Delivering Turnout Solutions
DESIGN SUPPLY INSTALL MAINTAIN Introduction
GLOBAL TURNOUT SOLUTIONS Introduction
BROWNFIELD CONSTRUCTION SOLUTIONS Introduction
MAJOR PROJECTS Introduction
CRANE RAIL CONSTRUCTION Introduction
We specialise in: ▪ Turnout design and integration ▪ Developing turnout technology ▪ Turnout supply management ▪ Critical junctions design and installation ▪ Turnout pre-assembly and installation ▪ Turnout installation staging solutions ▪ Turnout refurbishment and track reconditioning ▪ Crane rail specialist (supply and construct) ▪ Slab track construction ▪ Turnout and track inspections, maintenance and asset management Design – Supply – Install – Maintain Introduction
Turnout range:
▪ Light rail ▪ Metro ▪ Passenger and freight ▪ Heavy haul ▪ High Axle Load Heavy Haul (HAL-HH) ▪ All gauges and rail profiles
Design – Supply – Install – Maintain Projects WE HAVE BEEN BUSY AT MARTINUS RAIL
347 TURNOUTS SUPPLIED SUPPLIED 51 BUFFER STOPS CONTRACTED FOR THE SUPPLY OF 400+ TURNOUTS 60KM OF TRACK INSTALLED 33KM OF CRANE RAIL INSTALLED INSTALLED 102 TURNOUTS Projects Kiwi Rail
▪ 22.5t axle load ▪ AS60 rail ▪ 200+ tangential turnouts Projects
Doha Education City – Qatar
▪ 96 Turnouts and Diamonds ▪ 17t axle load ▪ S49, 60R2 rail ▪ Groove and full depth turnouts ▪ Direct fix Vossloh ▪ Edilon Sedra Encapsulation Projects Projects Sydney Ports – Botany third line and yard upgrade
▪ 30t axle load ▪ 60E1 rail ▪ 26 Tangential turnouts Projects OneSteel – Whyalla – Iron Ore Project
▪ 32t axle load ▪ 60E1 rail ▪ 9 Tangential and conventional turnouts ▪ 54t axle load flangeway running diamond Projects
ARTC – 30TAL Gunnedah
▪ 30t axle load ▪ AS60 rail ▪ 15 Tangential and conventional turnouts Projects
ARTC – HRR & LTTSF Hexham ▪ 32.5t axle load ▪ AS60 rail ▪ 41 Tangential turnouts ▪ swing nose crossings Projects
ARTC – Kooragang Island
32.5t axle load AS60 rail 8 Tangential turnouts Monoblock crossings Projects
ARTC – Upper Hunter Valley
32.5t axle load AS60 rail 12 Tangential turnouts Monoblock crossings Projects MBRL - Brisbane
• 30km of track • 19 turnouts Projects ARTC – East/West Productivity works turnout upgrade Projects PKCT
• Upgrade the 6km of rail system within the 1km long coal stockyard to facilitate the introduction of new stacker and reclaimer equipment in the yard. Projects Southpine bridge renewals
• 2 x 700m tracks along two bridges and an embankment, and was undertaken within a 168 hour rail closedown Projects Webb dock
• 1,304m of Gantrex Slab Track – Ship to Shore (STS) • 5,680m of Gantrex Ballasted – Automatic Stacking Crane (ASC) track Projects GCLR Stage 2
• Light rail turnouts (49E1 & 51R1) • Diamonds and scissor crossovers • 13km ballast track • 2km embedded track Projects Buffer stops
• NWRL (NRTIJV) – x23 stops • MBRL – x13 stops • SEQ Yards – x8 stops • Wickham – x5 stops • Perth stadium – x2 stops • Katoomba – x2 stops • MTM – x1 stop • GCLR – x2 stops Factories
Manufacturing facility – Century, Australia Factories
Manufacturing facility – DT, Czech Republic Factories
GlobalManufacturing Turnout Solutionsfacility- GWQC, China Factories
GlobalManufacturing Turnout Solutionsfacility- CRSBG, China Products
What is a turnout? Products
Breakdown of a turnout
1. Switch panel 2. Closure panel 3. Crossing panel Products
Breakdown of a turnout Products
Breakdown of a turnout
• Bearers • Switch set • Infill closure rails • Crossing • Check rail unit • End infill closure rails • Points machine • Rodding • Platework • Jewellery Products
Different types of turnout
▪ Similar flexure ▪ Contra flexure ▪ Crossover ▪ Diamond ▪ Scissor crossover ▪ Single slip ▪ Double slip ▪ Catchpoints Products
Conventional vs Tangential Products
Conventional vs Tangential Products
Conventional vs Tangential
• Tangential = improved technology – Reduced forces – Increased speed – Longer service life – Improved ride quality – Concrete bearers – Asymmetric thick web switch – Resilient fastened stock rail – Raised adjustable check rails Products
Conventional vs Tangential Products
Conventional vs Tangential Products
Conventional vs Tangential Products
Conventional vs Tangential Products
Rail Bound Manganese (RBM)
▪ Fully cast manganese insert ▪ Explosively hardened ▪ AS60 Wing rail ▪ CNC machined nose profile to suit client wheel profile ▪ Life expectancy: 300MGT Products
Monoblock
▪ Fully cast manganese ▪ Explosively hardened ▪ No bolts ▪ FBW 60kg Legs ▪ CNC machined WR & nose profile to suit client wheel profile ▪ Life expectancy: 400MGT Products
Swing nose crossing
▪ Rail type ▪ Frame type ▪ Manganese cradle - Eliminates impact - Reduced noise - Suitable for longer rate turnout (high speed) - Life Expectancy: Greater than 1000 MGT Products High axle load (48T) heavy haul turnout Products Designs according to axle loads and speed Products
Temporary Takeoff Turnout
The Temporary turnout creates a temporary siding allowing track machines to move on and off track at will.
▪ Allows safe and easy removal of track machines with up to 23T axle loads from mainline ▪ Once the track machine is located on the temporary siding it is as simple as removing two switch ramps and a crossing ramp, weighing only 350kg each, in order to restore mainline running Products Temporary Takeoff Turnout
PWI Ken Erickson Innovation Award Winners Products Points operation rodding Deflection Plates Rear Drive Rod
Linking rods
Backdrive Crank Heel of Switch
Drive Locking Bars Detection Bars
Points Motor
Points of switch Products Hydraulic points machine – Alstom CTS2 Products Electric points machine - Siemens M3A/20A Products Electric points machine - Siemens D84M Products Track forms – Concrete bearers Products Track forms – Composite bearers Products Expansion Switches
▪ Used for thermal and subsidence management ▪ Moving Stockrail - gauge is kept within tolerance ▪ Small Expansion – Up to 100mm ▪ Medium Expansion – Up to 330mm ▪ Long Expansion – Up to 600mm Products
Buffer Stop systems – Friction Hydraulic R&D
• New product development is key to ensure that Martinus Rail stays at the forefront of turnout technology and meets increasing network and operational demands from the client • Martinus Rail carries out design validation (can be by an independent third party) to: – Ensure product conformance – Ensure product suitability – Ensure product life cycle • Validation will include: – Engineering reports – Design review – Risk analysis review R&D
• All new crossing designs are verified for performance using finite element analysis (FEA) techniques • Tested up to 48T for both static and fatigue analysis • Fatigue life tested for 2.4 x 107 cycles. R&D
• New crossing designs undergo wheel / rail interface design studies to ensure that new and hollow wheel profiles transfer through the crossing in the most efficient manner without causing impacts, wheel strikes or wear R&D • All products undergo rigorous QA testing and follow up analysis Install KR Supply Kiwi Rail – NZR50 Turnouts • Martinus Rail designed brand new tangential turnout design solutions in collaboration with KiwiRail based around the in track conventional turnouts currently installed in track. The following table displays current details of turnouts in use in Kiwi Rail:
Crossing Rate (Strike) Crossing Angle (°) Speed (km/h)
1 in 7.5 7.59463 25
1 in 9 6.34019 30
1 in 12 4.76364 40
1 in 18 3.17983 60
• Martinus Rail has reverted to turnout design fundamentals to provide a newly designed suite of the turnout sizes to incorporate full tangential design and features that will provide a turnout with an increased life cycle giving Total Cost of Ownership (TCO) benefits for Kiwi Rail. Martinus Rail has designed the four new layouts to the following details:
Radius (m) Crossing Rate (Strike) Crossing Angle (°) Lead Length (m) Divergent Road Speed (km/h)
R96 1 in 7.5 Straight 7.59463 14.675 28 R140 1 in 9 Straight 6.34019 17.386 33 R250 1 in 12 Straight 4.76364 22.393 42 R560 1 in 18 Straight 3.17983 34.487 66 KR Supply Kiwi Rail – NZR50 Turnouts
Item Description Reference Document In accordance with Turnout Type Tangential – mixed traffic AS1085 and EN 13232 Turnout 96m, 140m, 250m, 560m Radius Crossing Rate 1 in 7.5, 1 in 9, 1 in 12, 1 in 18 Gauge 1068mm Kiwi Rail T151 GB 2585-2007 & Rail Size NZR50 Kiwi Rail dwg. 88323/1 Kiwi Rail T151, T160 & Bearers Concrete / Composite AS1085.14 Turnout Design Criteria Dimension (mm) As per Table 7 Road Speed Nominal track gauge 1068 Axle Load 22.5T Kiwi Rail T151 Wheel Kiwi Rail dwg. 7604-11,- Design wheelset back to back dimension 993 - 998 NZ A,C & E series Profile 13 & -15 Check rail effectiveness 1026 - 1032 Rail Cant in Zero Turnout Crossing Flangeway width 41 Points Suitable for M3A, CTS-2 & Racor Check rail gap 38 Operation Lever Maximum superelevation (cant) deficiency Yearly 60 18 MGT P.A. through diverging track Tonnage Switch rail toe / stock rail open throw ≥ 115 dimension Switch rail throat opening ≥ 50
Check rail flared end opening to gauge ≥ 80
Check rail height above the running rail 0
Flangeway depth clearance 45 KR Supply Kiwi Rail – NZR50 Turnouts
Switch assembly – The switch assembly is fabricated from 50AT asymmetric switchblades and NZR50 head hardened stockrail. Asymmetric tangential switchblades – The switchblade is manufactured from 50AT rail. The last 500mm of the switchblade is forged to the NZR50 profile for connection to the infill closure rails. • Rail type 50AT, U71 V quality according to TB/T 3109-2005. Rail head is post CNC machined factory pearlitized to produce a head hardened grade material
Stockrail – Manufactured from NZR50 head hardened (to HB 340) rail. Stock rails are drilled for locking device, anti-creep device and switch stops. • Rail type NZR50 quality U75V (HT) according to GB2585-2007
• Head of stockrail undercut to 1:3
Monoblock Crossing Assembly – Manufactured from cast austenitic manganese steel manufactured to TB/T 447-2004 • Explosively hardened within range 320 – 350 HB, all running surfaces up to 100mm from ends of casting, 20mm from top of rail
• FBW Crossing legs NZR50 quality U75V (HT) according to GB2585-2007 KR Supply Kiwi Rail – NZR50 Turnouts
Adjustable Check Rail - The check rail unit (two per turnout) comprises the check rail and the check rail bracket. The check rail is bolted to the bracket using M24 x 80 fasteners. The ends of the check rail are flared to allow gathering of the wheel flange. • Check rail type 33C1 (UIC33) to EN 13674-3
• Closure rail clipped to the check rail plate using resilient clips
• Fully adjustable using shim set
Closure Rail - The infill closure rails (rails between the end of the switches and start of the crossing) are supplied either straight or pre-curved from NZR50 quality U75V (HT) according to GB2585-2007.
Concrete Bearers – Prestressed concrete bearers to AS1085.14 with M24 Screwspike ferrules and Pandrol shoulders KR Supply Kiwi Rail – NZR50 Turnouts KR Supply Kiwi Rail – NZR50 Turnouts KR Supply Kiwi Rail – NZR50 Turnouts KR Supply Kiwi Rail – NZR50 Turnouts KR Supply Kiwi Rail – NZR50 Turnouts KR Supply Kiwi Rail – NZR50 Turnouts KR Supply Kiwi Rail – NZR50 Turnouts KR Supply Quality Management Plans KR Supply
Risk management KR Supply KR Supply Quality Inspections
• Manufacturing inspection – In process inspection by the manufacturer • Third party inspection - In process and post production inspection by a third party expert • FAT – Factory Acceptance Test carried out by Martinus Rail senior engineers • 100% inspection at factory – All products 100% inspected by Martinus Rail prior to shipping • 100% inspection on delivery– All products 100% inspected by Martinus Rail on delivery • Trial lay – First off article trial lay for KiwiRail proving KR Supply Quality Inspections
ITEM VERIFYING INSPECTED PROCESS / OPERATION / DESCRIPTION TARGET ACTUAL TOLERANCE COMMENTS No. DOCUMENTS BY
122.4 Gauge to Gauge Distance at A/B/C/D/E 122 ±1 mm (pass) (Switch closed) 156.2 156 1 193.5 (note) 1.13 SG.NZR50-7.5-101 193 KJ 233 x>1.5mm 232 (adjust with 275.5 shim) 275 1.14 Switch assembly end opening SG.NZR50-7.5-101 427 426 ±1 mm KJ 1.15 Switch tip to end of stock rail SG.NZR50-7.5-101 1090 1090 ±3 mm KJ ø22 22 ±0.5 mm Stockrail Drilling from End of Stockrail 1.16 SG.NZR50-7.5-101 1500 1500 ±2 mm KJ (diameter/distance/height from foot) 63 64 ±1 mm 1.17 Switch Drilling Hole Diameter – Foot SG.NZR50-7.5-101 Ø32 32 ±0.5 mm KJ 1.18 Switch Drilling Hole Diameter – Web SG.NZR50-7.5-101 Ø22 22 ±0.5 mm KJ 1.19 Stock rail head machining clearance to switch tip SG.NZR50-7.5-101 40 39 ±10 mm KJ +2 mm 1.20 Foot of the rail to the inside edge of the hole - 17 17.5 KJ -0 mm +2 mm 1.21 From the foot relief to the bottom of the holes - 14 14 KJ -1mm KR Supply Quality Inspections ITEM VERIFYING INSPECTED PROCESS / OPERATION / DESCRIPTION TARGET ACTUAL TOLERANCE COMMENTS No. DOCUMENTS BY Ø32 Holes: Ø32 Holes: Switch Drilling from Toe of Switch 50, 49.7, 117, 116.7, 184, 184.5, 690, 690, Ø22 Holes: Ø22 Holes: ±1 mm 1.22 SG.NZR50-7.5-101 KJ 294 294.5 +232 +232 +253 +253 +100 +100 Check M20 Checked Bolt Fit Switch stops correctly positioned 1.23 VISUAL 0 0 +2, -0 mm KJ (gap between switch stop and rail web) 450 450 Length of plates under switch: 650 649 50-FLAT 50-SW/50-SWH 790 790 1.24 50-7.5-13-RH-RS/50-7.5-13-LH-LS - KJ ±2 mm (OK) 50-7.5-14-RH-RS/50-7.5-14-LH-LS 840 841 50-7.5-15-RH-RS/50-7.5-15-LH-LS >2 mm 50-7.5-16-RH-RS/50-7.5-16-LH-LS 850 849 (Check Hole to Hole 906 (Loose) L-70mm, ±1) KR Supply Quality Inspections KR Supply Product Marking rnout ITEM DESCRIPTION Left Hand Turnout LeftHand Left Hand Turnout LeftHand Tu LeftHand Right Hand Turnout Hand Right Left Hand Turnout LeftHand Right Hand Turnout Hand Right Turnout Hand Right - - - Right Hand Turnout Hand Right - - - - - 1 in 9 9 in 1 1 in 12 12 in 1 18 in 1 1 in 9 9 in 1 1 in 7.5 7.5 in 1 1 in 12 12 in 1 18 in 1 1 in 7.5 7.5 in 1 1 Left hand side - switch rail + stock rail * I * I * I * I 2 Right hand side - switch rail + stock rail * I * I * I * I 3 Crossing * I * I * I * I 4 Check rails – C * I * I * I * I 5 Check rails – K * I * I * I * I 6 Closure – C * I * I * I * I 7 Closure – K * I * I * I * I 8 Closure – F * I * I * I * I 9 Closure – D * I * I * I * I 10 Closure – A N/A N/A N/A N/A * I * I 11 Closure – H N/A N/A N/A N/A * I * I 12 Loose Items (Box) * I * I * I * I KR Supply Delivery KR Supply Logistics KR Supply Trial Lay KR Supply Trial Lay KR Supply Trial Lay KR Supply Trial Lay KR Supply Installation KR Supply Installation KR Supply Points operation rodding KR Supply Points operation rodding KR Supply Teamwork KR Supply Teamwork KR Supply Summary • Challenges • Brand new turnout design • New manufacturer • Shipping rail from NZ • Logistics of moving parts around the world • Earthquake! • Successes • Turnouts on the ground • Rodding installed • Working relationships • Manufacturing quality