
time
COMPACT SYSTEMS – – +/- – +/- – – – – +/- +/- – – +/- + +/- +/-

BLOCK SYSTEMS +/- +/- +/- – – +/- – – – – – +/- + + – – –

EMBEDDED RAIL
SYSTEMS + + + +/- – – +/- +/- + – +/- – +/- + + +/- –

PORR SLAB TRACK

SYSTEM + + + + + + + + + + + + + + + + +

BASEPLATE SYSTEMS
& PLINTH SYSTEMS + + + – – +/- – – – +/- +/- – – + + +/- –

+ very good +/- medium – poor

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01 General
Langenlebarn – First Installation PORR Slab Track System in 1989

Under operation since 1989

till today without any
relevant maintenance.

Heaviest operated track

(ÖBB Western Railway
Line) approx. 1 billion gross
tons to date (25 tons axle
load).

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01 General
Approvals for PORR Slab Track System

Austrian Federal Railways EBA (Germany) - General Approval EBA (Germany) – Approval for S&C

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01 General
Approvals for PORR Slab Track System

Certificate Network Rail (UK) EC Certificate (TSI compatibility)

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01 General
Up to date the PORR Track Slab System has been implemented for:

►  High-Performance: ~ 300 km

►  High-Speed: ~ 300 km

►  Heavy Haul: test track at Technical University Munich,

Germany

►  Urban/light-weight: ~ 200 km

►  Others: tunnel rehabilitation

(increase of clearance profile, …)

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02 High-Performance

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02 High-Performance
General

►  Mixed Traffic
►  Axle Load 25 tons
►  Freight Trains Vmax 100 km/h
►  Passenger Trains Vmax 250 km/h

Austria, Germany, Slovenia, Czech Republic:

PORR Slab Track System in total ~ 300 km

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03 High-Speed:
Cross-section on Earthwork - Austria

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02 High-Performance
Westbahn By-pass Melk, Austria

Year 2000
Length 8 612 m

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02 High-Performance
Lainzer Tunnel, Austria – PORR Slab Track System on MSS

Year 2010
Length 18 075 m

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02 High-Performance
Wienerwald Tunnel, Austria – PORR Slab Track System on MSS

Year 2010/2011
Length 26 406 m

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03 High-Speed

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03 High-Speed
General

►  Mixed Traffic
►  Axle Load 22.5 tons
►  Freight Trains Vmax 120 km/h
►  Passenger Trains Vmax 330 km/h

Germany VDE:
PORR Slab Track System in total ~ 300 km

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03 High-Speed: PORR Slab Track System for a Curved Section

Reference Values for Power-density Spectrum for
Longitudinal Level and Direction Deviations

Characteristic deviation < 0.3 mm (≙ 4.5 E-07)

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03 High-Speed Line VDE 8

Cross-section on Earthwork

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02 High-Performance
VDE 8, Germany Installation of Porr System on Earthwork

Year 2015/2016
Length > 300 km

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03 High-Speed Line VDE 8

Cross-section on Long Bridges

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04 Special Solutions

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04 Special Solutions
Mass-Spring-Systems

Modification of superstructure for ground born noise

and vibration attenuation
Æ Mass-Spring-Systems (floating track slab systems)

2.5
ξ=0
D... dynamic maginification factor
ξ=0.25 ξ... damping ratio
2.0
β... frequency ratio
2.5 ξ=0
concrete trough (mass)
ξ=0 ξ=0.50
1.5 D... dynamic maginification factor
rail carrying ξ=0.25 ξ... damping ratio
2.0
elements β... frequency ratio
P (t)
1.0 ξ=0
concrete trough (mass)
1.5 ξ=0.50
bearings ξ=1.00
rail carrying m 0.5
elements (springs) P (t) ξ=0
(wheel, track, sleeper,
1.0 ξ=0.50
base (e.g.: tunnel concrete track)
ξ=0.25
bottom floor) 0
k F (t) c 0.5 1 √2 2 3 4
ξ=1.00 5 6 7 8
bearings m β
(springs) 0.5
ξ=0
(wheel, track, sleeper, ξ=0.50
base (e.g.: tunnel concrete track)
ξ=0.25
bottom floor) 0
k F (t) c 0.5 1 √2 2 3 4 5 6 7 8
β

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04 Special Solutions
Transitions: Ballastless Track – Ballasted Track

Section A-A Section B-B

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04 Special Solutions
Bridge Gap with Special Track Base Plate

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04 Special Solutions
Accessibility for Tire-wheeled Vehicles and
Guide Rail System

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04 Special Solutions
Switches & Crossings

e.g. Prefabricated Slab System ÖBB – PORR

with Vossloh Fastening System 300 W on earthwork

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04 Special Solutions
Example of S & C

Top-view of frog area

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04 Special Solutions
S & C – Switch Box Area

Switch box areas

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04 Special Solutions
Manholes in track axis

Large Openings

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05 Conclusions

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05 Conclusions
PORR Slab Track Advantages

►  Applicable for high-performance and high-speed

►  Applicable for tunnels, bridges, troughs, earthwork
►  Minimum space requirements
►  High degree of prefabrication
►  Unsusceptible installation procedure
►  Low vibration & ground-borne noise level
►  Predicted working life > 80 years
►  Efficient and ease adjustment & repair concept
►  Best initial track quality
►  Compatibility with all kinds of CCS systems
►  Best RAMS performance & minimum LCC
►  Low derailment risk due to fail safe design
►  Large load carrying capacity and lateral resistance
►  Ease installation of additional equipment
►  Access with tyre-wheeled vehicles possible

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 BALLASTLESS TRACK ON EARTHWORK
Fixed Track Forms for High Speed Lines
PWI/UEEIV 2016 Technical Conference, Manchester, UK

Dieter PICHLER
Johann FLOH 11th October 2016

BALLASTLESS TRACK ON EARTHWORKS

www.vce.at
BALLASTLESS TRACK/ ON
www.porr-group.com
EARTHWORKS www.vce.at / www.porr-group.com