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EDILON Corkelast Embedded Rail System

(ERS-LR) Rail Fastening System for tram, LRT and metro

Solutions that wont shake the world

www.edilonsedra.com

EDILON Corkelast Embedded Rail System


(ERS-LR) Rail Fastening System for tram, LRT and metro
Trams, LRT and metro systems have traditionally operated since the beginning of the 20th century extensively on ballastless tracks, and not only on ballasted systems. More demanding requirements arising for example from high-speed trains, greater axle loads, increasing train frequencies, and enhanced environmental consciousness have given rise to the need for further ballastless development.

The EDILON Corkelast Embedded Rail System (ERS) has been developed as the logical response to this challenge: as a high-performance and maintenance-free rail fastening system with especially elastic characteristics.

The ERS rail fastening system is characterized by continuous support of the rails, as well as by the elimination of any and all forms of small hardware components and gauge tie bars. This also means avoidance of the support-point frequencies of traditional, discrete rail fastening systems and it enables trans-fer of live traffic loads more uniformly and with reduced load peaks into the supporting track substructure. The main component of the ERS rail fastening system results from enclosing and bonding the rails with the 2 component dual EDILON Corkelast embedding compound in a concrete or steel trough structure. This unique, long-life material ensures that the rails have homogeneous support throughout, with specifically determined elasticity, in accordance with specified conditions. EDILON Corkelast is a polymer embedding compound with hardness and quantities of filling material (e.g., cork) that depend on the product type. EDILON Resilient Strip controls the rail deflection for ERS rail fastening systems, under the prevailing loads. Such strip mats are available with various thickness and hardness characteristics, according to requirements for system stiffness. The filling material used here primarily serves to reduce the use of embedding compound. Empty pipes employed for the same purpose can also be used to enclose cables for signals and other functions.

BENEFITS

All rail types (e.g. 60Ri2)

Continuously elastic rail support Life cycle > 30 years Minimized life-cycle costs

Filling material

Fast en efficient installation Virtually no maintenance Low track structural height Flexible adjustment of spring stiffness Use with all rail profiles

EDILON Resilient strip

Corekelast

Selection of various track-covering material Maximum of chemical resistance

Concrete- or steel-trough structure

Maximum of stray-current insulation

The ERS rail fastening system was developed in the early 1970s, in collaboration with Dutch National Railways (NS). ERS has been used since 1982 throughout Europe and the rest of the world for applications for tram networks, commuter trains, and underground railway systems. The fields of application for ERS rail fastening systems in the light-rail (LR) version today primarily include urban environments sensitive to airborne and structure-bore noise, as well as urban areas heavily burdened by motor-vehicle and bus traffic. The ERS light-rail versions are designed for axle loads between 8 and 13 metric tonnes (i.e., for trams and commuter trains, with vmax = 80 km/h) and for underground railways with axle loads up to a maximum of 16 tonnes and top speeds of 80 to 100 km/h.

Unique flexibility
RAILS FLUSH WITH SURROUNDING SURFACES Paving blocks, asphalt, or concrete cover Effective for bus and heavy vehicle loads Reduction of structure-borne noise possible Reduction of airborne noise possible Versions as mass-spring systems available TURF TRACKS Optically appealing design Maximum of stray-current installation No maintenance Reduction of structure-borne noise possible Reduction of airborne noise possible LEVEL CROSSINGS / STREET CROSSINGS Models: INFUNDO-LC and EDILON-LC Particular effectiveness for heavy loads Track surface that cannot settle No Maintenance Life cycle > 20 years (complete system) BRIDGES Steel, concrete or composite steel Reduction of track structural height Significant weight reduction Spans to 30m without rail expansion joint Reduction of secondary airborne noise possible

The special flexibility of the ERS rail fastening system is evident in all feasible types of track covering materials as well as in a great variety of application environments: e.g., turf tracks, bridges, tunnels, etc. The ERS of course enables implementation with all track gauges and all types of track geometry, and all railway signalling systems can be effectively integrated.

RADIUS DATA Superelevation upermiss = 180 mm Min. radius 12 m bzw. 15 m (gauge 1.000 / 1.435) Track gauge widening with tight Installation of guiderails possible as option Reduction in tendency to rail corrugation TURNOUTS AND RAIL CROSSINGS In-situ or precast track-supporting layers Possible as mass-spring system Track surface that cannot settle No maintenance Can be fitted to all types of track geometry

TUNNELS Tram, commuter, underground tunnels Rescue and service vehicles can drive over Reduction of tunnel construction height Maximum stray-current insulation Versions as mass-spring system possible CIVIL-ENGINEERING STRUCTURES For example, as trough / cover Low weight Reduction of track structural height Reduction of structure-borne noise possible Reduction of secondary airborne noise possible WORKSHOPS AND DEPOTS Washing and painting lines Great (good) chemical resistance to acidic and alkaline substances Flat and stable surfaces High-load supporting joint sealing TRAIN STATIONS AND STOPPING POINTS Appealing design of the track Simple cleaning of the track surface Rescue and service vehicles can drive over Versions as mass-spring system possible

In combination with the ERS rail fastening system, edilon)(sedra also offer standardized ballastless-track level-crossing and bridge systems. For more information, please consult www.edilonsedra.com.

SPECIAL DESIGNS / ACCESSORY SYSTEMS Tracks with 3 and more rails Drainage boxes and channels Branche-line boxes Signal boxes and signalling loops Turnout heating units, etc. RAIL EXPANSION JOINTS Vignole, grooved, and special profiles Buses and lorries can drive over Reduction of structure- and airborne noise Reduction in wear Reduced and simple maintenance

ERS system design

The flexible application possibilities of the rail fastening systems for EDILON Corkelast Embedded Rail System (ERS) result from decades of development work and experience gained from employment of the systems. The ERS rail fastening systems have been reorganized in application groups (see table at the right). These groups serve as starting point for customer- and project-specific implementation models, as well as for application in ballastless tracks, level-crossing, and bridge systems. These groups accordingly define the basic geometric conditions for trough structures made of concrete or steel. In addition, the ERS stiffness categories provide orientation for resilience and cushioning behaviour under assumption of various load models. It is possible in individual projects to modify the static and dynamic spring stiffness, as well as sound-attenuation level, so as to achieve special matching to technical characteristics for airborne- and structure-borne noise. Each ERS system design undergoes extensive internal and external system testing (e.g., according to EN 13481-5 and EN 13146) as well as official-approval tests. The latest in compu-ter-supported procedures furthermore enable simulation of all conditions acting on the railfastening system. For example, great temperature stability between -20 and +50C can be verified in our own climate-controlled testing chambers

ERS application groups


Group B - Basic Group LV - Serves as vehicle roadway Group LG - Steel bridges/tracks

ERS-LR Stiffness Typical static category spring stiffness (rail) SS MS LS Standard Medium Low 60 kN/mm/m 15 kN/mm/m 9 kN/mm/m

Max. static rail deflection (typical axle loads) < 1.0 mm 1.0 - 2.0 mm > 2.5 mm

NOISE AND VIBRATIONS


Spring stiffness and damping characteristics can be flexibily adjusted Resilience / cushioning of 0.3 - 4.0 mm possible Reduction of structure-borne noise possible Reduction of secondary airborne noise possible Reduction of airborne noise possible

Vertical rail deection under two 10-tonne axles

The standard designs of the ERS-LR rail fastening system are based on an axle interval of 1.8 m and on speeds of vmax = 80 km.

Rail deection (mm)

Axle interval (in m)

Group B - Basic

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AREAS OF APPLICATION FOR GROUP SB


Turf tracks Bridges

50

for example

49E1

35
For example: ERS-LR-B-49E1-MS

Trough constructions Tunnels Civil-engineering structures

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1:40

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ERS rail fastening systems in Group B applications are designed for Vignole or special rail profiles in track areas that are not used by street vehicles driving along or across the tracks. The heads of the rails are open, which allows automatic drainage as well as grinding and re-profiling with high performance grinding machines. In cases of tight radi (less than approx. 100 m), the sealing compound is poured at the outside of the rail heads up to 35 mm below top of rail. The embedding height on the inner side is in all cases 50 mm below the top edge of the rail.
STANDARD PROFILES IN GROUP B
41E1 / 46E1 / 49E1

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SPECIAL PROFILES IN GROUP B
SA42 / S33 / R6 / R41 / etc.

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Group L: Serves as vehicle roadway / Vignole profiles


APPLICATION AREAS FOR GROUP L / VIGNOLe
Tracks flush with surroundings Turf tracks
for example

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Workshop and depots Civil-engineering structures

50

49E1

5
For example: ERS-LR-LV- 49E1-MS

Crossings for pedestrians and vehicles

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STANDARD PROFILES IN GROUP LV / VIGNOLe


41E1 / 46E1 / 49E1

ERS rail fastening systems in Group LV are designed for the use of Vignole or special rail profiles in track areas that can also serve as roadway surfaces for motor vehicles crossing the tracks, or moving along or over the tracks (e.g., for tyred rescue and service vehicles). In standard configurations, the top of the rail is located 5 mm above the surface of the paved track surface. The depth of the flange groove is 50 mm in all cases. Narrow track groove widths (e.g., 40 to 52 mm) assure safety at level crossings, and enable reduced impacts by and for lorries, busses, and the like.

SPECIAL PROFILES IN GROUP LV / VIGNOLe


SA42 / S33 / R6 / R41 / u.v.m.

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Group LG: Serves as vehicle roadway / grooved-rail profile


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APPLICATIONS FOR GROUP LG-grooves
Tracks flush with their surroundings Turf tracks

e.g. for example SEI41GP 59R2

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For example: ERS-LR-LG-59R2-MS

1: 1:

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Group LG versions of ERS rail fastening systems for grooved-rail and special grooved-rail profiles are designed for applications in track areas which are used by pedestrians and bicyclists, or which are crossed or used by roadway motor vehicles as a roadway. According to the profile version, the rail heads are as a rule approx. 5 to 6 mm above the top of the groove head or the top edge of EDILON Corkelast. With tight track radii (less than approx. 100 m), a harder embedding compound can be used to limit head deflection in the upper 4 cm. Generally, no types of rail tie bars are used here.

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STANDARD PROFILES GROUP LG-Grooves


60R1 / 63R1 / 60R2 / 59R2 / 53R1 / 51R1

SPECIAL PROFILES GROUP LG-Grooves


PR55-112 / LK1 / SEI35GPB / SEI35 / SEI41 / Ri45 / Ph37 / Ph37a / u.v.m.

Installation

Installation and geometric alignment of the rails take place in accordance with the two techniques described below (topdown and bottom-up). For the embedding work (emplacing the casting compound), project-dedicated machines pour the compound, or it is emplaced (PLACED) by manual pouring from buckets.
TOP-DOWN
Suspension of the rails by their heads EDILON ERS frame every 3.0m Track position system tolerance= 0.5 mm Precise adjustment of the rail cant

BOTTOM-UP
Installation beginning at trough bottom EDILON Shims and wedges every 1.5 m Track position system tolerance = 1.0 mm Simple handling Traditional mode of construction

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Preventive and remedial maintenance / Exchange of rails / disposal of material


Preventive and remedial maintenance For over 35 years, experience has demonstrated the advantages of ERS rail fastening systems: for significantly reduced maintenance in comparison to traditional track forms. In addition, conventional maintenance work is of course also possible with the ERS-LR system. For more details, please consult the data sheets for EDILON products and systems. Exchange of rails As a result of complete elimination of small hardware components and rail tie bars, it is also possible with ERS rail fastening systems to exchange individual rails without breaking up the track surface. edilon)(sedra leases special asphalt-cutting wheels to effectively perform this work.
ADVANTAGES
Virtually no maintenance Optimal ride comfort over decades Reduced tendency to rail corrugation Reduced wear on the rail head

CONVENTIONAL MAINTENENCE WORK


Cleaning of flangeways (e.g. crossings) Rail grinding (acoustic) Rail re-profiling Surface welding

Disposal of ERS rail fastening systems and packing material


All EDILON pouring and embedding materials are completely recyclable and are classified in accordance with the European Waste Catalogue. For more detailed information, please see the Material Data Sheets. EDILON pouring and embedding materials are classified in hardened condition as domestic waste. Packaging materials are disposed of at no cost to the user.

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edilon)(sedra bv
Nijverheidsweg 23 NL-2031 CN Haarlem T +31 / (0)23 / 531 95 19 F +31 / (0)23 / 531 07 51 mail@edilonsedra.com www.edilonsedra.com

edilon)(sedra GmbH
Kistlerhofstrae 168 D-81379 Mnchen T +49 / (0)89 / 89 28 64-0 F +49 / (0)89 / 89 28 64-20 muenchen@edilonsedra.com www.edilonsedra.com

edilon)(sedra GmbH
Rheingaustrasse 77 D-65203 Wiesbaden T +49 / (0)611 / 928 01-0 F +49 / (0)611 / 928 01-15 wiesbaden@edilonsedra.com www.edilonsedra.com

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