Case Study Berlin to Cottbus Line (DE) Eficient vibration protection for adjacent buildings with an increase in train speeds Specially developed polyurethane sleeper pad with effective acoustic damping World’s largest railway project using sleeper pads for vibration protection Berlin-Cottbus Description of the project The Getzner Solution Development of the Berlin-Cottbus Padded railway sleepers as protec- Product development in close railway line tion against vibrations cooperation n 2010 Deutsche Bahn (DB) up- Getzner worked closely with DB to Getzner developed the new sleeper Igraded the heavily used railway line develop a special polyurethane slee- pad which was designed to suit the between Berlin and Cottbus, which per pad with effective acoustic dam- Berlin-Cottbus line in close cooper- lies in the county of Brandenburg. ping for the Berlin-Cottbus line. The ation with DB‘s Technology and Acous- Following the southerly section of pad was designed within the scope of tics Department in the course of the the Berlin-Cottbus line, the middle the research project “Quiet train on LZarG research project. The solution section of the route was also up- real track” (LZarG) which was aimed reached production stage and ulti- graded to allow trains to run on it at at developing new technologies for mately received approval by DB higher speeds. The entire railway track lower-noise railway trafic. The PUR Technology. structures were replaced along a 60 mats dampen the vibrations of trains km long section between the spring as they pass through built-up areas. While the R&D work was in process, and autumn of 2010. The challenge Getzner had the product tested at the facing us in this project was to provide The new pad has been specially tail- Technical University of Munich. Those buildings in close proximity to the ored to meet the requirements of tests have conirmed the high quality track with eficient protection against these projects. “DB already had good and durability of the product. “We vibrations, despite the faster train experience of working with us before conducted a rigorous series of tests in travel which had been planned. we embarked upon this major project. a very short time. We now have a well- Faith in our expertise and in our ability engineered, highly resilient product in What is more, in order to keep this to deliver the right product were key use. In addition, compared to extensive project on budget and on to securing the order. So far, Berlin- schedule, the complete track structure Cottbus has been the biggest railway could not be removed. Since the com- project of its kind in the world in- pletion of the construction work, the volving the use of sleeper pads to track which was previously designed protect against vibrations. All in all, to accommodate a top speed of some 52,000 sleepers and 17 points 120 km/h can now be used by trains were itted with pads made from our travelling at speeds of up to 160 km/h material,” pointed out Christian and at greater frequency, without Dullinger, project manager of the Rail causing additional structural stress Division at Getzner‘s plant in Grünwald due to vibrations or noise. near Munich, emphasising the signif- icance of this major project. By using sleeper pads, specialists were able to integrate the vibration protection without completely removing the track structure. Feedback conventional solutions, the sleeper scale, this project provided us with What does the sleeper manufacturer pads also boast longevity on account valuable experience, which will bene- have to say about the project? of the improved way in which they are it our clients in future projects.” connected,” said Christian Dullinger, “The cooperation with the Getzner summing up the special features of Given the high production capacity team was exemplary. The quality of the major order. utilisation, the new elastic layer for the pads for the sleepers was con- the sleepers was produced at the sistently high and enabled us to afix Just-in-time logistics Getzner plant in Bürs under great time them to our concrete sleepers with- pressure and under the most stringent out any trouble. Deliveries were Dullinger described how “this order quality controls. Liaising closely with excellently coordinated: they arrived presented a big challenge for project the company that manufactures on time and in the agreed volume.” management, quality management, the sleepers, Getzner delivered over production and logistics – around 30 50,000 pads to Frankfurt and to people worked on its successful Neumarkt in der Oberpfalz between Gundolf Spitzner, implementation.” Finally he stated June and September 2011. They were Head of European Sales, that “Volumes of this great magnitude then afixed to the sleepers at Rail. RAIL.ONE GmbH create high demands: Not only did One‘s two plants. As this then meant we manage to coordinate the internal that sleepers could be delivered to processes excellently, we were also the track with the pads already in able to coordinate the timing of the place, which made installation quick manufacturing of the sleepers and and straightforward. pads with our customers on site to great effect. By virtue of its sheer Germany Poland Berlin Getzner created pads for Brandenburg 50,000 sleepers along a sec- Königs Wusterhausen tion of over 60 km between Königs Wusterhausen and Lübbenau Lübbenau. Cottbus Leipzig Dresden 50 km Czech republic Facts and igures at a glance Berlin-Cottbus line Long upgrade section between Königs Wusterhausen and Lübbenau: around 60 km Target speed: up to 160 km/h Order details Scope of the order: Pads for around 50,000 sleepers and 17 points Client: Deutsche Bahn AG Project manager: Dipl.-Ing. Dipl.-Wirtsch.Ing. Christian Dullinger Completion: Autumn 2011 Sleeper manufacturer: RAIL.ONE GmbH Construction company: Eiffage Rail GmbH Data and facts regarding Getzner Werkstoffe GmbH Rail references (Extract) Foundation: 1969 (as a subsidiary of Getzner, — Brynsbacken (NO) Mutter & Cie) — Metro Seoul (KR) Chief Executive Oficer: Ing. Jürgen Rainalter — Metro Amsterdam, Eastern Line (NL) Employees: 340 — Bruchsal Tunnel (DE) 2015 turnover: EUR 77.9 million — Matstetten-Rothrist (CH) Business areas: Railway, construction, industry — Umegaoka-Odakyu Electric Railway (JP) Headquarter: Bürs (AT) — Britomart Station (NZ) Locations: Berlin (DE), Munich (DE), Stuttgart (DE), — Northern approach line to the Brenner Lyon (FR), Amman (JO), Tokyo (JP), Base Tunnel (AT) Pune (IN), Beijing (CN), Kunshan (CN), Charlotte (US) Ratio of exports: 85 % CS BC en © Copyright by Getzner Werkstoffe GmbH | 07-2016 Werkstoffe Getzner by en © Copyright BC CS AUSTRIA — Bürs GERMANY — Berlin — Munich — Stuttgart FRANCE — Lyon JORDAN — Amman JAPAN — Tokyo INDIA — Pune CHINA — Beijing USA — Charlotte www.getzner.com .