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

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BALLASTLESS TRACK on EARTHWORKS Fixed Track Forms for High Speed Lines PWI/UEEIV 2016 Technical Conference, Manchester, UK BALLASTLESS TRACK ON EARTHWORKS Fixed Track Forms for High Speed Lines PWI/UEEIV 2016 Technical Conference, Manchester, UK Dieter PICHLER th Johann FLOH 11 October 2016 BALLASTLESS TRACK ON EARTHWORKS BALLASTLESSwww.vce.at TRACK / ON www.porr-group.com EARTHWORKS www.vce.at / www.porr-group.com 2 Content 01 General 02 High-Performance 03 High-Speed 04 Special Solutions 05 Conclusions BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 3 01 General BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 4 01 General Ballasted Track Heavy concrete sleeper track Ballasted track (uniform European track) Elasticity without subsoil ballast substructure 40% rail fastening rail pads 60% BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 5 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 BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 6 01 General Vertical Loading [prEN 16432-2] Determination of vertical stresses in unbound layers by distribution of vertical loading BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 7 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 BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 8 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 BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 9 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 5 1 4 6 2 3 1 4 7 BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 10 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% BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 01 General Construction Sequence BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 12 01 General Methodology – Structural Implementation of PORR Slab Track System: TOP-DOWN 1 2 3 4 5 BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 01 General Repair Concept BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 14 01 General Large Settlement Adjustment BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 15 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] BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 16 01 General System Comparison GEOMETRY CONSTRUCTION OPERATION ADDITIONAL Aspects SYSTEM with cars Openings shafts for Error-rate Track quality Adjustment range Noise and vibration Life cycle Space requirements Construction height Pre-assembling On siteinstallation time Work accident risk Qualitycontrol Maintenanceneeds Repair concept Passibility Applicableon open surface Long timeexperience COMPACT SYSTEMS – – +/- – +/- – – – – +/- +/- – – +/- + +/- +/- BLOCK SYSTEMS +/- +/- +/- – – +/- – – – – – +/- + + – – – EMBEDDED RAIL SYSTEMS + + + +/- – – +/- +/- + – +/- – +/- + + +/- – PORR SLAB TRACK SYSTEM + + + + + + + + + + + + + + + + + BASEPLATE SYSTEMS & PLINTH SYSTEMS + + + – – +/- – – – +/- +/- – – + + +/- – + very good +/- medium – poor BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 17 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). BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 18 01 General Approvals for PORR Slab Track System Austrian Federal Railways EBA (Germany) - General Approval EBA (Germany) – Approval for S&C BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 19 01 General Approvals for PORR Slab Track System Certificate Network Rail (UK) EC Certificate (TSI compatibility) BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 20 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, …) BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 21 02 High-Performance BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 22 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 BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 23 03 High-Speed: Cross-section on Earthwork - Austria BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 24 02 High-Performance Westbahn By-pass Melk, Austria Year 2000 Length 8 612 m BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 25 02 High-Performance Lainzer Tunnel, Austria – PORR Slab Track System on MSS Year 2010 Length 18 075 m BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 26 02 High-Performance Wienerwald Tunnel, Austria – PORR Slab Track System on MSS Year 2010/2011 Length 26 406 m BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 27 03 High-Speed BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 28 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 BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 29 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) BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 30 03 High-Speed Line VDE 8 Cross-section on Earthwork BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 31 02 High-Performance VDE 8, Germany Installation of Porr System on Earthwork Year 2015/2016 Length > 300 km BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 32 03 High-Speed Line VDE 8 Cross-section on Long Bridges BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 33 04 Special Solutions BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 34 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 =0.25 ... damping ratio 2.0 ξ ξ β... frequency ratio 2.5 ξ=0 concrete trough (mass) ξ=0 =0.50 1.5 ξ D... dynamic maginification factor =0.25 ... damping ratio rail carrying 2.0 ξ ξ elements P (t) β... frequency ratio 1.0 ξ=0 concrete trough (mass) 1.5 ξ=0.50 bearings ξ=1.00 rail carrying m 0.5 elements (springs) ξ=0 (wheel, track,P (t) sleeper, 1.0 ξ=0.50 base (e.g.: tunnel concrete track) ξ=0.25 bottom floor) 0 c 0.5 1 2 3 4 5 6 7 8 bearings k F (t) √2 ξ=1.00 m 0.5 β (springs) ξ=0 (wheel, track, sleeper, ξ=0.50 base (e.g.: tunnel concrete track) ξ=0.25 bottom floor) 0 k c 0.5 1 √2 2 3 4 5 6 7 8 F (t) β BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 35 04 Special Solutions Transitions: Ballastless Track – Ballasted Track Section A-A Section B-B BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 36 04 Special Solutions Bridge Gap with Special Track Base Plate BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 37 04 Special Solutions Accessibility for Tire-wheeled Vehicles and Guide Rail System BALLASTLESS TRACK ON EARTHWORKS www.vce.at / www.porr-group.com 38 04 Special Solutions Switches & Crossings e.g.
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