Case Study Berlin to Cottbus Line

Eficient vibration protection for adjacent buildings with an increase in train speeds

Specially developed polyurethane tie pad with effective acoustic damping

World’s largest railway project using tie pads for vibration protection Berlin-Cottbus

Description of the project The Getzner Solution

Development of the Berlin-Cottbus Padded railway tie as protection against Product development in close railway line vibrations cooperation

n 2010 Deutsche Bahn (DB) up-graded Getzner worked closely with DB to develop Getzner developed the new sleeper pad Ithe heavily used railway line between a special polyurethane tie pad with which was designed to suit the Berlin- Berlin and Cottbus, which lies in the county effective acoustic damping for the Berlin- Cottbus line in close cooperation with DB‘s of Brandenburg. Following the southerly Cottbus line. The pad was designed within Technology and Acoustics Department in section of the Berlin-Cottbus line, the the scope of the research project “Quiet the course of the LZarG research project. middle section of the route was also up- train on real track” (LZarG) which was The solution reached production stage graded to allow trains to run on it at higher aimed at developing new technologies for and ultimately received approval by DB speeds. The entire railway track structures lower-noise railway trafic. The PUR mats Technology. were replaced along a 37.3 mi long section dampen the vibrations of trains as they between the spring and autumn of 2010. pass through built-up areas. While the R&D work was in process, The challenge facing us in this project was Getzner had the product tested at the to provide buildings in close proximity to The new pad has been specially tailored to Technical University of Munich. Those the track with eficient protection against meet the requirements of these projects. tests have conirmed the high quality and vibrations, despite the increased velocity “DB already had good experience of durability of the product. “We conducted a which had been planned. working with us before we embarked upon rigorous series of tests in a very short this major project. Faith in our expertise time. We now have a well-engineered, What is more, in order to keep this and in our ability to deliver the right highly resilient product in use. In addition, extensive project on budget and on product were key to securing the order. So compared to conventional solutions, schedule, the complete track structure far, Berlin-Cottbus has been the biggest could not be removed. Since the com- railway project of its kind in the world in- pletion of the construction work, the volving the use of sleeper pads to protect track which was previously designed to against vibrations. All in all, some 52,000 accommodate a top speed of 75 mph can ties and 17 turnouts were itted with pads now be used by trains travelling at speeds made from our material,” pointed out of up to 100 mph and at greater frequency, Sascha Reuter, project manager of the Rail without causing additional structural Division at Getzner‘s plant in Grünwald stress due to vibrations or noise. near Munich, emphasising the signiicance of this major project. By using sleeper pads, specialists were able to integrate the vibration protection without completely removing the track structure. Feedback the tie pads also boast longevity on this project provided us with valuable What does the tie manufacturer account of the improved way in which they experience, which will beneit our have to say about the project? are connected,” said Sascha Reuter, clients in future projects.” summing up the special features of the “The cooperation with the Getzner team major order. Given the high production capacity was exemplary. The quality of the pads for utilization, the new elastic layer for the ties the ties was consistently high and enabled Just-in-time logistics was produced at the Getzner plant in Bürs us to afix them to our concrete ties under great time pressure and under the without any trouble. Deliveries were Reuter described how “this order most stringent quality controls. Liaising excellently coordinated: they arrived on presented a big challenge for project closely with the company that time and in the agreed volume.” management, quality management, manufactures the ties, Getzner delivered production and logistics – around over 50,000 pads to Frankfurt and to 30 people worked on its successful Neumarkt in Oberpfalz between June and Gundolf Spitzner, implementation.” Finally he stated that September 2011. They were then afixed to Head of European Sales, “Volumes of this great magnitude create the ties at Rail.One‘s two plants. As this RAIL.ONE GmbH high demands: Not only did we manage then meant that ties could be delivered to to coordinate the internal processes the track with the pads already in excellently, we were also able to coordinate place, which made installation quick and the timing of the manufacturing of the ties straightforward. and pads with our customers on site to great effect. By virtue of its sheer scale,

GermanyDeutschland PolandPolen

Berlin Getzner created pads for Brandenburg 50,000 tie along a section of Königs Wusterhausen over 37.3 mi between Königs Wusterhausen and Lüb- Lübbenau benau. Cottbus Leipzig

Dresden

50 km CzechTschechische republic Republik Facts and igures at a glance

Berlin-Cottbus line

Long upgrade section between Königs Wusterhausen and Lübbenau: around 37.3 mi Target speed: up to 100 mph

Order details

Scope of the order: Pads for around 50,000 ties and 17 turnouts Client: Deutsche Bahn AG Project manager: Betriebswirt (VWA) Sascha Reuter Completion: Autumn 2011 Sleeper manufacturer: RAIL.ONE GmbH Construction company: Eiffage Rail GmbH

Data and facts regarding Getzner Werkstoffe GmbH

Foundation: 1969 (as a subsidiary of Getzner, Rail references (Extract) Mutter & Cie) Managing Director: Ing. Jürgen Rainalter — Brynsbacken (NO) Employees: 215 in Bürs, 85 abroad — Metro Seoul (KR) 2012 turnover: $ 79.3 Mio. — Metro Amsterdam, Eastern Line (NL) Business areas: Railway, construction, industry — Bruchsal Tunnel (DE) 2012 output: 6488 Tons of technical PU materials — Matstetten-Rothrist (CH) 2012 recycling: 41 Tons of residual PU materials — Umegaoka-Odakyu Electric Railway (JP) Locations: Bürs (AT), Munich (DE), Berlin (DE), — Britomart Station (NZ) Amman (JO), Tokyo (JP), Pune (IN), — Northern approach line to the Brenner Beijing (CN), Kunshan (CN), Charlotte (US) Base Tunnel (AT) Ratio of exports: 80 percent CS BC US en © Copyright by Getzner Werkstoffe GmbH | 01-2014 Werkstoffe Getzner by US en © Copyright BC CS

AUSTRIA — Bürs GERMANY — Berlin — Munich FRANCE — Lyon JORDAN — Amman JAPAN — Tokyo INDIA — Pune CHINA — Beijing USA — Charlotte www.getzner.com