A Guide to Permanent Way Design
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A Guide to Permanent Way Design by Paul King A Guide to Permanent Way Design A Guide to Permanent Way Design Contents Page No Introduction 2 Horizontal Design a. Basic Elements 3 b. Cant and Deficiency 5 c. Transitions 8 Vertical Design a. Terminology 11 b. Constraints 11 c. Design Methods 12 d. Design for canted track 13 e. Calculation example 14 Switch and Crossing Geometry a. Basic elements 16 b. Switch details 17 c. Crossing details 18 d. Turnout types 19 e. Speed characteristics 20 f. Design guidelines 20 Track Layouts 22 Clearances and Vehicle Envelopes 25 Hallade Design 35 Survey Requirements a. S&C 43 b Plain Line 44 Author – Paul King Date – September 2011 - 1 – Copyright – P.J. King A Guide to Permanent Way Design Introduction This booklet is the combination of a series of design lectures given by me over the past ten years. The intention was to provide the beginner / novice with simple guidelines to give an appreciation of the basics elements of track design starting with horizontal and vertical design. These are the basic elements upon which track design is built. Sections are also included on switch and crossing geometry, clearances and track survey requirements. Network standards have been referenced where appropriate. It should be noted that these do change from time to time. - 2 – Copyright – P.J. King A Guide to Permanent Way Design Track Geometry Horizontal Design – Plain Line a. Basic Elements i. Elements of STRAIGHTS and CIRCULAR CURVES Design They can be linked by spirals known as TRANSITIONS. Transitions can also link different curves. They are not elements but LINKS. ii. Definitions STRAIGHT- Shortest distance between 2 points, line of constant bearing. CIRCULAR CURVE - Line that is a fixed distance (radius) from a point (circle centre). TRANSITION - Curve of constantly changing radius – a spiral. Diagram 1 – Low speed layouts – Typically sidings (Element) (Element) Tangent Point Diagram 2 – Main Line arrangement (Element) Tangent Point (Link) (Element) Note – Tangent point is where 2 elements or an element and a link meet. - 3 – Copyright – P.J. King A Guide to Permanent Way Design iii. Theory Why have straights? Easy to design, set out and maintain Constant force on track from train wheels Shortest-quickest – distance to travel Why have Circular curves? Constant force from train wheels which can be offset by cant (see later) Easy to design, set out and maintain Transitions – They avoid an instant change of radius, which What are they for? would be very noticeable at high speed inside the train – see rules in following section. Provide area for cant (super elevation) –– to be built up. See following section for details. Transitions – What shape? This depends on design method used but all are very similar 1. Hallade – Cubic Parabolic 2. Mx or BRT – Clothoid or Bloss ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ - 4 – Copyright – P.J. King A Guide to Permanent Way Design b. Cant and Deficiency Rails inclined at 1:20 (to match train wheels) i. Straight Track towards track centre Diagram 3 Cant = Difference in rail levels Note – Track gauge (G) = 1435mm or 1432mm for older Cen56 designs (Distance between inside edges – running edges - of rail) Other Typical Dimensions Depth of Track Construction (D) = 365mm Length of Sleeper (L) = 2500mm – 2600mm ii. Curved Track Diagram 4 W - Weight of vehicle F - Acceleration force R – Resultant of W&F E – Cant/mm E = 11.82V2 For R = W+F R 1 R = Radius in metres V = Speed in Kph - E = Equilibrium cant in millimetres – Train wheels exert no sideways force on the rails - 5 – Copyright – P.J. King A Guide to Permanent Way Design Generally a cant less than E is applied because: E is designed for the maximum speed and not all trains run at this speed Applying a lower cant will result in a force between the high wheel and the rail – this ‘guides’ the train around the curve Reduces contact fatigue To apply a cant less than the equilibrium will result in a deficiency. This value is called the ‘CANT DEFICIENCY’ (D). (It creates an outward force on the high rail (Y)). The designed cant (Ea) and deficiency total the equilibrium cant: Ea + D = E iii. Limiting Values Non tilting trains These are shown in Railtrack standard NR/L2/TRK/2049 – Track Design Handbook (TDH) – pages B2.1 – B2.4. The cant deficiency (for conventional trains) should not normally exceed 60% of the applied cant on jointed track or 73% of this figure for continuously welded track (CWR). Exceptionally these figures may be increased to 73.3% and 100% respectively. This can be summarised: Jointed Track - Dmax = 0.6Ea = 0.375E Dexp = 0.733Ea =0.423E CWR Track - Dmax = 0.73Ea = 0.422E Dexp = Ea =0.5E The above maximum values apply to a general cross section of lines. High speed lines should be designed such that the deficiency is a minumum of half the cant: D = 0.5Ea = 0.667E - 6 – Copyright – P.J. King A Guide to Permanent Way Design The maximum values of cant and deficiency are shown in the TDH on Pages B2.1 – 2.3, these can be summarised: Jointed Track - Dmax = 90mm Dexp = 110mm Emax = 150mm Eexp = 180mm CWR Track - Dmax = 110mm Dexp = 150mm Emax = 150mm Eexp = 180mm The maximum and not exceptional figures should be generally used. iii. Limiting Values Tilting trains Tilting trains can run at what’s known as Enhanced Permissible Speed (EPS) – conventional trains run at Permissible Speeds (PS). PS characteristics have generally been shown throughout this paper. At EPS speeds the maximum permitted cant deficiency is 265mm and this depends on the radius. For full EPS data refer to the TDH on Page B2.2. iv. Calculation Example Determine Ea for the following: V = 50 mph (x by 1.609 for Kph) R = 500m If D = 0.5Ea Using equation 1 E = 11.82 v2/R E = 11.82 x (50 x1.609)2 500 E = 153.00mm Ea = 0.667E = 102mm In practical terms cant is set in 5mm increments therefore: Ea is set as 100mm D = 153 – 100 = 53mm ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ - 7 – Copyright – P.J. King A Guide to Permanent Way Design c. Transitions As previously defined these are links between curved and straight tracks (or curve to curve), they are a form of spiral which smoothly forms the link. Diagram 5 (Element) (Link) Tangent Point (Element) Transitions are needed on all alignments except: Sidings Low speed areas such as stations/depots Compound curves of similar radii Where cant is applied to a curve this is built up at a constant rate through the transition. (Transitions are usually marked on site showing the cant at 5mm steps, the limits of the transition are also marked.) i. Design Requirements Having determined the cant required for the circular curve an appropriate length of transition needs to be designed. This is done by using limiting values laid down in the Track Design Handbook (TDH). These are shown on page B2.1. The two critical factors are: Cant gradient (Egrad) Egrad = 1 in Transition length (TL)/Ea 2 Rates of change (RoC) of cant (Ea) and cant deficiency(D) RoC = (Ea or D) x V (mm/second) 3.6 x TL 3 TL = Transition length in metres If the transition links two curves, Ea = Ea1– Ea2 for curves 1 & 2. Similarly D = D1 – D2. - 8 – Copyright – P.J. King A Guide to Permanent Way Design ii. Limiting Values TDH page B2.1 Cant gradient = 1 in 400 – 1 in 1500 ( normal limits) Rate of change Ea or D = 35mm/sec desirable 55mm/sec maxiumum 70mm/sec exception maximum The above values for rates of change do not apply to tilting trains, these are 35mm/s, 110mm/s and 150mm/s respectively from the TDH page B2.3. A practible arrangement is to fix the change of cant at 1mm/ sleeper. This gives values of between 1:600 and 1:760. iii. Calculation example TL to be determined from the following values: V = 50mph R = 500m E = 100mm From equation 3 using a rate of change of cant of 35mm/sec we can calculate TL using either Ea or D whichever is greater. From the example worker in section 2 it can be seen that Ea is the critical factor here. 35 = Ea x V 3.6 x TL TL = Ea x V 35 x 3.6 = 100 x (50 x 1.609) 35 x 3.6 TL = 63.84m It would be usual to round this to the nearest 5m to make it a ‘tidy’ length. Therefore TL = 65m Check this for gradient limits using equation 2 Egrad = 1 in 65/0.1 ( units in m) Egrad = 1 in 650 This is within the limits as outlined above and is acceptable. - 9 – Copyright – P.J. King A Guide to Permanent Way Design iv. Additional Information i) For curve equations – See TDH pages C2.1 – C2.5 v. Summary a. The elements in horizontal alignment are straights and circular curves, they can be linked with transitions. b. The applied cant is a factor of the square of the speed divided by the track radius. c. Cant is always designed with a deficiency. d. Transitions are fixed by their length and are determined by the rate of change of cant or deficiency and cant gradient. vi. References a. Design Methods – MX Rail Bentley Railtrack Hallade – See section 1F b. Standards Factors concerning speed, cant and transitions are shown in the TDH section B. For mathematical formulae regarding curves and transitions see section C of this document. ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ - 10 – Copyright – P.J. King A Guide to Permanent Way Design Vertical Profile Design To accompany any horizontal track design a vertical profile will be needed.