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Content

Preliminary

Preface for the second

Page: 000-01

remark

edition

Preface for second edition

The Railway Track manual is now available, the second edition of it was first published in December 2004. Completely revised and expanded, this comprehensive reference book provides up-to-date information about the railway track.

A compendium of the practice for the practice. It focuses on the application and provides empirical knowledge on types of track systems and materials, especially about

• Rails, • Barriers, • Turnouts,

• Fasteners as well as • Other accessories

As a Q1-supplier of the Deutschen Bahn AG and as a system provider with a decades of gathered experience, we hereby put all our expertise on the complete railway track.

(2)

Content

Preliminary

Instructions for use

Page: 000-02

remark

Instructions for use

The department of Planning and Development of ThyssenKrupp GfT Gleistechnik GmbH has created a manual for you, which represents the current state of engineering. All content has been reviewed by our colleague for accuracy and timeliness.

However they do not replace the critical review done by an experienced expert. Therefore we do not take any responsibility for the issue.

In case you come across with something on our Railway Track Manual that requires correction or amendment, please contact us. Your contact person at ThyssenKrupp GfT Gleistechnik GmbH, Dr.-Ing. Siear Qaimi gladly welcomes your suggestions and contrary comments.

Contact:

Dr.-Ing. Siear Qaimi Tel.: +49 234 9114-541 Fax: +49 234 9114-316

E-Mail: siear.qaimi@thyssenkrupp.com We look forward to working with you.

(3)

Content

Preliminary

Addresses, sales offices

Page: 000-03

remark

and engineering

SALES

Regional office Location of sales North Vahrenwalder Str. 205 D-30165 Hannover Phone: +49 511 6703-25 Fax: +49 511 6703-37 Waidmannstraße 26 D-22769 Hamburg Phone: +49 40 85340-700 Fax: +49 40 85340-701 West Hollestr. 7a D-45127 Essen Phone: +49 201 844-563745 Fax: +49 201 844-563750 East Rotherstr. 7 D-10245 Berlin Phone: +49 30 628901-15 Fax: +49 30 628901-20/-21 An der Kreuzkirche 6 D-01067 Dresden Phone: +49 351 4902040 Fax: +49 351 4902480 Humboldtstr. 3 D-04105 Leipzig Phone: +49 341 6017054 Fax: +49 341 6017055 Vertriebsbereich Waggonausrüstung Rotherstr. 7 D-10245 Berlin Phone: +49 30 628901-15 Fax: +49 30 628901-22 South Fürstenrieder Str. 267 D-81377 München Phone: +49 89 7871-300 Telefax: +49 89 7871-343 South-West Weilimdorfer Str. 74/2 D-70839 Gerlingen Phone: +49 7156 430730 Fax: +49 7156 430740 Dortmunder Str. 2 D-68219 Mannheim Phone: +49 621 8906-120/-121 Fax: +49 621 8906-122 EXPORT SALES Export Hollestr. 7a D-45127 Essen Phone: +49 201 844-563764 Fax: +49 201 844-563757 MRT Track & Services Co., Inc.

270 Broad Street 07003 Bloomfield • NJ-USA Phone: +1 973 748-8899 Fax: +1 973 748-9243 ThyssenKrupp GfT Polska Sp. z o.o. Al. Slowackiego 66 30-004 Kraków • Poland Phone: +48 12 6204130 Fax: +48 12 2677548 MANUFACTURING PLANT Holzschwellenwerk Am Bahnhof 2 D-29393 Groß Oesingen Phone: +49 5838 9905-0 Fax: +49 5838 9905-79 ThyssenKrupp Weichenbau Obere Stahlindustrie 4 D-44793 Bochum Phone: +49 234 9114-343 Fax: +49 234 9114-557 Betrieb Industrieweichen Am Wasserturm 3b D-06869 Coswig/Anhalt Phone: +49 34903 4741-0 Fax: +49 34903 4741-20 Betrieb Spannmittel Am Wasserturm 3b D-06869 Coswig/Anhalt ThyssenKrupp Langschienen Ladestr. 8 D-39175 Königsborn

(4)

Content

Preliminary

Information service

Page: 000-04

remark

This information service serves exclusively the function, modifications, amendments and other important informations on the Railway Track manual if required and to transfer to the interested individuals and companies in a defined time. It is not used for sending of advertisements, information sheets or the similar! Of course, your data will be kept confidential and not disclosed to third parties.

Data exchange takes place exclusively via e-mail.

To participate in the information service please fill in the following fields below and send this page by fax to +49 234 9114-316 or email to gleistechnik@thyssenkrupp.com. The required fields are marked with *.

Alternatively you may also register under www.tkgftgleistechnik.de and keep yourself updated.

REGISTRATION FOR INFORMATION SERVICE

Company*: Contact partner*: Street: Place: Tel.No. E-Mail*:

(5)

Railway Track

Table of contents

Preface, Table of contents,

Page: 000-11

Manual

Railway Track terms

000-00 Preliminary remark

000-01 Preface for second edition 000-02 Instructions for use

000-03 Addresses of sales office and engineering 000-04 Information service

000-10 Table of contents

000-11 Preliminary remark, Table of contents, General terms of tracks 000-12 Types of track systems

000-13 Vibration-damping rail bedding 000-14 Slab track / Crane and depot tracks 000-15 Special constructions / Track materials 000-16 Turnouts / Crossings / Rail expansion joints 000-17 Track accessories

000-20 General Railway Track terms

000-21 Development, Railway Track, Classification 000-22 Gauge of the track, Gauge widening

000-23 Track distance

000-24 Overview of various standards and regulations

000-25 Overview of various standards and regulations (Continued) 000-26 Track system abbreviations

000-27 Track system abbreviations 000-28 Thanks

(6)

Railway Track

Table of contents

Types of track systems

Page: 000-12

Manual

100-00 Types of track systems

110-00 Standard variants 110-01 Overview

111-00 Variant W 3 - Concrete sleepers 111-01 W 3 - 60E2 made of concrete sleeper

111-02 W 3 - Width of the rail flange 125 mm made of concrete sleeper B70/B90 112-00 Variant W 14 - Concrete sleepers

112-01 W 14 - 60E2 made of concrete sleeper

112-02 W 14 - Width of the rail flange 125 mm made of concrete sleeper B70/B90 113-00 Variant K - Concrete sleeper

113-01 K - Width of the rail flange 125 mm made of concrete sleeper 114-00 Variant K - Wood sleepers

114-01 K - 60E2 made of wood sleepers

114-02 K - Width of the rail flange 125 mm made of wood sleeper 115-00 Variant KS-H - Wood sleepers

115-01 KS-H - 60E2 Wood sleeper

115-02 KS-H - Width of the rail flange 125 mm wood sleeper 116-00 Variant KS-St - Steel sleepers

116-01 KS-St - 60E2 made of steel sleeper

116-02 KS-St - Width of rail flange 125 mm made of steel sleeper 116-03 KS-St-Iso - 60E2 made of steel sleeper

116-04 KS-St-Iso - Width of rail flange 125 mm made of steel sleeper 117-00 Variant Y-Steel sleepers

117-01 Rail fastening S15 made of Y-Steel sleeper 118-00 Variant grooved rails with guardrail

118-01 Installation views 59R1, 59R2, 60R1, 60R2 118-02 Installation views 57R1, 67R1, Ph 37N 118-03 Guardrail details

118-04 Material requirement / 15 m

118-05 Indoor track 57R1 made of situ-concrete plate 119-00 Variants Vossloh / ThyssenKrupp

119-01 System W 3 - Standard for Concrete sleepers 119-02 System W 14 - Standard for Concrete sleepers

119-04 System E14 / E21 - Highly elastic for Concrete sleepers 119-06 System 300 - for Slab track

119-08 System KS - for ribbed base plates

119-09 System W-Tram - with Wedge angle plates 119-10 System W97 - for reground concrete sleepers

(7)

Railway Track

Table of contents

Vibration-damping

Page: 000-13

Manual

rail bedding

120-00 Vibration-damping rail bedding

120-01 Overview of rail bedding 121-00 Continuous rail bedding 121-01 ThyssenKrupp Railflex 121-02 ISOLast 121-03 ThyssenKrupp Flexpoint 121-04 Whisper rail 121-05 Railcover 121-06 VIBRALast

121-07 Highly elastic grooved rail turnouts 121-08 Potting material Powerflex

121-09 ThyssenKrupp Flattrack 122-00 Discrete rail bedding 122-01 Delta stock 122-02 Krupp ECF-System 122-03 EASYLast 122-04 TK 99 / TK 99 S 122-05 TK07-R 122-06 TK 04-R 122-07 Ei-attachment 122-08 Acoustical Loadmaster

(8)

Railway Track

Table of contents

Slab track

Page: 000-14

Manual

Crane and depot tracks

130-00 Slab tracks

131-00 NFF (New slab tracks) 131-01 General

131-03 Engineering structure

131-04 Schematic construction cycle 132-00 NBU (Naumburg Bauunion) 132-01 Introduction

132-02 Schematic construction cycle

140-00 Crane and depot tracks

141-00 Crane runways 141-01 MX-System

141-02 MX-System description 141-03 MX-System screwed 141-04 MX-System welded

141-05 MX-System discontinuous rail bedding 141-06 MXA-System discontinuous rail bedding 141-07 MX-System continuous rail bedding 141-08 MXA-System continuous rail bedding 141-09 MX-Bottom casting

141-10 Surveying System Railcontrol 141-11 Crane runway beams

142-00 Railroad depot

142-01 Rail support point for side track and wash tracks 142-02 Rail fastening on working pits

(9)

Railway Track

Table of contents

Special constructions

Page: 000-15

Manual

Track materials

150-00 Special constructions 151-01 Guardrail 152-01 Guide rails 153-01 Rut rails 200-00 Track materials 210-00 Rails

211-01 Overview of commonly used track types 212-01 Flange rails

213-01 Grooved rails 214-01 Crane rails Form A 214-02 Crane rail AS 86 214-03 Crane rails bevel cuts 215-01 Special sections

216-01 Rails for crossings and turnouts 217-01 Perforation plates Rail perforation 220-00 Sleepers

221-01 Y-Steel sleepers

222-01 Pre stressed concrete sleepers 223-01 Wood sleepers

224-01 Steel sleepers

225-01 Steel bridge sleepers SBS 230-00 Ironmongery and accessories 231-01 Fastening clamping plates 232-01 Fastening rib based plates 232-02 Rib based plates for guide rails

233-03 Rib based plates for guide rails and supporting rails 233-01 Screw sleeper screws

233-02 Screw hook screws 234-01 Plastic screw anchor 235-01 Plastic spacer plate

(10)

Railway Track

Table of contents

Turnouts / crossings /

Page: 000-16

Manual

Rail expansion joints

300-00 Turnouts and crossings

300-01 Preface

300-02 General switch description 310-00 Switch

311-01 Switch description

312-01 Types of switches / Split locking plans for Vignol- and Ph 37a Switch 313-01 Tram railed grooves

314-01 Tables

315-01 Layout plan according to VDV track 1435, system of units C 316-01 Turnout definition 317-01 Turnout parts 318-01 Turnout accessories 319-01 Changeover system 320-00 Crossings, EKW, DKW 321-01 Turnout parts

322-01 Crossing variant LSH, Linear slidable centrepiece 330-00 Rail expansion joints

331-01 Flange rails 332-01 Grooved rails

(11)

Railway Track

Table of contents

Track accessories

Page: 000-17

Manual

400-00 Track accessories

411-00 De-watering boxes 411-00 Overview

411-01 for grooved rail variant "DENA" 411-04 for grooved rail variant "RIECKEN" 411-06 for vignol rail variant "DENA" 411-07 for elastic rail bearings whisper rail 412-00 Track endings

412-01 General

412-02 Overview of the variants 412-03 Buffer stops

413-00 Plastic cable channel 413-01 DRAE - KA

413-02 AU – KA

414-00 Insulated splicing

414-01 MT-Insulated splicing rail foot width 125 mm 414-02 MT-Insulated splicing 60E2

414-04 MT-Insulated splicing 60E2 increased

414-05 MT-Insulated splicing rail foot width 125 mm increased 414-06 Transition 49E5 to 54E4

415-00 Railway plates 415-01 Other signals 415-03 Speed limit signal

415-04 Signal for electrical traction 415-05 Additional signal at home signal 415-06 Signal for shunting operation 415-07 Turnout signal

(12)

Content

General Railway

Development, Railway

Page: 000-21

Track terms

Track, Classification

Formation of rail forms

The tracks should take the wheel load and transferred to the sleepers. They should also run the wheel and have a levelled railway. To reach present level, the rail profile has gone through various stages of development.

From the variety of rail forms, the wide foot rail, today called vignol rails consists of head, base and foot. The rail is symmetrically shaped in cross section. The rail cross section is designed due to the extensive experience and detailed considerations on today's valid profiles. The resisting torque and carrying capacity of the rail is determined primarily by their height and weight as an I-beam. It is the rolling friction of the wheels of the vehicle and thus exposed to material wear. The rail should remain only up to a certain degree of wear and tear on the track.

Railway track

The route for railway vehicle is to be understood under railway track. The Railway track includes: • die tracks, turnouts and crossings,

• the concrete as well as • the sub-structure

Classification of tracks and turnouts

The tracks and turnouts are divided according to operational and railway track technical aspects. 1. Operational aspects: Differentiation between the tracks and turnouts according to main and side

tracks. Main tracks are scheduled traffic tracks of the trains. Main tracks of the free routes and continued through the stations are known as continued main tracks. All other tracks are side tracks.

2. Railway track technical aspects: The tracks and turnouts are divided in 3 orders according to operating characteristics and specially in

1. Order: strong mode, high travelling speeds and large axle loads

2. Order: moderate strong operation and slower travelling speeds without regard to the axle loads

(13)

Content

General Railway

Gauge of the track ,

Page: 000-22

Track terms

Gauge of the track

Gauge of the track

The gauge of the track is the smallest distance between inner surfaces of the rail heads in the range of 0-14 mm below rail level.

The basic size of the gauge of the track is 1435 mm.

Deviations from the basic size of the gauge of the track are allowed. Thus, for example turnouts for non-federal railways (NE-turnouts) can also be prepared with a basic gauge of 1432 mm.

The gauge of the track in any case must not be smaller than 1430 mm and - also including

curve radius of the required extension -not more than 1465 by main line and 1470 mm by loop lines. The gauge of tracks in rail and turnout curve parts with radius less than 240 m must not fall below the following values:

Radius of the rail curve parts (m) The minimum size of the gauge of track (mm)

under 175 to 150 1435

under 150 to 125 1440

under 125 to 100 1445

Gauge widening

A) Federally owned railway capital

Radius of the rail curve parts (m) manufactured gauge of track (mm)

under 175 to 150 1440

under 150 to 125 1445

under 125 to 100 1450

The gauge of the track in turnouts is set in the control drawings (low).

Standard turnout 54E4 and 60E2 for railway tracks DB AG have no gauge widening. Turnouts with 49E5 rails and diverging track radius from 150 to 190 m have 6 mm gauge widening.

B) Non-federally owned railway capital

Radius of the rail curve parts (m) manufactured gauge of track (mm)

under 190 to 140 1440

under 140 to 100 1445

The gauge widening in rail curve parts is to be produced by impressions of the inner stand in steps of 5 mm. The length of a step in each case is 5 sleeper fields. Before the first stage with a track gauge from 1440 mm, 5 sleepers with a track gauge of 1435 mm.

(14)

Content

General Railway

Railway Track distance

Page: 000-23

Track terms

Track distance

1.) Standard gauge railway

The usual track distance is according to EBO for new buildings on free routes in curved parts with a radius of ≥ 250 m and in the line of 4, 00 m. This measure applies to speeds > 160 km/h to 200 km/h. The dimension refers to the distance from rail centre to rail centre.

In rail curves with radius of ≤ 250 m, the rail distance must be enlarged according to EBO § 10. Curve radius Increased distance by:

250 m 0 mm

200 m 115 mm

150 m 300 mm

For existing attachments, the track distance at right operation must be even less than 4.00 m. The minimum track distance for existing plants according to EBO § 10(1) is 3.50 m.

On diverging track routes, the reverse to be driven in right operation and whose tracks have a

distance of 3.50 m, no security space exists for adjacent track. It is just barely a measure for minimum clearance. During structural alteration works, the desirable track distance for these plants is 4.00 m. Should this not be possible for compulsory reasons, exceptionally a distance of 3.75 m and 4.00 m can be permitted.

The distance between track pairs or a track pair and a third track should be minimum 4.50 m. For better security of rail staff during maintenance work on the inner tracks and possibly to store building materials on inner tracks, the track distance possible should be 5.40 m.

The required track distance apart from over loaded tracks should be at least 4.50 m, with new buildings at least 4.75 m and with intermidiate platform at least 6.00 m.

2.) Track distance from narrow gauge lines of general traffic:

A

)

On the free routes and on loading tracks:

Track gauge 600 mm 2,100 mm Track distance

Track gauge 750 mm 2,900 mm Track distance

Track gauge 900 mm 3,100 mm Track distance

Track gauge 1000 mm 3,100 mm Track distance

B) At stations apart from loading tracks:

Track gauge 600 mm 3,000 mm Track distance

Track gauge 750 mm 3,800 mm Track distance

Track gauge 900 mm 4,000 mm Track distance

Track gauge 1000 mm 4,000 mm Track distance

(15)

Content

General Railway

Overview of different

Page: 000-24

Track terms

Standards and regulations

Overview of various standards and regulations: DIN / BN / TL / UIC Kodex / DS/RIL

Name DIN BN/TL UIC Kodex DS/Ril

Lock washer made of steel for

Railway track 918 006 864-3 V

Clamping plates rolled 5906 918 025

Crane rails form F 536/2

Crane rails with bottom flange A 536/1

Plastic material for railway tracks 918 280

Brief description of the railway track

systems 820.0101

Tabs for groove less

bottom rails 5902

Fish bolts with

Slotted round head / Oval neck 5903/1

Fish bolts with

Square head 5903/2

Railway tracks, basics,

General, guidelines 820.0101

Rising height in track curves 820.3030

Guide rail; Release planned EN 13674-3 918 168

Standard gauge railways,

Railway track recommended practice 820.01

Rails,

Flash butt welded, new

and reground 918 255

Rails, General 820.2120

Rails, bottom rails (old description) Profile S 10, S 14,

S 18, S 20, 33E1, 41E1, 49E5 EN 136741

Rails, for turnouts and crossings, in connection with vignol used from 46 kg/m;

Release planned EN 13674-2 918 254 860 V

Rails, 30E1 and fish plates Fl 30 20501

Rails, Bus bars made of steel 17122

Rails, use 820.2121

Rails, Vignol rails 27 kg/m up to under 46 kg/m;

Release planned EN 13674-4

Rails, Vignol rails from 46 kg/m EN 13674-1 918 254 860 V

(16)

Content

General Railway

Overview of different standards

Page: 000-25

Track terms

and regulations (Cont.)

Overview of various standards and regulations: DIN / BN / TL / UIC Kodex / DS/RIL (continuation)

Name DIN BN/TL UIC Kodex DS/Ril

Rail base plate made of rolled steel 864-6 V

Sleepers 820.0105

Sleepers, wood, non-impregnated 918 144 863 V

Sleepers, prestressed concrete 918 143

Sleepers, steel 918 123

Sleeper screw 918 024-1 864-1 V

Rail clamps, rail nails

Clamping yoke 918 127

Track gauge and rail cant

Structure of rails 820.2110

Steel upper wall screws 918 024-2

Butt plate made of rolled steel 864-4 V

Turnouts and crossings, Technical foundation for

complete tracks 820.0142

Turnouts, crossings and Crossover made of wood and

steel sleepers 918 120

Turnouts, crossings and Rail expansion joint,

Heat treated components 918 142

Intermediate layers of rubber

Driveway 918 234

Intermediate layers, elastic 918 235

(17)

Content

General Railway

Railway Track abbreviations

Page: 000-26

Track terms

Railway track-Abbreviations

ABS Upgrade of existing line

ATD Asphalt-base course with directly stored sleepers ATS Asphalt-base course

Az Obv Appendix additional provision for railway track specifications

B Concrete sleeper

BN Railway standard

BTD Concrete-base course with directly stored sleepers BTS Concrete base course

BZA Central Office of the German Federal Railways of the former German Federal Railways CEN European Committee for Standardisation

DB AG German National Railway Company DIN German Institute for Standardisation DKW Double-slip diamond crossing Dann Double clamping nail

DS Leaflet

EBA German federal railway organisation EBO Railway engineering- and work rules

Ei Insulating insert (in turnouts: Arch support - Ei = Anti-creep device)

EN Eurocode

EW Standard turnout Fe Spring lock washer

FF Slab tracks

Fl Fish plates

Fsch Flexible rail switch-turnout FSS Anti-freeze layer

Fz Flexible switch-turnout

Grp Base plate

Gz Pivoted heel-turnout

H Wood sleeper

HGT Hydraulically bound base course HGV High speed traffic

Hs Hook screws

ISO International organisation for standardisation

Kp Clamping plate

KS Crane rail

Ksp Clamping track plate

LfB Country representative for rail road supervision LIS Light industrial sleeper

MFS Mass-Spring-System

N Newton (Measuring unit according to English natural scientist) NBS New upgrade of existing line

Obv Railway track specification for standard gauge railway

Ri Grooved rail

(18)

Content

General Railway

Railway Track abbreviations

Page: 000-27

Track terms

(Continuation)

Railway Track Abbreviations (Continued)

Rp Ribbed base plate

Rpb Ribbed base plate for concrete sleepers Rph Ribbed base plate for wood sleepers Rps Ribbed base plate for steel sleepers Rsw Ribbed base track plate

Rus Weldable ribbed base space plate

Rz Control drawing

S Rail

SbS City rail road ties

SBS Steel beam bridge sleepers

Sbü Clamping yoke

Sdü Sleeper anchor

SO Elastic sole of concrete sleepers

SO Rail level

Sp Track adjustment plates

Ss Sleeper screw

St Steel sleeper

TBS Tramway sleeper

TL Technical delivery condition

UIC Union Internationale de Chemin de Fer (International Union of Railways) UIG Unternehmensinterne Genehmigung (Deutsche Bahn AG)

Uls Washer

VDV Association of German Transport Companies VOB German Construction Contract Procedures

(Before 2002: Contracting rules for award of public works VOB 2000) WA Start of turnout

WE End of turnout Wfp Angular guide plate Yno Y-Normal rail YÜli Y-Transition rail left YÜre Y-Transition rail right Zw Intermediate level Zwp Spacer plate

(19)

Content

Thanks

Page: 000-28

For their assistance and support in creating this manual, we heartly thank:

A. Rawie GmbH & Co KG 49090 Osnabrück

DENA Stahlbau GmbH & Co 49086 Osnabrück

Deutsche Bahn AG 60326 Frankfurt am Main

DW Schwellen GmbH 39317 Güsen

Elektro-Thermit GmbH & Co KG 06132 Halle

Gebr. Marmetschke GmbH & Co KG 29393 Groß Oesingen

Hanning & Kahl GmbH & Co KG 33813 Oerlinghausen

Heinrich Krug GmbH & Co KG 44145 Dortmund

H.+ R. Riecken Maschinenbau GmbH 49565 Bramsche

Leonhard Moll Betonwerke GmbH & Co KG 30629 Hannover Ortec Gesellschaft für schienentechnische Systeme mbH 50668 Köln

Rail.ONE GmbH 92318 Neumarkt

Schilderwerk Beutha GmbH 09366 Stollberg OT Beutha

ThyssenKrupp Weichenbau GmbH 44793 Bochum

TSTG Schienen Technik GmbH 47166 Duisburg

Vossloh Fastening Systems GmbH 58778 Werdohl

(20)
(21)

Railway tracks

Standard variant

Overview

Page: 110-01

Overview of Standard variants

Captive gradient 1:40 A nc hor S dü 9 S dü 9 S dü 9 S dü 9 S dü 9a S dü 13 Dü S15a Sdü 25 S dü 25 S dü 26 S dü 25 S dü 25 S pr ing -lo ck w ash er Fe 6 Fe 6 Fe 6 Fe 6 Fe 6 Fe 6 S leep er -scr ew S s 25 S s 25 S s 35 S s 35 S s 8-150 S s 8-150 S s 8-150 S s 8-150 S s 8-150 S s 8-150 S s 8-150 Ss 34 S s 36 -220 S s 36 S s 36 S s 36 S s 25 D isc/ w ash er Ul s 7 Ul s 7 Ul s 7 Ul s 7 Ul s 6 Ul s 6 Ul s 6 Ul s 6 Ul s 6 Ul s 6 Ul s 7 Ul s 7 Ul s 7 Ul s 7 Ul s 7 Ul s 7 H ook -scr ew s Hs 2 6-65 Hs 2 6-65 Hs 2 6-65 Hs 2 6-65 Hs 2 6-65 Hs 3 2-55 Hs 3 2-55 Hs 3 2-55 Hs 3 2-55 Hs 3 2-55 Hs 3 2-55 Ra il -fast en in g S kl 1 S kl 1 S kl 14 S kl 14 K po 6 K po 9 K po 9 K po 6 K po 9 S kl 12 S kl 12 S kl 12 S kl 12 S kl 12 S kl 12 S kl 14 S kl 14/ S kl 21 S kl 15 S kl 14/ 92 v S kl 14 S kl 1/ 97 P la te Wf p 3b Wf p 3b Wf p 14k Wf p 14k R pb 1 R pb 1 R ph 6* * R ph 1* * R ph 1* * R ph 6* * R ph 1* * R ps 15* * R ps 8* * R ps 15 i a* * R ps 8 i a* * Zw p 192* * Wf p E 14 Wf p 15a K -Wf p 14 R / L K-Wf p 14 R / L Wfp 3b – 22 W fp 3b - 28 In ter m ed iat e level Zw 687a* Zw 686a* Zw 700* Zw 700* Zw 672, Zw 691* Zw 672, Zw 691* Zw 661a Zw 687* Zw 664a Zw 686* Zw 664a Zw 686* Zw 661a Zw 687* Zw 664a Zw 686* Zw 690* Zw 691* Zw 697a* Zw 697* Zw 401* Zw E 14 Zw 692* Zw p10 4 N T Zw 900 -180 Zw 900 -180 Zw 687a* Ra il -gr a di e nt 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 1: 40 w ithout without 1:40 Ra il 60E 2 R ai l f oot w idt h 125m m 60E 2 R ai l f oot w idt h 125m m R ai l f oot w idt h 125m m R ai l f oot w idt h 125m m 60E 2 R ai l f oot w idt h 125m m R ai l f oot w idt h 125m m 60E 2 R ail foot w idt h 125m m 60E 2 R ai l f oot w idt h 125m m 60E 2 R ai l f oot w idt h 125m m 60E 2 60E 2 60E 2 59R 1 / 60R 1 57R 1 R ai l f oot w idt h 125m m S tor a ge C onc ret e sl eeper Conc ret e sl eeper Conc ret e sl eeper Conc ret e sl eeper Conc ret e sl eeper Conc ret e sl eeper Wood sl eeper Wood sl eeper Wood sl eeper Wood sl eeper Wood sl eeper S teel s leeper S teel s leeper S teel s leeper w ith Iw 16 S teel s leeper w ith Iw 16 Y -S teel s leeper C onc ret e sl eeper Slab trac k S lab trac k w ith U pl 180/ 120 C onc ret e sl eeper Conc ret e sl eeper R ai lw ay tr ack -syst em W 3 W 3 W 14 W 14 K K K K K Ks Ks Ks Ks Ks-is o Ks -is o S 15 E 14/ E 21 Sytem 300 W-Tra m W -T ra m W 97 e

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Railway track

Standard variant

W3 – 60E2

Page: 111-01

systems

Concrete sleeper B70 / B90

Tightening torque 200 Nm

6 1 Intermediate level Zw 687a

5 2 Plastic dowel Sdü 9

4 2 Angular guide plate Wfp 3b

3 2 Rail clamps Skl 1

2 2 Sleeper screws with track Ss 25 with Uls 7

1 1 Rail 60E2

(23)

Railway track

Standard variant

W3 - Width of rail flange

Page: 111-02

systems

125 mm / Concrete sleeper

Tightening torque 200 Nm

6 1 Intermediate level Zw 686a

5 2 Plastic dowel Sdü 9

4 2 Angular guide plate Wfp 3b

3 2 Rail clamps Skl 1

2 2 Sleeper screws with track Ss 25 with Uls 7

1 1 Rail 49E5 or 54E4

Pos. Number/Support

(24)

Railway track

Standard variant

W 14 - 60E2

Page: 112-01

systems

Concrete sleeper B70 / B90

Tightening torque 200 Nm

6 1 Intermediate level Zw 700

5 2 Plastic dowel Sdü 9

4 2 Angular guide plate Wfp 14k

3 2 Rail clamps Skl 14

2 2 Sleeper screws with track Ss 25 with Uls 7

1 1 Rail 60E2

(25)

Railway track

Standard variant

W14 - Width of rail flange

Page: 112-02

systems

125 mm / Concrete sleeper

Tightening torque 200 Nm

6 1 Intermediate level Zw 700

5 2 Plastic dowel Sdü 9

4 2 Angular guide plate Wfp 14k

3 2 Rail clamps Skl 14

2 2 Sleeper screws with track Ss 25 with Uls 7

1 1 Rail 49E5 or 54E4

Pos. Number/Support

(26)

Railway track

Standard variant

K - rail flange width

Page: 113-01

systems

125 mm / Concrete sleeper

9 1 Intermediate level Zw 672 or Zw 691

8 2 Plastic dowel Sdü 9a

7 2 Hexagonal nut DB M22

6 2 Clamping plate Kpo 6 (49E5) Kpo 9 (54E3)

5 2 Hook screws Hs 26-65

4 1 Ribbed base plate Rpb 1

3 4 Spring lock washer Fe 6

2 2 Sleeper screws Ss 8-150

1 1 Rail 49E5 or 54E4

(27)

Railway track

Standard variant

K - 60E2

Page: 114-01

systems

made of wood sleeper

Tightening torque 180 - 250 Nm

8 1 Intermediate level Zw 661a or Zw 687

7 2 Hexagonal nut DB M22

6 2 Clamping plate Kpo 9

5 2 Hook screws Hs 26-65

4 1 Ribbed base plate Rpb 6

3 6 Spring lock washer Fe 6

2 4 Sleeper screws Ss 8-150

1 1 Rail 60E2

Pos. Number/Support

(28)

Railway track

Standard variant

K - Width of rail flange

Page: 114-02

systems

125 mm made of wood sleeper

Tightening torque 180 - 250 Nm

8 1 Intermediate level Zw 664a or Zw 686

7 2 Hexagonal nut DB M22

6 2 Clamping plate Kpo 6 (49E5) Kpo 9 (54E3)

5 2 Hook screws Hs 26-65

4 1 Ribbed base plate Rpb 1

3 6 Spring lock washer Fe 6

2 4 Sleeper screws Ss 8-150

1 1 Rail 49E5 or 54E4

Pos. Number/Support

(29)

Railway track

Standard variant

KS - H - 60E2

Page: 115-01

systems

made of wood sleeper

Tightening torque 180 - 250 Nm

9 1 Intermediate level Zw 661a or Zw 687

8 2 Rail clamps Skl 12

7 2 Washer Uls 6

6 2 Hexagonal nut DB M22

5 2 Hook screws Hs 32-55

4 1 Ribbed base plate Rpb 6

3 4 Spring lock washer Fe 6

2 4 Sleeper screws Ss 8-150

1 1 Rail 60E2

Pos. Number/Support

(30)

Railway track

Standard variant

KS - H - Width of rail flange

Page: 115-02

systems

125 mm made of wood sleeper

Tightening torque 180 - 250 Nm

9 1 Intermediate level Zw 664a or Zw 686

8 2 Rail clamps Skl 12

7 2 Washer Uls 6

6 2 Hexagonal nut DB M22

5 2 Hook screws Hs 32-55

4 1 Ribbed base plate Rpb 6

3 4 Spring lock washer Fe 6

2 4 Sleeper screws Ss 8-150

(31)

Railway track

Standard variant

KS - 60E2

Page: 116-01

systems

made of Y-Steel sleepers

Tightening torque 200 Nm 7 1 Intermediate level Zw 690 6 2 Rail clamps Skl 12 5 2 Washer Uls 6 4 2 Hexagonal nut DB M22 3 2 Hook screws Hs 32-55

2 1 Ribbed base plate Rpb 15

1 1 Rail 60E2

Pos. Number/Support

(32)

Railway track

Standard variant

KS - Width of rail flange

Page: 116-02

systems

125 mm made of steel sleepers

Tightening torque 180 - 250 Nm 7 1 Intermediate level Zw 691 6 2 Rail clamps Skl 12 5 2 Washer Uls 6 4 2 Hexagonal nut DB M22 3 2 Hook screws Hs 32-55

2 1 Ribbed base plate Rpb 8

1 1 Rail 49E5 or 54E4

(33)

Railway track

Standard variant

KS - St - Iso - 60E2

Page: 116-03

systems

made of Y-Steel sleepers

Tightening torque 180 - 250 Nm

8 1 Intermediate level Zw 697a

7 2 Insulating insert Iw 16

6 2 Rail clamps Skl 12

5 2 Washer Uls 6

4 2 Hexagonal nut DB M22

3 2 Hook screws Hs 32-55

2 1 Ribbed base plate Rpb 15 ia

1 1 Rail 60E2

Pos. Number/Support

(34)

Railway track

Standard variant

KS -St - Iso - Rail foot width

Page: 116-04

systems

125 mm made of steel sleeper

Tightening torque 180 - 250 Nm

8 1 Intermediate level Zw 697a

7 2 Insulating insert Iw 16

6 2 Rail clamps Skl 12

5 2 Washer Uls 6

4 2 Hexagonal nut DB M22

3 2 Hook screws Hs 32-55

2 1 Ribbed base plate Rpb 8 ia

(35)

Railway track

Standard variant

Rail fastening S15

Page: 117-01

systems

made of Y-Steel sleepers

Tightening torque 200 Nm

9 1 Spacer plate Zwp 192 (or Zwp 193)

8 2 Intermediate level Zw 401

7 2 Clamping dowel Dü S 15

6 1 Guide plate (outside) Fpa 15

5 1 Guide plate (inside) Fpi 15

4 2 Rail clamps Skl 14

3 2 Washer Uls 7

2 1 Sleeper screws Ss 34

1 1 Rail 60E2 (49E5 / 54E4)

Pos. Number/Support

(36)

Railway track

Grooved rail

Installation views 59R1 /

Page: 118-01

systems

with guardrail

59R2 / 60 R1 / 60 R2

Track 1435/1000

Correction plates 2 and 3 mm thick

Splice joint Guardrail perforation – ovalholes only for steel grade 700

Welding joint 750 for 15 and 18 m rails

End

per

for

at

(37)

Railway track

Grooved rail

Installation views

Page: 118-02

systems

with guardrail

57R1 / 67R1 / Ph 37N

Track 1435

Correction plates 2 and 3 mm thick

Splice joint

Guardrail perforation – oval holes only for steel grade 700

Welding joint 937.5 for 15 m rails (900 for 18 m rails) End per for at ion H = 75 for 57R1

(38)

Railway track

Grooved rail

Guardrail

Page: 118-03

systems

with guardrail

Details

Dimensions / Weights Profile Track A L kg / St. 59R1 - 59R2 1000 1018.5 1015 7.233 60R1 - 60R2 1000 1018.5 1015 7.233 59R1 - 59R2 1435 1453.5 1450 9.623 60R1 - 60R2 1435 1453.5 1450 9.623 59R1 - 59R2* 1450 1468.5 1465 - 60R1 - 60R2* 1450 1468.5 1465 - 59R1 - 59R2** 1458 1476.5 1473 - 60R1 - 60R2** 1458 1476.5 1473 - 57R1 1435 1444 1442 9.579 Ph 37N 1435 1453.5 1451 9.628 67R1 1435 1453.5 1451 9.628 Track

A = Clear width between the bars L = length of guard rail

Correction plates

2 and 3 mm thick Guard rails Fl. 70 x 10 mm

(39)

Railway track

Grooved rail

Material requirement

Page: 118-04

systems

with guardrail

15 m

Material for a 15 m long track length (without tabs)

59R1 / 59R2 track 1435

lg, mm kg / pc. zus. kg kg / m

2 Rails 59R1 / 59R2 N 15000 884.55 / 872.10 1769.1 / 1744.2

10 Guard rails 1450 9.623 96.2

10 Correction plates (2 mm dick) 0.135 1.4

10 Correction plates (3 mm dick) 0.202 2.0

40 Guardrail perforation M22 x 55 0.456 18.2 Sum 15 m = 1886.9 / 1862.0 125.8 / 124.1 59R1 / 59R2 track 1000 lg, mm kg / pc. zus. kg kg / m 2 Rails 59R1 / 59R2 N 15000 884.55 / 872.10 1769.1 / 1744.2 10 Guard rails 1015 7.233 72.3

10 Correction plates (2 mm dick) 0.135 1.4

10 Correction plates (3 mm dick) 0.202 2.0

40 Guardrail perforation M22 x 55 0.456 18.2 Sum 15 m = 1886.9 / 1862.0 124.2 / 122.5 60R1 / 60R2 track 1435 lg, mm kg / pc. zus. kg kg / m 2 Rails 60R1 / 60R2 15000 908.85 / 896.25 1817.7 / 1792.5 10 Guard rails 1450 9.623 96.2

10 Correction plates (2 mm dick) 0.135 1.4

10 Correction plates (3 mm dick) 0.202 2.0

40 Guardrail perforation M22 x 55 0.456 18.2 Sum 15 m = 1935.5 / 1910.3 129.0 / 127.4 60R1 / 60R2 track 1000 lg, mm kg / pc. zus. kg kg / m 2 Rails 60R1 / 60R2 15000 908.85 / 896.25 1817.7 / 1792.5 10 Guard rails 1015 7.233 72.3

10 Correction plates (2 mm dick) 0.135 1.4

10 Correction plates (3 mm dick) 0.202 2.0

40 Guardrail perforation M22 x 55 0.456 18.2 Sum 15 m = 1911.6 / 1886.4 127.4 / 125.8 57R1 / 67R1 / Ph37 N track 1435 lg, mm kg / pc. zus. kg kg / m 2 Rails 57R1 / 67R1 Ph 37N 15000 847.50 / 1003.65 988.20 1695.0 / 2007.3 1976.4 8 Guard rails 1442 / 1451 1451 9.528 / 9.577 9.577 76.2 / 76.6 76.6

8 Correction plates (2 mm dick) 0.135 1.4

8 Correction plates (3 mm dick) 0.202 2.0

32 Guardrail perforation M22 x 55 0.456 18.2

Sum 15 m = 1788.5 / 2101.2

(40)

Railway track

Grooved rail

Indoor track 57R1

Page: 118-05

systems

with guardrail

made of situ-concrete plate

Indoor track 57R1 / 67R1 made of situ-concrete plate

The usual guard rails made of flat steel are for for grooved rails that are embedded in the final state are not recommended. Round bar with threaded ends according to the conventional reinforcement. The site concrete in this case is produced up to 16 cm below SO. For including the width of rail flange, recesses are provided. The grooved rails are installed with track holders to the rails, laid and aligned according to location and height. The rails with MINEX-grout to be grouted in the gaps. Subsequently, the remaining site concrete is introduced, if necessary. with asphalt coating in crossing areas before the halls or special industrial floors in the hall.

Grooved rail 57R1 / 67R1

Guard rail with threaded ends M 20

(41)

Railway track

Variant

System W 3 / standard

Page: 119-01

systems

Vossloh

for concrete sleepers

System W 3 for concrete sleepers

Extract from the Technical Communication RO 26 / 05 of DB AG from 08.11.2005: Replacement of the rail fastening W 3 on site W 14. According to the Directive RiL 820.2010. The rail fastening W 3 with rail clamp Skl 1 and angular guide plate Wfp 3b is to be installed instead of the previously used rail fastening W 14 k made of concrete sleepers B70 W, B70 W-2.4 and B90.

Rail fastening with rail clamp Skl 1

The rail is placed with the elastic intermediate layer on the concrete sleeper. The lateral position of the rail is secured by the angular guide plate Wfp 3. The Wfp is made of steel (with insulating insert) or glass fibre reinforced plastic. They transfer the lateral forces on the concrete body, without claiming the screw to bend and without effecting adversely for the track gauge formation. The resultant of vertical force and screw clamping force is directed obliquely. The angular guide plate and the support in the concrete sleeper are shaped in such a way, so that a tight fit is ensured even with loosened tie screws. The insulating insert between steel angular guide plate and concrete allows a complete attachment and an electrical insulation. The rail clamp Skl 1 is supplied with a permanent rust preventive coating.

The non-positive bracing

between rails and sleepers is achieved by using the listed parts.

Advantages

• Exact track gauge even by heavy load operation and in curved parts. • High creep distance and torque resistance to prevent fracture gap openings. • High frame rigidity to secure the position of the track.

• Low maintenance, no rework after installation.

• No route blocking on suspended sleeper screws (stress equalisation). Captive pre-assembly in the sleeper factory. After installation of the rails, and intermediate layers, the sleeper screw is loosened, the rail clamp is rotated around 180° and the screw tightened with a torque of approx. 200 Nm. The correct mounting poition is to be identified so that the intermediate loop touches the angular guide plate. The clamping force of the spring arm is then approx. 11.5 kN at a deflection of 14.5 mm. There is an air space of about 1.5 mm between rail clamps intermediate loop and rail flange. The lifting or tilting of the rail is executed by the intermediate loop and thus excluded overexpanding of the spring arms.

6 1 Intermediate level Zw 686a / Zw 687a

5 2 Plastic dowel Sdü 9

4 2 Angular guide plate Wfp 3b

3 2 Rail clamps Skl 1

2 2 Sleeper screws with track Ss 25 with Uls 7

1 1 Rail 49E5 / 54E4 / 60E2

Pos. Number/Support

point Designation Brief description

(42)

Railway track

Variant

System W 14 / standard

Page: 119-02

systems

Vossloh

for concrete sleepers

System W 14 for concrete sleepers Characteristics:

Different rail profile on the the same sleeper

On the same sleeper in same track gauge, the rail profiles 60E2, 54E1 and 49E5 can be used by simply changing the angular guide plates.

Gauge widening

A gauge widening of +/-10 mm in levels of 2.5 mm is available by default.

Tilting table

Lifting or tilting the track during the way maintenance or while passing through the narrow track curves is braced after overcoming the small air gap (between intermediate loop of the rail clamp and rail flange) with an

intermediate loop. Thus a permanent deformation of the outer spring arms is excluded.

Track maintenance

The Vossloh rail fastening system requires no regular maintenance.

Rail bracing and creep distance

The rails consistently braced non-positively through the free spring arms in a deflection of approx. 13 mm and a retaining force of approx. 2 x 10 kN. This will require the high creep resistance of the rail, which prevents dangerous gap openings in welded rails, as well as a sufficient frame rigidity of the track section is achieved.

Neutralisation

For continuous welding of the rails (CWR), no fastening parts are removed from the sleeper. Only the sleeper screws are loosened but not removed.

6 1 Intermediate level Zw 700

5 2 Plastic dowel Sdü 9

4 2 Angular guide plate Wfp 14k

3 2 Rail clamps Skl 14

2 2 Sleeper screws with track Ss 25 with Uls 7

1 1 Rail 60E2

Pos. Number/Support

point Designation Brief description

pre-installed installed

(43)

Railway track

Variant

System W 14 / standard

Page: 119-03

systems

Vossloh

for concrete sleepers

Height adjustment

In Vossloh-rail fastening system W 14, a height adjustment of 8 mm is possible by inserting height correction plates.

Interchangeability

All components are interchangeable.

Electrical insulation

Since the angular guide plate, the intermediate layer and the anchor screw is made of plastic, the fastening system W 14 is completely electrically insulated. No additional insulated parts are required between the rail flange and rail clamps.

Pre-assembly

All the fastening parts can be pre-assembled in the sleeper factory manually or automatically. Only the rail is inserted at the installation site. Either during transport or during track construction, the fastening parts are missing.

Mounting

Simple mechanical installation with standard screw machine.

Use of angular guide plates

The Wfp 14 K as a standard railway track, the Wfp 14 S, with Ei and 32 is used only in exceptional cases depending on the type of earthing.

Installation instructions

Correct

The correct installation clamping position is achieved when the intermediate loop touches the rib of angular guide plate by tightening the sleeper screw.

(max. permissible air gap: 0.5 mm). A tightening torque of

approx. 200 Nm is required.

Wrong

Intermediate loop does not rest, air gap is too large.

Desired clamping force is

(44)

Railway track

Variant

System 14 / E 21

Page: 119-04

systems

Vossloh

highly elastic for concrete sleepers

System E 14 for concrete sleepers

Railway track E 14 with rail clamps Skl 14 is a highly elastic rail fastening system for concrete sleepers in gravel tracks.

When upgrading from W 14 to E 14, the sleeper in gravel bed remain stuffed.

Features:

• fully compatible to railway track W 14 • Improved travelling comfort

• improved modulus of grade reaction • lower gravel erosion

It is achieved with the large elastic intermediate plate with surface pressure distribution plate, similar to the system 300 for slab track, large deflection of the rails. The Skl 14 is also fatigue endurable in these high vertical dynamic rail movements. All fastening parts can be captively installed in sleeper factory on the sleeper. Hence mechanised and fully automatic installation in the track is possible. A possible efficient increase of drive comfort on gravel tracks, equipped with standard railway track W 14, and/or a reduction which takes place under heavy loads gravel destruction can be achieved with compatible rail fastening system E 14.

Gravel tracks often have insufficient deflection values when used in high-speed traffic on new tracks. With EVA

intermediate layers, the maximum of 0.2 mm compressed under rolling wheel, achieved together with the gravel elasticity of about 0.6 mm on new tracks of the highest values of 0.8 mm. Even the use of so-called "soft" intermediate layers with static spring digits of

c = 50 - 70 kN/mm brings an improvement of about 1.0 mm of rail depression.

8 1 Intermediate level Zwp E 14

7 1 Base plate Grp E 14

6 1 Intermediate level Zw E 14

5 2 Plastic dowel Sdü 25

4 2 Angular guide plate Wfp E 14

3 2 Rail clamps Skl 14 / Skl 21

2 2 Sleeper screws with track Ss 36-220 with Uls 7

1 1 Rail 60E2

Pos. Number/Support

point Designation Brief description

(45)

Railway track

Variant

System 14 / E 21

Page: 119-05

systems

Vossloh

highly elastic for concrete sleepers

It was therefore the task of finding possible solution by using standard elements that can be achieved with the desired rail deflection values of 1.5 mm.

The railway track E 14 uses the monoblock concrete sleeper B 70 W 60 with the rail flange Skl 14. Thus, this railway track system are both on existing routes as well as on new lines to be built for use.

Structure:

The E 14 fastening system is a direct high elastic rail fastener for standard concrete sleepers B70 W60 for the slab track. It is analogously built to the rail fastening system 300. Lateral forces are transferred via angular guide plates. The rail is still braced with usual elastic rail flange Skl 14 in ballasted track. The two free spring arms are located on the rail foot. The superior intermediate loop of the rail foot acts as a tilting table.

Controllability:

The fastening system is designed in such a way that the height adjustments are possible up to 5 mm as in W 14 railway track, without darning.

If desired, a gauge widening of up to +/- 10 mm are provided even in levels by changing the angular guide plates, as in systems W 14 and 300.

The System E 14 is available for local public transport under the name 300 UTS with rail flange Skl 21 and adapted intermediate plate.

(46)

Railway track

Variant

System 300 / for Slab

Page: 119-06

systems

Vossloh

Lane

System 300 with rail 60E2 and Skl 15 for the slab track

Slab tracks meet all the requirements for combined high-speed and heavy traffic. The pre-assembled rail fastening system 300 is suitable for all types of installation of the slab track.

The highly elastic intermediate plate replaces the elasticity of gravel bed. For better load distribution, a steel pressure distribution plate which rests on the customary interposition of a conventional interlayer rail. Laterally the rail is held in position by the plastic angular guide plates. The rail flange Skl 15 is braced non-positively by the long elastic deflection.

The slab track rail fastening system 300 with Skl 15 is analogously built of the fastening W 14. The lack of gravel elasticity is replaced with the rail fastening system 300 for the slab track by using the highly elastic intermediate plate. While using a spring constant of 22.5 kN/mm, measured as secant stiffness between 18-68 kN, a depression of rail is achieved from up to 1.5 mm in the standard gauge railway (22.5 t axle load).

Construction of the slab track: • Monolithic:

• Stored

• Special systems

The fastening can be provided on both the sleepers and for individual bases.

Regulatory options:

Height adjustability +6

-4 ∑10 mm using intermediate levels +26

-4 ∑ 30 mm using intermediate levels and height balancing plates Side controllability +/- 5 ∑ 10 mm using angular guide plates

(47)

Railway track

Variant

System 300 / for Slab

Page: 119-07

systems

Vossloh

Lane

Rail flange Skl 15

Installation instructions

Correct

The correct installation clamping position is achieved when the intermediate loop touches the rib of angular guide plate by tightening the sleeper screw. (max. Permissible air gap: 0.5 mm). A tightening torque of approx. ≤ 200 Nm is required.

Wrong

Intermediate loop does not rest, air gap is too large. Desired clamping force is not reached!

8 1 Intermediate level Zwp 104 NT

7 1 Base plate Grp 21

6 1 Intermediate level Zw 692

5 2 Plastic dowel Sdü 25

4 2 Angular guide plate Wfp 15a

3 2 Rail clamps Skl 15

2 2 Sleeper screws with track Ss 36 with Uls 7

1 1 Rail 60E2

Pos. Number/Support

point Designation Brief description

(48)

Railway track

Variant

System KS -

Page: 119-08

systems

Vossloh

for rib based plates

System KS with rail flange Skl 12 for rib based plates

The rail flange Skl 12 was designed for rail fastening on rib based plates with "hard" intermediate layers (c ≥ 200 kN/m). The rail flange Skl 24 is available as an alternate.

All fastening parts can be captively installed in sleeper factory on the sleeper. Hence mechanised and fully automatic installation in the track is possible.

With the two free spring arms of the rail flange, a permanently non positively braced rail with approx. 13 kN clamping force is achieved with approx. 14.5 mm deflection per rail flange, whereby the fastening do not require any maintenance.

The tilting movement of the rail is executed by the intermediate loop of the rail flange. A temperature stress equalisation of the rails is made easier by only loosening the screws. Any necessary rail requirement can be done easily, in which the rail flange while installation is pushed back.

Installation instructions

1. Loosen hexagonal nut of the screw-hook (approx. 1-2 revolutions)

2. Bring rail flange in installation position (Spring arms must rest on the rail foot)

3. The installation position is achieved when the interediate loop of the rail flange touches by tightening the screw of the rail foot, or an air gap is up to 2 mm (tightening torque 180-250 Nm).

9 1 Intermediate level Zw 687 Zw 687

8 2 Rail clamps Skl 12 Skl 12

7 2 Washer Uls 6 Uls 6

6 2 Hexagonal nut DB M22 DB M22

5 2 Hook screws Hs 32-55 Hs 32-55

4 1 Ribbed base plate Rph 6 Rph 1

3 4 Spring lock washer Fe 6 Fe 6

2 4 Sleeper screws Ss 8-150 Ss 8-150

1 1 Rail 60E2 49E5 / 54E4

Pos. Number/Support

point Designation Brief description

(49)

Railway track

Variant

System W-Tram - with

Page: 119-09

systems

Vossloh

Wedge angle plates

Rail fastening system W-Tram with wedge angular guide lates K-Wfp 14 R and L

With the wedge angular guide plates with a continuous adjustment, the limited rail foot tolerance related to manufacturing process, above all balanced in grooved rails, and so the track width can be regulated upto +/-10 mm.

In the slab track, the use of insulated anchor bolts is possible, alternatively the proven anchor screw combination Sdü 26/Ss 36. The lateral forces of the rail is carried on the angular guide plate and the base plate in the concrete support plate.

Does not have the bending or shear forces on the embedded anchorage system. High power

dissipation by the profiled bottom of the base plate. The sleeper screw / anchor bolts is only subjected to train. Completely electrically insulated.

For laying the rail grooves on concrete sleepers, the system W is used, for slab track the system W-Tram is used.

Application examples

W-Tram on slab track W made of concrete sleepers

7 1 Intermediate level Zw 900/180 Zw 900/180

6 2 Plastic dowel Sdü 26 Sdü 25

5 1 Base plate Upl 180/120

4 2 Angular guide plate K-Wfp 14 K-Wfp 14

3 2 Rail clamps Skl 14 Skl 14

2 2 Sleeper screws with track Ss 36 + Uls7 Ss 35 + Uls7

1 1 Grooved rail Pos. Number/Support point Designation W-Tram W-Sleeper Brief description installed pre-installed Concrete-sleeper Slab track

(50)

Railway track

Variant

System W 97 / for 49E5 /

Page: 119-10

systems

ThyssenKrupp

54E4 made of concrete sleepers

System W 97 for concrete sleepers

Characteristics:

The rail fastening W 97 was developed as an adapter solution for using the rails with rail flange width of 125 mm (rails 49E5, 54E4) on concrete sleepers B 70 W-60 that requires the rail flange width of 150 mm.

Here, specifically, the use of reclaimed sleepers B 70 W-60 is considered (from the year 1974), as standard equipment of DB.

• Tracks with a permissible speed v < 160 km/h • Tracks with a traffic density < 30,000 Lt/d • Routing and marshalling attachments Authorisation under:

• DBS 918127 • DIN EN 13481-2 • Creep distance in

Rail longitudinal direction F = 10 kN (according to 3.0 Mio. load changes)

• Electrical resistance R33 = 7,11 k Ω (average)

7 1 Intermediate level Zw 686a

6 2 Plastic dowel Sdü 25 (alternatively Sdü 9)

5 1 Angular guide plate Wfp 3b - 22

4 1 Special angular guide plate Wfp 3b - 28

3 2 Rail clamps Skl 1 / 97

2 2 Sleeper screws with track Ss 25 (alternatively Ss 35) with Uls 7

1 1 Rail 49E5 / 54E4

pre-installed installed

(51)

Railway track

Variant

System W 97 / for 49E5 /

Page: 119-11

systems

ThyssenKrupp

54E4 made of concrete sleepers

Resultant track gauge:

Depending on the large sick dimension of the sleeper, there is a resulting theoretical track gauge when using of rail fastening W 97.

See the below table:

resultant track gauges

gr. sick

dimension Field side Track gauge Track gauge Field side Gauge of the track

1810 28 22 22 28 1432 1811 1433 1812 1434 1813 1435 1814 1436 1815 1437 1815.5 1437.5 Economy:

Compared to the supply of new concrete sleepers, by using the rail fastener W 97 on reclaimed concrete sleepers B70, W 60 indicates possible savings of about 30%.

(Source: DB, TM 2009-030 I.NVT4 (F) 10.02.2010).

Mounting / Installation:

The following points must be considered in planning and installation:

• Providing the right Ironmongery (sleeper screws) depending on the used plastic screw anchor (Sdü 9 / 20 or Sdü 25).

• Installing two different angular guide plates on the specified positions

Installation instructions after inserting the rails: 1. Release sleeper screw - approx. 1.5 turns.

2. Rail clamps rotate by 180° → Spring arms are placed on the rail flange 3. Interlocking the rail fastening as per the Directive 824 5050.

(52)

Elastic

Overview

Page: 120-01

rail bedding

Road cross section

Operational area (Axle load)

Tram

(up to 100 kN) (up to 135 kN) City railway (up to 160 kN) Metro

Standard gauge railway (up to 250 kN) constructive possible deflection (in mm) Continuous

rail bedding Rail cover up to 1.5

Railflex up to 1.5

ISOLast up to 1.5

Flexpoint up to 1.5

Whisper rail up to 10

VIBRALast up to 2

Highly elastic grooved rail

turnouts up to 4

Powerflex variable

Flattrack up to 1.5

Discrete

rail bedding Delta stock between 2-8

TK 07-R up to 1.5 TK 04-R up to 5 TK 99 up to 3 EASYLast up to 3 Krupp ECF-System up to 3 Ei-attachment up to 3 Acoustical Loadmaster up to 4

(53)

Elastic

Continuous

ThyssenKrupp

Page: 121-01

Rail bedding

Rail bedding

Railflex

The system RAILFLEX is a continuous elastic rail bending system for city rails and trams. It consists of the main elastic components, electrically insulating base element, electrical chamber element for inner and outer side, elastic and electrical insulating coatings for the track holder, rail fastening and

installation base plate. The rail bedding is continuously horizontally and vertically adjustable. Application for all tracks with asphalt, concrete, paved areas, surface as well as for crossings. No track geometry limitations, use on bridges and in tunnels. High damping effect for air-borne and structure-borne sound. Application with all known grooved rails and vignol rail profile. Operational info systems sice 1993 with approx. 180,000 m rail and 80 crossings.

8 1 Foot coating profile -

7 1 Chamber element inside -

6 1 Chamber element outside -

5 2 Adjustable foot -

4 1 Support plate with adjusting anchor -

3 2 Insulation barrel -

2 1 Hexagon head bolt -

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2

Pos. Number/Support

(54)

Elastic

Continuous

ISOLast

Page: 121-02

Rail bedding

Rail bedding

ISOLast stores grooves and vignol rails continuously and elastically, and significantly reduces shocks and vibrations in railway vehicles by degenerating the entire track of this type (slab track, pavement, and plantation) from the environment. Due to the installation situation a deflection of more than 1.5 mm is recommendable.

The chamber filling profiles are waterproof. The track should be laid on a situ-concrete plate and encapsulated with low-shrinkage cement mortar for height adjustment. The width of the chamber filling profiles is recessed during construction of the surface and later encapsulated to the rail level with highly elastic compound based on bitumen (Ortec.ESV).

Applications for all tracks and crossings with roofing: • Asphalt

• Concrete / Asphalt

• Concrete / Natural stone paving • Crossings

9 2 Clamping plate IL-3062-04-A4

8 2 Hexagonal nut DIN 985 - M24

7 1 Base coat profile GP-1215-00-A3

6 1 Base plate IL-3135-00-A3

5 2 Lock-nut DIN 7967 - M24

4 2 Thread block DIN 976 - M24 IL-3126-00-A4

3 1 Chamber filling profiles outside IL-2029-03-A1

2 1 Chamber filling profiles inside IL-2028-02-A1

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2

(55)

Elastic

Continuous

ThyssenKrupp

Page: 121-03

Rail bedding

Rail bedding

Flexpoint

The system FLEXPOINT is a discontinuous elastic rail bending system on the basis of rail support point TK07-R, which is is so provided with an integral elastomer element so that no dynamic gauge widening is possible under the vehicle. It further consists of both sided elastic chamber elements, the cover cap on the rail fastenings and the insulating base profile between rail support points.

Application for all tracks with asphalt, concrete, paved areas, crossings. No track geometry limitations, use on bridges and in tunnels possible.

Application with all known grooved rails and vignol rail profile.

10 1 Intermediate level -

9 2 Chamber element -

8 2 Anchor -

7 1 Baseplate with ribbing -

6 1 Elastic base plate -

5 1 Support plate - 4 2 Rail clamps Skl 1 3 2 Washer Uls 7 2 2 Sleeper screws Ss 25 1 1 Rail 59R1 / 59R2 / 60R1 / 60R2 Pos. Number/Support

(56)

Elastic

Continuous

Whisper rail

Page: 121-04

Rail bedding

Rail bedding

The whisper rail offers the possibility of deflections to reach up to 10 mm due to their construction. Rail car sound and vibrations are reduced up to 90% in densely built areas especially in trams. The enclosure profile decouples the inner movement of the rail from the environment. The rail flooring is not affected by the movement. For open cross-sections, like gravel bed, the whisper rail can be constructed as a header rail, whereby to stop the enclosure profile below the rail head.

Applications for all tracks and crossings with roofing: • Asphalt

• Concrete / Asphalt

• Concrete / Natural stone paving • Crossings

12 1 Hexagonal nut DIN 980 - M20

11 1 Hexagon head bolt ISO 4014 - M20 x 160

10 2 Lock-nut DIN 7967 - M24

9 2 Hexagonal nut DIN 985 - M24

8 2 Thread block DIN 976 - M24x240

7 1 Base plate RI-2754-00-A3

6 2 Clamping plate KS-2210-00-A4

5 1 Base coat profile GP-1122-03-A3

4 1 Elastomer profile head GP-1160-04-A3

3 1 Elastomer profile groove GP-1158-08-A3

2 2 Enclosure profile RI-2334-01-A3

1 1 Rail 49E5 / 54E4

Pos. Number/Support

(57)

Elastic

Continuous

Rail cover

Blatt: 121-05

Rail bedding

Rail bedding

Primarily the system railcover provides the protection against stray current corrosion. For this reason, the rail is coated with a profile made of plastic. The system design permits a deflection of up to 1.5 mm. The plastic profile is connected on Th rail with a special adhesive. Within the profiles, under the rail foot, an elastic intermediate layer is inlaid to achieve the desired deflection.

The system is attached to underground guard rail with MX-guide rail clamps. Thus a wheel truing of +/- 8 mm can be set.

Applications for all tracks and crossings with roofing: • Asphalt

• Concrete / Asphalt

• Concrete / Natural stone paving • Crossings

10 2 Washer ISO 7090-20

9 2 Hexagonal nut ISO 4032 - M16

8 2 Hexagon head bolt ISO 4017 - M16 x 120

7 1 Underfloor steering track rod ER-1001-00-A3

6 2 Hexagon head bolt ISO 4017 - M20 x 65

5 2 Hexagonal nut ISO 4032 - M20

4 2 MX-fasteing MX 2424

3 1 Base coat profile GP-1262-03-A3

2 1 Rail bedding GP-1269-02-A3

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2

Pos. Number/Support

(58)

Elastic

Continuous

VIBRALast

Page: 121-06

Rail bedding

Rail bedding

The system VIBRALast is a channel system that is used with a 2-component material based on polyurethane. The system can be loaded with grooved rails and also with vignol rails. The rail foot is furnished with a base coat profile to achieve required deflection of up to 2 mm. All parts are

prefabricated, delivered on the installation site, whereby significantly reducing the installation time. Applications for all tracks and crossings with roofing:

• Asphalt

• Concrete / Asphalt

• Concrete / Natural stone paving • Crossings

7 1 Hexagonal nut ISO 4032 - M24

6 1 Threaded rod DIN 975 - M24x600

5 1 Tightener DIN 1480 SP - M24x255

4 1 Base coat profile GP-1215-00-A3

3 1 Chamber filling profiles outside IL-2029-03-A1

2 1 Chamber filling profiles inside IL-2028-02-A1

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2 49E5 / 54E4

Pos. Number/Support

(59)

Elastic

Continuous

Highly elastic

Page: 121-07

Rail bedding

Rail bedding

Soft grooves

For using within the rail turnouts, system VIBRALast is expanded in view of the deflection. It consists of the similar components as in VIBRALast, only within the rail foot, modified elastomer elements are arranged to brace the different rigidity within the crossings and to achieve a uniform deflection of up to 4 mm. The system is suitable for road-aligned cross-sections.

Applications for all tracks and crossings with roofing: • Asphalt

• Concrete / Asphalt

• Concrete / Natural stone paving • Crossings

6 1 Steel cable coating EWL-1025-00-A3

5 1 Elastomer pad GP-1297-00-A3

4 1 Foam carpet EWL-1028-00-A3

3 1 Chamber filling profiles outside IL-2029-03-A1

2 1 Chamber filling profiles inside IL-2028-02-A1

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2 49E5 / 54E4

Pos. Number/Support

point Designation Brief description

References

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