EDILON EDF fastening system by edilon)(sedra bv

EDILON B.V. P.O. box 1000 2003 RZ Haarlem, The Netherlands T: +31 (0)23 - 531 95 19 F: +31 (0)23 - 531 07 51 mail@edilon.com www.edilon.com

EDILON DIRECT FASTENING SYSTEMS (EDF)

www.edilon.com

EDILON RAIL SYSTEMS GENERAL ADVANTAGES OF THE EDILON EDF

EDILON SLAB TRACK SYSTEMS For over 130 years, tracks for mainline rail traffic and urban mass rapid transit systems were based almost exclusively on track panels and cross sleepers supported on stone ballast. During the 1960’s, increasing train loads, higher speeds and the demand for more cost effective track installation methods, led to the development of ballastless track or slab track systems. Since the introduction of ballastless track systems, Edilon has developed and become a specialist of ballastless rail systems. Currently, Edilon supplies three ballastless track systems each with its own individual characteristics. These systems are:

• Edilon Corkelast ® Embedded Rail System (ERS) Installed since1970 • Edilon Corkelast ® Embedded Block System (EBS) Installed since 1974 • Edilon Direct Fastening System (EDF)® Installed since1964

• • • • • • • • • • • •

Low maintenance requirements Long life span No high elastic rail clamps Reduced construction height Top down or bottom up installation possible Different support stiffness possible Vibration attenuation Vertical & Horizontal post adjustment Direct access to the rail Excellent electrical insulation of the track Easy to clean track Proven Technology

EDILON DIRECT FASTENING SYSTEM (EDF) The Edilon EDF fastenings system is discretely supported rail fastening system for ballastless track. The intended use is for all kind of rail traffic such as tram, metro, freight & commuter trains and high speed trains. And all kind of rail types such as the standard vignole and groove rail. The system consists of: • steel base plate in 2 holes or 4 holes configurations with various railclip systems such as SKL or e type or other • Edilon designed rail pad or other • Edilon designed base plate pad or other • Edilon Dex-G epoxy or Edilon Corkelast for grouting the base plate • Various types of Edilon EDF rail anchors such EDF HD or EDF MD and various types of nuts • Edilon Dex-R 2K 2-component adhesive or EDF cast-in insert. All components are tuned for different requirements such as straight track, curves, speed and axle loads and are tested according to the internationally accepted rail standard EN13146 and DIN 45673. Edilon supplies the Edilon EDF system as a complete system according to the quality assurance system ISO 9001-2000.

EDF APPLICATION AREAS ELEVATED STRUCTURES

The Edilon EDF system is applied over a range of rail constructions, such as open track, switches, depots, maintenance pits, station areas, tunnels and elevated structures. It gives the user the advantages of minimal maintenance requirements, low construction height and excellent electrical insulation.

• • • • • • •

Reduced construction height Smaller tunnel cross section Minimal maintenance requirements Stray current insulation Simple drainage Easy to clean track Vibration insulation

TUNNELS • • • • • • •

Reduced construction height Smaller tunnel cross section Minimal maintenance requirements Stray current insulation Simple drainage Easy to clean track Vibration insulation

BRIDGES • Applicable on steel, concrete and hybrid bridges • Low construction height • Reduced height of the supporting structure and track structure • Weight reduction • Watertight surface with simple drainage • Reduced bridge vibration • Secondary noise counter measures are simple to implement on the track and bridge structure

STATIONS • Low construction height • Reduced height of the supporting structure and track structure • Weight reduction • Water tight surface with simple drainage • Easy to clean track

SPECIAL TRACK STRUCTURES • • • • • • •

Check Rails Compensation Joints Transition zones Washing plants Insulated joints Maintenance Pits Switches

EDF-FOR HEAVY RAIL (HR) AND HIGH SPEED RAIL (HSR) The Edilon EDF-HR/HSL meets the various requirements for heavy rail and high speed rail. All system variations of the Edilon EDF are designed according to UIC code 700, or according to UIC load model 71 as specified in the UIC Code 702.

EDF-HR/HSL SYSTEM VARIATIONS Different support stiffness is possible with the Edilon EDF system, so optimising the EDF system for the required track characteristics and supporting distances. Hence it is possible to influence the ride comfort and vibration attenuation.

SYSTEM

VARIATION

SUPPORTING STIFFNESS

DEFLECTION (STATIC)

EDF-HR/HSL-SS EDF-HR/HSL-MS

Standard Stiffness Medium Stiffness

60 kN/mm 30 kN/mm

< 1,0 mm 1,0 - 2,0 mm

EDF-LR SYSTEM VARIATIONS

The Edilon EDF-LR meets the requirements for tram, light rail and metro. With Edilon EDF it is possible to change the supporting stiffness.

SYSTEM CHARACTERISTICS • • • • • • • • •

EDF-LR FOR TRAM LINES, LIGHT RAIL AND METRO

Permanent and accurate track geometry Maximum operational speed 300km/h Maximum super elevation: 150mm Maximum super elevation deﬁciency 120mm Vertical and horizontal adjustability according to requirements Applicable to all standard rail proﬁles Rail inclination 0 or 1:20 or 1:40 or as required Meets the requirements for stray current insulation and electrical insulation (EN 13146-4/ EN 50122-2) Compatible with the European Train Control systems: e.g. ETCS, ASFA, ATB, LZB, ZUB 121, ZUB 262/ Integra, Indusi/PZB

In the Edilon EDF system it is possible to change the supporting stiffness and optimise the track to the required track characteristic and supporting distances. Hence optimising the ride comfort and vibration attenuation.

SYSTEM

VARIATION

SUPPORTING STIFFNESS

DEFLECTION (STATIC)

EDF-LR-SS EDF-LR-MS

Standard Stiffness Medium Stiffness

60 kN/mm 15 kN/mm

< 1,0 mm 1,0 - 2,5 mm

SYSTEM CHARACTERISTICS • • • • • •

Given values are just indications. All design criteria are dependant on speeds, curve radius, braking and acceleration forces and other operational criteria. For advice please contact Edilon.

Permanent and accurate track geometry Vertical and horizontal adjustability according to requirements Applicable to all standard rail proﬁles Rail inclination 0 or 1:20 or 1:40 or as required Meets the requirements for stray current insulation and electrical insulation (EN 13146-4/ EN 50122-2) Compatible with the European Train Control systems: e.g. ETCS, ASFA, ATB, LZB. ZUB 121, ZUB 262/ Integra, Indusi/PZB

EDF SYSTEM DESIGN AXLE LOADS AND SPEEDS Edilon EDF can be applied in a broad range of applications eg Tram, Metro, Light Rail, Heavy Rail and High Speed Rail, with different axle loads and operational speeds.

BASIC CONFIGURATIONS EDF system

Support stiffness*

EDF Rail anchor

Trafﬁc load according to UIC 700**

Speed upto:

A 160 kN

100k m/h (120k m/h)

D4 225 kN

200k m/h (220k m/h)

C3 200 kN

300k m/h (330k m/h)

A 160 kN

100k m/h (120k m/h)

D4 225 kN

200k m/h (220k m/h)

D3 200 kN

300k m/h (330k m/h)

EDF MD EDF MD 4 EDF HD EDF HD 2 hole baseplate 4-hole baseplate 2-hole baseplate 4-hole baseplate Curve radius <300m > 100m LR Light Rail

HR Heavy Rail HSL High Speed

* ** ***

X Cant deﬁciency >30mm <120mm

HR Heavy Rail HSL High Speed LR Light Rail

Curve radius <300m

X X

X Cant deﬁciency >30mm <120mm

X Cant deficiency >30mm <120mm X Cant deficiency >30mm <120mm X Cant deficiency >30mm <120mm X Cant deficiency >30mm <120mm X Cant deficiency >30mm <120mm X Cant deficiency >30mm <120mm

60 kN/mm

15 kN/mm

30 kN/mm

Stiffness is also dependant on frequency and condition of supporting surface Base plate supporting intervals is 600-650mm Curve radius is used as an indication. Smaller curve radii are possible or larger curve radii are required. Values depend of speed, super elevation, accelerating and braking forces and temperature

EDF INSTALLATION TOP DOWN INSTALLATION For the Top Down installation, the Edilon EDF Baseplate is grouted. To realize & is easily fitted the required quality, the Edilon Dex-G (Fast Curing Epoxy pouring grout) is used to produce a strong baseplate support. When grouting with Edilon Dex-G a space of 5 up to 35 mm is required between the supporting construction and the elastic base plate pad.

ADJUSTING

DRILLING

GLUEING

GROUTING

SUPPORTING CONSTRUCTION Edilon EDF is easily fitted onto the supporting construction. Depending on the installation method used for the Edilon EDF system the following will have to be considered.

EDF INSTALLATION BOTTOM UP INSTALLATION For Bottom Up Installation, the supporting construction is manufactured according to the required tolerances for height and super elevation and in such manner that during installation of the EDF system the Rail alignment can be realised. There are different proven techniques to achieve accurate concrete support tolerances. These tolerances can be realised by:

ADJUSTING

DRILLING

• accurate casting moulds • grinding the top of the concrete plinth

When installing the EDF system on the concrete support structure, a drilling depth for the EDF rail anchor has to be allowed for. There either has to be a clear zone, free from steel reinforcement bars, or it has to be constructed to be acceptable that reinforcement bars are cut during drilling.

GLUEING

BUILDING SURFACE AFTER CASTING

BUILDING SURFACE AFTER GRINDING

GROUTING

GLUEING

EDF FF (FIT & FORGET) & EDF POLIVALENT

EDF INSTALLATION

Installations dimensions & application limit

EDF FF

INSTALLATION EDILON EDF RAIL ANCHOR EDF Rail anchor

HD T

Installation Method

HD E

HD T

Top Down

HD E

MD T

Bottom Up

MD E

MD T

Top Down

MD E

Bottom UP

Anchor Bold length

260

225

260

225

Drill Depth (mm)

110/135mm

105

110/135mm 110/135mm 105

105

Drill Diameter (mm)

Ø 32 mm

Ø 32 mm Ø 32 mm

Ø 26 mm

Grout layer (mm)

10-35 mm

None appl. None appl. 10-35

10-35 mm

Vert.Adjustable (mm)

Collar Bush (mm)

Ø 35 mm

Ø 35

Ø 26 mm

Ø26

None appl.

Other dimensions can be used in client speciﬁcations!

Edilon can supply the Edilon EDF system in a Fit & Forget version. The Edilon EDF FF is installed according to a Top Down installation method in which the Edilon EDF FF is pre-assembled and mounted on to the rail. Then the track is aligned in height, position and gauge. After correct alignment of the track, the concrete is cast under and around the EDF system.

ADVANTAGES OF THE EDF FF Concrete track supporting plinth/slab is easy to install Relatively high casting tolerances

EDF POLIVALENT The Edilon EDF system can be supplied as a polivalent version. With the Edilon EDF polivalent system it is possible to alter the track gauge. For example from 1668mm to 1435mm. The Edilon EDF polivalent system is supplied such that all provisions for altering the track gauge are already incorporated in the initial installation of the track system. To achieve this, the Edilon EDF baseplate is mounted on a soleplate. In this soleplate sockets are mounted at the required positions for installing the Edilon EDF rail anchors for the different track width.

EDILON DEX-R 2K® The Edilon Dex-R 2K is a high performance anchor adhesive for constructive bonding of anchors in concrete. The Edilon Dex-R 2K is formulated to perform under the most critical conditions which can occur in practice and is tested according the European Technical Approval Guideline (ETAG1/001-5).

ADVANTAGES OF THE EDF FF EDILON DEX-R 2K INSTALLATION REQUIREMENT Drill Method Conditions Application

T (ºC) 35

ADVANTAGES EDILON EDF POLIVALENT Easy reassembly of the track gauge A standard Edilon EDF fastening system is used The Edilon fastening system is mounted on a soleplate which guarantees the maintaining the Top of Rail and inclinations after altering the track gauge.

Diamond Core or Hammer bit drill Dry/Damp/Flooded Hand or Pneumatic dispensor

t-notouch

t-install

t-operate

10 5 1/2

24 (HOUR)

EDILON EDF SYSTEM DEVELOPMENT AND PRODUCTION As with all EDILON products the Edilon EDF system must undergo extensive external system testing to satisfy the strict approval criteria of their various user organizations. These clients include railway companies (e.g. NS, SBB-CFF-FFS, RENFE), metro operators (e.g. Madrid and Rotterdam), and companies that operate tram and light rail lines (e.g. Bilbao, the Hague, Utrecht and Dublin). For many years the Edilon Research and Development Department has collaborated closely with research institutes, certification agencies and the technical universities in Delft, Munich Budapest, Barcelona and Cambridge

PRODUCTION The production of all parts in the Edilon EDF systems EDF are carried out under a strict quality regime. All parts leaving Edilon undergo thorough quality control inspection before shipped to the client.

EDILON, places great emphasis on the continuous development and quality control of all the components contained in the Edilon EDF system. Our goal is to satisfy the special needs of our customers and to develop individual solutions when required.

MAINTENANCE AND REPLACEMENT OF THE EDILON EDF

EDILON EDF SYSTEM

Edilon B.V achieves these objectives by drawing on experience gained in more then 30 years of supplying systems for rail track operations. It employs comprehensive simulation and test facilities such as: climate-testing laboratories, finite element method (FEM) calculations and servo hydraulic testing machines for long-term load testing. In addition to system design from the structural engineering and noise abatement aspects, Edilon has concentrated its efforts towards the following areas:

Edilon supplies the Edilon EDF in different configurations, depending upon requirements such as speed, curve radii, axle loads and required installation method etc.

Edilon EDF can be adjusted both horizontally and vertically allowing small alignment corrections to be made. Edilon also has an EDF version available in which extra correction options are incorporated. These systems have a horizontal adjustability of 15mm (left or right) and a vertical adjustability up to 30mm (height). All parts of the Edilon EDF are easy to replace, including the rail anchor by diamond core drilling and re-installing.

• Lateral stability • Deflection characteristics • Vibration performance • Rail-lift resistance • Temperature stability • Fatigue strength of system and components • Anti-corrosion resistance • Anchor pull out test • Isolation measurements

EDILON RAIL ANCHOR EDF MD/HD E/T

EDILON RESILIENT BASEPLATE PADS Edilon Resilient Baseplate Pads are specifically developed for the Edilon EDF rail fastening system. The baseplate pads can by supplied in different sizes and with different stiffness and vibration damping properties (type 3000 and type 4000). The final choice will depend on the client’s required track characteristics.

The rail anchors, EDF HD and EDF MD have been specially developed for the application in Edilon EDF rail fastening systems and other direct fastening rail systems. Edilon supplies different versions of the Edilon EDF rail anchor for Tram, Metro, Light Rail, Heavy Rail and High Speed Lines. Dependent on the traffic loads Edilon EDF HD or MD rail anchors are used.

The development of Edilon Resilient Baseplate Pads started in the late 1960s when Edilon focused on elastically supported slab track systems. Edilon has thus gained long experience and a good reputation in this field

The Edilon Resilient Baseplate Pad forms part of the product range of special elastomers for rail and track applications, such as:

The Edilon EDF rail anchors are suitable for Top Down installation and Bottom Up installation. The chosen building method defines the length of the rail anchor.

ADVANTAGES OF THE EDILON RAIL ANCHOR EDF E Rail anchor and spring are protected against dirt, salt and moisture, so increasing the life span of the EDF rail anchor The EDF plastic cap is not subjected to corrosion and can be easily loosened when required, even after many years of service The EDF plastic cap gives an excellent reference for installation height of the EDF spring, so reducing installation failure of the spring. When settlement occurs high loadings on the rail anchor can occur which will result in failure of the rail anchor or concrete. The EDF plastic cap will act as a warning because it will fail well before the rail anchor or the concrete will fail

EDF HD T

Edilon Edilon Edilon Edilon

EDF HD E

Combined with the collar bush, additional plastic rings can be installed. This allows the Edilon EDF E rail anchor be adjusted vertical when slab settlement occurs. The plastic rings are removed and the space under the baseplate can be grouted using Edilon Dex-G.

Durable and weather resistant Little variation in properties over wide temperature range (-20 till +50oC) High energy absorption Little creep sensitivity under permanent load Tuneable vertical stiffness Low static-to-dynamic stiffening ratio Low stiffening for higher frequencies Negligible water absorption Very good electrical insulation Fire retardant Resistant to impact loads and extreme loads

Resilient Strips for Embedded Rail Slab Track Mats for Floating Slab Corkelast® Dex®

EDILON RESILIENT 3000 BASEPLATE PAD

MAIN PROPERTIES OF EDILON RESILIENT BASEPLATE PADS

Storage Modulus (MPa)

Edilon supplies the EDF HD rail anchors and the EDF MD rail anchors in two types of locking nut. Edilon EDF T version uses a self locking nut, Edilon EDF E version is supplied with a plastic cap with a integrated nut.

1000

0.8

100

0.6

0.4

0.2

0.1

-80

-60

-40

-20

0 20 Temperature (ºC)

100

CHARACTERISTICS OF EDILON RESILIENT BASEPLATE PADS Type

Compression modulus (typical)

Load range (nominal)

3000 4000

approx. 2.4 MPa approx. 7.5 MPa

to 0.8 MPa to 2.0 MPa

Speciﬁc electrical surface resistance (IEC 60093) Dry Wet >3000 MΩ >150 MΩ >3000 MΩ >150 MΩ

Water absorption (EN ISO 62) <1.0% <1.0%

00 120