RIGID CATENARY

COMPANY PROFILE

Innovation in power transmission

2 | CARIBONI ALSTOM |

Cariboni, an Alstom company since 2008, is a leading

European player in the design and manufacturing of

materials for power transmission. Established in 1908,

with about 85 employees operating in the surroundings

of Lake Como – one of the main industrialised areas of

Northern Italy – the company specialises in:

- Design and manufacturing of components for railways,

tramways and trolley bus contact lines

- Bus-bar ducts for power plants

- HV/MV connectors and fittings

- Power supply systems for overhead cranes and hoists

Our excellent workforce is committed in the seamless

effort to manage the most demanding projects aiming at

achieving top notch customer satisfaction.

Nowadays, we can offer our customers all kinds of

products and services, ranging from the design, engineering,

testing and manufacturing of complete cantilevers to the

manufacturing of all sorts of droppers, fittings and clamps based

on customer-specific requirements. Our mission is to meet our

customers’ expectations, both when they need an integrated

service or when they need products manufactured on time and

according to the highest quality level.

Cariboni is proud of being included in the list of the most

important European manufacturers of railway systems and

of being a reliable partner of all the major worldwide leading

manufacturers of overhead contact line systems.

Cariboni specialises in the design and manufacturing of contact

lines for railways, metro lines, tramways, undergrounds and

trolley-buses.

We are ready to fully meet all your needs.

CONTENTS

INTRODUCTION 4

CONDUCTOR PROFILE 5

JOINT PLATES 5

EXPANSION JOINTS 6

“AIR GAP” EXPANSION JOINTS 6

MECHANIC EXPANSION JOINT 6

SECTION INSULATOR 7

TRANSITION BAR 7

THE PROTECTIVE SHEATH 8

SUPPORT HANGERS 8

CLAMPS AND ANCHORAGES 9

ANCHORAGES 9

FIXED POINT CLAMPS 9

SUSPENSION SYSTEM 10

POWER FEEDER CLAMP 10

GROUNDING CLAMP 11

SPECIAL EQUIPMENTS FOR THE INSTALLATION 11

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RIGID CATENARY

I. INTRODUCTION The rigid catenary comes from the needed to reduce height

during the construction of electrification systems, mostly in

metropolitan tunnels but also in parking and railway line.

In contrast with the “traditional” one, it no needs auxiliary

droppers to ensure straight contact wire that so works

without any mechanical tensile.

The maximum span between two suspensions is 12 m

and varies in relation to the speed of the electric tractive

units. The contact line in a rigid catenary is comprised

of an aluminum conductor profile with insert a copper

contact wire, the staggering of contact line is done by adjusting

the position of the suspension clamps.

The fixed point clamps, installed in the middle of the rigid

catenary, allow to split in two directions the variations of length

due to the thermal expansion caused by temperature changes.

To allow for expansion without deformation, the sections of rigid

catenary have a maximum length of 400 m. At the entrance of

tunnels, the contact wire and the messenger wire of the traditional

line are anchoring to the front wall of the tunnel.

In the area of transition between the traditional line and the rigid

catenary, special bars are used to ensure a smooth passage of the

pantograph between two areas with different elasticity.

4 | CARIBONI ALSTOM |

Bars are made of a special aluminum-magnesium-silicon

alloy. Each side has eight holes to allow the installation of

junction plates. Eight vents (made at a distance of 4 m from

one another) ensure that any condensed water buildup in the

bar itself is discharged. The elasticity of the aluminum alloy

facilitates assembly, without distorting the contact line.

II. CONDUCTOR PROFILE

CHARACTERISTICS OF CONDUCTOR PROFILE

NUMBER CHARACTERISTIC UNIT OF MEASUREMENT

VALUE

1 Cross Section Area mm2 22942 Equivalent Copper Cross Section mm2 12543 Theoretical Weight kg/m 6,194 20°C Resistance µΩ*cm 3,255 Linear Expansion Coefficient 1/K 24*10-66 Tensile Strength Rm N/mm2 1857 2% Proof Strength (Rp 0.2) N/mm2 1458 Min. manual bent radii of conductor profile on horizontal m 1209 Min. mechanical bent radii of current bar profile on horizontal m 4510 Length of Current bar profile m 12

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The joint plates are made in order to allow for the connection

between the aluminum conductor profile in rigid catenary.

The geometric shape of the plates fits the bar’s cavity. The

whole joint is made of two plates that connect the contiguous

ends of the aluminum conductor profile using stainless steel

bolts. The mechanical and electric continuity between the

aluminum conductor profile that form the catenary is achieved

by tightening sixteen screws.

III. JOINT PLATES

Air gap” expansion joints allow for the longitudinal expansion

of the conductor profile caused by thermal expansion. They

consist of a conductor profile bent at one end that allows for a

smooth contact of the pantograph. The maximum absorbed

length variation is about 250 mm.

Considering the linear expansion coefficient of aluminum, the

maximum length of a continuous line of catenary is 300-

400 m, depending on the ambient temperature range. The

lower part of the expansion joint ensures a regular passage

of the pantograph while the upper part is equipped with

copper braided flexible connections to guarantee continuity of

electricity supply along the catenary.

IV. EXPANSION JOINTS IV.1 “Air Gap” Expansion Joints

IV.2 Mechanic Expansion Joint

6 | CARIBONI ALSTOM |

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It is comprised of a central body made of fiberglass. At

each end a clamp is provided to fix the system to the bars

while two “blades” allow for the passage of pantograph.

V. SECTION INSULATOR

The insulating system is made of a silicon-coated fiberglass part

that is capable of withstanding the mechanical stress due to

traction of the system load.

The bar allows for a stepwise transition from the traditional

catenary to the rigid one, allowing for a smooth passage of the

pantograph between two areas with different elasticity, thus

preventing detachment of the pantograph. These components

consist of a 4m-8m long segment onto which notches are

made to reduce the section in order to increase the elasticity

and flexibility of the profile.

On one side are eight holes for fixing joint plates. A special

plastic protection can be used to prevent the formation of

water and dust buildups on the transition bar.

VI. TRANSITION BAR

6x480 = 2880

L variable

110

Where leakage or other risks are present, a protective

sheath is placed onto the conductor profile. Such

protection prevents the formation of dust and liquids

buildups on top of the transition bar. It is made of PVC

and its shape facilitates installation on the aluminum

conductor profile.

VII. THE PROTECTIVE SHEATH

VIII. SUPPORT HANGERS

89

110

L variable

1.5

89

110

L variable

1.5

8 | CARIBONI ALSTOM |

Support hangers are made of bronze. A plastic insert

allows the bar to slide in the event of expansion while

reducing friction

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Anchor plates are made of stainless steel.

They anchor the rigid catenary at the beginning of the

tunnel.

IX. CLAMPS AND ANCHORAGESIX.1 Anchorages

To split in the two directions the variation of length of the

aluminum conductor profile caused by thermal expansion, a

fixed point is made halfway between the two expansion joints

or overlaps. It is made by putting together two anchoring

devices composed of a stainless steel plate placed on the

upper part of the aluminum conductor profile and wired to the

tunnel.

IX.2 Fixed Point Clamps

In order to electrical feed the rigid catenary power feed

clamps must be used.

The number of this clamps depends of the electrical

features of the line. It is installed on the upper part of the

conductor profile, and there are holes to connect the cable

lugs. When necessary bimetallic (Cu-Al) plates can be

provide.

XI. POWER FEEDER CLAMP

10 | CARIBONI ALSTOM |

ALUMINIUM RIGID CATENARY PROFILE

THREADED ROD

INSUALTED TRAVERSE

SUPPORT HANGER

Composed by an insulated traverse, it can be connected to

the roof of the tunnel by means of threaded rods and bronze

clamps.

X. SUSPENSION SYSTEM

Grounding is necessary to create an attachment point for

the grounding foil on the aluminium conductor profile that

forms the rigid catenary. It is installed on the upper part of

the conductor profile that forms the contact line.

XII. GROUNDING CLAMP

In order to install the components of the catenary,

special equipments are used such as: railcar for the contact

wire insertion, special cutting tools; drilling tools,

and a special antioxidant paste made of grease

with powdered zinc specifically used

during installation.

XIII. SPECIAL EQUIPMENTS FOR THE INSTALLATION

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Alstom S.p.A.Viale Regina Margherita, 26200198 RomaTel. + 39 06 42038901Fax + 39 06 42038920 Alstom Ferroviaria S.p.A.BariVia dei gladioli, 570026 Modugno Z.I. (Ba)Tel. 080 5380811Fax 080 5380812

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www.alstom.com/transport