PEOPLE, PLACES AND COUNTRIESConnecting

As a concrete precast manufacturer, we are helping to build a strong and mobile society for tomorrow.

We provide sustainable solutions for urban and rural planning, water treatment and distribution, transportation infrastructure (roads, railways, airports, bridges and tunnels) and energy management hubs.

CONSOLIS Rail is a European leader in designing and manufacturing concrete sleepers and bearers for railways. With almost a century of experience in the fi eld, we constantly strive to hone our expertise to offer our clients the best solutions. Whether it’s for urban, main or high-speed lines, heavy haul and mining freight, ballasted or ballastless tracks, training, factory construction or R&D, we know what it takes to meet their needs.

We build trust with our clients through a keen interest in challenging projects and truly innovative products. Our R&D teams are part of ambitious research and development programs that focus on product and system development, operational performance and process improvement.

Moreover, as part of our long-standing commitment to sustainability, we contribute to developing local engineering services when manufacturing know-how and technology is needed.

Not only do we provide solutions that fi t the needs of a rapidly evolving global marketplace, but we also anticipate the market’s future requirements.

Our focus on innovation and on exceeding our customers’ expectations is what makes us a key player in the building, infrastructure and rail markets, and we are proud to play a central role in Connecting People, Places and Countries.

Wherever people live, work, play and travel, our products are present.

"

"Pierre Brousse, President and CEO

CoNNECTiNG PEOPLE, PLACES AND COUNTRIES

CONSOLIS Rail is a European leader in the design and manufacture of precast concrete sleepers and bearers. CONSOLIS Rail operates in 14 countries and manufactures more than 3.5 million concrete sleepers each year while continually developing new technologies through a strong R&D program. CONSOLIS Rail also provides engineering services for the construction of sleeper factories.

CONSOLIS Rail serves an extensive number of end markets, such as high-speed and main lines, urban transportation, heavy haul and mining freight.

Countries

14

2013 sales

€174m

Thanks to its presence in 14 different countries, CONSOLIS Rail has brought a truly international dimension to its railway track offer. This has enabled us to export our experience worldwide, giving our customers an ideal opportunity to find a reliable local partner.

Worldwide Experience

LEADING THE WAY

Ballasted and Ballastless SolutionsWith a strong presence in Europe and more than 80 years of experience, CONSOLIS’ expertise in manufacturing concrete sleepers and bearers is unmatched in the European market.We serve all market segments – high-speed and main lines, urban networks, heavy haul and mining – and are able to work with all types of fastenings, gauges and standards.

Being an industry leader is not just about sales volume. It is a commitment to perfectly meeting our customers’ needs while always putting quality, reliability and safety first.We are dedicated to understanding the constraints and challenges of our customers’ railway infrastructure projects in order to offer the appropriate solutions to the following:• Reducing set-up time• Limiting noise pollution• Decreasing maintenance costs

Working closely with national railways and their contractors, we provide technology leadership in design and production, engineering services and training. Our range – 50 products and 180 elements – is the widest available. Moreover, we have experience in producing precast concrete sleepers in extreme weather conditions (-40° to +50°C).Our key customers include numerous major national railways and large contractors.

Thanks to our strong focus on R&D, we're always refining the design and manufacture of our products to ensure the highest quality while optimizing maintenance costs for railway operators.

"

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Rail | Leading the Way Leading the Way | Rail6 7

Lifecycle costs are a constant concern for us, from the design phase right through to RAMS (Reliability, Availability, Maintainability, Safety) analysis.Regardless of where we're at in a project, we focus on developing solutions that reduce maintenance costs.

LoWErING coSTS For rAILWAY opErATorS

Easier Maintenance• The rail/sleeper interface is the same on slab tracks

and on ballast sleepers, therefore rails and fasteners can be replaced easily.

• The design of our slab track system enables easy replacement of the sleepers.

• Our Harmelen level crossing solution eliminates the maintenance that is required on traditional level crossing systems.

Reducing Ballast Maintenance operations• In minimizing the friction between ballast and

sleepers, our under sleeper pad (USP) solutions help in reducing maintenance needs from 20 to 30%.

• Our Points Motor Ballast Guard is a cost-effective precast solution designed to retain the ballast and provide support to switches and crossing points' motors.

Reduced Track laying Time• Our monoblock High Attenuation System (HAS)

sleeper is a cost-effective alternative to floating slab tracks (FSTs), enabling tracks to be laid ten times as fast.

The Harmelen level crossing system

S312 for twin block slab track Our rigid hull system, S312, enables easy sleeper replacement without damaging the slab.

Innovative solutions bring about lower costs for railway operators.The use of under pads minimizes friction between the sleeper and the ballast and can reduce maintenance operations from 20 to 30%.

Rail | Lowering Costs for Railway Operators Lowering Costs for Railway Operators | Rail8 9

Delivered in 2014, the fi rst SMART SLEEPERS® will be in operation in 2015, in France, on the East high-speed line extension (SNCF)

SMART SLEEPERS® have been created in order to monitor the behaviour of the sleepers when subjected to rolling stock traffi c.

Data collected provides railway operators with a better understanding of the slab tracks, providing the basis for predictive maintenance.

SMART SLEEPERS® is an innovative solution, developed by SATEBA, the French CONSOLIS Rail subsidiary, and CEMENTYS (specialized in concrete structure instrumentation for public works).

SMART SLEEPERS® is a prestressed monoblock sleeper, which integrates six Microlux sensors located horizontally at each rail seat and at the centre.

SMART SLEEPERS® provide real-time measurement of the bending moment and information related to the state of the ballasted track, the way that sleepers lay on the ballast.

SmArT SLEEpErS®

SMART SlEEPERS® & Microlux SensorsSensors can be integrated into every type of sleeper during the normal production process. The track properties are not modified by adding SMART SLEEPERS®.Sensors are protected by the sleeper's concrete.

These real-time data also measure the behaviour of the sleepers, particularly the following:• Real bending moments inside the sleeper, helping to

optimize design• The impact of the rolling stock speed and weight, as well

as the distribution factor• The influence of under sleeper pads (USP), rail pad

stiffness, ballast and platform quality

Our sensors are designed to carry out durable rail track monitoring: • They function during track maintenance and with high

traffi c loads. • Electromagnetic fi elds do not interfere with them. • They provide dynamic high-resolution measurements

of traffi c loads.

In order to match to these specifications, SMART SLEEPERS® sensors integrate Fiber Bragg Grating (FBG).

This technology combines the benefits of vibrating wire sensors and electronic strain gauges, providing reliable and dynamic measurements.

Moreover, FBG sensors are completely insensitive to electromagnetic fi elds.

as the distribution factor• The influence of under sleeper pads (USP), rail pad

stiffness, ballast and platform qualitystiffness, ballast and platform quality

Recognized Rail Track Expertise

Rail | SMART SLEEPERS® SMART SLEEPERS® | Rail10 11

VIbrATIoN mITIGATIoN SoLuTIoNS

When the Eurostar arrives in London, it does so in style – and with admirable serenity. This is partly thanks to the S312 slab track sleeper, designed to respond to the noise and vibration mitigation requirements of London tunnels.

S312 Monoblock S312 Twin Block Bearers for switches and crossings

Laboratory test for vibration mitigration performanceHigh Attenuation System

312 Systems – S312 A full range of complete systems – Sleepers and SwitchesS312 is a sleeper integrating a complete cost-effective maintenance solution, as well as vibration mitigation performances.

S312 is available in either twin block, monoblock or switches and crossing bearer configurations and can be tuned to specific performance requirements.

S312 consists of a concrete sleeper, with a traditional elastic fastening. It is mounted within a rigid plastic hull, which makes maintenance operations easier and quicker. The system has a resilient pad, offering a second level of elasticity under the sleeper block.

High Attenuation Systems (HAS)HAS for sleepers and bearersThe High Attenuation System sleeper provides our highest level of vibration reduction and is a cost-effective alternative to fl oating slab tracks (FSTs).The system is the result of extensive research carried out with Alstom Transport. It has been tested at the SNCF track research centre in France.

HAS is an integrated system dedicated to mitigating ground vibrations generated from rolling stock. Although HAS provides the same level of performance as FSTs, HAS tracks can be laid ten times faster.

Rail | Vibration Mitigation Solutions Vibration Mitigation Solutions | Rail12 13

CONSOLIS supplies complete engineering services, from turnkey solutions to facility management and training.

We work together with local railway providers to develop sleepers tailored to specifi c projects.

We also provide complete training programs and are able to carry out studies and/or launch joint development solutions.

ENGINEErING SErVIcESIn 2011, SATEBA Maroc, CONSOLIS' Moroccan subsidiary, signed a contract with ONCF (Office National des Chemins de Fer), the local railway operator, to build a factory to produce the prestressed concrete sleepers for the high-speed line Tangier-Kenitra. Launched in 2012, this contract will end in 2015 with the completion of the first phase, which entails the production of 685,000 sleepers (411km) and on-site training for employees. The ONCF will subsequently take over management of the factory.

Complete Engineering ServicesSATEBA signed a contract in May 2014 with the Algerian railways to supply them with technical studies, public works and the construction of a monoblock sleepers factory, as well as technical assistance, employee training and the manufacture and follow-up of sleeper production and aftermarket services.

This factory will be built on an Algerian INFRARAIL site at Hassi-Bahbah Wilaya de Djelfa. It is slated to open in April 2015 following an estimated ten-month construction period. Technical assistance comprises a period of two years, beginning right after site opening.

CONSOLIS also signed a contract in August 2014 to supply a twin block sleepers factory, which will be built on an Algerian INFRARAIL site at Boutih Sayad Wilaya de M’Sila.

We design our engineering services with long-term partnerships and technology transfer in mind.

We strive to offer the CONSOLIS Group's latest technology.

As a European leader in precast concrete slab tracks, our customers benefi t from our global experience and expertise.

In countries where rail infrastructure is being deve-loped, CONSOLIS is able to bring a comprehensive offering, from studies, complete factory construction and production management to on-site training and concrete sleeper and bearer design.

Teaming Up with Railway operators for the long Term

Engineering Services | Rail 15Rail | Engineering Services14

A complete range of twin block and monoblock sleepers are available for main and high-speed lines and light rapid transit.

We design and manufacture sleepers tailored to project specifi cations, optimizing costs while offering the best performance for a variety of rail gauges and fastening types.

Very high-speeds mean very high requirements:• Compliance with extremely tight geometrical

tolerance

• High degree of quality and repetition

• Tightly controlled logistics management

• Adaptable to ever-increasing speeds (commercial speeds between 260km/h and 320km/h and up to a record breaking 574.8km/h)

HIGH-SpEED AND mAIN LINES

CONSOLIS and its brands have over 30 years' experience in designing and producing concrete sleepers for high-speed and very high-speed lines. Over this time we have made signifi cant contributions to prestigious projects such as ICE, TGV and Eurostar.

World high-speed train record

574.8km/hron SATEBA sleepers

ICE, Germany Eurostar

Prestressed concrete bearers for switches and crossings

Monoblock sleepers with Derailment Containment System

Twin block sleepers are lightweight and easy to install

Rail | High-Speed and Main Lines High-Speed and Main Lines | Rail16 17

CONSOLIS designs slab track solutions for various types of urban transportation, such as tramways, undergrounds or light rapid transit (LRT).

The sustainable development of urban transport presents numerous challenges:

• Minimizing disruption and blending in with the landscape

• Reducing noise and vibration

• Limiting the duration of the installation and maintenance works

Designed to meet the highly specifi c requirements of each city, our solutions are the results of close co-operation between all stakeholders.

CONSOLIS solutions make it easier to construct tracks in urban environments:

• Shallow depth sleepers can reduce overall construction depths.

• Direct fastening systems for bridges and civil art work.

• Specifi c turnout concrete bearers for LRT.

urbAN TrANSporTATIoN

Modular precast concrete ladder track Grooved narrow bearers for turnout tramway tracks

Sleepers with under sleeper pads for vibration mitigation (tramway line)

Precast concrete ladder track provides a cost- effective and robust method of slab track cons-truction. It can be manufactured in both straight and curved sections. The ladder track system was awarded the Track Construction Quality Award by üGG (German organisation for track construction monitoring).• Dimensional accuracy• Well-proven manufactured processes• Easy to install• Adaptable to all types of systems and multiple

confi gurations

Shallow depth twin block sleepers. A cost-effective method of building slab tracks in depots and in urban environments. Tie bar and leveling inserts assist with track aligment prior to second stage concreting.

SATEBA Maroc has been based in Casablanca for ten years and has manu-factured sleepers in co-operation with the Morrocan national railway (ONCF - Office National des Chemins de Fer). As of today, we’ve produced more than 1 million sleepers (600km).

We’ve produced 200,000 sleepers (120km) for the tramway lines of Rabat and Casablanca.

Rail | Urban Transportation Urban Transportation | Rail18 19

Our solutions comply with heavy haul and mining requirements and fit all existing track system specifi cations, be it for fastenings, vignole rails, rail seat inclinations (1 to 40, 1 to 20, etc.), gauges or climatic conditions (-40°C to +50°C).Pre-mounted under sleeper pads, fastening systems for fi xing safety rails and special impre-gnation for exposed environments are also available. ANSWErING THE NEEDS

oF THE mINING INDuSTrYStrong growth in the mining industry in recent years has created a pressing need for its infrastracture to be modernized, particularly freight railways.

Most of the countries extracting raw materials must overcome important challenges to improve their railway infrastructure in order to better serve both their mines and logistics sites.

Benefiting from CONSOLIS’ extensive experience in high-speed lines, main lines and urban transportation, our heavy haul and mining solutions comprise high-quality, efficiently laid systems and maintenance costs, as well as engineering services.

Designed to carry 30t to 35t axle loads, our sleepers meet the needs of heavy haul and mining freight. Our factories operate all year long, manufacturing products suited to harsh conditions (-40°C to +50°C).

We tailor our services to our customers’ needs, providing training, R&D programs, turnkey manufacture and production management.

in overseas MarketsCONSOLIS has also had the opportunity to deliver heavy haul sleepers for different uses in international markets:

• Testing tracks in a harsh climate in Mauritania (extreme temperature, sand and a corrosive environment)

• For transporting rockets at the French Space Agency in Guyana

• Testing tracks operated by the Burlington Northern network in the US

All our Solutions Take into Account The Cost of ownership

Rail | Heavy Haul and Mining Heavy Haul and Mining | Rail20 21

A RECOGNIZED EXPERT CONSOLIS Rail implements an active co-development policy with national railways. Our business units ensure a strong local presence, enabling us to foster long-standing partenerships with key decision makers and maintain our competitive edge.

GERMANY - MAINTENANCE OPERATIONS � Sleepers, turnouts and ladder tracks

400,000 sleepers and 150 turnouts delivered to Deutsche Bahn � DW SCHWELLEN, Germany� 2013

SPORVEIEN - KOLSÅSBANEN METRO LINE� Sleepers and turnouts

15,000 sleepers (9km) � SPENNCON, Norway� 2012 to 2014

PARIS METRO & SUBURBAN LINES� Sleepers and bearers (maintenance operations)

A total of 100,000 sleepers (60km) � SATEBA, France� 30 years' presence

CASABLANCA & RABAT TRAMWAY LINES� Tramway sleepers

200,000 sleepers (120km) � SATEBA Maroc, Morroco� 2010/2012

MIDLAND METRO - BIRMINGHAM CITY CENTRE EXTENSION� Twin block sleepers, sleepers for ballasted and slab tracks

1,800 sleepers supplied � SBC Rail, UK� 2013 - ongoing

POLAND - URBAN AND MAIN LINES � Sleepers, bearers, railroad crossings and foundation piles

13 million precast concrete sleepers supplied to the Polish Railways � WPS, Poland � 40 years' presence

HELSINKI METRO� Precast concrete sleepers and bearers

3,600 sleepers � PARMA Rail, Finland� 2012

BOTHNIA LINE - NYLAND TO UMEÅ � Precast concrete sleepers

190km � STRANGBETONG Rail, Sweden� 2010

Rail | A Recognized Expert A Recognized Expert | Rail22 23

A rEcoGNIzED ExpErT

EUROSTAR, ChAnnEl TUnnEl (CTRl 1 & 2) Paris-London travel time reduced by 20 minutes

253,000 twin block sleepers (152km) + 70,000 USP slab track sleepers (42km)

SBC Rail, UK 2001/2006

TAngiER - KEniTRA high-SpEEd linE On-site training in dedicated factory and manufacture

of precast concrete sleepers 685,000 precast concrete sleepers (411km)

SATEBA Maroc, Morroco 2015

high-SpEEd linES BRiTTAny/pAyS dE lOiRE, SOUThERn EUROpE-ATlAnTiC, EAST ExTEnSiOn Rail sleepers and bearers

For all three lines a total of 117,000 linear meters of bearers and 1.4 million sleepers (840km)

SATEBA, France 2012-2015

SWEdiSh TRAnSpORTATiOn AdminiSTRATiOn Mining industry

Delivered 600,000 monoblock sleepers since 1998 for 30t to 35t axle loads

STRANGBETONG Rail, Sweden

ESTOniAn FREighT linES Heavy haul

400,000 monoblock sleepers for 32t axle loads Russian gauge 1,520mm

SWETRAK, Estonia

SEnA linE – mOATizE COAl BASin TO BEiRA pORT Heavy haul line refurbishment to increase traffic

capacity by 20 million tonnes 60,000 monoblock sleepers, metric gauge

SATEPOR, Portugal

Rail | A Recognized Expert A Recognized Expert | Rail24 25

WoRlDWiDE

BElgiUmcoNSoLIS Services co SpANbEToN NVSolaris Building Chaussée de la Hulpe, 120 BE - 1 000 BrusselsBelgiumTel: +32 2 290 3600www.consolis.com

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Photos: © Consolis - © Bonna Sabla / Jean Lacombe / So&Co / Franck Deletang / Shutterstock: © Alice-photo, © Amy Johansson, © Ari N, © Maoyunping, © Pedrosala, © Sam DCruz, © Scandphoto. Design: Malika Benamara & Laurence André for le8au22 Copywriting: Victoria Marshall, Benjamin Eskinazi, Richard Venturi / September 2014

Rail | Consolis Worldwide Consolis Worldwide | Rail26 27

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