Prospekt OEBB-Porr FF-System En

SLAB TRACKSYSTEM ÖBB–PORR ELASTICALLY SUPPORTED TRACK BASE PLATE

70270 Feste Fahrbahn Englisch 16.02.2007 12:26 Uhr Seite 1

2

Optional intermediate storage of track base plates

Production of track base plates in prefabrication plant

GENERAL

The slab track (ST), system ÖBB–PORR elastically supportedtrack base plate, has been jointly developed by the AustrianRailway Corporation (ÖBB) and Allgemeine Baugesellschaft –A. Porr AG. Since 1995 it has been the obligatory system inAustria and since 2001 it has also been used in the construc-tion of bridges and tunnels in Germany. No problems haveoccurred on the tracks already in operation, covering a dis-tance of approximately 100 km. The oldest section has beenin operation for 17 years without maintenance and servicecosts.

TRACK BASE PLATE (TP)

CONSTRUCTION

The principal element of this system is the elastically supportedtrack base plate. The track-base-plate-system ÖBB–PORR isbased on a 5,16 m long pre-fabricated reinforced concreteplate with untensioned reinforcement. Thus eight pairs ofsupporting points type Vossloh 300-1 are integrated at inter-vals of 65 cm. The sole of the plate as well as the taperedgrouting openings are provided with an elastic layer fordecoupling. This results in a reduction in the vibrations emit-ted into the foundation (damping of structure-borne noise).The system weighs 1 t per linear meter and is therefore a lightmass-spring-system.

PRODUCTION, STORAGE AND TRANSPORT

Production is made in a prefabrication plant and/or a fieldplant and is therefore independent of weather conditions. Dueto a complete quality assurance system a constant high qual-ity is guaranteed and documented. The used steel formworksare adjustable and so they completely cover all radii ranges.Reductions, block outs, coverings, dowels etc. can be fore-seen with millimetre accuracy using adequate layers. Due tothe “just-in-time-principle” storage place is as a rule providedin the company plant only. From there the track base platesare normally transported to their destination by wagon. The5 t heavy plates are fastened using a special traverse grab-bing into the grouting opening. Each of the track base platetypes is unmistakably marked with a corresponding bar codeset in concrete and can therefore be easily identified at anytime if intermediate storage is necessary. The unloading ishandled with the necessary unloading equipment (portalcrane or lorry with crane) or with any other lifting device ifintermediate storage is essential.

TRACK BASE PLATE SYSTEM ÖBB–PORR

Length 5,16 m (2,56 up to 5,16m)

Width 2,40 m (2,10 up to 2,40m)

Depth 16 cm (16 / 24 cm)

Openings 91 x 64 cm (top)87 x 60 cm (bottom)

Weight: 50,00 KN (gross)51,40 KN (using Vossloh 300-1)

Types: Linear (R>3697 m)Radii (R=200 up to 3697m)Railway/suburban railway/undergroundRail: 60E1 (E2) / S54 / S48U


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Slab track system ÖBB–PORR – cross section + top view

Block out in track base plate for pump shaft – longitudinal section

SLAB TRACK, SYSTEM“TRACK BASE PLATE ÖBB–PORR”

ASSEMBLING

The slab track system ÖBB–PORR elastically supported trackbase plate, is built on a solid or low-subsidence base struc-ture such as, for example, a tunnel invert, bridge constructionor hydraulically bond base layer on mass spring systems. Asa rule, the grouting thickness is > 8 cm and therefore the sub-structure height up to the upper edge of the track is 60 E1(E2) > 47,3 cm. Through the tapered grouting openings apositive locking compound of the track base plate and theconcrete joint sealing compound is achieved.

If a modified concrete joint sealing compound without rein-forcement is used (> 4 cm), a construction height of > 43,3 cm60 E1 (E2) can be achieved if necessary. This ensures theessential flexibility, for example, to optimise cross sections oftunnels and bridges or to realise track lowering in order toobtain a bigger cross section (clearance) in already existingold tunnels (for example Arlbergtunnel and Tauerntunnel).

Unlike sleeper systems, track base plates can provide bigblock outs, for example for revision and bearing shafts wher-ever needed. Block outs of 1,80 m x 0,80 m have alreadybeen utilized in the tunnel of the north-south-connection inBerlin. By reduction of the track base plates, cable crossingsof 250 mm width can be planned.

BASIS FOR MEASUREMENTS AND SPECIFICATIONSACCORDING TO EUROCODE (EC)

Vertical loadsFreight train UIC 71Heavy load train SW 0 acc. UIC 776-1ESpeed v = 250 km/h (A) respectively v = 330 km/hAxle weight Pmaxstat. = 250 kN at v = 120 km/hWear out per support point:Qdyn = 125 x 1,67 x 1,25 = 261 kN

Horizontal loadsSide shock H = 100kN, but horizontal force ina mounting axle H = 60 kN; effects of startingand braking

ReinforcementProportion of steel approximately 6 % - mildsteel 550, in case of mild steel 500 appropri-ately higher

Quality of concreteTrack base plates

C 30/37 / XC3 / XF3 / XA1L / GK 16 / F 52Concrete joint sealingcompound > 8 cm

C 25/30 / XC3 / XF3 / XA1L / GK 8 / F 73 (scc)C 25/30 / XC3 / XF3 / XA1L / GK 16 / F 73 (scc)

Concrete joint sealingcompound > 4 cm

C 55/67 / XC3 / XF1 / XA1L / GK 4 / F 73 (scc)

Weather conditionsBesides the safe carrying of the loads of therailway traffic, the absorption of environmentalinfluences (temperatures) and the discharge ofsurface flood water has to be secured reliablyon a long term basis. The track base plates areconnected with each other only by the passingthrough tracks enabling a length compensationwithin the 40 mm wide joints. Therefore any deformations caused by temperature cannotcause any damage. Furthermore the joints canalso be used for drainage.

823

concrete subbase

upper edge ofthe track 0.00

-1.32

drainage piping

tubbing segment

16

-1.55

incline concrete

1.836

1.800

-0.47

1.80050 50

30 302 2

18 18

block out1800/700

chequer plate 7/9 zinc-dipped

zinc-dipped angle ironelasticlayer

track base plate

concrete jointsealingcompound

393

≥80

5.200

640

650650 650 650 650 650

earth connection track supporting component

≥473

upper edge ofthe track 0.00

2.400

640

concrete jointsealing compound

elastictrack bed

rough clean surface -- invert concreteelastic layer

240

160

80

reinforcement

60E1(E2)

650

concrete joint sealingcompound opening

920


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Bedding of the supporting points and track base plates under traffic load

Portal crane

Laying of track base plates with lorry

MODE OF OPERATION

The bedding necessary for the load distribution on the track isguaranteed by the elasticity of the track mounting. In additionthe elastic rubber granulate layer, amounting to approximate-ly 10 % of the total elasticity, has the effect that high forces arewell distributed and causes a reduction of the stress in themulti-layered system.

PRODUCTION

Laying

The laying of the track base plates, which have a width of just2,40 m (2,10 m), is normally done with portal cranes. Thisenables the plates to be lifted forwards in the smallest possi-ble space. In addition, no reloading or intermediate storage isnecessary, because the plates can be taken directly from thetransport wagon. In the case of islands or missing track con-nection, the take over and the laying of the track base platesby lorry with loader arm is the usual practice.

In any case, the track base plates are being laid at the desti-nation with an accuracy of + 1 cm in order to minimize thework needed to adjust them.

Adjustment of tracks

After the partial spreading of the tracks positioned at the side,the work of adjusting the final track begins by using a M36-spindle. This method guarantees precise track set accuracy insetting the track requiring no further correction.

Adjustment work is further reduced by an adequate trackgeometry of the track base plates. Therefore the time involvedfor the adjustment is reduced by up to 50 % in comparison toother slab track systems.

Laying of under traffic load

free bearing

stressed track

under consideration for plate bedding

MP1 MP2 MP3 MP4 MP5 MP6 MP7 MP8 MP9 MP10 MP11 MP12

bedd

ing

in m

m

-4,00

-3,50

-3,00

-2,50

-2,00

-1,50

-1,00

-0,50

0,00

bedding measured in 6 MP /calculated according to stress application


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Measurement of track positioning with track measurement wagon

Concrete pumps up to 500 m

Concreting of track base plate with scc (self compacting concrete)

Cut out – top view + longitudinal section

Lifting – top view – longitudinal section

Concrete

According to the space available, the concrete joint sealingcompound is applied either directly or through a hose pumpup to a maximum of 500 m. The use of a self-compacting con-crete joint sealing compound enables a holohedral embeddingof the track base plate. As a result of the vibration-free concret-ing process (without vibrator), the fine-tuning of the track unitis not affected. Furthermore, it is possible for these slab tracksto be installed in a short railway block (example: East-West-Connection Berlin 2002) due to the fast setting process of thescc-concrete. The concrete joint sealing compound is ade-quately reinforced in order to limit wide cracks.

DAMAGE CONCEPT

A further advantage of the elastic layer is its separation fromthe concrete. Therefore the two tapered grouting openings,which prevent a lift off of the track base plate, can be cut freeor chiselled out and the track base plates can be replacedseparately within three to four hours.


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Concreting of refurbishment-track base plate – top view + longitudinal view

Shield section – Sectional view

Slab track in shield section

Berlin – Main station – Lehrter railway bridges with slab track

BASE STRUCTURES

TUNNEL FLOOR

Tunnel floors have normally no or little subsidence andthey are therefore an ideal base structure for slab tracks.The slab track system ÖBB–PORR elastically supportedtrack base plate can be directly mounted onto the tunnelfloor. For surface dewatering every 50 m, or in the portalareas every 25 m, semi-troughs are put diagonally into theconcrete joint sealing compound. The remaining spacesup to the top layer of the concrete are usually filled withgravel or concrete.

BRIDGE

Bridge girder systems can, like tunnel floors, be used as adirect base structure for the slab track. The horizontal pressureis transferred within a narrow radius into the bridge construc-tion by the use of concrete blocks. In Austria it is refrained fromthe labour-intensive application of concrete blocks.

1.600 1.700

3.300

1.730 1.570

1.520

86.0 66.0 94.01.680

74.0

78.0

45.5

32.5

Tra

ck a

xle

Tun

nel a

xis

Concrete joint se al ing compound

Track base plate

Ballsting

+0,18

-0.60

SOK ±0.00

Bridge with slab track on Elastomer mat – sectional view

Track axle Bridge axle

Balast

1,5%

2%

Noise absober trackTrack base plate “ÖBB-PORR”Concrete joint sealing comoundElastomer structureSupporting structure

Ballast

Concrete blocks


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Track crossing construction (track support structure)

Track crossing construction – longitudinal section + cross section

Slab track – Open section

Open section – cross section

Essential differences occur due to the rather high deforma-tion, by disfigurement or shrinkage, caused by temperaturedifferences, subsidence, or traffic loads as well as creep andshrinkage. Especially at the bridge joints deformations cancause unacceptably high track tension and lifting of track sup-porting points. In such cases special track-crossing construc-tions are necessary in order to reduce deformations to anacceptable extent. For example, on the 25 bridge girder sys-tems of the east-west-connections, a total of 50 special track-crossing constructions were built, and twelve joining areaswere directly built over with slab tracks (on extensive slidingbearings).

EARTH STRUCTURE

The laying of earth structures is done on a load distributionplate or a hydraulically bond supporting layer. Based on thehigh degree of prefabrication of the track base plates and therelatively small grouting openings, quality influences due toweather conditions are kept fairly low. This also applies tomounting on bridge constructions.

210 210

A

A

Longitudinal member

Cross member

Bearing

Section A-ATrack 60E1(E2)

4x longitudinal member

Track 60E1(E2)

Steel wedge

4949

79.2 70.6 79.2

Concrete

Cross memberBearing

Track base plateTrack base plate

-0.80

Upper edgeof track± 0,00

Balast,granulate 1washed

WU concrete (C25/30)

Elastically supportedtrack base plate

Tra

ck a

xle

Soil exchange

Bitumen cating

Steel concrete distribution plate d = 30 cm

Concrete jointsealingcomound

Rai

l axl

e

Partialdrainage pipemade of concreteDN 200

Absorbing plates

Bitumen cating

6%

20 2.40 20

2:3

drainage materialballast


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Bearing shaft with bearings when lifting the mass trough

Slab track in shield section – cross section

Slab track on extensive elastomer bearing (massspring system without trough) – sectional view

Application of elastomer

MASS SPRING SYSTEMS

In case of increased demands on protection against structure-borne noise, the system can be layered on a mass springtrough (example: cross section mass spring system in tunnel)or in case of lower construction heights, directly on the exten-sive elastomer support (example: cross section mass springsystem on bridge).

The possibility of making block outs in any part of the trackbase plate, enables a space-saving positioning of the bearingshafts in the track axle.

Due to the low height of the system (> 47,3 cm), mass springsystems without troughs can be produced for low construc-tion heights, for example 25 Hz on approximately 50 cm. Onthe bridges of the main station Lehrter Bahnhof, a softer elas-tomer was applied in the centre of the concrete blocks area,unlike in the side areas, in order to avoid punching.

Steel concrete mass trough

elastic singel bearings

Rail 60E1 (E2)

Concentric noise absorberTrack base plateConcrete joint sealing compoundElastomer matSupportingstructure

Tra

ck a

xle

2%

Balast

Elastomer mat

Elastomer mat

Concrete block

Noise absorber at theedges


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Noise absorber

Section A-A

Guard railAdapter plate

Compensating plate

Elastomer base plate

Elastomerbase plate

Thread rod

Base plate

Anchorage device

Section B-B

Track magnet

Blockage

Coated reinforcementfor example using AGROVAN 209

Conductor rail support REHAUheight adjustable

Adapter plate

Compensation plate


Adapter plate

Compensation plate


Section C-C

AA

BB

CC

Additional equipment of the track slab system ÖBB-PORR – sectional view + top view

ADAPTATION OF ADDITIONAL EQUIPMENT

The track base plates provide a prefabricated bearing surfacewith millimetre accuracy, for example, in order to absorb thenoise of traffic and railway crossings. Therefore, dowels with millimetre accuracy, can be used, for example, for guard rails,

ADAPTATION OF ADDITIONAL EQUIPMENT

blockages, track magnets and conductor rails. In areas of fre-quency control, the reinforcement can be insulated againstoutside influences.


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Transition area slab track / ballast (Germany) – longitudinal section, top view + sectional view

TRANSITION FROM BALLAST TO SLABTRACK

Transition from ballast to slab track system, “track base plateÖBB–PORR”, is carried out according to the standard cata-logue for building slab tracks (4th edition) or in accordance

TRANSITION FROM BALLAST TO SLABTRACK

with the ÖBB regulation RZ no. 17220. The ballast area issolidified by the use of a well-tried procedure with syntheticresin.

AA BB

6060

2.40

02.

800

60606565

60

Slabtrack (FF)Track base plate

Slab Track withprestressed-concrete sleepersNumber of sleepers 2,4 m long

8 straight 16 bent

Slabtrack Ballast

Ballast15 reinforced concrete sleepers2,60 m long15m

20 Stk. Point concrete sleepers 12.00 m

Ballast withstandard sleepers

Partial bonding: (1) rail foot 0.7-0.8 m wide, 0.15 m deep2. Every second space 0.15 m deep

22.8 m≥

Elastically bonded ballast 30.00 m - 35.00 m

Surface bonding includes strip along sleeper ends, 0.2-0.3 m wide and 0.2-0.3 m deep30.00 m - 35.00 m

Full bonding 2.60 m wide approx0,15 m deep 7.2 m

Trackform 60E1(E2) Tuxiliary track: track form 60E1(E2)

65 65

Upper edgeof foundation

Concrete subbase

Concrete joint sealing compound

Track base plate

Hydralicallybond foundation

Section A-A

60 ca. 60

Section B-B

60

ca. 30

Elastic bond ballast

6.5

24.5

Österreich RZ 17220

Hydralicallybond foundation

Upper edgeof foundation


REFERENCES

Finally, the ÖBB–PORR slab track system, is impressivebecause of the visible concrete quality of the prefabricated

REFERENCES

parts and because its application has now been maintenance-free for over 17 years.

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TOTAL 124.038 m

Langenlebern 1989 Test track in the field 264 m

Tauerntunnel 1992 Tunnel refurbishment track 2 2.629 m

Helwagbrücke 1993 New bridge construction 52 m

Galgenbergtunnel 1996/1997 New tunnel construction, light mass spring system, bridge 11.040 m

Römerbergtunnel 1997 New tunnel construction, light and medium mass spring system 638 m

Zammertunnel 1998/1999 New tunnel construction, light and medium mass spring system 4.477 m

Kaponigtunnel 1999 New tunnel construction and bridge, light mass spring system 11.170 m

By-pass Melk 1999/2000 Wachbergtunnel, Melker tunnel, bridge 9.042 m

and field, light mass spring system

Wolfsgrubentunnel/Arlbergtunnel 1999/2000 New tunnel construction, medium mass spring system 3.730 m

Siebergtunnel 2000/2001 New tunnel construction 12.902 m

S7-Rennweg Airport 2001/2002 New tunnel construction, medium mass spring system 3.250 m

Blisadonatunnel 2002 New tunnel construction 4.865 m

Tauerntunnel 2002/2003 Tunnel refurbishment track 1 + 2 9.880 m

Unterwaldertunnel 2003 New tunnel construction 2.480 m

Junction Rohr 2003 New tunnel construction 1.691 m

Junction Wagram 2003 New tunnel construction 2.870 m

Lehrter Bahnhof 2001/2002 Bridges/light mass spring system track base plate on 4.690 m

(east-west-connection) slide bearings 50 joint crossing constructions

Lehrter Bahnhof 2002/2006 New tunnel construction / light, medium and heavy 8.944 m

(north-south connection) and heavy mass spring system / big block outs

Birgl- and Kennlachtunnel 2004 New tunnel construction and light mass spring system 2.650 m

Pistentunnel S7 2005 New tunnel construction, medium and heavy mass spring system 1.412 m

Lainzer Tunnel 2006/2007 under construction 4.550 m

Arlbergtunnel 2007/2009 under construction 20.812 m

PROJECT YEAR SPECIFIC FEATURES TRACK LENGTH


PORR TECHNOBAU UND UMWELT AGA-1103 Vienna, Absberggasse 47Tel. 0043 (0)50 626-1509 | Fax 0043 (0)50 626-1651www.porr.at | [email protected]

The reference brochures of the PORR Group (from ABAP Nr. 217 on) can be downloaded from www.porr.atAB

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Prospekt OEBB-Porr FF-System En