EDILON Level Crossing Systems (LC)
edilon)(sedra bv Nijverheidsweg 23 NL-2031 CN Haarlem
P.O.Box 1000 NL-2003 RZ Haarlem
T +31 / (0)23 531 95 19 F +31 / (0)23 531 07 51
mail@edilonsedra.com www.edilonsedra.com
Solutions that won’t shake the world...
www.edilonsedra.com
EDILON LC introduction
the history
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, resulted in the development of ballastless track or slab track systems. Since the introduction of slab track systems edilon)(sedra evolved as a specialist in this field. Based on 40 years of experience edilon)(sedra developed specially for road–rail intersections a range of EDILON Level Crossing Systems, called EDILON LC.
In EDILON LC the use of mechanical fastening systems, such as clips, anchors and baseplates, for both the crossing as well as the rail are made completely redundant because of EDILON Corkelast® ERS. By using EDILON Corkelast® ERS, the rails are connected to the EDILON LC concrete slab in a flexible yet extremely durable way. Continuous elastic rail support means that horizontal and vertical forces are more evenly distributed. Furthermore, the chance of rail breaks compared to traditional level crossing systems based on ballast track, is significantly reduced and rail corrugation is effectively eliminated. EDILON Corkelast® ERS also offers maximum electrical insulation.
EDILON LC have given assurance and comfort for more than 30 years, for both rail and road traffic. The weight and stiffness of the EDILON LC enables a good distribution
GENERAL ADVANTAGES
of forces, which guarantees both a durable as well as a
• Proven minimal costs-of-ownership
settlement free system. In addition the EDILON Corkelast®
• Durable long life structure
Embedded Rail System (ERS) also provides significant
• Proven technology resulting in a range of technical
noise and vibration reduction opportunities, more and more important these days in densely populated areas.
approvals • One structural monolithic unit • Continuous elastic rail support
The EDILON LC range consists of the following types:
• Smooth transition between rail and road
• EDILON LC-H, known as the Dutch “Harmelen”
• EDILON LC track elasticity matches elasticity of
level crossing, installed since 1976 • EDILON LC-1, known as the German “Stelfundo”
adjacent track • Excellent electrical insulation of the track
level crossing, installed since 1997 • EDILON LC-L installed since 2002
COST EFFECTIVENESS • Simple and fast installation • EDILON LC service life more than 30 years • Reduction of rail wear and rail corrugation • Maintenance free
Naturally edilon)(sedra is ISO 9001 certified.
2
• Low lifecycle costs (LCC)
3
Application areas
EDILON LC types
where a road meets rails EDILON LC-H
EDILON LC-1 and EDILON LC-L
EDILON LC is applied in all possible kinds of intersections
All EDILON LC systems meet the various requirements
EDILON LC-H is especially designed for continuous
EDILON LC-1 and EDILON LC-L are both EDILON LC
where road meets rail. There are almost no restrictions.
for heavy rail and high-speed rail. EDILON LC systems
welded track where the high weight of the slabs is of
systems that offer an optimized slab design which still
EDILON LC offers a unique solution, which combines in
all meet the requirements of UIC load model 71 as speci-
major importance to prevent track movement. Because
meets all rail and road requirements with a slab thickness
an ideal way the track ballast bed, rail fastening and the
fied in UIC code 702. The extremely durable longwearing
of the thickness of the EDILON LC-H concrete slabs, the
of 400 mm.
paved road into one structural monolithic unit.
surface meets the highest road load class standard of
structural stiffness is high, which allows application in
The installation of EDILON LC-L and EDILON LC-1 is
By combining EDILON LC concrete slabs, level crossings
load class 60. Certain EDILON LC systems are applicable
areas with a subsoil with low foundation coefficient, ks =
carried out with a “bottom-up” approach were the slabs
from 6 to 50 meters length can be installed in a period
in heavy loaded level crossings with train axle loads
20 MN/m³, which is equivalent to a subsoil modulus, Ev2
are placed on a smooth and levelled split bed with the
of 8 hours, including the removal of the old crossing as
up to 37 tons and heavy traffic axle loads up to 90 tons
= 35 MN/m².
appropriate subsoil foundation stiffness. Application of
well!
The top surface of EDILON LC slabs can be prepared in
The installation of EDILON LC-H is done with a “top-down”
these slabs is possible in subsoil areas with a foundation
Quality and installation speed are both very important.
such a way that high skid resistance values (SRV) can be
approach: the slabs are levelled at the proper Top of Rail
coefficient, ks = 70 MN/m³, which is equivalent to a subsoil
Depending on the condition of the subsoil and the
obtained. SRV of more than 45 up to 70, are possible with
position by using hydraulic jacks and an injection grout
modulus, Ev2 = 120 MN/m².
function of the level crossing in e.g. continuous welded
special concrete mixtures of the top surface.
is used to fix the correct slab position. In this way the
track a choice can be made between EDILON LC-H and
forces of the slab are evenly distributed over the supporting
Protection and strengthening of the rail channels is also
EDILON LC-L or EDILON LC-1.
subsoil. The rail channels are protected and strengthened
possible. Depending on the channel design all vignole
by strong steel edge profiles.
and grooved rails are accommodated.
The fields of application of EDILON LC • main roads with high density of traffic
Embedded Rail Characteristics
• industrial areas with intensive heavy traffic • rural routes
All EDILON LC systems include the EDILON Corkelast®
• in city track
Embedded Rail System (ERS) and offer the following ERS
• crossing with angles up to 0-180°
characteristics:
• S-shaped roads and horizontal turn movements • Continuous rail support • Track stiffness tunable following for instance UIC LM71 • Excellent electrical insulation • Top-down rail alignment and levelling
4
5
EDILON LC-H – type “Harmelen” edilon)(sedra obtained its Dutch product approval for EDILON LC-H concrete level crossing slabs type “Harmelen” in
Features
September 2007 but the principle of the heavy EDILON LC-H system was developed already in 1974 in close co-operation
• Used in heavily loaded road-rail combinations
with Netherlands Railways NS.
• Standard asphalt road approach
ProRail
Netherlands
Since 1976, more than 1250 level crossings of this type have been installed.
• Suitable for roads crossing at angles up to and
Infrabel
Belgium
SNCF
France
The EDILON LC-H level crossing is available in two standard slab lengths.
• Suitable for curved track sections with super elevation
MAV
Hungary
Ontario Northland
Canada
RENFE / ADIF
Spain
REFER EP
Portugal
even exceeding 45 degrees • Intensive heavy road traffic will not move nor damage Concrete slab type
Slab length [mm]
Slab width [mm]
Slab height [mm]
Weight [kg]
Radius [m]
Vmax [km/h]
LC-H6
6.000
2.300
580
20.000
1000
200
LC-H9
9.000
2.300
580
30.000
1500
200
EDILON LC-H • Standard level crossing drainage solutions
Approvals
Slab characteristics • Minimal slab settlement and optimal distribution of forces
Depending on track curvature and rail type the EDILON LC-H slabs can be tapered or wider channels or curved channels can
• Maintenance free
be applied.
• Ability to connect slabs to form longer crossings • Road surface is extremely durable (special dressings and treatments)
EDILON LC-H track curvature slab range
• Edges and channels protected with strong steel LC-H6
LC-H9
Standard slab type
R ≥ 1000m
R ≥ 1500m
Tapered slab with straight channels
225m ≤ R ≤ 1000m
500m ≤ R ≤ 1500m
Tapered slab with curved channels
R < 225m
R < 500m
profiles • Rails fastened securely using EDILON Corkelast® ERS • Reduced rail corrugation • Optimized reinforcement design with C45/55 concrete • Seamless connection to the road surface • Rapid installation method maximizes the track
EDILON LC-H system characteristics
availability
• Maximum train speed
V
200 km/h
• Rail traffic load classes
-
150, 250 and 270 kN
• Road traffic load class
-
Load class 60
• Maximum superelevation/track cant
D
75 mm
• Maximum cant deficiency
I
40 mm
• Maximum cant excess
E
40 mm
• Rail inclination
-
0 or 1:40 or 1:20 or as required
• High skid resistance value
SRV
70 (typical)
• Motorbike, bicycle and wheelchair friendly
• Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements
6
Prefab Embedded - Harmelen LC
7
EDILON LC-1 – type “Stelfundo” edilon)(sedra obtained its approval for EDILON LC-1 concrete level crossing slabs type “Stelfundo” from the German Federal Bureau of Railways already in September 2003. EDILON LC-1 is a logical addition to EDILON LC-H. Developed in the mid 1980’s, these crossings have also enjoyed worldwide acceptance. Although of lower weight, the reinforcement, surface treatments and various colours make the slabs also suitable for a wide range of applications.
EDILON LC-1 slabs are installed on a layer of well compacted levelled grit. Crossings of, for instance, 50m length can be installed in track possessions of only eight hours. Again, steel profiles can be used on the edges of the channels to increase slab durability. It is possible to couple individual slabs to prevent problems caused by subsoil settlements.
EDILON LC-1 system characteristics • Maximum train speed
V
160 km/h
• Rail traffic load classes
-
150, 250 and 270 kN
• Road traffic load class
-
Load class 60
• Rail inclination
-
0 or 1:40 or 1:20
• High skid resistance value
SRV
45 (typical)
• Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements Features • Suitable for all rail and road traffic
EBA
Germany
• Suitable for road crossing angles up to 45 degrees
DB Netz AG
Germany
• Ideal for curved and inclined track
ÖBB
Austria
SBB
Switserland
• Used in all types of road crossings
EDILON LC-1 is available in the following slab lengths:
Approvals
Concrete slab type
Slab length [mm]
Slab width [mm]
Slab height [mm]
Weight [kg]
Radius [m]
Vmax [km/h]
Slab Characteristics
2600
2.600
2.400
400
5.990
85
160
• Various slab lengths available (L codes)
3000
3.000
2.400
400
6.450
100
160
4000
4.000
2.400
400
8.600
200
160
• Maintenance free; no rutting, reduced rail corrugation
4500
4.500
2.400
400
9.675
255
160
• C45/55 concrete with optimized reinforcement design
5000
5.000
2.400
400
10.750
315
160
• Increased safety for cyclists, motorbike and wheel
5500
5.500
2.400
400
11.825
380
160
6000
6.000
2.400
400
12.900
450
160
• Minimal settlement and optimal distribution of forces • Available for curves (R codes) • Highly durable surfacing
chairs riders • Minimal installation times • Slabs can be connected to longer crossings • Re-adjustability after installation possible
8
9
EDILON LC-L edilon)(sedra obtained approvals for EDILON LC-L concrete level crossing in several countries i.e. Poland and France. The principle of EDILON LC-L is based on the proven concept of EDILON LC-H and EDILON LC-1. The EDILON LC-L slab design gives freedom to apply virtually all rail profiles and install track with different gauge widths. EDILON LC-L slabs are installed on a well compacted subgrade with a fine split bed top layer. Steel profiles can be used on the edges of the channels to increase the slab durability. EDILON LC-L is available in the following range of slab
Features
lengths:
• Used in highly loaded road-rail combinations
Approvals SNCF
France
RATP
France
PKP
Poland
Banverket
Sweden
DSB
Denmark
MAV
Hungary
SNCF
France
• Maintenance free
ENR
Egypt
• Ability to connect slabs to longer crossings
APTA
Alexandria
MTRC
Hong Kong
GVB
Amsterdam
• Standard asphalt road approach Concrete slab type
Slab length [mm]
Slab width [mm]
Slab height [mm]
Weight [kg]
Radius [m]
Vmax [km/h]
• Suitable for roads crossing at angles up to 45
LC-L1,5
1.500
2.400
400
3.300
75
80
• Standard level crossing drainage solutions
LC-L3
3.000
2.400
400
6.500
150
80
LC-L4
4.000
2.400
400
8.600
200
160
LC-L5
5.000
2.400
400
10.725
300
160
LC-L6
6.000
2.400
400
12.850
450
160
degrees
Slab characteristics • Minimal slab settlement and optimal distribution of forces
• Durable road surface, special dressings and EDILON LC-L system characteristics • Maximum train speed
treatments possible V
160 km/h
• Rail traffic load classes
-
150, 250 and 270 kN
• Road traffic load class
-
Load class 60
• Rail inclination
-
0 or 1:40 or 1:20 or as required
• High skid resistance value
SRV
45 (typical)
• Edges and channels protected with steel profiles • Rails fastened securely using EDILON
Corkelast® ERS
• Optimized reinforcement design with C45/55 concrete • Seamless connection to the road surfacing • Rapid installation method maximizes the track availability
• Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements
10
11
EDILON LC system design and installation method edilon)(sedra offers a range of EDILON LC systems optimized for supporting the forces from both rail as well as road traffic. A distinction is made in strength and deflection behaviour between different EDILON LC slabs. A common characteristic is that the slabs must be installed on stabilized ground. The ground support stiffness plays an important role in the choice between the different types of EDILON LC systems.
Design on rail and channel
On both ends of the crossing, a steel protection plate
Track facilities
The forces arising from rail and road traffic on the slab are
is mounted to protect the concrete and/or the drainage
EDILON LC systems are compatible with all international
most critical around the rail.
system from impact forces caused by loose couplings,
train control systems.
To understand this, extensive modelling and laboratory
hanging from passing trains
EDILON LC systems have been in service in a wide range
tests are performed to analyze and optimize the system.
of light rail, high-speed and heavy rail applications over a
Rail profile and mechanical properties, channel dimen-
Geotextile mats are preferred to be applied adjacent to
sions, materials and building tolerances are all included
EDILON LC to provide a long lasting stable ballasted
in the process of finding the most durable EDILON LC
track. The concrete slab reinforcement is optimized and
EDILON LC installation method
system possible.
together with the applied concrete the electrical insulation
For all EDILON LC systems a well consolidated subgrade
of the slabs is durably secured.
is essential. The excavation profile depends on the type
period of many years.
Depending on its application and the type of EDILON
of installation. In case of a level crossing replacement
LC a range of standardized channel designs have been
the excavation depth can be kept limited, whereas the
developed which gives freedom to apply each possible
bottom of the excavation should be disturbed as little as
rail profile and will also meet the requirements set by road
possible.
and rail authorities.
EDILON LC-H allows for a “top-down” approach were the slabs are levelled with hydraulic jacks and an injection
System features
grout is used to fix the correct slab position. Because of
The use of slabs means that provisions for cables for
the high structural stiffness of EDILON LC-H, a low ground
signalling, water drainage and a protection against loose
support stiffness is permitted.
train couplings, must be made. Standard solutions are available and can be included in the system design. In
EDILON LC-1 and EDILON LC-L have a reduced slab
EDILON Corkelast® ERS, multi functional plastic tubes
thickness, which requires a reduced excavation depth.
are applied.
The installation of both EDILON LC-1 and EDILON LC-L
These tubes offer the opportunity to:
is done with a “bottom-up” approach were the slabs are
• align the rails in the channels and to adjust the width
placed on a compacted smooth and levelled split bed
of the gauge
with the appropriate ground support stiffness.
• reduce the amount of Corkelast® and so the material costs
In all cases the forces of the EDILON LC slabs are evenly
• pull cables for signalling through the tubes
distributed over the supporting subsoil. Special attention must be paid to the adjacent ballasted track, which must be sound and stable.
EDILON Corkelast® ERS installation materials • EDILON Corkelast®
Rail fastening system EDILON Corkelast® Embedded Rail Systems (ERS) offers many advantages because of its continuous rail support. Track stiffness can be tuned by choosing the appropriate resilient ERS components. edilon)(sedra is able to perform stiffness analysis using finite element methods (FEM) and is able to test new system designs in
12
its own laboratory.
• EDILON Primer 21 • EDILON Primer U90WB • EDILON Resilient ERS Strip • EDILON Dex®-G • EDILON Fillerblocks and tubes • EDILON Nylon spacers • EDILON Polymer wedges • EDILON Polymer (inclination) shims
13
EDILON LC mainten ance and recycling Track with EDILON LC is designed to work exactly how our clients want it to work. Should, for any reason, the track no
recycling and environment
partnership
longer meets these expectations, either maintenance or rail replacement may be necessary. Height corrections of EDILON
All components used in EDILON LC systems are fully
edilon)(sedra supplies EDILON LC as a complete track
LC concrete slabs can be carried out easily by high pressure injecting a special mortar underneath the slabs and lift them in
recyclable. Cured embedding and pouring compounds
system, from initial contacts to system delivery, and from
this way.
can be disposed as domestic waste, in accordance with
commissioning to removal. We work with our clients on
Rail replacement of EDILON Corkelast® ERS is only necessary when rail wear or rail fatigue limits are exceeding the regula-
the European Waste Catalogue.
questions and advice. EDILON LC delivers the benefits
tions, or in the exceptional case that a rail break did occur. EDILON Corkelast® ERS can be removed completely from both
of prefab element quality and rapid installation, and
channels and after cleaning the channels new EDILON Corkelast® ERS can be installed. EDILON Corkelast® ERS installation
combines our specialists knowledge of track, concrete
can be done in very tight track possession periods.
and civil engineering.
rail wear It is well known that a well supported rail as well as one of good quality will have positive influences on the life of the rail. EDILON LC ensures a well supported rail through various aspects: the support of the slab, the weight of the slab, the tight tolerances of the slab, the alignment of the slab and the exceptionally accurate alignment of the rail on the slab. Connecting the slabs together also ensures for better slab support over a longer period of time. Furthermore, a well documented advantage of EDILON Corkelast® ERS is a reduction of rail wear. With EDILON Corkelast® ERS rigid points are omitted. This results in an improved spreading of the forces and significantly reducion of high dynamic forces in the rails. logistics and supply The logistic process for EDILON LC track follows a detailed and accurate planning. Each part, from initial discussions, channel design, production, transport, installation and commissioning, are all included in the planning. All materials supplied are subject to constant quality control.
14
15