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Sleeper Pads

for Ballasted Track


1 Getzner
Sleeper Pads
The elastic solution for
ballasted tracks and
switches
Increasing operational loads and
speeds in modern railway traffic
present new technical and economic
E lastic sleeper pads from Getzner
are a further development of the
classic railway superstructure. The
challenges to railway managers products are placed directly beneath
around the world. the track sleepers and increase the
vertical elasticity in the superstructure.

S leeper pads offer one opportunity


to meet these challenges: They
preserve the superstructure, improve
With sleeper pads, the load of the rail
cars is evenly distributed over the
elastic components in the subsoil.
the quality of the track geometry and Sleeper pads with defined elastic
reduce disruptive vibrations, both in properties significantly reduce wear
the track and in the switch. on the rail line.

Sleeper pads offer the following Highly elastic sleeper pads can also
advantages: represent an economical alternative to
sub-ballast mats as a vibration-isolat-
— Reduction of maintenance expenses ing measure.
— Lengthening of the service life of the
track structure Getzner has produced sleeper pads
— Reduction of disruptive vibrations since 1990. Today, they are used
successfully around the world on all
Sleeper pads offer operators the types of railway lines, from high-speed
opportunity to significantly reduce the networks to regional transport.
annual maintenance costs for tracks
and switches.

3
2 Functioning
Principle

Load distribution
with sleeper pads

Load distribution
without sleeper pads

4
Padded sleepers

T he most common type of super-


structure used in the world is
ballasted track. Ballast, as the weak-
est link in the system, is subject to
latent dynamic shifting. Constant loads
(ballast compression) lead to wear
and breaking up of the rocks. These
effects diminish the quality of the track
geometry, and the track bed must be
tamped.

The effective installation of sleeper


pads slows down this process in the
following ways:

Distribution of the axle Increase of the contact Weakening of the dynam-


load over a larger surface between sleeper ic forces and vibrations
number of sleepers and ballast in the ballast

The elastic properties of the The unique properties of the Sleeper pads from Getzner
sleeper pads lengthen the polyurethane material from reduce the direct dynamic load
bending line of the rails. The load Getzner result in an ideal embed- on the ballast. They reduce
from the train is distributed over ding of the ballast in the surface shifting of the ballast as well as
a larger number of sleepers and of the sleeper pads, stabilizing settling of the track.
therefore over a larger area. This the top-most ballast layer. This
reduced average compression yields an increase in the contact
also reduces the load on the surface between sleeper and
ballast. ballast from about 8% (without
padding) to up to 35% (with
padding).

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3 Applications

Improvement in the
long-term behavior of
ballasted track
The effective use of sleeper pads from shown that the length of tamping
Getzner results in a reduced load on intervals can be at least doubled with
the ballast. This in turn reduces this procedure. The positive effect of
ballast break-up and abrasion. sleeper padding becomes clear particu-
larly quickly in areas subject to heavy

T he ballast is optimally embedded


thanks to the plastic properties of
the pad, resulting in decreased ballast
loads, such as switches, structures or
track sections with very small curve
radii.
shifting. This method directly helps
preserve the ballast bed and slows The advantages of padded sleepers are
settling of the track considerably. particularly impressive on heavy-laden
Experiences in recent years have sections with up to 37 tons of axle load.

Track geometry quality

Insufficient
Changes in track geometry
Intervention threshold quality on a test stretch in
Sufficient Austria since 2001.

The improvements in track Straight tra


Good quality in track sections 1 Straight tra
and 2 as well as the station
area were achieved through Track sectio
Very good
tamping. Stop in stat
Straight track section 1 (unpadded)
2001 2002 2003 2004 2005 2006 2007 2008
Straight track section 2 (unpadded)Year

Straight track section 1 (unpadded) Track section radius 425 m with padded sleeper

Straight track section 2 (unpadded) Stop in station area (unpadded)

2006 2007 2008


Track section radius 425 m with padded sleeper
Year
6 Stop in station area (unpadded)
Vibration protection and
reduction of secondary
air-borne sound
Highly elastic pads offer a simple No significant changes to the directly vibration-isolating characteristics are a
method for reducing vibrations on emitted air-borne noise have yet been very effective measure for reducing
railway lines that is cost-effective in identified. secondary air-borne noise.
comparison with sub-ballast mats. In
addition, they exhibit all the positive Secondary air-borne noise arises due
properties of elastoplastic padding. to the sound emission of a structure
that is stimulated to vibrate, for

D epending on the maximum per-


missible rail deflection, padded
sleepers achieve insertion losses on
instance by a passing train.

This applies in particular to metal


the order of 10 dB(v) to 15 dB(v) (at structures, such as steel bridges and
63 Hz). viaducts. Elastic sleeper pads with

Effect of sleeper padding

30
Insertion loss (dB)

20

Reduction
10 The vibrations are reduced in the
Openfrequency
critical track sectionrange, which also

reduces
Tunnel far emissions
the track bench to the
0 neighboring environment.
Amplification Tunnel near track bench
Source: Köstli K.; Sleeper Padding for Reduction of Structure-
ction Borne Noise Immissions; p. 10; conference articles, 10th
Symposium on Structural Dynamics and Vibration Measurements,
Ziegler Consultants 2007.
-10 Open track section
5 6,8 8 10 12,5 16 20 25 31,5 40 50 63 80 100 125 160 200 250
Tunnel far track bench Frequency (Hz)

Open track section Tunnel near track bench

Tunnel far track bench

31,5 40 50 63 80Tunnel
100 near
125 track
160 bench
200 250
Frequency (Hz)
7
0 200 250
Reduction of Specifically defined elas-
short wave formation ticity for padded switches
Short waves are periodic bumps in the The bedding stiffness varies over the reduces passenger comfort. In addition,
track surface. course of a switch. This is due to the vibrations are transmitted to nearby
different sleeper lengths and stiffen- buildings via the subsoil.

M ulti-year studies have shown that


sleeper pads significantly slow the
occurrence of such track damage. This
ing components, such as the frog,
check rails or wing rails. Getzner offers a combination of
different sleeper pads (stiffnesses)
is particularly noticeable on narrow
track bends that are susceptible to
short waves.
T he different bedding stiffness
values result in a dynamic load
when a train passes. This leads to a
specifically for switches. The load
transmission to the superstructure can
be homogenized with these pads.
rapid wearing of the track, which Differences in deflection are minimized,
increases maintenance costs and resulting in smoothing of the switch.

Short wave development in track bends over time

0.20
Average wave depth in mm

25 million t*
Without
(Track bend radius: 230 m) sleeper pad
20 million t*
0.15

0.10 With Sylomer®


15 million t*
10 million t* sleeper pad with
bedding modulus
~0.15
~ N/mm3
5 million t*
0.05
0 million t*
*Track load
in gross tons Final report Hieflau,
0.00 University of Innsbruck 2001
2003 2004 2005 2006 2007 2008
Time

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An even load pattern is also produced, — Smoothing of deflection during train
which helps preserve the ballast. passes
— Increased passenger comfort
Sleeper pads from Getzner also — Preservation of the ballast
contribute here to lengthening the — Reduction of disruptive vibrations
intervals between tamping and — Reduction of life-cycle costs (LCC)
maintenance work. Increased passen-
ger comfort and lower life-cycle costs The deflection during train passes can
make sleeper pads from Getzner a be simulated with a specially developed
popular solution among railway computer model and optimized through
managers. the effective use of Getzner pads.

Adaptation of track
stiffness at transitions

S leeper padding helps to decrease


large jumps in stiffness and
thereby deflection as well as to reduce
voids under the sleepers. These occur
primarily at transitions where super-
structures with different stiffness
values meet. The sleeper padding
Ballasted track Bridge results in a more homogenous train
passage as well as preservation of the
superstructure components.

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4 Using Sleeper Pads
Pays Off

Consideration of the life-cycle costs (LCC)


when using sleeper pads
The extent to which the use of sleeper point to a significant lengthening of the
pads alters the track geometry quality life of the entire track bed.
has been systematically recorded for
several years. The results are continu- In addition, if costs for operating
ously influencing development work. complications that arise from track
closures for maintenance work are

O ne observation is a lengthening of
intervals between tamping work by
a factor of 2 to 2.5 thanks to the use of
considered, sleeper pads are an
extremely economical investment,
particularly on track sections subject
sleeper pads. If one considers the to heavy loads.
tamping cycle as an indicator for the
achievable service life of a track,
longer periods between tamping work

Composition of the normalized annual costs


(heavily used track)

120%

100
100%

80%
71
61
60%
48
Statistical analysis
40% (interest rate 0%)
23
Annual costs
20%
16 13 Depreciation
10
Operating complication costs
0% Maintenance costs
Conventional super- Superstructure
structure with 60E1 rails with 60E1 rails and
and concrete sleepers padded sleepers

10
5 Experience with
Sleeper Soles

Widely proven
Almost all major railway companies in Getzner pads that have been removed
Europe have successfully used sleeper for testing. In addition, measurements
pads from Getzner for over 18 years. taken on padded track sections also
verify the excellent quality of the

S leeper pads are used for vibration


protection, to provide elasticity for
large bridge structures, to improve
sleeper pads.

To ensure a long service life for sleepers,


track geometry quality and to reduce the durability of all types is inspected
track maintenance costs. according to BN 918 145-1. These tests
are either performed externally at a
The sleeper pads from Getzner have certified testing agency (e.g. Munich
outstanding long-term properties. This University of Technology) or internally
is demonstrated by sleepers with on Getzner’s large test bench.

Getzner’s large test bench

Getzner padding SLB 2210G after 190


million total tons. The plastic impres-
sions in the material prevent shifting
by the top ballast layer. No cracks or
perforations can be seen in the
padding.

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6 Sleeper Selection – The Right
Getzner Pads for Every Application

Getzner sleeper pads, the


broad product selection

T hree materials – available with


different stiffness values – com-
pletely cover the application spectrum
The three materials:
SLB – Elastoplastic material
SLS – Elastic material with damping
from highly effective vibration protec- properties
tion to improvement of track geometry SLN – Highly elastic material without
quality. damping

SLB
types

Vibration protection

SLS Tram line


types 100 kN

Underground line
120 kN

Standard-gauge railway
SLN 250 kN
types

Freight train
Axle load (heavy axle loads)
370 kN

 12
Oresund Bridge

The right pad for Selection of the


every track ideal Getzner pad
Getzner’s specialty is microcellular If a reduction of vibrations is the Getzner has the optimal pad type for
polyurethane elastomers with a wide primary aim, SLS-type (Sylomer®) every application. The appropriate
range of properties for railway elastic pads and the highly effective types are selected according to the
superstructures. Sylomer® and SLN (Sylodyn®) types are used. maximum permissible rail deflection
Sylodyn® components have proven under a defined load.
themselves for decades under ex- While pads made of Sylomer® still
treme conditions in a wide range of
industries.
exhibit certain damping properties,
solutions with Sylodyn® achieve a
nearly identical relationship between
T he individual pad types within a
material group differ primarily in
terms of their elasticity. The elasticity

G etzner offers the optimal sleeper


pad for every application: from the
elastoplastic SLB types exclusively for
static and dynamic stiffness. This
makes an extremely effective solution
possible even with minimal additional
is determined using the bedding
modulus. This takes place according to
DIN 45673-1 in a test on a ballast
improvement of track geometry quality rail deflection. profile slab (standard ballast slab).
to the highly elastic pads made of Getzner provides optimized pad types
Sylomer® (SLS types) and Sylodyn® for tram lines, underground lines, rapid
(SLN types) for effective reduction of transit, standard-gauge railways,
vibrations. high-speed tracks and special applica-
tions, such as heavy axle loads of up to
SLB-type elastoplastic pads are used to 37 tons.
reduce the load on the ballast. The
optimized material properties of these
types permit a particularly stable
embedding of the ballast. The high
damping of these pad types has a
positive effect on the vibration behav-
ior of the sleeper.

Elastoplastic pads reduce the annual


maintenance costs and lengthen the
service life of a track.

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7 Secure
Fastening

Assembly at the Installation of padded


sleeper plant concrete sleepers
Sleeper pads from Getzner can be Padded sleepers can be installed
adapted to every sleeper type. using all typical methods.

P ads for concrete sleepers are


typically manufactured with an
installation grate (“G” at the end of the
D ue to the relatively low weight of
the pads, the number of sleepers
per car can remain unchanged. There
type designation). This unique installa- are also no restrictions on track
tion grate from Getzner is integrated maintenance work.
into the padding and permits a full-
surface attachment of the pad to the At the transitions between padded and
sleeper. The installation grate is unpadded tracks, it may be necessary
pressed into the concrete while it is still to change the stiffness in stages. This
Sleeper production moist during the production of the applies primarily to soft pads (bedding
sleepers. The form-fitting, full-surface modulus < 0.15 N/mm3). Getzner
connection ensures a lasting bond recommends using padding with a
between the pad and the concrete higher stiffness over a length of 20 to
sleeper independent of the production 30 meters for such stiffness adapta-
process and concrete consistency. tion.

The connection process requires no


additives or extensive preliminary work
while fulfilling even the very high
requirements of the standard BN 918
145-1. If desired by the customer, pads
can also be attached to concrete
sleepers that have already hardened.
Installation train with switch padding In such cases, the sleeper pads are
delivered without an integrated
installation grate. The pads are glued
on with a suitable adhesive, which
Getzner can also supply, if desired.

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8 International
References

Getzner projects
speak for themselves

Getzner solutions can be found around Goal: Sleeper pads for vibration Goal: Elastically supported
the world – as can the Getzner team. isolation switches

G etzner Werkstoffe is present in the


most strategically important parts
of the world with its four branch offices.
— Metro Amsterdam East Line,
Netherlands
— Bruchsal Tunnel, Germany
— ÖBB, Austria
— DB, Germany
— SBB, Switzerland
The company serves practically all of — Umega Oka Line, Japan — CR, Czech Republic
the relevant markets in the world — Britomart Station, New Zealand — Pro Rail, Netherlands
through numerous sales partners. — Matstetten-Rothrist, Switzerland — Jernbaneverket, Norway
— Timelkam, Feldkirch and Hallwang,
“Sleeper Padding for Ballasted Track” Austria
reference list (excerpt):

Goal: Ballast preservation and im-


provement of track geometry
quality

— ÖBB, Austria
— DB, Germany
— SBB, Switzerland
— SNCF, France
— Bane Denmark, Denmark
— KR, Korea
— Jernbaneverket, Norway
— CR, Czech Republic
— Infrabel, Belgium
— ADIF, Spain

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Getzner Werkstoffe GmbH Getzner Werkstoffe GmbH
Herrenau 5 Middle East Regional Office
6706 Bürs Abdul - Hameed Sharaf Str. 114
Austria Rimawi Center - Shmeisani
Phone +43-5552-201-0 P. O. Box 961 303
Fax +43-5552-201-899 Amman 11196, Jordan
info.buers@getzner.com Phone +9626-560-7341
Fax +9626-569-7352
Getzner Werkstoffe GmbH info@geme.jo
Am Borsigturm 11
13507 Berlin Nihon Getzner K.K.
Germany Landmark Plaza, 8F
Phone +49-30-405034-00 Shiba Koen 1-6-7, Minato-ku
Fax +49-30-405034-35 105-0011 Tokyo, Japan
info.berlin@getzner.com Phone +81-3-5402-5340
Fax +81-3-5402-6039
Getzner Werkstoffe GmbH
Nördliche Münchner Str. 27a
82031 Grünwald
Germany
Phone +49-89-693500-0
Fax +49-89-693500-11
SchwSohl. SO E © Copyright by Getzner Werkstoffe GmbH | 09-2008

info.gruenwald@getzner.com www.getzner.com

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