Precast Concrete Solutions for All Seasons

SATEBA is a leader in precast concrete solutions for sustainable rail infrastructure, developed in a safe and responsible way

SATEBA’s rail portfolio includes noise and vibration attenuation sleepers, slab track and ballasted track sleepers, level crossings, embankment erosion management, foundations, signal bases, drainage channels, retaining walls, embankment access stairs, tunnel segments and cable troughs.

Key benefits of working with SATEBA include:

• A range of innovative products proven in the UK and overseas.

• Over 40 years High Speed Rail experience within 85 years+ of UK infrastructure expertise.

• Offsite manufacturing at 27.5 hectare (68 acres) central UK location with easy distribution links.

• SATEBA rail engineers are experts in anything precast combining high performance with sustainability.

• Broad portfolio of precast concrete under track, over track and embankment solutions.

Vibration Mitigation Solutions

SATEBA 312 Sleepers and Bearers can be adapted to any type of sleeper: twinblock, monoblock or bearers, and can accommodate any type of fastening. They are suitable for high speed, mainline and urban lines.

When the Eurostar arrives in London, it does so with serenity. This is partly thanks to the SATEBA S312 twinblock booted slab track sleeper, designed to respond to the noise and vibration mitigation requirements of London tunnels with various levels of performance (5db – 15db). This reinforced sleeper is approved by Network Rail with Certificate of Acceptance PA05/06822.

The M312 monoblock high attenuation booted sleeper, is the result of a joint development between SATEBA and Alstom. The sleeper mass combined with the resilient boot provides extremely high levels of acoustic performance (insertion gain is >20db) comparable to the performance of traditional floating slab track and can be installed up to ten times faster.

M312 sleepers were used on the Elizabeth Line (Crossrail) project which benefited from safe, easy, rapid installation of up to 250 metres per day using the same installation methodology as standard booted sleepers. The M312 is also easier to maintain thanks to the rigid boot.

TW120 installed at Dudley on the Midland Metro Line

All of these benefits result in significant savings in cost, programme and maintenance over traditional Floating Slab Track installation. In favourable circumstances it is estimated that the M312 track can be up to 30 per cent less costly to construct.

Integrated Systems

The SATEBA TW120 sleeper system generates significant cost and time savings on both the track construction and programme. It is used for embedded rail slab track construction and can be used with all fastening systems. For example the TW120 has been used in combination with Trelleborg pre-encapsulated rail, which was directly fixed by a Pandrol Nabla fastening system on the Midland Metro line.

S312 installed at Plumstead on the Elizabeth Line (Crossrail)

This flexible solution allows for rapid installation and accurate alignment of the track by using levelling inserts precast into the sleeper blocks resulting in significant cost and time savings on both construction and programme. It also removes the need for structural support of the rail from the surrounding concrete slab. As a result the TW120 system only requires concreting up to the underside of the rail foot and can then be finished with a variety of materials e.g. grass, asphalt, and block paving. Around 15,000 SATEBA TW120 Sleepers have been supplied to the Midland Metro line.

Carbon Reduction and Sustainability

Decarbonization is a major focus of SATEBA’s environmental strategy. The specialist team has developed pioneering sustainable sleepers using the latest technology, resulting in new profiles with less material incorporating fibre and material with high performance properties. Other developments include products made using recycled steel and decarbonated cement known as green cement with the lowest possible clinker content.

Intensive research and development trials will continue on all aspects of the materials, production, processes and delivery of precast concrete rail infrastructure products. This emphasis will be a normal part of everyday production to ensure the product offering is the best, lowest carbon. SATEBA also buys raw materials as close as possible to production sites to limit transport related CO2 emissions. Precast concrete is highly recyclable so often used in other products or backfill for highway projects.

Each sleeper has a validated carbon value (EPD), guaranteeing a reduced CO2 impact. This is only the beginning as SATEBA is committed to ever decreasing decarbonization to further contribute to preserving the environment. This includes SATEBA targets of ten per cent carbon reduction by 2026 and a 30 per cent carbon reduction by 2030.

MaxumStone Retaining Wall System

MaxumStone is a big block hollow core retaining wall system, manufactured using 40 per cent less concrete than traditional blocks. Free draining material is backfilled into the hollow blocks allowing for a smaller footprint and helping to minimise the effects of hydrostatic pressures behind the wall.

The versatile system utilises big block to reduce construction time, yet the hollow core ensures all units weigh under 650kg enabling lighter weight machinery to be used e.g. 5 ton excavators. The lighter weight does not compromise on strength.

It is also a three in one system that allows gravity, reinforced and cantilever wall solutions without the need to change blocks.

Gravity walls, Geogrid Walls, Terraced Plantable Walls and Cantilever Walls are all easily achievable with this user friendly system that has proven successful on hundreds of projects throughout the world.

Accreditations include RISQS, Supply Chain Sustainability School, Constructionline Gold, ISO 9001, ISO 14001 and ISO 45001.

Projects supplied include:

• Grand Paris Express (current supplier).

• Elizabeth Line (Crossrail).

• High Speed 1 (CTRL).

• TGV in France.

• ICE in Germany.

• Light Rail schemes including Nottingham (NET), Manchester and the Midland Metro.

For further information, get in touch via the contact information below or visit the rail section of the Stanton Precast website.

Tel: 0115 944 1448

Email: info@stantonprecast.co.uk

Visit: stantonprecast.co.uk

Precast concrete is recycled and repurposed