EDILON Level Crossing Systems (LC)

Solutions that edilon)(sedra bv Nijverheidsweg 23 P.O.Box 1000 T +31 / (0)23 531 95 19 [email protected] NL-2031 CN Haarlem NL-2003 RZ Haarlem F +31 / (0)23 531 07 51 www.edilonsedra.com won’t shake the world... www.edilonsedra.com EDILON LC introduction the history

For over 130 years tracks for mainline rail traffi c and In EDILON LC the use of mechanical fastening systems, such as clips, anchors and urban mass rapid transit systems were based almost exclusively on track panels and cross sleepers baseplates, for both the crossing as well as the rail are made completely redundant supported on stone ballast. During the 1960’s, increasing because of EDILON Corkelast® ERS. train loads, higher speeds and the demand for more By using EDILON Corkelast® ERS, the rails are connected to the EDILON LC concrete cost effective track installation methods, resulted in the development of ballastless track or slab track systems. slab in a fl exible yet extremely durable way. Continuous elastic rail support means that horizontal and vertical forces are Since the introduction of slab track systems edilon)(sedra evolved as a specialist in this fi eld. Based on 40 years of more evenly distributed. Furthermore, the chance of rail breaks compared to experience edilon)(sedra developed specially for road–rail traditional level crossing systems based on ballast track, is signifi cantly reduced intersections a range of EDILON Level Crossing Systems, and rail corrugation is effectively eliminated. called EDILON LC. EDILON Corkelast® ERS also offers maximum electrical insulation. EDILON LC have given assurance and comfort for more than 30 years, for both rail and road traffi c. The weight and stiffness of the EDILON LC enables a good distribution GENERAL ADVANTAGES of forces, which guarantees both a durable as well as a • Proven minimal costs-of-ownership settlement free system. In addition the EDILON Corkelast® • Durable long life structure Embedded Rail System (ERS) also provides signifi cant • Proven technology resulting in a range of technical noise and vibration reduction opportunities, more and approvals more important these days in densely populated areas. • One structural monolithic unit • Continuous elastic rail support The EDILON LC range consists of the following types: • Smooth transition between rail and road • EDILON LC-H, known as the Dutch “Harmelen” • EDILON LC track elasticity matches elasticity of level crossing, installed since 1976 adjacent track • EDILON LC-1, known as the German “Stelfundo” • Excellent electrical insulation of the track level crossing, installed since 1997 • EDILON LC-L installed since 2002 COST EFFECTIVENESS • Simple and fast installation • EDILON LC service life more than 30 years • Reduction of rail wear and rail corrugation • Maintenance free Naturally edilon)(sedra is ISO 9001 certifi ed. • Low lifecycle costs (LCC)

2 3 Application areas EDILON LC types where a road meets rails EDILON LC-H EDILON LC-1 and EDILON LC-L EDILON LC is applied in all possible kinds of intersections All EDILON LC systems meet the various requirements EDILON LC-H is especially designed for continuous EDILON LC-1 and EDILON LC-L are both EDILON LC where road meets rail. There are almost no restrictions. for heavy rail and high-speed rail. EDILON LC systems welded track where the high weight of the slabs is of systems that offer an optimized slab design which still EDILON LC offers a unique solution, which combines in all meet the requirements of UIC load model 71 as speci- major importance to prevent track movement. Because meets all rail and road requirements with a slab thickness an ideal way the track ballast bed, rail fastening and the fi ed in UIC code 702. The extremely durable longwearing of the thickness of the EDILON LC-H concrete slabs, the of 400 mm. paved road into one structural monolithic unit. surface meets the highest road load class standard of structural stiffness is high, which allows application in The installation of EDILON LC-L and EDILON LC-1 is By combining EDILON LC concrete slabs, level crossings load class 60. Certain EDILON LC systems are applicable areas with a subsoil with low foundation coeffi cient, ks = carried out with a “bottom-up” approach were the slabs from 6 to 50 meters length can be installed in a period in heavy loaded level crossings with train axle loads 20 MN/m³, which is equivalent to a subsoil modulus, Ev2 are placed on a smooth and levelled split bed with the of 8 hours, including the removal of the old crossing as up to 37 tons and heavy traffi c axle loads up to 90 tons = 35 MN/m². appropriate subsoil foundation stiffness. Application of well! The top surface of EDILON LC slabs can be prepared in The installation of EDILON LC-H is done with a “top-down” these slabs is possible in subsoil areas with a foundation Quality and installation speed are both very important. such a way that high skid resistance values (SRV) can be approach: the slabs are levelled at the proper Top of Rail coeffi cient, ks = 70 MN/m³, which is equivalent to a subsoil Depending on the condition of the subsoil and the obtained. SRV of more than 45 up to 70, are possible with position by using hydraulic jacks and an injection grout modulus, Ev2 = 120 MN/m². function of the level crossing in e.g. continuous welded special concrete mixtures of the top surface. is used to fi x the correct slab position. In this way the track a choice can be made between EDILON LC-H and forces of the slab are evenly distributed over the supporting Protection and strengthening of the rail channels is also EDILON LC-L or EDILON LC-1. subsoil. The rail channels are protected and strengthened possible. Depending on the channel design all vignole by strong steel edge profi les. and grooved rails are accommodated.

The fi elds of application of EDILON LC

• main roads with high density of traffi c Embedded Rail Characteristics • industrial areas with intensive heavy traffi c • rural routes All EDILON LC systems include the EDILON Corkelast® • in city track Embedded Rail System (ERS) and offer the following ERS • crossing with angles up to 0-180° characteristics: • S-shaped roads and horizontal turn movements • Continuous rail support • Track stiffness tunable following for instance UIC LM71 • Excellent electrical insulation • Top-down rail alignment and levelling

4 5 EDILON LC-H – type “Harmelen”

Features edilon)(sedra obtained its Dutch product approval for EDILON LC-H concrete level crossing slabs type “Harmelen” in Approvals September 2007 but the principle of the heavy EDILON LC-H system was developed already in 1974 in close co-operation • Used in heavily loaded road-rail combinations ProRail Netherlands with Netherlands Railways NS. • Standard asphalt road approach Infrabel Belgium Since 1976, more than 1250 level crossings of this type have been installed. • Suitable for roads crossing at angles up to and even exceeding 45 degrees SNCF France • Suitable for curved track sections with super elevation The EDILON LC-H level crossing is available in two standard slab lengths. MAV Hungary • Intensive heavy road traffi c will not move nor damage Ontario Northland Canada Concrete Slab length Slab width Slab height Weight Radius Vmax EDILON LC-H slab type [mm] [mm] [mm] [kg] [m] [km/h] • Standard level crossing drainage solutions RENFE / ADIF Spain

LC-H6 6.000 2.300 580 20.000 1000 200 REFER EP Portugal Slab characteristics LC-H9 9.000 2.300 580 30.000 1500 200 • Minimal slab settlement and optimal distribution of forces

Depending on track curvature and rail type the EDILON LC-H slabs can be tapered or wider channels or curved channels can • Maintenance free be applied. • Ability to connect slabs to form longer crossings • Road surface is extremely durable (special dressings and treatments) EDILON LC-H track curvature slab range • Edges and channels protected with strong steel LC-H6 LC-H9 profi les • Rails fastened securely using EDILON Corkelast® Standard slab type R ≥ 1000m R ≥ 1500m ERS Tapered slab with straight channels 225m ≤ R ≤ 1000m 500m ≤ R ≤ 1500m • Reduced rail corrugation Tapered slab with curved channels R < 225m R < 500m • Optimized reinforcement design with C45/55 concrete • Seamless connection to the road surface • Rapid installation method maximizes the track EDILON LC-H system characteristics availability • Maximum train speed V 200 km/h • Motorbike, bicycle and wheelchair friendly • Rail traffi c load classes - 150, 250 and 270 kN • Road traffi c load class - Load class 60 • Maximum superelevation/track cant D 75 mm • Maximum cant defi ciency I 40 mm • Maximum cant excess E 40 mm • Rail inclination - 0 or 1:40 or 1:20 or as required • High skid resistance value SRV 70 (typical) • Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements

6 Prefab Embedded - Harmelen LC 7 EDILON LC-1 – type “Stelfundo”

edilon)(sedra obtained its approval for EDILON LC-1 concrete level crossing slabs type EDILON LC-1 system characteristics “Stelfundo” from the German Federal Bureau of Railways already in September 2003. • Maximum train speed V 160 km/h EDILON LC-1 is a logical addition to EDILON LC-H. Developed in the mid 1980’s, these crossings have also enjoyed worldwide acceptance. Although of lower weight, the reinforcement, • Rail traffi c load classes - 150, 250 and 270 kN surface treatments and various colours make the slabs also suitable for a wide range of applications. • Road traffi c load class - Load class 60 • Rail inclination - 0 or 1:40 or 1:20 • High skid resistance value SRV 45 (typical) EDILON LC-1 slabs are installed on a layer of well compacted levelled grit. Crossings of, for instance, • Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements 50m length can be installed in track possessions of only eight hours. Again, steel profi les can be used on the edges of the channels to increase slab durability. It is possible to couple individual slabs Features Approvals to prevent problems caused by subsoil settlements. • Suitable for all rail and road traffi c EBA Germany • Used in all types of road crossings EDILON LC-1 is available in the following slab lengths: • Suitable for road crossing angles up to 45 degrees DB Netz AG Germany • Ideal for curved and inclined track ÖBB Austria SBB Switserland Concrete Slab length Slab width Slab height Weight Radius Vmax Slab Characteristics slab type [mm] [mm] [mm] [kg] [m] [km/h] • Minimal settlement and optimal distribution of forces 2600 2.600 2.400 400 5.990 85 160 • Various slab lengths available (L codes) • Available for curves (R codes) 3000 3.000 2.400 400 6.450 100 160 • Highly durable surfacing 4000 4.000 2.400 400 8.600 200 160 • Maintenance free; no rutting, reduced rail corrugation 4500 4.500 2.400 400 9.675 255 160 • C45/55 concrete with optimized reinforcement design 5000 5.000 2.400 400 10.750 315 160 • Increased safety for cyclists, motorbike and wheel chairs riders 5500 5.500 2.400 400 11.825 380 160 • Minimal installation times 6000 6.000 2.400 400 12.900 450 160 • Slabs can be connected to longer crossings • Re-adjustability after installation possible

8 9 EDILON LC-L

edilon)(sedra obtained approvals for EDILON LC-L concrete level crossing in several countries i.e. Poland and France. The principle of EDILON LC-L is based on the proven concept of EDILON LC-H and EDILON LC-1. The EDILON LC-L slab design gives freedom to apply virtually all rail profi les and install track with different gauge widths.

EDILON LC-L slabs are installed on a well compacted subgrade with a fi ne split bed top layer. Steel profi les can be used on the edges of the channels to increase the slab durability.

EDILON LC-L is available in the following range of slab Features Approvals lengths: • Used in highly loaded road-rail combinations SNCF France • Standard asphalt road approach RATP France Concrete Slab length Slab width Slab height Weight Radius Vmax • Suitable for roads crossing at angles up to 45 slab type [mm] [mm] [mm] [kg] [m] [km/h] degrees PKP Poland LC-L1,5 1.500 2.400 400 3.300 75 80 • Standard level crossing drainage solutions Banverket Sweden LC-L3 3.000 2.400 400 6.500 150 80 DSB Denmark Slab characteristics LC-L4 4.000 2.400 400 8.600 200 160 MAV Hungary • Minimal slab settlement and optimal distribution of LC-L5 5.000 2.400 400 10.725 300 160 forces SNCF France LC-L6 6.000 2.400 400 12.850 450 160 • Maintenance free ENR Egypt • Ability to connect slabs to longer crossings APTA Alexandria • Durable road surface, special dressings and MTRC Hong Kong EDILON LC-L system characteristics treatments possible • Maximum train speed V 160 km/h • Edges and channels protected with steel profi les GVB Amsterdam • Rail traffi c load classes - 150, 250 and 270 kN • Rails fastened securely using EDILON Corkelast® ERS • Optimized reinforcement design with C45/55 concrete • Road traffi c load class - Load class 60 • Seamless connection to the road surfacing • Rail inclination - 0 or 1:40 or 1:20 or as required • Rapid installation method maximizes the track • High skid resistance value SRV 45 (typical) availability • Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements

10 11 EDILON LC system design and installation method

edilon)(sedra offers a range of EDILON LC systems optimized for supporting the forces from both rail as well as road traffi c. A distinction is made in strength and defl ection behaviour between different EDILON LC slabs. A common characteristic is that the slabs must be installed on stabilized ground. The ground support stiffness plays an important role in the choice between the different types of EDILON LC systems.

Design on rail and channel On both ends of the crossing, a steel protection plate Track facilities The forces arising from rail and road traffi c on the slab are is mounted to protect the concrete and/or the drainage EDILON LC systems are compatible with all international most critical around the rail. system from impact forces caused by loose couplings, train control systems. To understand this, extensive modelling and laboratory hanging from passing trains EDILON LC systems have been in service in a wide range tests are performed to analyze and optimize the system. of light rail, high-speed and heavy rail applications over a Rail profi le and mechanical properties, channel dimen- Geotextile mats are preferred to be applied adjacent to period of many years. sions, materials and building tolerances are all included EDILON LC to provide a long lasting stable ballasted in the process of fi nding the most durable EDILON LC track. The concrete slab reinforcement is optimized and EDILON LC installation method system possible. together with the applied concrete the electrical insulation For all EDILON LC systems a well consolidated subgrade of the slabs is durably secured. is essential. The excavation profi le depends on the type Depending on its application and the type of EDILON of installation. In case of a level crossing replacement LC a range of standardized channel designs have been the excavation depth can be kept limited, whereas the developed which gives freedom to apply each possible bottom of the excavation should be disturbed as little as rail profi le and will also meet the requirements set by road possible. and rail authorities. EDILON LC-H allows for a “top-down” approach were the slabs are levelled with hydraulic jacks and an injection System features grout is used to fi x the correct slab position. Because of The use of slabs means that provisions for cables for the high structural stiffness of EDILON LC-H, a low ground signalling, water drainage and a protection against loose support stiffness is permitted. train couplings, must be made. Standard solutions are available and can be included in the system design. In EDILON LC-1 and EDILON LC-L have a reduced slab EDILON Corkelast® ERS, multi functional plastic tubes thickness, which requires a reduced excavation depth. are applied. The installation of both EDILON LC-1 and EDILON LC-L These tubes offer the opportunity to: is done with a “bottom-up” approach were the slabs are • align the rails in the channels and to adjust the width placed on a compacted smooth and levelled split bed of the gauge with the appropriate ground support stiffness. • reduce the amount of Corkelast® and so the material costs In all cases the forces of the EDILON LC slabs are evenly • pull cables for signalling through the tubes distributed over the supporting subsoil. Special attention must be paid to the adjacent ballasted track, which must be sound and stable. EDILON Corkelast® ERS installation materials

• EDILON Corkelast® • EDILON Primer 21 Rail fastening system • EDILON Primer U90WB EDILON Corkelast® Embedded Rail Systems (ERS) • EDILON Resilient ERS Strip offers many advantages because of its continuous rail • EDILON Dex®-G support. Track stiffness can be tuned by choosing the • EDILON Fillerblocks and tubes appropriate resilient ERS components. edilon)(sedra is • EDILON Nylon spacers able to perform stiffness analysis using fi nite element • EDILON Polymer wedges methods (FEM) and is able to test new system designs in • EDILON Polymer (inclination) shims 12 its own laboratory. 13 EDILON LC mainten ance and recycling

Track with EDILON LC is designed to work exactly how our clients want it to work. Should, for any reason, the track no recycling and environment partnership longer meets these expectations, either maintenance or rail replacement may be necessary. Height corrections of EDILON All components used in EDILON LC systems are fully edilon)(sedra supplies EDILON LC as a complete track LC concrete slabs can be carried out easily by high pressure injecting a special mortar underneath the slabs and lift them in recyclable. Cured embedding and pouring compounds system, from initial contacts to system delivery, and from this way. can be disposed as domestic waste, in accordance with commissioning to removal. We work with our clients on Rail replacement of EDILON Corkelast® ERS is only necessary when rail wear or rail fatigue limits are exceeding the regula- the European Waste Catalogue. questions and advice. EDILON LC delivers the benefi ts tions, or in the exceptional case that a rail break did occur. EDILON Corkelast® ERS can be removed completely from both of prefab element quality and rapid installation, and channels and after cleaning the channels new EDILON Corkelast® ERS can be installed. EDILON Corkelast® ERS installation combines our specialists knowledge of track, concrete can be done in very tight track possession periods. and civil engineering. rail wear It is well known that a well supported rail as well as one of good quality will have positive infl uences on the life of the rail. EDILON LC ensures a well supported rail through various aspects: the support of the slab, the weight of the slab, the tight tolerances of the slab, the alignment of the slab and the exceptionally accurate alignment of the rail on the slab. Connecting the slabs together also ensures for better slab support over a longer period of time. Furthermore, a well documented advantage of EDILON Corkelast® ERS is a reduction of rail wear. With EDILON Corkelast® ERS rigid points are omitted. This results in an improved spreading of the forces and signifi cantly reducion of high dynamic forces in the rails.

logistics and supply The logistic process for EDILON LC track follows a detailed and accurate planning. Each part, from initial discussions, channel design, production, transport, installation and commissioning, are all included in the planning. All materials supplied are subject to constant quality control.

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