D3.1.1 – Review of existing practices to improve CAPACITY4RAIL capacity on the European rail network SCP3-GA-2013-605650 Design requirements, concepts and prototype test results (final) Submission date: 30/09/2017 Public deliverable D 11.3 D11.3 – Design requirements, concepts and CAPACITY4RAIL prototype test results (final) SCP3-GA-2013-605650 2017-09-30 Lead contractor for this deliverable: • ACCIONA Project coordinator • International Union of Railways, UIC www.Capacity4rail@eu CAPACITY4RAIL PUBLIC Page 2 D1.1.3 – Design requirements, concepts and CAPACITY4RAIL prototype test results (final) SCP3-GA-2013-605650 2016/09/30 Executive Summary This report is the third deliverable for Work Package 1.1 under Sub-Project1 (SP1) of the Capacity4Rail (C4R) project. The aim of this deliverable is to present the 2 new slab track concepts that address the general objectives of the project, i.e. an affordable, adaptable, automated, resilient and high capacity railway infrastructure. To that extent, the deliverable documents the structural and functional design, describes the developed installation and maintenance procedures and presents the results of the studied business cases. Additionally, as both concepts were prototyped, installed full-scale in the CEDEX railway section testing facilities and tested, the deliverable strives to describe the unexpected difficulties and conclusions related to the installation procedure extracted from the prototype construction, record the parameters and particularities of the tests performed on the prototypes and present the analysis of the data recovered during the testing. In Section 3, the deliverable recaps the general requirements for designing an innovative slab track concept. These requirements are mainly based on the feedbacks from current operated slab track systems. A special attention is paid for construction costs and maintenance costs requirements in order to design a financially more attractive product. Section 4 provides a detailed geometric description of both slab track concepts, as well as a general overview of the structural and functional design process, including the most relevant features of the FE models and a general approach to the results Section 5 and 6 describe the component fabrication process, system installation procedure and foreseen maintenance operations Sections 7 documents the installation, testing procedure and data analysis performed of the two concept prototypes Sections 8 and 9 document the Life Cycle Cost and studied business cases and their most relevant conclusions. CAPACITY4RAIL PUBLIC Page 3 D1.1.3 – Design requirements, concepts and CAPACITY4RAIL prototype test results (final) SCP3-GA-2013-605650 2016/09/30 Table of content Executive Summary ................................................................................................................................. 3 Abbreviations and acronyms ................................................................................................................... 6 1 Introduction ..................................................................................................................................... 7 2 Objectives ........................................................................................................................................ 8 3 Requirements .................................................................................................................................. 9 3.1 Geometrical requirements ...................................................................................................... 9 3.2 Mechanical requirements ....................................................................................................... 9 3.3 Environmental requirements ................................................................................................ 10 3.4 Construction requirements ................................................................................................... 11 3.5 Maintenance requirements ................................................................................................... 12 3.6 Cost requirements ................................................................................................................. 12 3.7 Operational/safety requirements ......................................................................................... 13 4 Novel Slab Track concepts ............................................................................................................. 14 4.1 Concept inception ................................................................................................................. 14 4.2 Geometric and functional description .................................................................................. 17 4.2.1 Moulded Multi Modular Block system .......................................................................... 17 4.2.2 L-Track System ............................................................................................................... 22 4.3 Detailed design of the selected concepts.............................................................................. 25 4.3.1 Design and dimensioning of the 3MB concept ............................................................. 26 4.3.2 Design and dimensioning of the L-track concept .......................................................... 57 5 Construction procedure ................................................................................................................ 80 5.1 3MB Concept: Construction procedure ................................................................................ 80 5.1.1 General procedure for the construction of the 3MB system ........................................ 80 5.1.2 Stages for the 3MB system construction ...................................................................... 80 5.2 L-Track Concept: Construction procedure ............................................................................ 88 5.2.1 General procedure for the construction of the LT system ............................................ 88 5.2.2 Stages for the L-Track system construction .................................................................. 88 6 Maintenance.................................................................................................................................. 95 6.1 Overview of maintenance aspects ........................................................................................ 95 6.2 Maintenance operations in slab track ................................................................................... 95 6.3 Maintenance analysis to slab track systems. ........................................................................ 96 6.4 Defects identified .................................................................................................................. 97 6.5 General procedure for the maintenance of the 3MB system ............................................... 98 CAPACITY4RAIL PUBLIC Page 4 D1.1.3 – Design requirements, concepts and CAPACITY4RAIL prototype test results (final) SCP3-GA-2013-605650 2016/09/30 6.5.1 Overview ........................................................................................................................ 98 6.5.2 Preventative maintenance ............................................................................................ 98 6.5.3 Corrective maintenance ................................................................................................ 99 6.6 General procedure for the maintenance of the LT system ................................................. 100 6.6.1 Overview ...................................................................................................................... 100 6.6.2 Preventative maintenance .......................................................................................... 100 6.6.3 Corrective maintenance .............................................................................................. 101 7 Testing and prototyping .............................................................................................................. 102 7.1 3MB Tests ............................................................................................................................ 102 7.1.1 Introduction ................................................................................................................. 102 7.1.2 Description of the experimental section ..................................................................... 102 7.1.3 Instrumentation installed ............................................................................................ 102 7.1.4 Tests performed .......................................................................................................... 103 7.1.5 Results obtained .......................................................................................................... 104 7.2 L-TRACK Tests ...................................................................................................................... 105 8 Life Cycle Cost .............................................................................................................................. 106 8.1 Construction costs ............................................................................................................... 106 8.1.1 Estimation of manufacturing costs for the 3MB System. ............................................ 107 8.1.2 L-Track construction