Railway Track Manual Part 1

8/10/2019 Railway Track Manual Part 1

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Content

Preliminary Preface for the second Page: 000-01remark edition

Without scale/schematic diagram

Date of issue 08/10

Preface for second edition

The Railway Track manual is now available, the second edition of it was first publishedin December 2004. Completely revised and expanded, this comprehensive reference book

provides up-to-date information about the railway track.

A compendium of the practice for the practice. It focuses on the application and provides empiricalknowledge on types of track systems and materials, especially about

Rails, Barriers, Turnouts, Fasteners as well as Other accessories

As a Q1-supplier of the Deutschen Bahn AG and as a system provider with a decades

of gathered experience, we hereby put all our expertise on the complete railway track.

We are therefore confident to provide you with Railway Track Manual valuable services for your work.


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Content Preliminary Instructions for use Page: 000-02remark


Date of issue 08/10

Instructions for use

The department of Planning and Development of ThyssenKrupp GfT Gleistechnik GmbHhas created a manual for you, which represents the current state of engineering. All

content has been reviewed by our colleague for accuracy and timeliness.However they do not replace the critical review done by an experienced expert. Thereforewe do not take any responsibility for the issue.

In case you come across with something on our Railway Track Manual thatrequires correction or amendment, please contact us. Your contact person atThyssenKrupp GfT Gleistechnik GmbH, Dr.-Ing. Siear Qaimi gladly welcomes yoursuggestions and contrary comments.

Contact:Dr.-Ing. Siear Qaimi

Tel.: +49 234 9114-541Fax: +49 234 9114-316E-Mail:[email protected]

We look forward to working with you.
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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Content Preliminary Addresses, sales offices Page: 000-03remark and engineering


Date of issue 08/10

SALES

Regional office Location of sales

NorthVahrenwalder Str. 205

D-30165 HannoverPhone: +49 511 6703-25Fax: +49 511 6703-37

Waidmannstrae 26

D-22769 HamburgPhone: +49 40 85340-700Fax: +49 40 85340-701

WestHollestr. 7aD-45127 EssenPhone: +49 201 844-563745Fax: +49 201 844-563750

EastRotherstr. 7D-10245 Berlin

Phone: +49 30 628901-15Fax: +49 30 628901-20/-21

An der Kreuzkirche 6D-01067 Dresden

Phone: +49 351 4902040Fax: +49 351 4902480

Humboldtstr. 3D-04105 Leipzig

Phone: +49 341 6017054Fax: +49 341 6017055

VertriebsbereichWaggonausrstungRotherstr. 7D-10245 Berlin

Phone: +49 30 628901-15Fax: +49 30 628901-22

SouthFrstenrieder Str. 267D-81377 MnchenPhone: +49 89 7871-300Telefax: +49 89 7871-343

South-WestWeilimdorfer Str. 74/2D-70839 GerlingenPhone: +49 7156 430730Fax: +49 7156 430740

Dortmunder Str. 2D-68219 MannheimPhone: +49 621 8906-120/-121Fax: +49 621 8906-122

EXPORT SALES

ExportHollestr. 7aD-45127 EssenPhone: +49 201 844-563764Fax: +49 201 844-563757

MRT Track &Services Co., Inc.270 Broad Street07003 Bloomfield NJ-USAPhone: +1 973 748-8899Fax: +1 973 748-9243

ThyssenKruppGfT Polska Sp. z o.o.Al. Slowackiego 6630-004 Krakw PolandPhone: +48 12 6204130Fax: +48 12 2677548

MANUFACTURING PLANT

HolzschwellenwerkAm Bahnhof 2D-29393 Gro OesingenPhone: +49 5838 9905-0Fax: +49 5838 9905-79

ThyssenKruppWeichenbauObere Stahlindustrie 4D-44793 BochumPhone: +49 234 9114-343Fax: +49 234 9114-557

BetriebIndustrieweichenAm Wasserturm 3bD-06869 Coswig/AnhaltPhone: +49 34903 4741-0Fax: +49 34903 4741-20

Betrieb SpannmittelAm Wasserturm 3bD-06869 Coswig/AnhaltPhone: +49 34903 4741-0Fax: +49 34903 4741-24

ThyssenKruppLangschienenLadestr. 8D-39175 KnigsbornPhone: +49 39292 6958-17Fax: +49 39292 6958-20


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Content Preliminary Information service Page: 000-04

remark


Date of issue 08/10

This information service serves exclusively the function, modifications, amendments and otherimportant informations on the Railway Track manual if required and to transfer to the interestedindividuals and companies in a defined time. It is notused for sending of advertisements, informationsheets or the similar! Of course, your data will be kept confidential and not disclosed to third parties.

Data exchange takes place exclusively via e-mail.

To participate in the information service please fill in the following fields below and send this page byfax to +49 234 9114-316or email to [email protected]. The required fields aremarked with *.

Alternatively you may also register under www.tkgftgleistechnik.deand keep yourself updated.

REGISTRATION FOR INFORMATION SERVICE

Company*:

Contact partner*:

Street:

Place:

Tel.No.

E-Mail*:


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Railway Track Table of contents Preface, Table of contents, Page: 000-11

Manual Railway Track terms


Date of issue 08/10

000-00 Preliminary remark

000-01 Preface for second edition000-02 Instructions for use

000-03 Addresses of sales office and engineering000-04 Information service

000-10 Table of contents

000-11 Preliminary remark, Table of contents, General terms of tracks000-12 Types of track systems000-13 Vibration-damping rail bedding000-14 Slab track / Crane and depot tracks000-15 Special constructions / Track materials000-16 Turnouts / Crossings / Rail expansion joints000-17 Track accessories

000-20 General Railway Track terms

000-21 Development, Railway Track, Classification000-22 Gauge of the track, Gauge widening000-23 Track distance000-24 Overview of various standards and regulations000-25 Overview of various standards and regulations (Continued)000-26 Track system abbreviations000-27 Track system abbreviations000-28 Thanks


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Railway Track Table of contents Types of track systems Page: 000-12

Manual


Date of issue 08/10

100-00 Types of track systems

110-00 Standard variants110-01 Overview

111-00 Variant W 3 - Concrete sleepers111-01 W 3 - 60E2 made of concrete sleeper111-02 W 3 - Width of the rail flange 125 mm made of concrete sleeper B70/B90

112-00 Variant W 14 - Concrete sleepers112-01 W 14 - 60E2 made of concrete sleeper112-02 W 14 - Width of the rail flange 125 mm made of concrete sleeper B70/B90

113-00 Variant K - Concrete sleeper113-01 K - Width of the rail flange 125 mm made of concrete sleeper

114-00 Variant K - Wood sleepers114-01 K - 60E2 made of wood sleepers114-02 K - Width of the rail flange 125 mm made of wood sleeper

115-00 Variant KS-H - Wood sleepers115-01 KS-H - 60E2 Wood sleeper115-02 KS-H - Width of the rail flange 125 mm wood sleeper

116-00 Variant KS-St - Steel sleepers116-01 KS-St - 60E2 made of steel sleeper116-02 KS-St - Width of rail flange 125 mm made of steel sleeper116-03 KS-St-Iso - 60E2 made of steel sleeper116-04 KS-St-Iso - Width of rail flange 125 mm made of steel sleeper

117-00 Variant Y-Steel sleepers117-01 Rail fastening S15 made of Y-Steel sleeper

118-00 Variant grooved rails with guardrail118-01 Installation views 59R1, 59R2, 60R1, 60R2118-02 Installation views 57R1, 67R1, Ph 37N118-03 Guardrail details118-04 Material requirement / 15 m118-05 Indoor track 57R1 made of situ-concrete plate

119-00 Variants Vossloh / ThyssenKrupp119-01 System W 3 - Standard for Concrete sleepers119-02 System W 14 - Standard for Concrete sleepers119-04 System E14 / E21 - Highly elastic for Concrete sleepers119-06 System 300 - for Slab track119-08 System KS - for ribbed base plates119-09 System W-Tram - with Wedge angle plates119-10 System W97 - for reground concrete sleepers


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Railway Track Table of contents Vibration-damping Page: 000-13

Manual rail bedding


Date of issue 08/10

120-00 Vibration-damping rail bedding

120-01 Overview of rail bedding

121-00 Continuous rail bedding121-01 ThyssenKrupp Railflex

121-02 ISOLast121-03 ThyssenKrupp Flexpoint121-04 Whisper rail121-05 Railcover121-06 VIBRALast121-07 Highly elastic grooved rail turnouts121-08 Potting material Powerflex121-09 ThyssenKrupp Flattrack

122-00 Discrete rail bedding

122-01 Delta stock122-02 Krupp ECF-System122-03 EASYLast122-04 TK 99 / TK 99 S122-05 TK07-R122-06 TK 04-R122-07 Ei-attachment122-08 Acoustical Loadmaster


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Railway Track Table of contents Slab track Page: 000-14

Manual Crane and depot tracks


Date of issue 08/10

130-00 Slab tracks

131-00 NFF (New slab tracks)131-01 General131-03 Engineering structure131-04 Schematic construction cycle

132-00 NBU (Naumburg Bauunion)132-01 Introduction132-02 Schematic construction cycle

140-00 Crane and depot tracks

141-00 Crane runways141-01 MX-System

141-02 MX-System description141-03 MX-System screwed141-04 MX-System welded141-05 MX-System discontinuous rail bedding141-06 MXA-System discontinuous rail bedding141-07 MX-System continuous rail bedding141-08 MXA-System continuous rail bedding141-09 MX-Bottom casting141-10 Surveying System Railcontrol141-11 Crane runway beams

142-00 Railroad depot

142-01 Rail support point for side track and wash tracks142-02 Rail fastening on working pits142-03 Rail fastening on steel colum


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Railway Track Table of contents Special constructions Page: 000-15

Manual Track materials


Date of issue 08/10

150-00 Special constructions

151-01 Guardrail

152-01 Guide rails153-01 Rut rails

200-00 Track materials

210-00 Rails211-01 Overview of commonly used track types212-01 Flange rails213-01 Grooved rails214-01 Crane rails Form A214-02 Crane rail AS 86214-03 Crane rails bevel cuts215-01 Special sections216-01 Rails for crossings and turnouts217-01 Perforation plates Rail perforation

220-00 Sleepers221-01 Y-Steel sleepers222-01 Pre stressed concrete sleepers223-01 Wood sleepers224-01 Steel sleepers225-01 Steel bridge sleepers SBS

230-00 Ironmongery and accessories231-01 Fastening clamping plates232-01 Fastening rib based plates232-02 Rib based plates for guide rails233-03 Rib based plates for guide rails and supporting rails233-01 Screw sleeper screws233-02 Screw hook screws234-01 Plastic screw anchor235-01 Plastic spacer plate236-01 Discs and spring lock washer


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Railway Track Table of contents Turnouts / crossings / Page: 000-16

Manual Rail expansion joints


Date of issue 08/10

300-00 Turnouts and crossings

300-01 Preface

300-02 General switch description

310-00 Switch311-01 Switch description312-01 Types of switches / Split locking plans for Vignol- and Ph 37a Switch313-01 Tram railed grooves314-01 Tables315-01 Layout plan according to VDV track 1435, system of units C316-01 Turnout definition317-01 Turnout parts318-01 Turnout accessories319-01 Changeover system

320-00 Crossings, EKW, DKW321-01 Turnout parts322-01 Crossing variant LSH, Linear slidable centrepiece

330-00 Rail expansion joints331-01 Flange rails332-01 Grooved rails


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Railway Track Table of contents Track accessories Page: 000-17

Manual


Date of issue 08/10

400-00 Track accessories

411-00 De-watering boxes

411-00 Overview411-01 for grooved rail variant "DENA"411-04 for grooved rail variant "RIECKEN"411-06 for vignol rail variant "DENA"411-07 for elastic rail bearings whisper rail

412-00 Track endings412-01 General412-02 Overview of the variants412-03 Buffer stops

413-00 Plastic cable channel413-01 DRAE - KA413-02 AU KA

414-00 Insulated splicing414-01 MT-Insulated splicing rail foot width 125 mm414-02 MT-Insulated splicing 60E2414-04 MT-Insulated splicing 60E2 increased414-05 MT-Insulated splicing rail foot width 125 mm increased414-06 Transition 49E5 to 54E4

415-00 Railway plates

415-01 Other signals415-03 Speed limit signal415-04 Signal for electrical traction415-05 Additional signal at home signal415-06 Signal for shunting operation415-07 Turnout signal


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Content General Railway Development, Railway Page: 000-21Track terms Track, Classification


Date of issue 08/10

Formation of rail formsThe tracks should take the wheel load and transferred to the sleepers. They should also run thewheel and have a levelled railway. To reach present level, the rail profile has gone through various

stages of development.

From the variety of rail forms, the wide foot rail, today called vignol rails consists of head, base andfoot. The rail is symmetrically shaped in cross section. The rail cross section is designed due to theextensive experience and detailed considerations on today's valid profiles. The resisting torque andcarrying capacity of the rail is determined primarily by their height and weight as an I-beam. It is therolling friction of the wheels of the vehicle and thus exposed to material wear. The rail should remain

only up to a certain degree of wear and tear on the track.Railway trackThe route for railway vehicle is to be understood under railway track. The Railway track includes:

die tracks, turnouts and crossings, the concrete as well as the sub-structure

Classification of tracks and turnoutsThe tracks and turnouts are divided according to operational and railway track technical aspects.

1. Operational aspects: Differentiation between the tracks and turnouts according to main and sidetracks. Main tracks are scheduled traffic tracks of the trains. Main tracks of the free routes andcontinued through the stations are known as continued main tracks. All other tracks are sidetracks.

2. Railway track technical aspects: The tracks and turnouts are divided in 3 orders according tooperating characteristics and specially in

1. Order: strong mode, high travelling speeds and large axle loads2. Order: moderate strong operation and slower travelling speeds without regard to the

axle loads

3. Order: weak operation, slower travelling speeds.


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Content General Railway Gauge of the track , Page: 000-22Track terms Gauge of the track


Date of issue 08/10

Gauge of the track

The gauge of the track is the smallest distance between inner surfaces of the rail heads in the range

of 0-14 mm below rail level.The basic size of the gauge of the track is 1435 mm.

Deviations from the basic size of the gauge of the track are allowed. Thus, for example turnouts fornon-federal railways (NE-turnouts) can also be prepared with a basic gauge of 1432 mm.

The gauge of the track in any case must not be smaller than 1430 mm and - also includingcurve radius of the required extension -not more than 1465 by main line and 1470 mm by loop lines.

The gauge of tracks in rail and turnout curve parts with radius less than 240 m must not fall belowthe following values:

Radius of the rail curve parts (m) The minimum size of the gauge of track (mm)

under 175 to 150 1435

under 150 to 125 1440

under 125 to 100 1445

Gauge widening

A) Federally owned railway capital

Radius of the rail curve parts (m) manufactured gauge of track (mm)under 175 to 150 1440

under 150 to 125 1445

under 125 to 100 1450

The gauge of the track in turnouts is set in the control drawings (low).Standard turnout 54E4 and 60E2 for railway tracks DB AG have no gauge widening.Turnouts with 49E5 rails and diverging track radius from 150 to 190 m have 6 mmgauge widening.

B) Non-federally owned railway capital

Radius of the rail curve parts (m) manufactured gauge of track (mm)

under 190 to 140 1440

under 140 to 100 1445

The gauge widening in rail curve parts is to be produced by impressions of the inner stand in steps of5 mm. The length of a step in each case is 5 sleeper fields. Before the first stage with a track gaugefrom 1440 mm, 5 sleepers with a track gauge of 1435 mm.


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Content General Railway Railway Track distance Page: 000-23Track terms


Date of issue 08/10

Track distance

1.) Standard gauge railway

The usual track distance is according to EBO for new buildings on free routes in curved parts with a

radius of 250 m and in the line of 4, 00 m. This measure applies to speeds > 160 km/h to 200 km/h.The dimension refers to the distance from rail centre to rail centre.

In rail curves with radius of 250 m, the rail distance must be enlarged according to EBO 10.

Curve radius Increased distance by:

250 m 0 mm

200 m 115 mm

150 m 300 mm

For existing attachments, the track distance at right operation must be even less than 4.00 m.The minimum track distance for existing plants according to EBO 10(1) is 3.50 m.On diverging track routes, the reverse to be driven in right operation and whose tracks have adistance of 3.50 m, no security space exists for adjacent track. It is just barely a measure for minimumclearance. During structural alteration works, the desirable track distance for these plants is 4.00 m.Should this not be possible for compulsory reasons, exceptionally a distance of 3.75 m and 4.00 mcan be permitted.

The distance between track pairs or a track pair and a third track should be minimum 4.50 m. Forbetter security of rail staff during maintenance work on the inner tracks and possibly to store buildingmaterials on inner tracks, the track distance possible should be 5.40 m.

The required track distance apart from over loaded tracks should be at least 4.50 m, with new

buildings at least 4.75 m and with intermidiate platform at least 6.00 m.2.) Track distance from narrow gauge lines of general traffic:

A) On the free routes and on loading tracks:

Track gauge 600 mm 2,100 mm Track distance




B) At stations apart from loading tracks:Track gauge 600 mm 3,000 mm Track distance




For increasing the track distance in curved parts with narrow gauge rails there are special guidelines.The dimensions are given in the appropriate tables.


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Content General Railway Overview of different Page: 000-24Track terms Standards and regulations


Date of issue 08/10

Overview of various standards and regulations:DIN / BN / TL / UIC Kodex / DS/RIL

Name DIN BN/TL UIC Kodex DS/RilLock washer made of steel forRailway track 918 006 864-3 V

Clamping plates rolled 5906 918 025

Crane rails form F 536/2

Crane rails with bottom flange A 536/1

Plastic material for railway tracks 918 280Brief description of the railway tracksystems 820.0101Tabs for groove lessbottom rails 5902

Fish bolts withSlotted round head / Oval neck 5903/1Fish bolts withSquare head 5903/2Railway tracks, basics,General, guidelines 820.0101

Rising height in track curves 820.3030

Guide rail; Release planned EN 13674-3 918 168Standard gauge railways,Railway track recommended practice 820.01Rails,Flash butt welded, newand reground 918 255

Rails, General 820.2120Rails, bottom rails (olddescription) Profile S 10, S 14,S 18, S 20, 33E1, 41E1, 49E5 EN 136741Rails, for turnouts and crossings,in connection with vignolused from 46 kg/m;Release planned EN 13674-2 918 254 860 V

Rails, 30E1 and fish plates Fl 30 20501

Rails, Bus bars made of steel 17122

Rails, use 820.2121Rails, Vignol rails 27 kg/mup to under 46 kg/m;Release planned EN 13674-4

Rails, Vignol rails from 46 kg/m EN 13674-1 918 254 860 V

Rail expansion joints, arrangement of 820.0134


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Content General Railway Overview of different standards Page: 000-25Track terms and regulations (Cont.)


Date of issue 08/10

Overview of various standards and regulations:DIN / BN / TL / UIC Kodex / DS/RIL (continuation)

Name DIN BN/TL UIC Kodex DS/Ril

Rail base plate made of rolled steel 864-6 V

Sleepers 820.0105

Sleepers, wood, non-impregnated 918 144 863 V

Sleepers, prestressed concrete 918 143

Sleepers, steel 918 123

Sleeper screw 918 024-1 864-1 VRail clamps, rail nailsClamping yoke 918 127Track gauge and rail cantStructure of rails 820.2110

Steel upper wall screws 918 024-2

Butt plate made of rolled steel 864-4 VTurnouts and crossings,Technical foundation forcomplete tracks 820.0142Turnouts, crossings andCrossover made of wood andsteel sleepers 918 120Turnouts, crossings andRail expansion joint,Heat treated components 918 142Intermediate layers of rubber

Driveway 918 234Intermediate layers, elastic 918 235

Intermediate layers, under rails 864-5 V


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Content General Railway Railway Track abbreviations Page: 000-26Track terms


Date of issue 08/10

Railway track-Abbreviations

ABS Upgrade of existing line

ATD Asphalt-base course with directly stored sleepersATS Asphalt-base courseAz Obv Appendix additional provision for railway track specificationsB Concrete sleeperBN Railway standardBTD Concrete-base course with directly stored sleepersBTS Concrete base courseBZA Central Office of the German Federal Railways of the former German Federal RailwaysCEN European Committee for StandardisationDB AG German National Railway CompanyDIN German Institute for StandardisationDKW Double-slip diamond crossing

Dann Double clamping nailDS LeafletEBA German federal railway organisationEBO Railway engineering- and work rulesEi Insulating insert (in turnouts: Arch support - Ei = Anti-creep device)EN EurocodeEW Standard turnoutFe Spring lock washerFF Slab tracksFl Fish platesFsch Flexible rail switch-turnoutFSS Anti-freeze layer

Fz Flexible switch-turnoutGrp Base plateGz Pivoted heel-turnoutH Wood sleeperHGT Hydraulically bound base courseHGV High speed trafficHs Hook screwsISO International organisation for standardisationKp Clamping plateKS Crane railKsp Clamping track plateLfB Country representative for rail road supervision

LIS Light industrial sleeperMFS Mass-Spring-SystemN Newton (Measuring unit according to English natural scientist)NBS New upgrade of existing lineObv Railway track specification for standard gauge railwayRi Grooved railRil Directive with modules


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Content General Railway Railway Track abbreviations Page: 000-27Track terms (Continuation)


Date of issue 08/10

Railway Track Abbreviations (Continued)

Rp Ribbed base plate

Rpb Ribbed base plate for concrete sleepersRph Ribbed base plate for wood sleepersRps Ribbed base plate for steel sleepersRsw Ribbed base track plateRus Weldable ribbed base space plateRz Control drawingS RailSbS City rail road tiesSBS Steel beam bridge sleepersSb Clamping yokeSd Sleeper anchorSO Elastic sole of concrete sleepers

SO Rail levelSp Track adjustment platesSs Sleeper screwSt Steel sleeperTBS Tramway sleeperTL Technical delivery conditionUIC Union Internationale de Chemin de Fer (International Union of Railways)UIG Unternehmensinterne Genehmigung (Deutsche Bahn AG)Uls WasherVDV Association of German Transport CompaniesVOB German Construction Contract Procedures

(Before 2002: Contracting rules for award of public works VOB 2000)

WA Start of turnoutWE End of turnoutWfp Angular guide plateYno Y-Normal railYli Y-Transition rail leftYre Y-Transition rail rightZw Intermediate levelZwp Spacer plate


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Content Thanks Page: 000-28


Date of issue 08/10

For their assistance and support in creating this manual, we heartly thank:

A. Rawie GmbH & Co KG 49090 OsnabrckDENA Stahlbau GmbH & Co 49086 OsnabrckDeutsche Bahn AG 60326 Frankfurt am MainDW Schwellen GmbH 39317 GsenElektro-Thermit GmbH & Co KG 06132 HalleGebr. Marmetschke GmbH & Co KG 29393 Gro OesingenHanning & Kahl GmbH & Co KG 33813 OerlinghausenHeinrich Krug GmbH & Co KG 44145 DortmundH.+ R. Riecken Maschinenbau GmbH 49565 BramscheLeonhard Moll Betonwerke GmbH & Co KG 30629 HannoverOrtec Gesellschaft fr schienentechnische Systeme mbH 50668 KlnRail.ONE GmbH 92318 NeumarktSchilderwerk Beutha GmbH 09366 Stollberg OT Beutha

ThyssenKrupp Weichenbau GmbH 44793 BochumTSTG Schienen Technik GmbH 47166 DuisburgVossloh Fastening Systems GmbH 58778 WerdohlWirthwein AG 97993 Creglingen


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Railway tracks Standard variant Overview Page: 110-01


Date of issue 08/10

Overview of Standard variantsCaptive gradient 1:40

Anchor

Sd9

Sd9

Sd9

Sd9

Sd9a

Sd13

D

S15a

Sd25

Sd25

Sd26

Sd25

Sd25

Spring

-

lock

washe

r

Fe6

Fe6

Fe6

Fe6

Fe6

Fe6

Sleeper-

screw

Ss25

Ss25

Ss35

Ss35

Ss8-150

Ss8-150

Ss8-150

Ss8-150

Ss8-150

Ss8-150

Ss8-150

Ss34

Ss36-220

Ss36

Ss36

Ss36

Ss25

Disc/

washer

Uls7

Uls7

Uls7

Uls7

Uls6

Uls6

Uls6

Uls6

Uls6

Uls6

Uls7

Uls7

Uls7

Uls7

Uls7

Uls7

Hook-

sc

rews

Hs26-65

Hs2

6-65

Hs2

6-65

Hs2

6-65

Hs2

6-65

Hs3

2-55

Hs3

2-55

Hs3

2-55

Hs3

2-55

Hs3

2-55

Hs3

2-55

Rail-

fastening

Skl1

Skl1

Skl14

Skl14

Kpo6

Kpo9

Kpo9

Kpo6

Kpo9

Skl12

Skl12

Skl12

Skl12

Skl12

Skl12

Skl14

Skl14/

Skl21

Skl15

Skl14/92v

Skl14

Skl1/97

Plate

Wfp3b

Wfp3b

Wfp14k

Wfp14k

Rpb1

Rpb1

Rph6**

Rph1**

Rph1**

Rph6**

Rph1**

Rps15**

Rps8**

Rps15ia**

Rps8ia**

Zwp192**

WfpE14

Wfp15a

K-Wfp14R

/L

K-Wfp14R

/L

Wfp3b22

Wfp3b-28

Intermediate

leve

l

Zw687

a*

Zw686

a*

Zw700

*

Zw700

*

Zw672

,

Zw691

*

Zw672

,

Zw691

*

Zw661

a

Zw687

*

Zw664

a

Zw686

*

Zw664

a

Zw686

*

Zw661

a

Zw687

*

Zw664

a

Zw686

*

Zw690

*

Zw691

*

Zw697

a*

Zw697

*

Zw401

*

ZwE14

Zw692

*

Zwp104

NT

Zw900

-

180

Zw900

-

180

Zw687

a*

Rail-

gradient

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

1:40

without

without

1:40

Rail

60E2

Railfoot

width125mm

60E2

Railfoot

width125mm

Railfoot

width125mm

Railfoot

width125mm

60E2

Railfoot

width125mm

Railfoot

width125mm

60E2

Railfoot

width125mm

60E2

Railfoot

width125mm

60E2

Railfoot

width125mm

60E2

60E2

60E2

59R1/

60R1

57R1

Railfoot

width125mm

Storage

Concrete

sleeper

Concrete

sleeper

Concrete

sleeper

Concrete

sleeper

Concrete

sleeper

Concrete

sleeper

Woodsleeper

Woodsleeper

Woodsleeper

Woodsleeper

Woodsleeper

Steelsleeper

Steelsleeper

Steelsleeper

withIw16

Steelsleeper

withIw16

Y-Steelsleepe

r

Concrete

sleeper

Slabtrack

Slabtrackwith

Upl180/120

Concrete

sleeer

Concrete

sleeper

Railway

track-

system

W3

W3

W1

4

W1

4

K K K K K Ks

Ks

Ks

Ks

Ks-iso

Ks-iso

S15

E14/

E21

Sytem

300

W-Tram

W-Tram

W9

7

Page

111-01

119-01

111-02

112-01

119-02

112-02

113-01

113-01

114-01

114-02

114-02

115-01

119-08

115-02

119-08

116-01

116-02

116-03

116-04

117-01

119-03

119-06

119-09

119-09

119-10


22/167

Railway track Standard variant W3 60E2 Page: 111-01systems Concrete sleeper B70 / B90


Date of issue 08/10

Tightening torque 200 Nm

6 1 Intermediate level Zw 687a5 2 Plastic dowel Sd 9

4 2 Angular guide plate Wfp 3b

3 2 Rail clamps Skl 1

2 2 Sleeper screws with track Ss 25 with Uls 7

1 1 Rail 60E2

Pos.Number/Support

pointDesignation Brief description


23/167

Railway track Standard variant W3 - Width of rail flange Page: 111-02systems 125 mm / Concrete sleeper


Date of issue 08/10


6 1 Intermediate level Zw 686a5 2 Plastic dowel Sd 9




1 1 Rail 49E5 or 54E4

Pos.Number/Support



24/167

Railway track Standard variant W 14 - 60E2 Page: 112-01systems Concrete sleeper B70 / B90


Date of issue 08/10


6 1 Intermediate level Zw 7005 2 Plastic dowel Sd 9

4 2 Angular guide plate Wfp 14k



1 1 Rail 60E2

Pos.Number/Support



25/167

Railway track Standard variant W14 - Width of rail flange Page: 112-02systems 125 mm / Concrete sleeper


Date of issue 08/10


6 1 Intermediate level Zw 700

5 2 Plastic dowel Sd 9




1 1 Rail 49E5 or 54E4

Pos.Number/Support



26/167

Railway track Standard variant K - rail flange width Page: 113-01systems 125 mm / Concrete sleeper


Date of issue 08/10

9 1 Intermediate level Zw 672 or Zw 691

8 2 Plastic dowel Sd 9a

7 2 Hexagonal nut DB M22

6 2 Clamping plateKpo 6 (49E5)Kpo 9 (54E3)

5 2 Hook screws Hs 26-65

4 1 Ribbed base plate Rpb 1

3 4 Spring lock washer Fe 6

2 2 Sleeper screws Ss 8-150

1 1 Rail 49E5 or 54E4

Pos.Number/Support


Tightening torque 180 - 250 Nm


27/167

Railway track Standard variant K - 60E2 Page: 114-01systems made of wood sleeper


Date of issue 08/10


8 1 Intermediate level Zw 661a or Zw 687


6 2 Clamping plate Kpo 9

5 2 Hook screws Hs 26-654 1 Ribbed base plate Rpb 6



1 1 Rail 60E2

Pos.Number/Support



28/167

Railway track Standard variant K - Width of rail flange Page: 114-02systems 125 mm made of wood sleeper


Date of issue 08/10




6 2 Clamping plateKpo 6 (49E5)

Kpo 9 (54E3)5 2 Hook screws Hs 26-65




1 1 Rail 49E5 or 54E4

Pos.Number/Support



29/167

Railway track Standard variant KS - H - 60E2 Page: 115-01systems made of wood sleeper


Date of issue 08/10




7 2 Washer Uls 6






1 1 Rail 60E2

Pos.Number/Support



30/167

Railway track Standard variant KS - H - Width of rail flange Page: 115-02systems 125 mm made of wood sleeper


Date of issue 08/10



8 2 Rail clamps Skl 127 2 Washer Uls 6






1 1 Rail 49E5 or 54E5

Pos.Number/Support



31/167

Railway track Standard variant KS - 60E2 Page: 116-01systems made of Y-Steel sleepers


Date of issue 08/10




5 2 Washer Uls 6




1 1 Rail 60E2

Pos.Number/Support



32/167

Railway track Standard variant KS - Width of rail flange Page: 116-02systems 125 mm made of steel sleepers


Date of issue 08/10




5 2 Washer Uls 6




1 1 Rail 49E5 or 54E4

Pos.Number/Support



33/167

Railway track Standard variant KS - St - Iso - 60E2 Page: 116-03systems made of Y-Steel sleepers


Date of issue 08/10


8 1 Intermediate level Zw 697a

7 2 Insulating insert Iw 166 2 Rail clamps Skl 12

5 2 Washer Uls 6



2 1 Ribbed base plate Rpb 15 ia

1 1 Rail 60E2

Pos.Number/Support



34/167

Railway track Standard variant KS -St - Iso - Rail foot width Page: 116-04systems 125 mm made of steel sleeper


Date of issue 08/10


8 1 Intermediate level Zw 697a7 2 Insulating insert Iw 16


5 2 Washer Uls 6



2 1 Ribbed base plate Rpb 8 ia

1 1 Rail 49E5 or 54E4

Pos.Number/Support



35/167

Railway track Standard variant Rail fastening S15 Page: 117-01systems made of Y-Steel sleepers


Date of issue 08/10


9 1 Spacer plate Zwp 192 (or Zwp 193)


7 2 Clamping dowel D S 15

6 1 Guide plate (outside) Fpa 155 1 Guide plate (inside) Fpi 15


3 2 Washer Uls 7

2 1 Sleeper screws Ss 34

1 1 Rail 60E2 (49E5 / 54E4)

Pos.Number/Support



36/167

Railway track Grooved rail Installation views 59R1 / Page: 118-01systems with guardrail 59R2 / 60 R1 / 60 R2


Date of issue 08/10

Track 1435/1000

Correction plates

2 and 3 mm thick

Splice jointGuardrail perforation ovalholes only for steel grade 700

Welding joint

750 for 15 and 18 m rails

Endperforation


37/167

Railway track Grooved rail Installation views Page: 118-02systems with guardrail 57R1 / 67R1 / Ph 37N


Date of issue 08/10

Track 1435

Correction plates2 and 3 mm thick

Splice joint

Guardrail perforation ovalholes only for steel grade 700

Welding joint

937.5 for 15 m rails(900 for 18 m rails)

Endperforation

H = 75 for 57R171 for Ph 37N and 67R1

h = 65 for 57R163 for Ph 37N and 67R1


38/167

Railway track Grooved rail Guardrail Page: 118-03systems with guardrail Details


Date of issue 08/10

Dimensions / Weights

Profile Track A L kg / St.

59R1 - 59R2 1000 1018.5 1015 7.233

60R1 - 60R2 1000 1018.5 1015 7.23359R1 - 59R2 1435 1453.5 1450 9.62360R1 - 60R2 1435 1453.5 1450 9.62359R1 - 59R2* 1450 1468.5 1465 -60R1 - 60R2* 1450 1468.5 1465 -59R1 - 59R2** 1458 1476.5 1473 -60R1 - 60R2** 1458 1476.5 1473 -

57R1 1435 1444 1442 9.579Ph 37N 1435 1453.5 1451 9.62867R1 1435 1453.5 1451 9.628

* Dresden/ ** Leipzig

Track

A = Clear width between the bars

L = len th of uard rail

Correction plates2 and 3 mm thick

Guard railsFl. 70 x 10 mm

2 or 3


39/167

Railway track Grooved rail Material requirement Page: 118-04systems with guardrail 15 m


Date of issue 08/10

Material for a 15 m long track length (without tabs)

59R1 / 59R2 track 1435lg, mm kg / pc. zus. kg kg / m

2 Rails 59R1 / 59R2 N 15000 884.55 / 872.10 1769.1 / 1744.210 Guard rails 1450 9.623 96.210 Correction plates (2 mm dick) 0.135 1.410 Correction plates (3 mm dick) 0.202 2.040 Guardrail perforation M22 x 55 0.456 18.2

Sum 15 m = 1886.9 / 1862.0 125.8 / 124.1


2 Rails 59R1 / 59R2 N 15000 884.55 / 872.10 1769.1 / 1744.210 Guard rails 1015 7.233 72.310 Correction plates (2 mm dick) 0.135 1.4

10 Correction plates (3 mm dick) 0.202 2.040 Guardrail perforation M22 x 55 0.456 18.2

Sum 15 m = 1886.9 / 1862.0 124.2 / 122.5


2 Rails 60R1 / 60R2 15000 908.85 / 896.25 1817.7 / 1792.510 Guard rails 1450 9.623 96.210 Correction plates (2 mm dick) 0.135 1.410 Correction plates (3 mm dick) 0.202 2.040 Guardrail perforation M22 x 55 0.456 18.2

Sum 15 m = 1935.5 / 1910.3 129.0 / 127.4


2 Rails 60R1 / 60R2 15000 908.85 / 896.25 1817.7 / 1792.510 Guard rails 1015 7.233 72.310 Correction plates (2 mm dick) 0.135 1.410 Correction plates (3 mm dick) 0.202 2.040 Guardrail perforation M22 x 55 0.456 18.2

Sum 15 m = 1911.6 / 1886.4 127.4 / 125.8

57R1 / 67R1 / Ph37 N track 1435lg, mm kg / pc. zus. kg kg / m

2 Rails 57R1 / 67R1Ph 37N

15000 847.50 / 1003.65988.20

1695.0 / 2007.31976.4

8 Guard rails 1442 / 14511451

9.528 / 9.5779.577

76.2 / 76.676.6

8 Correction plates (2 mm dick) 0.135 1.48 Correction plates (3 mm dick) 0.202 2.0

32 Guardrail perforation M22 x 55 0.456 18.2Sum 15 m = 1788.5 / 2101.2

2070.3119.2 / 140.1

138.0


40/167

Railway track Grooved rail Indoor track 57R1 Page: 118-05systems with guardrail made of situ-concrete plate


Date of issue 08/10

Indoor track 57R1 / 67R1 made of situ-concrete plate

The usual guard rails made of flat steel are for for grooved rails that are embedded in the final stateare not recommended. Round bar with threaded ends according to the conventional reinforcement.The site concrete in this case is produced up to 16 cm below SO. For including the width of rail flange,recesses are provided. The grooved rails are installed with track holders to the rails, laid and alignedaccording to location and height. The rails with MINEX-grout to be grouted in the gaps. Subsequently,the remaining site concrete is introduced, if necessary. with asphalt coating in crossing areas beforethe halls or special industrial floors in the hall.

Grooved rail 57R1 / 67R1

Guard rail with threaded ends M 20

Rail grouting MINEY-grout


41/167

Railway track Variant System W 3 / standard Page: 119-01systems Vossloh for concrete sleepers


Date of issue 08/10

System W 3 for concrete sleepers

Extract from the Technical Communication RO 26 / 05 of DB AG from 08.11.2005: Replacement of the railfastening W 3 on site W 14. According to the Directive RiL 820.2010. The rail fastening W 3 with rail clamp Skl 1and angular guide plate Wfp 3b is to be installed instead of the previously used rail fastening W 14 k made ofconcrete sleepers B70 W, B70 W-2.4 and B90.

Rail fastening with rail clamp Skl 1

The rail is placed with the elastic intermediate layer on the concrete sleeper. The lateral position of the rail issecured by the angular guide plate Wfp 3. The Wfp is made of steel (with insulating insert) or glass fibrereinforced plastic. They transfer the lateral forces on the concrete body, without claiming the screw to bend andwithout effecting adversely for the track gauge formation. The resultant of vertical force and screw clampingforce is directed obliquely. The angular guide plate and the support in the concrete sleeper are shaped in such away, so that a tight fit is ensured even with loosened tie screws. The insulating insert between steel angularguide plate and concrete allows a complete attachment and an electrical insulation. The rail clamp Skl 1 issupplied with a permanent rust preventive coating.

The non-positive bracingbetween rails and sleepers is achieved by using the listed parts.

Advantages

Exact track gauge even by heavy load operation and in curved parts. High creep distance and torque resistance to prevent fracture gap openings. High frame rigidity to secure the position of the track. Low maintenance, no rework after installation. No route blocking on suspended sleeper screws (stress equalisation). Captive pre-assembly in the

sleeper factory. After installation of the rails, and intermediate layers, the sleeper screw is loosened, therail clamp is rotated around 180 and the screw tightened with a torque of approx. 200 Nm. The correctmounting poition is to be identified so that the intermediate loop touches the angular guide plate. Theclamping force of the spring arm is then approx. 11.5 kN at a deflection of 14.5 mm. There is an air

space of about 1.5 mm between rail clamps intermediate loop and rail flange.The lifting or tilting of therail is executed by the intermediate loop and thus excluded overexpanding of the spring arms.

6 1 Intermediate level Zw 686a / Zw 687a





1 1 Rail 49E5 / 54E4 / 60E2

Pos.Number/Support


installed pre-installed


42/167

Railway track Variant System W 14 / standard Page: 119-02systems Vossloh for concrete sleepers


Date of issue 08/10


Characteristics:

Different rail profile on the the same sleeperOn the same sleeper in same track gauge, the rail profiles 60E2, 54E1 and 49E5 can be used by simply

changing the angular guide plates.Gauge widening

A gauge widening of +/-10 mm in levels of 2.5 mm is available by default.

Tilting table

Lifting or tilting the track during the way maintenance or while passing through the narrow track curves is bracedafter overcoming the small air gap (between intermediate loop of the rail clamp and rail flange) with anintermediate loop. Thus a permanent deformation of the outer spring arms is excluded.

Track maintenance

The Vossloh rail fastening system requires no regular maintenance.

Rail bracing and creep distance

The rails consistently braced non-positively through the free spring arms in a deflection of approx. 13 mm and aretaining force of approx. 2 x 10 kN. This will require the high creep resistance of the rail, which preventsdangerous gap openings in welded rails, as well as a sufficient frame rigidity of the track section is achieved.

Neutralisation

For continuous welding of the rails (CWR), no fastening parts are removed from the sleeper. Only the sleeperscrews are loosened but not removed.

6 1 Intermediate level Zw 7005 2 Plastic dowel Sd 9




1 1 Rail 60E2

Pos.Number/Support


pre-installedinstalled


43/167


44/167

Railway track Variant System 14 / E 21 Page: 119-04systems Vossloh highly elastic for concrete sleepers


Date of issue 08/10

System E 14 for concrete sleepers

Railway track E 14 with rail clamps Skl 14 is a highly elastic rail fastening system for concretesleepers in gravel tracks.When upgrading from W 14 to E 14, the sleeper in gravel bed remain stuffed.

Features:

fully compatible to railway track W 14 Improved travelling comfort improved modulus of grade reaction lower gravel erosion

It is achieved with the large elastic intermediate plate with surface pressure distribution plate, similarto the system 300 for slab track, large deflection of the rails. The Skl 14 is also fatigue endurable inthese high vertical dynamic rail movements. All fastening parts can be captively installed in sleeperfactory on the sleeper. Hence mechanised and fully automatic installation in the track is possible.

A possible efficient increase of drive comfort on gravel tracks, equipped with standard railway track W14, and/or a reduction which takes place under heavy loads gravel destruction can be achieved withcompatible rail fastening system E 14.

Gravel tracks often have insufficientdeflection values when used in high-speedtraffic on new tracks. With EVAintermediate layers, the maximum of 0.2mm compressed under rolling wheel,achieved together with the gravel elasticityof about 0.6 mm on new tracks of thehighest values of 0.8 mm. Even the use ofso-called "soft" intermediate layers withstatic spring digits ofc = 50 - 70 kN/mm brings an improvementof about 1.0 mm of rail depression.

8 1 Intermediate level Zwp E 14

7 1 Base plate Grp E 14

6 1 Intermediate level Zw E 145 2 Plastic dowel Sd 25

4 2 Angular guide plate Wfp E 14

3 2 Rail clamps Skl 14 / Skl 21

2 2 Sleeper screws with track Ss 36-220 with Uls 7

1 1 Rail 60E2

Pos.Number/Support




45/167

Railway track Variant System 14 / E 21 Page: 119-05systems Vossloh highly elastic for concrete sleepers


Date of issue 08/10

It was therefore the task of finding possible solution by using standard elements that can be achievedwith the desired rail deflection values of 1.5 mm.

The railway track E 14 uses the monoblock concrete sleeper B 70 W 60 with the rail flange Skl 14.Thus, this railway track system are both on existing routes as well as on new lines to be built for use.

Structure:

The E 14 fastening system is a direct high elastic rail fastener for standard concrete sleepers B70W60 for the slab track. It is analogously built to the rail fastening system 300. Lateral forces aretransferred via angular guide plates. The rail is still braced with usual elastic rail flange Skl 14 inballasted track. The two free spring arms are located on the rail foot. The superior intermediate loopof the rail foot acts as a tilting table.

Controllability:

The fastening system is designed in such a way that the height adjustments are possible up to 5 mmas in W 14 railway track, without darning.

If desired, a gauge widening of up to +/- 10 mm are provided even in levels by changing the angularguide plates, as in systems W 14 and 300.

The System E 14 is available for local public transportunder the name 300 UTSwith rail flange Skl21 and adapted intermediate plate.

The Sk 21 in this case replaces the Skl 14 with higher vertical and dynamic fatigue strength.


46/167

Railway track Variant System 300 / for Slab Page: 119-06systems Vossloh Lane


Date of issue 08/10

System 300 with rail 60E2 and Skl 15 for the slab track

Slab tracks meet all the requirements for combined high-speed and heavy traffic. The pre-assembledrail fastening system 300 is suitable for all types of installation of the slab track.

The highly elastic intermediate plate replaces the elasticity of gravel bed. For better load distribution,a steel pressure distribution plate which rests on the customary interposition of a conventionalinterlayer rail. Laterally the rail is held in position by the plastic angular guide plates. The rail flangeSkl 15 is braced non-positively by the long elastic deflection.

The slab track rail fastening system 300 with Skl 15 is analogously built of the fastening W 14.

The lack of gravel elasticity is replaced with the rail fastening system 300 for the slab track by usingthe highly elastic intermediate plate. While using a spring constant of 22.5 kN/mm, measured assecant stiffness between 18-68 kN, a depression of rail is achieved from up to 1.5 mm in the standardgauge railway (22.5 t axle load).

Construction of the slab track:

Monolithic: Stored Special systems

The fastening can be provided on both the sleepers and for individual bases.

Regulatory options:

Height adjustability +6-4

10 mm using intermediate levels

+26-4 30 mm

using intermediate levels and height balancingplates

Side controllability +/- 5 10 mm using angular guide plates


47/167

Railway track Variant System 300 / for Slab Page: 119-07systems Vossloh Lane


Date of issue 08/10

Rail flange Skl 15

Installation instructionsCorrect

The correct installation clamping position isachieved when the intermediate loop touchesthe rib of angular guide plate by tightening thesleeper screw. (max. Permissible air gap: 0.5 mm).A tightening torque of approx. 200 Nm is required.

Wrong

Intermediate loop does not rest, air gap is too large.Desired clamping force is not reached!

8 1 Intermediate level Zwp 104 NT

7 1 Base plate Grp 216 1 Intermediate level Zw 692


4 2 Angular guide plate Wfp 15a



1 1 Rail 60E2

Pos.Number/Support




48/167

Railway track Variant System KS - Page: 119-08systems Vossloh for rib based plates


Date of issue 08/10

System KS with rail flange Skl 12 for rib based plates

The rail flange Skl 12 was designed for rail fastening on rib based plates with "hard" intermediatelayers (c 200 kN/m). The rail flange Skl 24 is available as an alternate.

All fastening parts can be captively installed in sleeper factory on the sleeper. Hence mechanised and

fully automatic installation in the track is possible.

With the two free spring arms of the rail flange, a permanently non positively braced rail with approx.13 kN clamping force is achieved with approx. 14.5 mm deflection per rail flange, whereby thefastening do not require any maintenance.

The tilting movement of the rail is executed by the intermediate loop of the rail flange. A temperaturestress equalisation of the rails is made easier by only loosening the screws. Any necessary railrequirement can be done easily, in which the rail flange while installation is pushed back.

Installation instructions

1. Loosen hexagonal nut of the screw-hook (approx. 1-2 revolutions)2. Bring rail flange in installation position (Spring arms must rest on the rail foot)3. The installation position is achieved when the interediate loop of the rail flange touches by

tightening the screw of the rail foot, or an air gap is up to 2 mm (tightening torque 180-250Nm).

9 1 Intermediate level Zw 687 Zw 687

8 2 Rail clamps Skl 12 Skl 12

7 2 Washer Uls 6 Uls 6

6 2 Hexagonal nut DB M22 DB M225 2 Hook screws Hs 32-55 Hs 32-55

4 1 Ribbed base plate Rph 6 Rph 1

3 4 Spring lock washer Fe 6 Fe 6

2 4 Sleeper screws Ss 8-150 Ss 8-150

1 1 Rail 60E2 49E5 / 54E4

Pos.Number/Support




49/167

Railway track Variant System W-Tram - with Page: 119-09systems Vossloh Wedge angle plates


Date of issue 08/10

Rail fastening system W-Tram with wedge angular guide lates K-Wfp 14 R and L

With the wedge angular guide plates with a continuous adjustment, the limited rail foot tolerancerelated to manufacturing process, above all balanced in grooved rails, and so the track width can beregulated upto +/-10 mm.

In the slab track, the use of insulated anchor bolts is possible, alternatively the proven anchor screwcombination Sd 26/Ss 36. The lateral forces of the rail is carried on the angular guide plate and thebase plate in the concrete support plate.

Does not have the bending or shear forces on the embedded anchorage system. High powerdissipation by the profiled bottom of the base plate. The sleeper screw / anchor bolts is only subjectedto train. Completely electrically insulated.

For laying the rail grooves on concrete sleepers, the system W is used, for slab track the system W-Tram is used.

Application examples

W-Tram on slab track W made of concrete sleepers

7 1 Intermediate level Zw 900/180 Zw 900/180

6 2 Plastic dowel Sd 26 Sd 25

5 1 Base plate Upl 180/120

4 2 Angular guide plate K-Wfp 14 K-Wfp 14

3 2 Rail clamps Skl 14 Skl 14

2 2 Sleeper screws with track Ss 36 + Uls7 Ss 35 + Uls7

1 1 Grooved rail

Pos.Number/Support

point Designation

W-Tram W-Sleeper

Brief description

installedpre-installed

Concrete-

sleeperSlab

track


50/167

Railway track Variant System W 97 / for 49E5 / Page: 119-10systems ThyssenKrupp 54E4 made of concrete sleepers


Date of issue 08/10


Characteristics:

The rail fastening W 97 was developed as an adapter solution for using the rails with rail flange width of 125 mm(rails 49E5, 54E4) on concrete sleepers B 70 W-60 that requires the rail flange width of 150 mm.

Here, specifically, the use of reclaimed sleepers B 70 W-60 is considered (from the year 1974), as standardequipment of DB.

Tracks with a permissible speed v < 160 km/h Tracks with a traffic density < 30,000 Lt/d Routing and marshalling attachments

Authorisation under:

DBS 918127 DIN EN 13481-2

Creep distance inRail longitudinal direction F = 10 kN (according to 3.0 Mio. load changes)

Electrical resistance R33 = 7,11 k (average)

7 1 Intermediate level Zw 686a6 2 Plastic dowel Sd 25 (alternatively Sd 9)

5 1 Angular guide plate Wfp 3b - 22

4 1 Special angular guide plate Wfp 3b - 28

3 2 Rail clamps Skl 1 / 97

2 2 Sleeper screws with trackSs 25 (alternatively Ss 35) with

Uls 71 1 Rail 49E5 / 54E4

Pos.Number/Support


pre-installedinstalledTightening torque 200 Nm


51/167


52/167

Elastic Overview Page: 120-01rail bedding


Date of issue 08/10

Road cross section Operational area (Axle load)

Tram

(up to 100 kN)

City railway

(up to 135 kN)

Metro

(up to 160 kN)

Standardgauge railway

(up to 250 kN)

constructivepossible

deflection(in mm)Continuousrail bedding

Rail cover up to 1.5

Railflex up to 1.5

ISOLast up to 1.5

Flexpoint up to 1.5

Whisper rail up to 10

VIBRALast up to 2

Highly elastic grooved railturnouts

up to 4

Powerflex variable

Flattrack up to 1.5

Discreterail bedding

Delta stock between 2-8

TK 07-R up to 1.5

TK 04-R up to 5

TK 99 up to 3

EASYLast up to 3

Krupp ECF-System up to 3Ei-attachment up to 3

Acoustical Loadmaster up to 4


53/167

Elastic Continuous ThyssenKrupp Page: 121-01Rail bedding Rail bedding Railflex


Date of issue 08/10

The system RAILFLEX is a continuous elastic rail bending system for city rails and trams. It consists ofthe main elastic components, electrically insulating base element, electrical chamber element for inner

and outer side, elastic and electrical insulating coatings for the track holder, rail fastening andinstallation base plate. The rail bedding is continuously horizontally and vertically adjustable.

Application for all tracks with asphalt, concrete, paved areas, surface as well as for crossings.No track geometry limitations, use on bridges and in tunnels. High damping effect for air-borne andstructure-borne sound. Application with all known grooved rails and vignol rail profile. Operational infosystems sice 1993 with approx. 180,000 m rail and 80 crossings.

8 1 Foot coating profile -

7 1 Chamber element inside -6 1 Chamber element outside -

5 2 Adjustable foot -

4 1 Support plate with adjusting anchor -

3 2 Insulation barrel -

2 1 Hexagon head bolt -

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2

Pos.Number/Support



54/167

Elastic Continuous ISOLast Page: 121-02Rail bedding Rail bedding


Date of issue 08/10

ISOLast stores grooves and vignol rails continuously and elastically, and significantly reduces shocksand vibrations in railway vehicles by degenerating the entire track of this type (slab track, pavement,and plantation) from the environment. Due to the installation situation a deflection of more than1.5 mm is recommendable.The chamber filling profiles are waterproof. The track should be laid on a situ-concrete plate andencapsulated with low-shrinkage cement mortar for height adjustment. The width of the chamberfilling profiles is recessed during construction of the surface and later encapsulated to the rail level

with highly elastic compound based on bitumen (Ortec.ESV).Applications for all tracks and crossings with roofing:

Asphalt Concrete / Asphalt Concrete / Natural stone paving Crossings

9 2 Clamping plate IL-3062-04-A4

8 2 Hexagonal nut DIN 985 - M24

7 1 Base coat profile GP-1215-00-A3

6 1 Base plate IL-3135-00-A3

5 2 Lock-nut DIN 7967 - M24

4 2 Thread block DIN 976 - M24 IL-3126-00-A4

3 1 Chamber filling profiles outside IL-2029-03-A1

2 1 Chamber filling profiles inside IL-2028-02-A1

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2

Pos.Number/Support



55/167

Elastic Continuous ThyssenKrupp Page: 121-03Rail bedding Rail bedding Flexpoint


Date of issue 08/10

The system FLEXPOINT is a discontinuous elastic rail bending system on the basis of rail supportpoint TK07-R, which is is so provided with an integral elastomer element so that no dynamic gaugewidening is possible under the vehicle. It further consists of both sided elastic chamber elements, thecover cap on the rail fastenings and the insulating base profile between rail support points.

Application for all tracks with asphalt, concrete, paved areas, crossings. No track geometry limitations,use on bridges and in tunnels possible.Application with all known grooved rails and vignol rail profile.

10 1 Intermediate level -

9 2 Chamber element -

8 2 Anchor -

7 1 Baseplate with ribbing -

6 1 Elastic base plate -

5 1 Support plate -4 2 Rail clamps Skl 1

3 2 Washer Uls 7

2 2 Sleeper screws Ss 25

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2

Pos.Number/Support



56/167

Elastic Continuous Whisper rail Page: 121-04Rail bedding Rail bedding


Date of issue 08/10

The whisper rail offers the possibility of deflections to reach up to 10 mm due to their construction.Rail car sound and vibrations are reduced up to 90% in densely built areas especially in trams. Theenclosure profile decouples the inner movement of the rail from the environment. The rail flooring isnot affected by the movement. For open cross-sections, like gravel bed, the whisper rail can beconstructed as a header rail, whereby to stop the enclosure profile below the rail head.

Applications for all tracks and crossings with roofing:

Asphalt Concrete / Asphalt

Concrete / Natural stone paving Crossings


11 1 Hexagon head bolt ISO 4014 - M20 x 160

10 2 Lock-nut DIN 7967 - M24


8 2 Thread block DIN 976 - M24x240

7 1 Base plate RI-2754-00-A3

6 2 Clamping plate KS-2210-00-A4

5 1 Base coat profile GP-1122-03-A34 1 Elastomer profile head GP-1160-04-A3

3 1 Elastomer profile groove GP-1158-08-A3

2 2 Enclosure profile RI-2334-01-A3

1 1 Rail 49E5 / 54E4

Pos.Number/Support



57/167

Elastic Continuous Rail cover Blatt: 121-05Rail bedding Rail bedding


Date of issue 08/10

Primarily the system railcover provides the protection against stray current corrosion. For this reason,the rail is coated with a profile made of plastic. The system design permits a deflection of up to1.5 mm. The plastic profile is connected on Th rail with a special adhesive. Within the profiles, underthe rail foot, an elastic intermediate layer is inlaid to achieve the desired deflection.The system is attached to underground guard rail with MX-guide rail clamps. Thus a wheel truing of+/- 8 mm can be set.



10 2 Washer ISO 7090-20

9 2 Hexagonal nut ISO 4032 - M16


7 1 Underfloor steering track rod ER-1001-00-A3



4 2 MX-fasteing MX 2424


2 1 Rail bedding GP-1269-02-A3

1 1 Rail 59R1 / 59R2 / 60R1 / 60R2

Pos.Number/Support



58/167

Elastic Continuous VIBRALast Page: 121-06Rail bedding Rail bedding


Date of issue 08/10

The system VIBRALast is a channel system that is used with a 2-component material based onpolyurethane. The system can be loaded with grooved rails and also with vignol rails. The rail foot isfurnished with a base coat profile to achieve required deflection of up to 2 mm. All parts areprefabricated, delivered on the installation site, whereby significantly reducing the installation time.




6 1 Threaded rod DIN 975 - M24x600

5 1 Tightener DIN 1480 SP - M24x255




1 1 Rail59R1 / 59R2 / 60R1 / 60R2

49E5 / 54E4

Pos.Number/Support



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Elastic Continuous Highly elastic Page: 121-07Rail bedding Rail bedding Soft grooves


Date of issue 08/10

For using within the rail turnouts, system VIBRALast is expanded in view of the deflection. It consistsof the similar components as in VIBRALast, only within the rail foot, modified elastomer elements are

arranged to brace the different rigidity within the crossings and to achieve a uniform deflection of up to4 mm. The system is suitable for road-aligned cross-sections.



6 1 Steel cable coating EWL-1025-00-A3

5 1 Elastomer pad GP-1297-00-A3

4 1 Foam carpet EWL-1028-00-A3



1 1 Rail59R1 / 59R2 / 60R1 / 60R2

49E5 / 54E4

Pos.Number/Support


standard cross-section


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Elastic Continuous Potting material Page: 121-08Rail bedding Rail bedding Powerflex


Date of issue 08/10

Our durable elastic product Powerflex can be used individually in order to grout grooved rails. Thematerial which sets rapidly after casting can be introduced manually or mechanically. The latter issuitable for larger projects. The deflection can be varied depending on customer requirements, butthey must not be more than 2 mm. No big actions must be taken for processing; disposal afterdecommissioning is possible without any special effort.


Asphalt Concrete / Asphalt

Concrete / Natural stone paving Crossings

4 1 Base coat GP-1148-03-A3



1 1 Rail59R1 / 59R2 / 60R1 / 60R2

49E5 / 54E4

Pos.Number/Support



61/167

Elastic Continuous ThyssenKrupp Page: 121-09Rail bedding Rail bedding Flattrack


Date of issue 08/10

The system FLATTRACK is a continuous elastic rail bending system on the basis of the new groovedrail FLAT RAIL, with the rail height of 100 mm enables a miimum construction height. It furtherconsists of the elastic; electrically insulating base element, electrical chamber element and rail

fastening and installation support point, so that the rails can be set continuously horizontal andvertical. By using the adapter elements on the long side of the chamber elemnt, an optial joint designis possible.

The FAT RAIL is possible with an advantageous wide rail head, the big rail depth und extended headthickness of an extended service compared to conventional rail service.

9 1 elastic foot element -

8 1 Chamber element -

7 2 Cover cap -6 2 Clamping plate -

5 2 Adjustable foot -

4 1 Support plate with anchor -

3 2 Eccentric -

2 2 Hexagon head bolt -

1 1 Rail Flat Rail ( Ri58N)

Pos.Number/Support


Joint sealing


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Elastic Discrete Delta-Stock Page: 122-01Rail bedding Rail bedding


Date of issue 08/10

The Delta-Lager can be designed in such a way for all local traffic loads, so that a vertical deflectionof 2-8 mm is achieved. The maximum horizontal deflection is < 2 mm. The system is suitable for

concrete sleepers with W-fastening.When using an additional base plate, the load can be used on concrete or wooden sleepers.Therefore the Delta-Lager is ideal for slab track.

12 4 Lock-nut DIN 7967 - M24


10 4 Thread block DIN 976 - M24 x 240

9 2 Spring washer DIN 6796-24


7 1 Base plate DL-1071-00-A2

6 1 Polyamide plate DZ-2187-00-A4

5 2 Insulating insert DZ-2123-03-A3

4 1 Intermediate level DZ-2126-01-A4

3 2 Spring element GP-1093-11-A3

2 2 Console DL-1104-01-A3

1 1 Rail 49E5 / 54E4 / 60E2

Pos.Number/Support



63/167

Elastic Discrete Krupp ECG-System Page: 122-02Rail bedding Rail bedding


Date of issue 08/10

The developed Krupp ECF-system for the slab track from ThyssenKrupp Gleistechnik is a height andside adjustable rail support which meets the catalogue of requirements of Deutsche Bahn. Within theconstruction, the ribbed base plate has a large hole for eccentric insulating cases, which is inserted byribbed base and damping plates and enables a continuous lateral adjustability from 10 mm. By usingslotted correction plates of appropriate thickness, height adjustability from +26 to -4 mm "under

operation" is possible. The Krupp ECF-system is used in precast slabs, concrete sleepers for slabtrack and in continuous concrete beam.

11 1 Intermediate level ZW 686 / Zw 687

10 1 Ribbed base plate ERp 1 / ERP 2

9 1 Spacer plate Zwp 194 - 125/150

8 2 Washer Uls 6




4 2/4 Spring lock washer Fe 31

3 2/4 Insulated collar brushing Fbu 8

2 2/4 Hexagon head bolt ISO 4014 - M22 x 230

1 1 Rail 49E5 / 54E4 / 60E2

Pos.Number/Support


Alternatively: Screw stay


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Elastic Discrete EASYLast Page: 122-03Rail bedding Rail bedding


Date of issue 08/10

The electrically insulating system EASYLast provides a flexible solution for the storage of vignol andgrooved rails. Using the elastic intermediate plate, it also provides an efficient protection fromvibrations, whereby the deflection should be limited to 3 mm.

The system consists of a ribbed base plate, which in addition has an intermediate layer under the railfoot and also an elastic intermediate plate. The rail fastening is supplied with conventional rail clamps.While fastening the rib based plate, the pressure springs are arranged to prevent lifting of the ribbased plate. Below the pressure spring, the plastic collar brushes are arranged, which provides theelectrical insulation. The necessary height compensation should be prepared with non-shrinking

cement mortar.

14 2 Protecting cover DZ-2259-00-A4

13 1 Base plate DZ-2172-00-A4



10 2 Pressure spring DZ-2238-01-A4

9 2 Washer DZ-2257-00-A4

8 2 Collar brushing EA-2033-02-A4

7 2 Washer Uls 66 2 Hexagonal screw with nut Hs 32 x55


4 1 Intermediate level ZW 677

3 1 Ribbed base plate EA-2025-01-A1

2 1 Elastic base DZ-1015-05-A1

1 1 Rail 49E5 / 54E4

Pos.Number/Support



65/167

Elastic Discrete ThyssenKrupp Page: 122-04Rail bedding Rail bedding TK 99 / TK 99 S


Date of issue 08/10

The TK 99 is an elastic rail support with 2 or 4 anchor bolts with proven construction design of thesystem 314 / 336 of the Deutsche Bahn. The elastic deflection is adjustable up to 3 mm. Theoptimised sub-structure leads to the improvement of technology and function.

In TK 99 S system, the load around the fastening of guard rail was extended. The system isconstructed as a composite structure made of cast steel for whisper rail and guard rail and is suitablefor all rail profiles. The elastic deflection is adjustable to the complete system.


12 1 Support plate -

11 1 Elastomer base -

10 1 Ribbed base plate -


8 2 Washer Uls 6


6 2 Hook screws Hs 32 x 55

5 2/4 Collar brushing -

4 2/4 Helical spring -

3 2/4 Hexagonal nut DIN 985 - M24

2 2/4 Anchor bolts -

1 1 Rail 54E1

Pos.Number/Support



66/167


67/167

Elastic Discrete ThyssenKrupp Page: 122-06Rail bedding Rail bedding TK 04-R


Date of issue 08/10

A standard solution developed for Metro and tram rails, the elastic rail support TK 04-R. An innovationwith many technical options. The elastic deflection up to 5 mm ensures driving comfort and low noise

emission. In addition TK 04-R provides a height adjustment between -3 and +10 mm as well as alateral adjustment between -10 and +10 mm.Through extensive use of plastic, the rail is electrically insulated against the concrete constructionoptimally. The low dead weight and the possibility of sub-assembly minimise substantially theinstallation time on-site.


10 2 Sliding wedge -

9 1 Base plate -

8 1 Elastic base -

7 1 Spacer plate -6 1 Support plate -


4 2 Disc/washer 44 / 25x4

3 2 Hexagonal nut M24

2 2 Anchor bolts -

1 1 Rail 49E5 / 54E4

Pos.Number/Support


with alternative anchoring


68/167

Elastic Discrete Ei-attachment Page: 122-07Rail bedding Rail bedding


Date of issue 08/10

The Ei-attachment - the name comes from the characteristic oval shape - was originally designed toreduce the impact sound. Because of the construction, consisting of the ribbed base plate and theframe, the deflection should be not more than 3 mm.The rail is mounted on the rib based plate using rail flange or E-clips. The outer side on the frame, theears cast integrally, that are provided with bolts for fastening with anchor bolts. Between the rib basedplate and frame, there is a tilted vulcanized elastomer ring, which provides a pressure-/ superimposedpower intake. This results in the excellent acoustical effectiveness of the Ei-attachment. Besides thetrack gauge is reliably maintained because of construction. When overloaded, the rib based platelowers maximum up to the dead end on the concrete. The elastomer ring dampens not only the

vibrations, but also offers excellent electrical insulation.

15 11 Lock-nut DIN 7967 - M22




11 7 Cog plate EI-0007-00-A1

10 2 Washer Uls 6


8 2 Hook screws Hs 32 x 55


6 5 Polyamide plate DZ-2254-00-A3

5 4 Intermediate level Ei-0009-00-A3

4 1 Ribbed base plate EI-0008-00-A1

3 1 Elastomer ring vulcanised

2 1 Frame EI-0002-00-A0

1 1 Rail 49E5 / 54E4

Pos.Number/Support



69/167

Elastic Discrete Acoustical Loadmaster Page: 122-08Rail bedding Rail bedding


Date of issue 08/10

The Acoustical LoadMaster has been developed in order to achieve low stiffness in the rail.Depending on the axle load, the deflection of the rib based plate as per the construction is designedup to 4 mm. The system consists of a ribbed base plate and a frame which are connected through avulcanised elastomer with each other. As per the requirements, the ribbed base plate aremanufactured straight or inclined (1:20 / 1:40). The frame is so shaped that the ends of the ribbedbase plate protrude. The gap is also filled with an elastomer and provides an elastic lift lock. On theframe of the load, the fastening points up to 4 are appropriate, which ensures an adequate lateraladjustability.


14 1 Polyamide plate -

13 2 Cog plate LM-1016-02-A4

12 2 Lock-nut DIN 7967 - M24




8 2 Washer Uls 6

7 2 Hexagonal nut DM M22

6 2 Hook screws Hs 32 x 555 2 Rail clamps Skl 12

4 1 Ribbed base plate DZ-2200-00-A1

3 1 Elastomer LM-1015-02-A0

2 1 Frame DZ-1114-00-A2

1 1 Rail 60E2

Pos.Number/Support



70/167

Fixed NFF General Page: 131-01Slab track


Date of issue 08/10

General Information

Gravel construction and conventional fixed slab track as e.g. the system NBU differ in the interface of base /railway track. Hydraulically Bound Base course (HGT) instead Sub Structure (PSS) and Concrete Base course(BTS) instead gravel.Gravel roads can be repaired in limits by considering height and position, in FF-systems, these ratios are

possible in limits in rail fastenings. The gravel roads requires more maintenance and has a shorter life until thecomplete reconstruction, FF systems have a long life and requires less maintenance but a more elaboratepreparation of the base (soil stabilisation, compaction, exchange etc.).The ThyssenKrupp GfT Gleistechnik GmbH comes with two different slab track (FF)-Systems:

System FF NBU New slab track NFF

New slab track - NFFIn poor soils, the cost for this soil stabilisation increases enormously. Here begins the operational area of NFF.It accounts to all base course work, that the system NFF loads from the dead weight and rail traffic over deepfoundation (bore piles, micro piles, etc.) directly initiates the bearing capacity of base course The necessarypickets and associated pile lengths are determined by a ground survey, so that only minimum setting can bedone. Thus, the advantages of the conventional slab tracks (low maintenance cost, long life) are connected to

safe load transfer through deep foundations (small settlements, no complex substructure etc.) the system NFF.The system "New slab track" (NFF) is looked from a structural point of view as a bridge-like construction with arailway track part.

Fig. 1: Schematic representation of NFF, here with each 6 pickets per CROSS BAR

Drilling or micro piles.

Longitudinal support unit

Chamber

(cross-fall)

+100mm

Chamber

(cross-fall)

+100mmCross bar


71/167

Fixed NFF General Page: 131-02Slab track


Date of issue 08/10

The NFF consists of the rails, the rail fastening of longitudinal support unit (e.g. rail fastening systemKrupp ECF), cross fall and the deep foundation consisting of drilling or micro-piles.

The LTE is stored as a two-span beam on the cross bar which in turn supports the piles.

Fig. 2: NFF longitudinal support unit in track curves with the chamber

Diameter, length, number and inclination of the pickets can be adjusted to the ground conditions, thereduction requirements and the rail characteristics. The inclination of the pickets in the ground canabsorb both vertical and horizontal forces.

The cross bar is advisable on the pickets. The cross bar in turn serves as a support for LTE. LTE andcross bar consists of precast concrete element, which are produced under optimal conditions and canbe delivered with consistent quality. Only the connection of the cross bar with the pickets is on theinstallation site.


72/167

Fixed NFF Constructive Page: 131-03Slab track construction cycle


Date of issue 08/10

Constructive constructionThe following are the individual modules of the NFF are briefly represented in the real buildingprocess.

Deep foundationThe deep foundation serves the load transfer in subsoil and is therefore dependant on load and soilconditions. The kind of pickets, lengths and diameters can be selected for each individual case. Thedimensioning and design is carried out according to the picket loads of tested statics and soilproperties per geological survey.

Cross barThe cross bars are pre-cast reinforced concrete dimensioned and reinforced according to the testedstatics. The 108 m long traversing length at the company Rheinkalk built in Wlfrath, cross bars havea length of (in the direction of the track) 1.5 m, a width of 3.0 m and a height of 0.5 m.

Longitudinal support units (LTE)The LTE are composite sections made of steel sections and concrete, which is produced as pre-castelements. They consist of two longitudinal sleepers, which are connected like a ladder at the endsand in the middle.The dimensioning and reinforcement of steel-concrete-composite sections takes place after testedstatistics. The device on the LTE test track has a length of 10.78 m (dimension between centre lines =10.80 m), a total width of 2.165 m and a height of 650 mm plus 38 mm bump for the rail fastenings.The LTE is constructed (dimension between centre lines = 5.40 m) as a two-span beam and lie on anauthorised rubber mat on the cross bar. The LTE are already factory provided equipped with railfastenings KRUPP ECF.

Fig. 3: NFF longitudinal beam showing the pickets


73/167

Fixed NFF Schematic Page: 131-04Slab track construction cycle


Date of issue 08/10

Schematic construction cycle

In figure a)is a track section to toughen up,

still shown in its original state.

a) a track section to toughen up

figure b)shows track section after settingThe deep foundation 1. The track still remainsboundless for use or drivable

b) Track section after settling thedeep foundation

figure c)shows the state of track sectionafter the dismantling of the old tracks andsleepers. The cross bars are already setand fixed.

c) Track section with cross bars


74/167



Date of issue 08/10

After the cross bars are set and fixed,the laying of LTE can be started(see Figure d and e).

d) Longitudinal support unit LTE is set

e) further LTE's are set

In figure f), the complete and approvedtracks are presented. The "voids" of LTEare filled with gravel.The stopper is completely eliminated!

f) complete gravel work and approvedtracks


75/167



Date of issue 08/10

An overview of the relevant modules is shown in figure g).

g) NFF Track section showing the three component groups


76/167

Fixed NBU Introduction Page: 132-01Slab track


Date of issue 08/10

The slab track "system NBU" is a sleeper free and so monolithic design with individual support on aconcrete base (BTS).

The "System NBU is for application area Ground construction

Bridges and tunnel (also in trough structures)applicable without restrictions to gauge railways and mass transit systems In 2008, the road networkof DB AG (route 2600 - Aachen - German border with Belgium), a trial track was successfully testedand approved for continuous operation.

The railway trac

Documents

Railway Track Manual Part 1