Rail Track Engineerin

Modern Railway TrackSecond Edition

MODERN RAILWAY TRACKSecond Edition

Coenraad EsveldProfessor of Railway Engineering

Delft University of Technology

2001MRT-Productions

Delft University of Technology

Editing: Dior Zwarthoed-van NieuwenhuizenLayout: Jan van ’t Zand, TU Delft

Drawings: TU DelftProduction: Koninklijke van de Garde BV

ISBN 90-800324-3-3SISO 696.3 UDC 625.1

© Copyright 2001 C. EsveldThis work is subject to copyright. All rights are reserved, whether the whole or part of the material is

concerned, specifically the right of translation, reprinting, re-use of illustrations, recitations, broadcas-tings, reproduction on microfilm or in other ways, and storage in data banks. Duplication of this publi-

cation or parts thereof is only permitted under the Dutch Copyright Law.

This book can be ordered from:MRT-Productions . P.O. Box 331 . NL-5300 AH Zaltbommel . The Netherlands

Tel.: +31 418 516369 . Fax: +31 418 516372 . Email: [email protected]: www.esveld.com

Major contributions to this Second Edition were made by the following persons:

Norbert Frank, Voest Alpine Schienen

Stanislav Jovanovic, TU Delft

Anton Kok, TU Delft

Amy de Man, TU Delft

Valeri Markine, TU Delft

Rainer Oswald, VAE

Peter Scheepmaker, TU Delft

Rainer Wenty, Plasser & Theurer

Gerard van der Werf, TU Delft and Arcadis

Jan van ‘t Zand, TU Delft

Arjen Zoeteman, TU Delft

Jan Zwarthoed, TU Delft and Volker Stevin Rail & Traffic

Modern Railway TrackSecond Edition

To my grandchildrenThomasMaudFiekeand

Douwe

Publication of this book has been made possible thanks to the sponsoring of the following companies:

Main SponsorsDelft University of Technology,The Netherlands

BAM NBM Rail bv, The NetherlandsGerman Track Systems Projektgesellschaft mbH, Germany

SponsorsPlasser & Theurer, Austria

Vossloh Rail Fastening Systems, Germany

AdvertisersElektro-Thermit, Germany

Speno International, Switzerland

Front Cover SponsorVossloh Rail Fastening Systems, Germany

Spine SponsorPandrol, England

Modern Railway Track PREFACE

ix

AcknowledgementWith the preparation of this Second Edition many experts have assisted to provide and check existingmaterial and to write additional sections. In the first place I would like to thank my staff of the railwayengineering group of Delft University of Technology: Jan van ‘t Zand, Peter Scheepmaker, Gerard vander Werf, Anton Kok, Valeri Markine, Ivan Shevtsov, Pedja Joksimovic and the secretaries JacquelineBarnhoorn and Sonja van den Bos. I am most indebted to my Ph.D. students: Akke Suiker, Amy deMan, Arjen Zoeteman, Søren Rasmussen, Stanislav Jovanovic and Jan Zwarthoed for their invalua-ble ideas, suggestions and contributions. Those who have drafted significant parts have been men-tioned explicitly in the outset of the book. From TU Delft I would like to mention in particular Jan van ‘tZand who made the entire layout of the book in Framemaker.

I would also like to express my gratitude to my colleagues of the management team of the Section forRoad and Railway Engineering at the Civil Engineering Department of TU Delft: André Molenaar,Peter Scheepmaker, Lambert Houben, Martin van der Ven and Abdol Miradi for their support in pro-ducing this Second Edition.

For the high-speed section I would like to thank the Korean High Speed Rail Corporation for contribu-ting information of the high-speed project between Seoul and Pusan. In this respect I would also liketo refer to the many interesting discussions in the Special International Track Advisory Committee(SITAC), comprised of Dr. Kee-Dong Kang, Dr. Yoshihiko Sato, Mr. Serge Montagné, Prof. KlausRiessberger, Mr. Gerhard Kaess and myself, with the active assistance of Mr. Arne Svensoy, Mr. Ber-told Pfeifer and Mr. Ki-Jun Son.

Valuable information was received from my Japanese colleagues Dr. Yoshihiko Sato from the RailwayTrack System Institute, Dr. Katsutoshi Ando and Mr. Noritsugu Abe from the Railway TechnicalResearch Institute (RTRI) and Mr. Tetsuhisa Kobayashi from the Japan Railway Construction PublicCorporation (JRCPC) for which I would like to express my gratitude.

I very much appreciated the indirect contributions by the companies and members participating in theCoordinating Committee for Railway Engineering of the Information and Technology Centre for Trans-port and Infrastructure (CROW) in The Netherlands.

I also owe much gratitude to Mr. Rainer Wenty from Plasser and Theurer for revising the section ontrack maintenance and renewal, and providing information on various other related subjects.

I highly appreciated the input on stone blowing from Mr. Peter McMichael of Railtrack and Mr. DavidHill-Smith of AMEC Rail.

The section on rail grinding was checked by Mr. Wolfgang Schöch for which I would like to expressmy thanks.

For the section on rails I am very grateful for the contribution of Dr. Norbert Frank from Voest AlpineSchienen, who revised large parts of the original text.

I very much appreciated the assistance of Mr. Paul Godart of NMBS/SNCB for providing the informa-tion on the work of CEN and UIC concerning new rail standards.

I would like to express my gratitude to Mr. Hugo Goossens of TUC Rail for the many interesting dis-cussions on track maintenance.

I owe much gratitude to Mr. Rainer Oswald from VAE, for his suggestions on revising the section onswitches and crossings.

I would like to thank Dr. Frank Kusters of Elektro-Thermit for checking the section on ET welding.

PREFACE Modern Railway Track

x

Thanks to Dipl.-Ing. Hans Bachmann, Dipl.-Ing. Jens Kleeberg and Dipl.-Ing. (FH) Martin Kowalski ofPfleiderer I was able to incorporate the latest information of the Rheda system in the chapter on slabtrack.

Furthermore essential information on track components were provided by the suppliers, for which Iwould like to thank in particular Mr. Gerrien van der Houwen of Edilon, Mr. Dirk Vorderbrück fromVossloh, Mr. Chris Eckebus from Phoenix Benelux, Mr. David Rhodes from Pandrol, Mr. PatrickCarels of CDM and Mr. Olaf Unbehaun of Cronau.

For the parts on inspection systems we received many contributions from the industry. I would like toexpress my thanks in particular to Mr. Anton Weel and Mr. Han Wendt of Eurailscout, Mr. Jaap Roosand Mr. Erwin Giling of TNO-TPD, Mr. Aad van der Linden and Mr. Jan van der Schee from Konink-lijke BAM NBM, Mr. Wido de Witte from Erdmann Softwaregesellschaft, Mr. Kevin Kesler of Ensco,Mrs. Danuše Marusicová of Czech Railways (CD), Prof. Willem Ebersohn of Amtrack, Mr. CharlesPenny of Balfour Beatty, Mr. Paolo Redi of S.E.I. Sistemi Energetici Integrati and Mr. Ted Slump of NSRail Infrabeheer.

Finally I would like to thank Dior van Nieuwenhuizen for her magnificent work to check and correct theEnglish text.

I would like to conclude with expressing the hope that this Second Edition will once again prove to bea useful contribution to the training of students and railway engineers.

Coenraad Esveld

Modern Railway Track PREFACE

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PREFACEAfter the success of Modern Railway Track this Second Edition is an extension and complete revisionof the original book, in which the developments of the last ten years have been incorporated. Theresearch projects carried out at the Railway Engineering Group of Delft University of Technology haveplayed a central role. The theory of railway track and vehicle track interaction has been substantiallyenhanced and much more attention has been given to dynamics. Undoubtedly one of the most impor-tant extensions was the part on slab track structures. But also track management systems have beengiven much more attention. Numerical optimization and testing, as well as acceptance are new chap-ters.

When revising the lecture notes for the railway course at the Civil Engineering Department of TU Delftin the period 1994 - 2000 the first edition of this book was taken as a starting point. The first editionand the TU Delft lecture notes, together with various publications and research reports, mainly of therailway engineering group of TU Delft, were then forming the base for the second edition.

The staff of the railway engineering group at TU Delft has made a great contribution to the composi-tion and revision of the various chapters. Also the industry provided some important contributions,specifically on the chapters dealing with rail manufacturing, track components, maintenance andrenewal, as well as inspection systems.

The first seven chapters are dealing with the basic theory of the wheel rail interface and track design.In the design attention is given to both static and dynamic aspects, whereby a number of examples isgiven of results obtained from computer models like RAIL, GEOTRACK and ANSYS. In the part onstability and longitudinal forces the CWERRI program is extensively discussed.

The discussion of track structures has been split up into a chapter on ballasted track and one on slabtrack. The first one is dealing with the conventional structures and modern ballasted designs,whereas the slab track chapter focuses on developments of the last decades. Both continuous slabsand prefabricated solutions are addressed in combination with discretely supported and continuouslysupported rails.

The chapter on rails has been brought to the state of the art, with introducing the new EN standardsand discussing the latest inspection systems. Also the latest information on bainitic rail steels hasbeen incorporated.

For switches and crossings high-speed turnouts are discussed, together with the geometrical designcriteria, and also modern inspection systems for controlling switch maintenance.

In railway engineering practice track maintenance and renewal forms a key factor. The latest trackmaintenance methods and the associated machines are presented, being a major extension com-pared to the first edition of this book. The part on track deterioration has now been incorporated in thischapter.

Optimization was one of the issues very much underestimated in railway engineering. Such tech-niques are not only applicable to components and structures, but also to decision support systemsand resource optimization. A separate chapter has been added called numerical optimization with themain emphasis on structural components.

From the outset railway engineering has always had a strong component in experimental work.Therefore a new section has been added on testing and acceptance, in which also the issue ofacceptance criteria for new railway components is addressed.

The chapter on noise and vibration is describing the fundamentals and has been taken over from thefirst edition with only a few modifications.

PREFACE Modern Railway Track

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The chapter on inspection and detection methods has been completely revised. The original chapterwas primarily based on NS experience. Now the state of the art inspection systems have been intro-duced. However the fundamental parts of the first edition have been left in tact.

The chapter on high-speed tracks contains some applications of high-speed projects and some dedi-cated issues such as pressure waves in tunnels. Also a section is devoted to magnetic levitation.

In track maintenance management systems various issues on track maintenance and renewal deci-sion support are described, as well as monitoring of phenomena relevant to the various maintenanceprocesses. Special attention is given to the ECOTRACK system, developed under the auspices ofUIC and maintained and supported by TU Delft.

Railway assets involve a large capital and need to be managed carefully. The chapter on this issuedeals with the general principles of asset management and the way in which such systems can be setup.

The final chapter is dealing with life cycle cost analysis. After describing the general principles anumber of case studies are discussed.

Zaltbommel, Summer 2001

Coenraad Esveld

Modern Railway Track TABLE OF CONTENTS

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TABLE OF CONTENTS1 INTRODUCTION

1.1 Historic development.......................................................................................................................... 11.2 Railways ............................................................................................................................................. 11.3 Tramways and metro.......................................................................................................................... 31.4 Operational aspects ........................................................................................................................... 4

1.4.1 Functions of a railway company.................................................................................................... 41.4.2 Infrastructure................................................................................................................................. 41.4.3 Rolling stock.................................................................................................................................. 51.4.4 Personnel...................................................................................................................................... 51.4.5 Electrification................................................................................................................................. 61.4.6 Catenary systems ......................................................................................................................... 71.4.7 Road crossings ............................................................................................................................. 81.4.8 Major rail infrastructure projects.................................................................................................... 91.4.9 Developing countries .................................................................................................................... 9

1.5 Geometry of a railway line ................................................................................................................ 101.5.1 Clearances.................................................................................................................................. 101.5.2 Alignment .................................................................................................................................... 13

1.6 General track considerations............................................................................................................ 131.6.1 Track requirements..................................................................................................................... 131.6.2 Load-bearing function of the track .............................................................................................. 141.6.3 Indication of rail forces and displacements................................................................................. 151.6.4 Track geometry components ...................................................................................................... 15

2 WHEEL-RAIL INTERFACE

2.1 Wheel-rail guidance.......................................................................................................................... 172.2 Wheelset and track dimensions ....................................................................................................... 172.3 Conicity............................................................................................................................................. 182.4 Lateral movement of a wheelset on straight track ............................................................................ 19

2.4.1 Theory according to Klingel ........................................................................................................ 192.4.2 Hunting movement...................................................................................................................... 20

2.5 Equivalent conicity............................................................................................................................ 212.6 Worn wheel profiles .......................................................................................................................... 222.7 Wheel-rail contact stresses .............................................................................................................. 23

2.7.1 Hertz theory ................................................................................................................................ 232.7.2 Hertz spring constant.................................................................................................................. 242.7.3 Single and two-point contact between wheel and rail ................................................................. 252.7.4 Spreading forces ......................................................................................................................... 262.7.5 Wheel-rail creep.......................................................................................................................... 272.7.6 Spin............................................................................................................................................. 282.7.7 Creepage coefficients ................................................................................................................. 29

2.8 Train resistances .............................................................................................................................. 302.8.1 Types of resistances ................................................................................................................... 302.8.2 Required pulling force................................................................................................................. 312.8.3 Adhesion force............................................................................................................................ 32

3 CURVES AND GRADIENTS

3.1 General considerations .................................................................................................................... 35

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3.2 Curvature and superelevation in horizontal curves .......................................................................... 353.2.1 Curve radius/curvature................................................................................................................ 353.2.2 Curve effects............................................................................................................................... 35

3.3 Superelevation................................................................................................................................. 363.3.1 General considerations ............................................................................................................... 363.3.2 Cant deficiency ........................................................................................................................... 373.3.3 Effect of suspension on lateral acceleration ............................................................................... 383.3.4 Effect of body tilt coaches on cant deficiency ............................................................................. 383.3.5 Switches and other constraints ................................................................................................... 393.3.6 Cant excess ................................................................................................................................ 393.3.7 Maximum cant............................................................................................................................. 39

3.4 Transition curves .............................................................................................................................. 393.4.1 General remarks ......................................................................................................................... 393.4.2 Clothoid ....................................................................................................................................... 403.4.3 Cubic parabola ............................................................................................................................ 413.4.4 Curve displacement .................................................................................................................... 41

3.5 Cross level transitions ...................................................................................................................... 423.5.1 Relation with the transition curve................................................................................................ 423.5.2 Length of normal transition curve................................................................................................ 433.5.3 Adjacent curves .......................................................................................................................... 43

3.6 Curve resistance............................................................................................................................... 433.7 Gradients .......................................................................................................................................... 44

3.7.1 Gradient resistance ..................................................................................................................... 443.7.2 Magnitude of gradient ................................................................................................................. 443.7.3 Vertical transition curves ............................................................................................................. 453.7.4 Guidelines for permissible quasi-static accelerations ................................................................. 45

3.8 Alignment in mountainous areas ...................................................................................................... 463.9 Computer-aided track design ........................................................................................................... 483.10 PASCOM - software to estimate passenger comfort...................................................................... 51

3.10.1 Numerical model....................................................................................................................... 513.10.2 Case 1: Investigation of dynamic effects .................................................................................. 523.10.3 Case 2: Track HSL-Zuid (NL) ................................................................................................... 53

4 TRACK LOADS

4.1 In general.......................................................................................................................................... 554.2 Axle loads ......................................................................................................................................... 554.3 Line classification ............................................................................................................................. 554.4 Tonnages.......................................................................................................................................... 564.5 Speeds ............................................................................................................................................. 564.6 Causes and nature of track loads..................................................................................................... 574.7 Vertical rail forces. ............................................................................................................................ 57

4.7.1 Total vertical wheel load ............................................................................................................. 574.7.2 Tilting risk. ................................................................................................................................... 58

4.8 Lateral forces on the rail................................................................................................................... 594.8.1 Total lateral wheel load ............................................................................................................... 594.8.2 Derailment risk ............................................................................................................................ 594.8.3 Lateral force on the track ............................................................................................................ 60

4.9 Longitudinal forces. .......................................................................................................................... 614.9.1 Causes ........................................................................................................................................ 614.9.2 Temperature forces..................................................................................................................... 614.9.3 Track creep ................................................................................................................................. 61


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4.9.4 Braking load ................................................................................................................................ 624.10 Influence of higher speeds and increased axle loads .................................................................... 62

4.10.1 Speed ....................................................................................................................................... 624.10.2 Increase in axle loads ............................................................................................................... 63

4.11 Wheel flats...................................................................................................................................... 674.12 Forces due to bad welds ................................................................................................................ 684.13 Axle box accelerations ................................................................................................................... 69

5 STATIC TRACK DESIGN

5.1 Introduction....................................................................................................................................... 715.2 Supporting models ........................................................................................................................... 71

5.2.1 Winkler support model ................................................................................................................ 715.2.2 Discrete rail support .................................................................................................................... 715.2.3 Exercise: Spring constant determination .................................................................................... 725.2.4 Continuous rail support ............................................................................................................... 735.2.5 Approximation of discrete rail support......................................................................................... 73

5.3 Beam on elastic foundation model ................................................................................................... 745.3.1 Solution of the differential equation............................................................................................. 745.3.2 Several wheel loads.................................................................................................................... 765.3.3 Two-axle bogie ............................................................................................................................ 775.3.4 Negative deflection ..................................................................................................................... 775.3.5 Beam with hinge (jointed track)................................................................................................... 785.3.6 Alternative expressions for characteristic length L ...................................................................... 795.3.7 Fast determination of vertical elasticity constants....................................................................... 795.3.8 Order of magnitude of elasticity constants.................................................................................. 79

5.4 Double beam model ......................................................................................................................... 805.5 Pasternak foundation model............................................................................................................. 815.6 Rail stresses ..................................................................................................................................... 83

5.6.1 Stresses in rail foot centre .......................................................................................................... 835.6.2 Dynamic amplification factor....................................................................................................... 835.6.3 Maximum bending stress in rail foot centre ................................................................................ 845.6.4 Stresses in the rail head ............................................................................................................. 865.6.5 Rail stresses due to a combined Q/Y load.................................................................................. 885.6.6 Rail tables ................................................................................................................................... 90

5.7 Sleeper stresses............................................................................................................................... 915.8 Stresses on ballast bed and formation ............................................................................................. 92

5.8.1 Introduction ................................................................................................................................. 925.8.2 Vertical stress on ballast bed ...................................................................................................... 925.8.3 Vertical stress on formation ........................................................................................................ 935.8.4 Odemark's equivalence method ................................................................................................. 935.8.5 Classification of the quality of soils ............................................................................................. 96

5.9 Some analytical exercises ................................................................................................................ 975.9.1 Fatigue rail foot ........................................................................................................................... 975.9.2 Fatigue rail head ......................................................................................................................... 975.9.3 Sleeper ....................................................................................................................................... 985.9.4 Ballast bed .................................................................................................................................. 985.9.5 Temperature effects.................................................................................................................... 98

5.10 Computer models ......................................................................................................................... 1005.10.1 GEOTRACK program ............................................................................................................. 1005.10.2 The ANSYS program .............................................................................................................. 102

5.11 Two Case ERS designs ............................................................................................................... 104


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5.11.1 Testing of the UIC54 ERS....................................................................................................... 1045.11.2 Testing of the SA42 ERS........................................................................................................ 1055.11.3 Input and output of static model.............................................................................................. 1065.11.4 Results.................................................................................................................................... 106

6 DYNAMIC TRACK DESIGN

6.1 Introduction..................................................................................................................................... 1076.2 Dynamic principles ......................................................................................................................... 108

6.2.1 In general.................................................................................................................................. 1086.2.2 One-mass spring system .......................................................................................................... 1086.2.3 Wheel/rail forces due to dipped rail joints ................................................................................. 1126.2.4 Track excitation origins ............................................................................................................. 113

6.3 Track modelling.............................................................................................................................. 1136.3.1 General considerations ............................................................................................................. 1136.3.2 Transfer function between track load and track displacement.................................................. 1136.3.3 Beam on an elastic foundation.................................................................................................. 1146.3.4 Discrete support........................................................................................................................ 121

6.4 Vertical wheel response ................................................................................................................. 1216.4.1 Hertzian contact spring ............................................................................................................. 1216.4.2 Transfer functions between wheel and rail ............................................................................... 122

6.5 Linear vehicle model....................................................................................................................... 1246.5.1 Schematisation ......................................................................................................................... 1246.5.2 Response to irregularities in level ............................................................................................. 1256.5.3 Combination of level results ...................................................................................................... 1286.5.4 Response to irregularities in alignment..................................................................................... 1296.5.5 Response to irregularities in cant.............................................................................................. 1296.5.6 Combination of cant results ...................................................................................................... 1316.5.7 ISO weighting of car body accelerations................................................................................... 1326.5.8 Calculated transfer functions for the NS measuring coach ....................................................... 133

6.6 Estimate of transfer functions using measured data ...................................................................... 1376.6.1 General concept........................................................................................................................ 1376.6.2 Basic principles for 1 input and 1 output ................................................................................... 1376.6.3 Multiple input single output (MISO)........................................................................................... 1406.6.4 Statistical reliability.................................................................................................................... 1416.6.5 Numerical aspects .................................................................................................................... 1436.6.6 Applications............................................................................................................................... 1446.6.7 Comparison between transfer functions estimated by MISO and calculated with models ........ 151

6.7 Vehicle response analysis in real time ........................................................................................... 1526.8 Relation between Sperling's Ride Index Wz and ISO-weighted accelerations............................... 1556.9 Applications of advanced dynamic models..................................................................................... 157

6.9.1 Introduction ............................................................................................................................... 1576.9.2 The RAIL-model........................................................................................................................ 1576.9.3 A comparison of several different track types ........................................................................... 1586.9.4 Transitions in railway track on embankments and bridges ....................................................... 162

6.10 Track response to a moving axle load .......................................................................................... 1646.10.1 Track response at the critical train velocity ............................................................................. 1646.10.2 Dynamic response of a ballast layer....................................................................................... 1676.10.3 Stiffness transitions................................................................................................................. 1686.10.4 Brief discussion....................................................................................................................... 170


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7 TRACK STABILITY AND LONGITUDINAL FORCES

7.1 Introduction..................................................................................................................................... 1717.1.1 Straight track and elastic lateral resistance .............................................................................. 1727.1.2 Track with misalignment and constant lateral shear resistance................................................ 174

7.2 Track stability: finite element modelling.......................................................................................... 1767.2.1 General considerations............................................................................................................. 1767.2.2 Finite element model................................................................................................................. 1767.2.3 Results...................................................................................................................................... 1807.2.4 Continuous welded switches..................................................................................................... 183

7.3 Longitudinal forces: analytical modelling ........................................................................................ 1847.3.1 General considerations............................................................................................................. 1847.3.2 Axial rail model.......................................................................................................................... 1847.3.3 Modelling of the longitudinal interaction problem...................................................................... 186

7.4 Longitudinal forces: finite element modelling ................................................................................. 1897.4.1 General considerations............................................................................................................. 1897.4.2 Finite element model................................................................................................................. 1897.4.3 Examples of longitudinal force calculations .............................................................................. 191

7.5 Advanced numerical models of track buckling ............................................................................... 1947.5.1 Introduction ............................................................................................................................... 1947.5.2 Analysis of track behaviour using CWERRI.............................................................................. 1957.5.3 Analysis of longitudinal forces................................................................................................... 1957.5.4 Track lateral behaviour ............................................................................................................. 1977.5.5 Vertical stability of track ............................................................................................................ 1987.5.6 Buckling mechanism ................................................................................................................. 1987.5.7 Approach in order to determine the allowable temperature T ALL ............................................ 1997.5.8 Study case: Stability of tram track............................................................................................. 201

8 BALLASTED TRACK

8.1 Introduction..................................................................................................................................... 2038.2 Formation ....................................................................................................................................... 2048.3 Ballast bed...................................................................................................................................... 2058.4 Rails ............................................................................................................................................... 206

8.4.1 Functions .................................................................................................................................. 2068.4.2 Profile types .............................................................................................................................. 2068.4.3 Geometry of flat-bottom rail ...................................................................................................... 207

8.5 Rail joints and welds....................................................................................................................... 2088.5.1 Introduction ............................................................................................................................... 2088.5.2 Fishplated joints........................................................................................................................ 2088.5.3 Expansion joints and expansion devices .................................................................................. 2098.5.4 Bridge transition structures ....................................................................................................... 2108.5.5 Insulated joint............................................................................................................................ 210

8.6 Sleepers ......................................................................................................................................... 2128.6.1 Introduction ............................................................................................................................... 2128.6.2 Timber sleepers ........................................................................................................................ 2138.6.3 Concrete sleepers..................................................................................................................... 2148.6.4 Steel sleepers ........................................................................................................................... 216

8.7 Improvements in ballasted tracks ................................................................................................... 2168.7.1 Introduction ............................................................................................................................... 2168.7.2 Wide sleeper ............................................................................................................................. 2178.7.3 Frame sleeper........................................................................................................................... 218


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8.7.4 Local ballast stabilisation by means of a chemical binder ........................................................ 2198.8 Fastening systems......................................................................................................................... 219

8.8.1 Introduction ............................................................................................................................... 2198.8.2 Subdivision of fastenings .......................................................................................................... 2208.8.3 Baseplates ................................................................................................................................ 2208.8.4 Elastic fastenings ...................................................................................................................... 2218.8.5 Rail pads ................................................................................................................................... 222

8.9 Track on structures with a continuous ballast bed and sleepers .................................................... 2238.9.1 Ballast mats .............................................................................................................................. 223

8.10 Reinforcing layers......................................................................................................................... 2258.11 Level crossings ............................................................................................................................. 2268.12 Tramway Track ............................................................................................................................. 227

8.12.1 Tramway track characteristics ................................................................................................ 2278.12.2 Examples of paved-in tramway track...................................................................................... 229

8.13 Crane Track .................................................................................................................................. 230

9 SLAB TRACK

9.1 Introduction..................................................................................................................................... 2319.2 Ballasted track versus slab track .................................................................................................... 231

9.2.1 Ballasted track .......................................................................................................................... 2329.2.2 Slab track .................................................................................................................................. 232

9.3 Designs of slab track superstructures ............................................................................................ 2339.4 Sleepers or blocks embedded in concrete ..................................................................................... 234

9.4.1 Rheda 2000 .............................................................................................................................. 2359.4.2 Züblin ........................................................................................................................................ 242

9.5 Structures with asphalt-concrete roadbed...................................................................................... 2459.6 Prefabricated slabs......................................................................................................................... 246

9.6.1 Shinkansen slab track............................................................................................................... 2479.6.2 Recent design of Shinkansen slab track ................................................................................... 2489.6.3 Bögl slab track .......................................................................................................................... 251

9.7 Monolithic slabs and civil structures ............................................................................................... 2529.8 Embedded Rail ...............................................................................................................................253

9.8.1 The characteristics of embedded rail ........................................................................................ 2539.8.2 Construction of embedded rail track ......................................................................................... 2549.8.3 Experiences with embedded rail ............................................................................................... 2559.8.4 DeckTrack ................................................................................................................................. 257

9.9 Flexural stiff slabs on top of soft soil............................................................................................... 2589.10 Clamped and continuously supported rail structures.................................................................... 261

9.10.1 CoconTrack............................................................................................................................. 2619.10.2 Continuously supported grooved rail ...................................................................................... 2639.10.3 Web-clamped rails .................................................................................................................. 264

9.11 EPS as subbase material in railway slab track structures ............................................................ 2659.11.1 Introduction ............................................................................................................................. 2659.11.2 Slab track structures with an EPS subbase ............................................................................ 2659.11.3 Static performance.................................................................................................................. 2659.11.4 Dynamic performance............................................................................................................. 2669.11.5 Applications............................................................................................................................. 267

9.12 Track resilience ............................................................................................................................ 2679.13 System requirements.................................................................................................................... 268

9.13.1 Requirements for the substructure.......................................................................................... 2699.13.2 Requirements for slab track in tunnels.................................................................................... 271


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9.13.3 Requirements for slab track on bridges .................................................................................. 2719.13.4 Requirements for transitions ................................................................................................... 272

9.14 General experiences with slab track systems .............................................................................. 2739.15 Maintenance statistics of slab track.............................................................................................. 274

10 THE RAIL

10.1 Introduction................................................................................................................................... 27510.2 Modern rail manufacturing............................................................................................................ 275

10.2.1 Blast furnace ........................................................................................................................... 27510.2.2 Steel-making ........................................................................................................................... 27710.2.3 Vacuum degassing and argon flushing ................................................................................... 27910.2.4 Continuous casting ................................................................................................................. 27910.2.5 Rolling mill............................................................................................................................... 28110.2.6 Finishing shop ......................................................................................................................... 28210.2.7 Inspection and acceptance ..................................................................................................... 28610.2.8 Rail profiles ............................................................................................................................. 28810.2.9 Indication of profile types according to CEN ........................................................................... 288

10.3 Rail properties .............................................................................................................................. 29210.3.1 Metallurgical fundamentals ..................................................................................................... 29210.3.2 Heat treatment........................................................................................................................ 29410.3.3 Rail grades.............................................................................................................................. 29610.3.4 Wear resistance ...................................................................................................................... 29910.3.5 Fatigue strength ...................................................................................................................... 30010.3.6 Fracture mechanics ................................................................................................................ 300

10.4 Rail welding .................................................................................................................................. 30610.4.1 Introduction ............................................................................................................................. 30610.4.2 Flash butt welding ................................................................................................................... 30610.4.3 Post-processing of flash butt welds in the NS welding depot ................................................. 30910.4.4 Thermit welding....................................................................................................................... 31010.4.5 Cooling rates........................................................................................................................... 31410.4.6 Improvement of weld geometry............................................................................................... 31610.4.7 Weld geometry standards....................................................................................................... 316

10.5 Rail failures................................................................................................................................... 31710.5.1 Defects in rail ends ................................................................................................................. 31710.5.2 Defects away from rail ends.................................................................................................... 31810.5.3 Weld and resurfacing defects ................................................................................................. 32310.5.4 Rail defect statistics ................................................................................................................ 326

11 SWITCHES AND CROSSINGS

11.1 The standard turnout .................................................................................................................... 33311.1.1 Set of switches........................................................................................................................ 33411.1.2 Common crossing ................................................................................................................... 33511.1.3 Closure rail.............................................................................................................................. 33711.1.4 Rails and sleepers in turnouts................................................................................................. 337

11.2 Geometry of the turnout ............................................................................................................... 33711.3 High-speed turnouts.................................................................................................................... 338

11.3.1 General ................................................................................................................................... 33811.3.2 Traditional turnout design method .......................................................................................... 338

11.4 Vehicle dynamic ........................................................................................................................... 33811.4.1 Examples of modern high-speed turnouts .............................................................................. 339


xx

11.5 Notations used for switches and crossings .................................................................................. 34011.6 Types of turnouts and crossings................................................................................................... 34011.7 Cross-overs .................................................................................................................................. 34111.8 Switch calculation ......................................................................................................................... 344

11.8.1 Relation between curve radius and crossing angle ................................................................ 34411.8.2 Calculation of main dimensions ............................................................................................. 34511.8.3 Geometrical design of switches and crossings...................................................................... 347

11.9 Production, transport and laying of switches................................................................................ 347

12 TRACK MAINTENANCE AND RENEWAL

12.1 Introduction................................................................................................................................... 34912.2 General maintenance aspects...................................................................................................... 35012.3 Spot maintenance of track geometry............................................................................................ 35012.4 Rail grinding and reprofiling .......................................................................................................... 352

12.4.1 Rail grinding machines............................................................................................................ 35212.4.2 Rail reprofiling machines......................................................................................................... 354

12.5 Correcting weld geometry............................................................................................................. 35612.5.1 STRAIT principle..................................................................................................................... 35612.5.2 Mobile weld correction ............................................................................................................ 357

12.6 Tamping machines ....................................................................................................................... 35712.6.1 General considerations ........................................................................................................... 35712.6.2 Tamping principle.................................................................................................................... 35912.6.3 Levelling and lining ................................................................................................................. 363

12.6.3.1 Smoothing principle of modern tamping machines ........................................................... 36312.6.4 ALC......................................................................................................................................... 36612.6.5 EM-SAT .................................................................................................................................. 367

12.7 Stone blowing ............................................................................................................................... 36912.7.1 General principle..................................................................................................................... 36912.7.2 Measuring philosophy used for the stone blower.................................................................... 37012.7.3 Stone blowing applications ..................................................................................................... 37112.7.4 Results of track geometry measurements .............................................................................. 37312.7.5 Stone blowing future ............................................................................................................... 373

12.8 Design overlift tamping ................................................................................................................. 37412.9 Ballast profiling and stabilization .................................................................................................. 37512.10 Mechanised track maintenance train .......................................................................................... 37712.11 Ballast cleaner ............................................................................................................................ 37712.12 Formation rehabilitation machines.............................................................................................. 37912.13 High temperatures...................................................................................................................... 38312.14 Maintenance of the track structure ............................................................................................. 38312.15 General observations on track renewal ...................................................................................... 38412.16 Manual track renewal ................................................................................................................. 38512.17 Mechanical track renewal ........................................................................................................... 386

12.17.1 Introduction ........................................................................................................................... 38612.17.2 Track possession .................................................................................................................. 38612.17.3 Gantry crane method ............................................................................................................ 38612.17.4 Track section method............................................................................................................ 38612.17.5 Continuous method ............................................................................................................... 38812.17.6 Track renewal trains.............................................................................................................. 392

12.18 Switch renewal ........................................................................................................................... 39312.19 Track laying ................................................................................................................................ 396

12.19.1 General considerations ......................................................................................................... 396


xxi

12.19.2 Track construction trains ....................................................................................................... 39612.19.3 Platow system ....................................................................................................................... 39712.19.4 TGV tracks ............................................................................................................................ 397

12.20 Deterioration of Track Geometry ................................................................................................ 39912.20.1 Introduction ........................................................................................................................... 39912.20.2 Historical records .................................................................................................................. 39912.20.3 Factors influencing the deterioration of track geometry ........................................................ 40012.20.4 Deterioration rates of geometry ............................................................................................ 40212.20.5 Effects of tamping ................................................................................................................. 40312.20.6 Effect of weld straightening................................................................................................... 40312.20.7 Development of corrugation.................................................................................................. 40512.20.8 Effect of stone blowing.......................................................................................................... 40612.20.9 Development of lateral track resistance................................................................................ 406

13 NUMERICAL OPTIMIZATION OF RAILWAY TRACK

13.1 Introduction................................................................................................................................... 40913.2 Elements of structural optimization .............................................................................................. 410

13.2.1 General optimization problem ................................................................................................. 41013.2.2 Solution process ..................................................................................................................... 41113.2.3 Approximation concept .......................................................................................................... 411

13.3 MARS method .............................................................................................................................. 41313.4 Optimal design of embedded rail structure (ERS)........................................................................ 415

13.4.1 Introduction ............................................................................................................................. 41513.4.2 Requirements for optimum design of ERS.............................................................................. 41613.4.3 Optimization problem .............................................................................................................. 42013.4.4 Remarks and conclusions ....................................................................................................... 426

13.5 Determination of ballast lateral resistance using optimization technique ..................................... 42613.5.1 Introduction ............................................................................................................................. 42613.5.2 Measuring the lateral resistance of track ................................................................................ 42813.5.3 Ballast parameter identification............................................................................................... 43013.5.4 Conclusions ............................................................................................................................ 435

13.6 Identification of dynamic properties of railway track..................................................................... 43513.6.1 Introduction ............................................................................................................................. 43513.6.2 Hammer excitation test ........................................................................................................... 43613.6.3 Numerical model ..................................................................................................................... 43713.6.4 Track parameter identification................................................................................................. 43813.6.5 Numerical results .................................................................................................................... 43913.6.6 Conclusions ............................................................................................................................ 440

14 TESTING AND ACCEPTANCE

14.1 Introduction................................................................................................................................... 44114.2 Component testing and acceptance............................................................................................. 441

14.2.1 Mechanical properties............................................................................................................. 44114.2.2 Elasticity properties ................................................................................................................. 44214.2.3 Strength properties ................................................................................................................. 44614.2.4 Stability properties .................................................................................................................. 44714.2.5 Durability and fatigue properties ............................................................................................. 44814.2.6 Specific component properties................................................................................................ 449

14.3 Structural testing and acceptance ................................................................................................ 45114.3.1 Noise and vibration testing of track structures ........................................................................ 451


xxii

14.3.2 Passenger comfort and ride quality ........................................................................................ 45314.3.3 Dynamic properties of track structures ................................................................................... 454

15 NOISE AND VIBRATION

15.1 Introduction................................................................................................................................... 45915.2 Some definitions........................................................................................................................... 45915.3 Ground vibrations ......................................................................................................................... 460

15.3.1 Introduction ............................................................................................................................. 46015.3.2 Wave propagation in soils....................................................................................................... 46215.3.3 Human perception................................................................................................................... 46415.3.4 Measured vibrations................................................................................................................ 46615.3.5 Vibration reduction .................................................................................................................. 46815.3.6 Measures for ballasted tracks................................................................................................. 46915.3.7 Measures for slab tracks......................................................................................................... 46915.3.8 Measures for tracks in the open.............................................................................................. 470

15.4 Railway noise ............................................................................................................................... 470

16 INSPECTION AND DETECTION SYSTEMS

16.1 Railway Infrastructure Monitoring ................................................................................................. 47516.2 Tunnel monitoring......................................................................................................................... 47516.3 Bridge monitoring and management ............................................................................................ 47616.4 Substructure Monitoring ............................................................................................................... 477

16.4.1 Substructure condition parameters......................................................................................... 47816.4.2 Ground Penetrating Radar...................................................................................................... 47916.4.3 Track Stiffness Measurement ................................................................................................. 48016.4.4 Infrared thermographic inspection data .................................................................................. 48416.4.5 Laser Induced Fluorescence (LIF) Cone Penetrometer measurement.................................. 48416.4.6 Non-invasive moisture monitoring........................................................................................... 485

16.5 Monitoring and management of switches and crossings .............................................................. 48616.5.1 Introduction ............................................................................................................................. 48616.5.2 Switches and crossings monitoring by EURAILSCOUT ......................................................... 48716.5.3 SwitchView.............................................................................................................................. 48816.5.4 Condition monitoring and maintenance management of switches.......................................... 48916.5.5 CEDIAS - Railway Lines Diagnostic System .......................................................................... 494

16.6 Ultrasonic rail inspection............................................................................................................... 49516.6.1 Introduction ............................................................................................................................. 49516.6.2 The EURAILSCOUT ultrasonic train....................................................................................... 49616.6.3 Architecture of the URS .......................................................................................................... 49716.6.4 Probe system .......................................................................................................................... 49816.6.5 Sensor electronics .................................................................................................................. 50016.6.6 Incident Processor .................................................................................................................. 50116.6.7 On-line control and data interpretation.................................................................................... 50116.6.8 Off-line data analysis and report generation........................................................................... 50316.6.9 NS Ultrasonic inspection program .......................................................................................... 504

16.7 Track Recording Cars................................................................................................................... 50616.7.1 Introduction ............................................................................................................................. 50616.7.2 Track recording systems......................................................................................................... 50616.7.3 Rail recording systems............................................................................................................ 50816.7.4 Overhead wire recording......................................................................................................... 50916.7.5 Video inspection...................................................................................................................... 510


xxiii

16.7.6 Processing and recording the measured data ........................................................................ 51016.7.7 Track recording cars ............................................................................................................... 511

16.8 Track recording systems .............................................................................................................. 51316.8.1 Introduction ............................................................................................................................. 51316.8.2 Some aspects of geometry recording ..................................................................................... 51316.8.3 Assessment of track quality for maintenance decisions ......................................................... 515

16.9 Universal measuring coach EURAILSCOUT ............................................................................... 51516.9.1 Introduction ............................................................................................................................. 51516.9.2 Track geometry measurement................................................................................................ 51616.9.3 Overhead wire measurement.................................................................................................. 51716.9.4 Rail Profile measurement........................................................................................................ 52016.9.5 Rail Check System.................................................................................................................. 52116.9.6 Video inspections systems...................................................................................................... 52216.9.7 Data processing and storing ................................................................................................... 523

16.10 The NS track recording system BMS ......................................................................................... 52616.10.1 Short-wave recording via axle box accelerations.................................................................. 52616.10.2 Inertial measuring principle ................................................................................................... 52616.10.3 Dynamic signals .................................................................................................................... 52716.10.4 Quasi-static signals ............................................................................................................... 53016.10.5 Signal combination for determining track parameters........................................................... 53116.10.6 Signal analysis ...................................................................................................................... 534

16.11 Vehicle response analysis according to VRA ............................................................................. 54316.11.1 Introduction ........................................................................................................................... 54316.11.2 Principle of calculation .......................................................................................................... 543

16.12 Results from BMS campaigns .................................................................................................... 54416.12.1 NS distribution functions ....................................................................................................... 54416.12.2 Results from the ORE D 161 Europe Tour ........................................................................... 54416.12.3 Track geometry spectra ........................................................................................................ 545

16.13 T-16: FRA's High Speed Research Car ..................................................................................... 54716.13.1 Introduction ........................................................................................................................... 54716.13.2 Instrumentation and measurement capabilities .................................................................... 547

16.14 Rail Profile Management ............................................................................................................ 54816.15 Rail Defect Management........................................................................................................... 549

16.15.1 Introduction ........................................................................................................................... 54916.16 Ballast monitoring and management.......................................................................................... 55116.17 Hand-held inspection equipment................................................................................................ 552

16.17.1 Ultrasonic Hand Equipment MT 95....................................................................................... 55216.17.2 Hand-held Georadar ............................................................................................................. 55216.17.3 AUTOGRAPH ....................................................................................................................... 55316.17.4 MINIPROF ............................................................................................................................ 55416.17.5 RAILPROF ............................................................................................................................ 561

16.18 Pandrol Jackson SYS-10 Rail Flaw Detector ............................................................................. 565

17 HIGH-SPEED TRACKS

17.1 Introduction................................................................................................................................... 56717.1.1 Vehicle reactions..................................................................................................................... 56717.1.2 Track geometry ....................................................................................................................... 56817.1.3 Rail geometry and weld geometry .......................................................................................... 57017.1.4 Track quality standards for 300 km/h ...................................................................................... 570

17.2 The Korean High Speed Railway Project..................................................................................... 57417.2.1 Introduction ............................................................................................................................. 574


xxiv

17.2.2 Civil Works .............................................................................................................................. 57417.2.3 Track Characteristics.............................................................................................................. 57517.2.4 Track Laying ........................................................................................................................... 57517.2.5 Track Installation..................................................................................................................... 57517.2.6 Catenary and Systems............................................................................................................ 576

17.3 Dimensions of railway tunnels ...................................................................................................... 57717.3.1 Introduction ............................................................................................................................. 57717.3.2 Air resistance in the open field situation ................................................................................. 57717.3.3 Tunnel situation....................................................................................................................... 57817.3.4 Basic design criteria for tunnels.............................................................................................. 57917.3.5 Calculations of external air pressures on the train.................................................................. 58017.3.6 Modeling of the tunnel............................................................................................................. 58017.3.7 Calculation of air-pressure variations in trains ........................................................................ 58117.3.8 Criteria .................................................................................................................................... 58317.3.9 Results of calculations for tunnels in the HSL in The Netherlands ......................................... 584

17.4 Maglev Applications...................................................................................................................... 58417.4.1 Introduction ............................................................................................................................. 58417.4.2 The Japanese system............................................................................................................. 58417.4.3 The German Transrapid system ............................................................................................. 586

18 TRACK MAINTENANCE MANAGEMENT SYSTEMS

18.1 Introduction................................................................................................................................... 59118.2 Basic data for prediction and planning ......................................................................................... 59218.3 Track geometry............................................................................................................................. 59318.4 Prediction of geometry deterioration............................................................................................. 59318.5 The basics of the analysis principle.............................................................................................. 59418.6 Monitoring system for wheel defects ............................................................................................ 59618.7 Rational rail management............................................................................................................. 59618.8 ECOTRACK.................................................................................................................................. 596

18.8.1 Introduction ............................................................................................................................. 59618.8.2 Overview................................................................................................................................. 59718.8.3 System functions and process ................................................................................................ 59818.8.4 Features of the ECOTRACK system ...................................................................................... 602

19 RAILWAY ASSET MANAGEMENT SYSTEMS

19.1 Railway Asset Management System concept .............................................................................. 60419.2 Development of an AMS............................................................................................................... 60419.3 Railway Assets Locating............................................................................................................... 605

19.3.1 Method using ortho-photo technology..................................................................................... 60519.3.2 Method using laser, video and GPS technology ..................................................................... 60619.3.3 Video Surveying...................................................................................................................... 60719.3.4 Method using Satellite Imagery............................................................................................... 610

19.4 Integrating a Railway Asset Management System ....................................................................... 61119.5 AMS subsystems.......................................................................................................................... 612

20 LIFE CYCLE COST ANALYSIS

20.1 Life Cycle Costing......................................................................................................................... 61520.1.1 Life Cycle Costing principles................................................................................................... 615

20.2 Track Life Cycle Cost DSS ........................................................................................................... 62020.3 Recent studies.............................................................................................................................. 625


xxv

20.3.1 Track design for a high-speed line.......................................................................................... 62520.3.2 M&R strategies for tracks and switches.................................................................................. 62720.3.3 Conclusion .............................................................................................................................. 629


xxvi

Modern Railway Track 1 INTRODUCTION

1

1 INTRODUCTION

1.1 Historic development

The rail as supporting and guiding element was first utilised in the sixteenth century. In those timesthe mines in England used wooden roadways to reduce the resistance of the mining vehicles. Therunning surface was provided with an uprising edge in order to keep the vehicles on the track.During a crises as a result of overproduction in the iron industry in England in 1760, the wooden railswere covered with cast iron plates which caused the running resistance to diminish to such an extentthat the application of such plates soon proliferated. About 1800 the first free bearing rails wereapplied (Outtram), which were supported at the ends by cast iron sockets on wooden sleepers.Flanged iron wheels took care of the guiding, as we still practice now. In the beginning the vehicleswere moved forward by manpower or by horses.

The invention of the steam engine led to the first steam locomotive, constructed in 1804 by the Eng-lishman Trevithick. George Stephenson built the first steam locomotive with tubular boiler in 1814. In1825 the first railway for passengers was opened between Stockton and Darlington. On the mainlandof Europe Belgium was the first country to open a railway (Mechelen - Brussels). Belgium was quickto create a connection with the German hinterland bypassing the Dutch waterways. The first railwayin The Netherlands (Amsterdam - Haarlem) came into existence much later: only in 1839. Here therailway was regarded as a big rival of the inland waterways.

The railways formed a brand new means of transportation with up till then unknown capacity, speed,and reliability. Large areas were opened which could not be developed earlier because of the primi-tive road and water connections. The railways formed an enormous stimulus to the political, econo-mical and social development in the nineteenth century. Countries like the United States and Canadawere opened thanks to the railways and became a political unity. In countries like Russia and Chinathe railway still plays a crucial roll.

The trade unions originated when the railways were a major employer (railway strikes in England in1900 and 1911 and in The Netherlands in 1903). The railway companies were also the first line ofbusiness which developed careful planning, organisation and control systems to enable efficient man-agement. Moreover, they gave the impulse to big developments in the area of civil engineering (rail-way track building, bridges, tunnels, station roofing).

1.2 Railways

While the railways found themselves in a monopoly position up to the twentieth-century, with theadvent of the combustion engine and the jet engine they had to face strong competition in the form ofbuses, cars and aeroplanes.

Mass motorization after World War II expressed by the growing prosperity brought about many prob-lems, especially in densely populated areas: lack of space, congestion, lack of safety, emission ofharmful substances and noise pollution. Exactly in these cases railways can be advantageous as theyare characterized by the following:

– Limited use of space compared to large transport capacity;

– Reliability and safety;

– High degree of automation and management;

– Moderate environmental impact.

1 INTRODUCTION Modern Railway Track

1.6.2 Load-bearing function of the track

Figure 1.8: Conventional track structure

Figure 1.9: Principle of load transfer

σ

σ

σ

σ

σ

σ

σ

σ

σ

σ

Modern Railway Track 2 WHEEL-RAIL INTERFACE

2.7.7 Creepage coefficients

Figure 2.24: Origination of pure spin

Tx Gc2C11εx=

Ty Gc2 C22εy C23cφ+( )=

Mz Gc3 C23εy C33cφ+( )=

c ab=

3 CURVES AND GRADIENTS Modern Railway Track

3.10.2 Case 1: Investigation of dynamic effects

Figure 3.16: Track geometry: horizontal plane (a) and cant (b)

Figure 3.15: Response function of train (ICE) moving at 300 km/h

Modern Railway Track 5 STATIC TRACK DESIGN

5 STATIC TRACK DESIGN

5.1 Introduction

5.2 Supporting models

5.2.1 Winkler support model

σ

5.2.2 Discrete rail support

Figure 5.1: Winkler support model

σ

σ Cw=

Figure 5.2: Discrete elastic support model

Rail support:Rail support:

F xi( ) CArsw xi( ) kdw xi( )= =

kd CArs=

kdΣFΣw-------- Q

Σw--------= =

5 STATIC TRACK DESIGN Modern Railway Track

5.11 Two Case ERS designs

5.11.1 Testing of the UIC54 ERS

Test Angle Load Type of Load

P

P

P P

P P

P

Table 5.11: Tests determining the elasticity

Figure 5.30: Standard UIC 54 Embedded Rail Structure

Figure 5.31: Testing with different loading cases

Modern Railway Track 6 DYNAMIC TRACK DESIGN

6 DYNAMIC TRACK DESIGN

6.1 Introduction

Figure 6.1: Dynamic model of vehicle-track interaction

Modern Railway Track 6 DYNAMIC TRACK DESIGN

6.3.4 Discrete support

6.4 Vertical wheel response

6.4.1 Hertzian contact spring

Figure 6.20: Actual measurement on soft soil

Figure 6.19: Wave propagation at high speed

c GT =

ρc G

T =ρ

wdynwstat------------ 1

1 vvcr-------

2–

---------------------------------=

F cH y3 2⁄=

Modern Railway Track 7 TRACK STABILITY AND LONGITUDINAL FORCES

7 TRACK STABILITY AND LONGITUDINAL FORCES

7.1 Introduction

Figure 7.1: Example of track buckling

Figure 7.2: Typical buckling shape

7 TRACK STABILITY AND LONGITUDINAL FORCES Modern Railway Track

Approach 1 for determining ΔT

Δ

Approach 2 for determining ΔT

Δ

Δ

Δ ΔΔΔΔ

Figure 7.47: Buckling energy concept illustration

ΔΔΔΔ ΔΔ

Modern Railway Track 8 BALLASTED TRACK

8 BALLASTED TRACK

8.1 Introduction

Figure 8.1: Principle of track structure: cross section

Figure 8.2: Principle of track structure: longitudinal section

Modern Railway Track 8 BALLASTED TRACK

8.8.4 Elastic fastenings

Figure 8.22: Effect of sleeper treatment with araldite

Figure 8.24: Pandrol FastclipFigure 8.23: Pandrol fastening system

Figure 8.26: Nabla fastening systemFigure 8.25: Vossloh fastening system

Modern Railway Track 9 SLAB TRACK

9 SLAB TRACK

9.1 Introduction

9.2 Ballasted track versus slab track

Figure 9.2: ... and slab trackFigure 9.1: Ballasted track ...

Modern Railway Track 9 SLAB TRACK

Integrated techniques for slab track installation

Figure 9.15: Track assembly, track on top of the concrete roadbedon the concrete roadbed (for the project Leipzig-Gröbers)

Figure 9.16: Alignment portals in the Leipzig-Gröbers project

Modern Railway Track 10 THE RAIL

10 THE RAIL

10.1 Introduction

10.2 Modern rail manufacturing

10.2.1 Blast furnace

10 THE RAIL Modern Railway Track

Figure 10.3: Basic Oxygen Furnace (BOF) (Corus) Figure 10.4: Filling proces of converter


10.2.3 Vacuum degassing and argon flushing

10.2.4 Continuous casting

Figure 10.5: Schematic representation of a vacuum degassing unit (Thyssen)

Figure 10.6: Principle of a Contin-uous Casting machine (Thyssen)

10 THE RAIL Modern Railway Track

°

Figure 10.7: Some pictures of the continuous casting process

Figure 10.8: Hot strands passing through cooling chambers in a circular arc


10.4.3 Post-processing of flash butt welds in the NS welding depot

Figure 10.48: NS post-processing flash butt welds

Figure 10.49: Press and operating console used at KHRC

Figure 10.50: Plasser & Theurer STS 220 stationary grinder

Modern Railway Track 11 SWITCHES AND CROSSINGS

11 SWITCHES AND CROSSINGS

11.1 The standard turnout

Figure 11.1: Standard right-hand turnout

Figure 11.2: Picture of right-hand turnout

11 SWITCHES AND CROSSINGS Modern Railway Track

11.1.1 Set of switches

Figure 11.3: Cross-sectional drawing of switch blade and stock rail

Figure 11.4: Switch blade and stock rail

Figure 11.5: Cross-sectional drawing of T-rail switch blade

Modern Railway Track 11 SWITCHES AND CROSSINGS

11.1.2 Common crossing

Figure 11.6: Switch with integrated hydraulic setting and locking sys-tem

Figure 11.7: Modern electrical point machine

Modern Railway Track 12 TRACK MAINTENANCE AND RENEWAL

12 TRACK MAINTENANCE AND RENEWAL

12.1 Introduction

Visual inspection

Safety

Figure 12.1: Schematic survey of maintenance and renewal process

Surface welding

Switches

Level crossings

Structures

Spots

Manual

Tamping

Ballast regulating

Ballast stabilizing

Rail grinding

Joint straightening

Ballast cleaning

Spots

Mechanical

Maintenance

Parts

Manual

Trackcontinuous or panels

Switchescomplete or parts

Formation

Structures

Mechanical

Renewal

Maintenance & Renewal

Surface welding

Switches

Level crossings

Manual Mechanical

Maintenance

Manual Mechanical

Renewal


Structures

Spots

Tamping

Ballast regulating

Ballast stabilizing

Rail grinding

Joint straightening

Ballast cleaning

Spots

Parts Trackcontinuous or panels

Switches

Formation

complete or parts

Structures

Surface welding

Switches

Level crossings

Structures

Spots

Manual

Tamping

Ballast regulating

Ballast stabilizing

Rail grinding

Joint straightening

Ballast cleaning

Spots

Mechanical

Maintenance

Parts

Manual

Trackcontinuous or panels

Switchescomplete or parts

Formation

Structures

Mechanical

Renewal


Surface welding

Switches

Level crossings

Manual Mechanical

Maintenance

Manual Mechanical

Renewal


Structures

Spots

Tamping

Ballast regulating

Ballast stabilizing

Rail grinding

Joint straightening

Ballast cleaning

Spots

Parts Trackcontinuous or panels

Switches

Formation

complete or parts

Structures


Figure 12.6: Grinding units with rotating stones Figure 12.7: Principle of pivoting the Speno grinding units

Figure 12.8: As-ground rail with the different facets clearly visi-ble

Figure 12.9: Asymmetric ground rail profiles

12 TRACK MAINTENANCE AND RENEWAL Modern Railway Track

Alignment

,Figure 12.30: Comparison of theoretical and actual transfer functionfor 07-32 tamper

λλ

Figure 12.31: 4-point lining principle Figure 12.32: 4-point lining system with error F0 at front endof lining chord

Yn x( ) ac--- α 1–

α-------------Yn x a c+–( ) b a–

b------------ a b c–( )

bc--------------------α 1–

α-------------– Yn x a–( ) 1

α---a

b---Y0 x b a–+( )+ +=


12.7.2 Measuring philosophy used for the stone blower

Figure 12.44: Stoneblower operated at RAILTRACK


12.10 Mechanised track maintenance train

12.11 Ballast cleaner

Figure 12.56: Mechanised track maintenance train MDZ 2000


Blanketing machine with ballast rehabilitation

Figure 12.61: Formation rehabilitation machine AHM 800 R

Modern Railway Track 13 NUMERICAL OPTIMIZATION OF RAILWAY TRACK

13 NUMERICAL OPTIMIZATION OF RAILWAY TRACK

13.1 Introduction

13 NUMERICAL OPTIMIZATION OF RAILWAY TRACK Modern Railway Track

B2

Figure 13.2: Extended (a) and random plan of experiments in MARS method

B2

F̃ x a,( ) a0aixi

i 1=

P

+= F̃ x a,( ) a0xi( )

ai

i 1=

P

∏=

xP 1–

x1

x3

x2

xP

B1kA1

kA1 B1

x1

x3

x2xP

B1kA1

kA1 B1

B2k

A2k

A2

xP 1–


Numerical models

.

Figure 13.5: 3-D (a) and 2-D (b) finite element models of ERS with SA42 rail

Figure 13.6: RAIL model of ERS (moving train loading case)

Kstat Kdyn Kstat Fy uy 1,⁄=Kdyn 2Kstat= uy 1,


Figure 13.11: Initial design of ERS with conventional rail (a) and result of multi criteria optimization with equal preference (b)

Figure 13.12: Geometrical results of multi criteria optimization, variation of preferences for noise ( ) and maintenance ( )wN wM

wC 0.1=

wNwM

wN 0.1=

wM

13 NUMERICAL OPTIMIZATION OF RAILWAY TRACK Modern Railway Track

13.6.3 Numerical model

Figure 13.26: Hammer Excitation Test on classical track (a) and Embedded Rail Structure (b)

HAF kg 1–[ ] FA

HAF f( )SAF f( )SFF f( )----------------=

SAF mN s⁄[ ]

SFF N2s[ ]

f Hz[ ]

HXF m N⁄[ ]F

X

HXF f( )SXF f( )SFF f( )---------------- 1

2πf( )2----------------

SAF f( )SFF f( )----------------= = SXF f( ) 2πf( ) 2– SAF f( )=

SXF mNs[ ]

HAF f( ) 2πf( )2HXF f( )=

Modern Railway Track 14 TESTING AND ACCEPTANCE

14 TESTING AND ACCEPTANCE

14.1 Introduction

14.2 Component testing and acceptance

14.2.1 Mechanical properties

Elasticity Strength Stability Durability

Table 14.1: Overview of the most important track properties of each component

Figure 14.1: New developments in railway track require testing before acceptance

Modern Railway Track 14 TESTING AND ACCEPTANCE

14.2.4 Stability properties

Figure 14.10: Longitudinal resistance test of a fastening system mounted on sleeper

Figure 14.9: Longitudinal resistance test of an embedded rail section

14 TESTING AND ACCEPTANCE Modern Railway Track

Figure 14.25: Extracting embedded rail dynamic properties by means of curve-fitting of the recorded transfer function

Figure 14.24: Recording properties of embedded rail test sample in laboratory

Figure 14.26: (a) Simulated and recorded transfer functions of embedded rail structure at rail head

Simulation RecordingSimulation Recording

Modern Railway Track 15 NOISE AND VIBRATION

15 NOISE AND VIBRATION

15.1 Introduction

15.2 Some definitions

Figure 15.1: Noise and vibration radiation principle

Noise:●

●

●

●

●

Vibrations:●

●

●

Noise:●

●

●

●

●

Vibrations:●

●

●

L dB[ ] 20p1

p2-----log=

Figure 15.2: Relationship between dB scale and linear scale

=≈ ≈≈≈≈≈=≈

15 NOISE AND VIBRATION Modern Railway Track

Silent steel bridges

Figure 15.19: Traditional embedded rail concept on steel bridge

Figure 15.20: Silent bridge cross section and view of a bridge

Figure 15.21: Measured noise energy levels at silent bridge and at conventional bridge

Modern Railway Track 16 INSPECTION AND DETECTION SYSTEMS

16 INSPECTION AND DETECTION SYSTEMS

16.1 Railway Infrastructure Monitoring

16.2 Tunnel monitoring

Figure 16.1: Tunnel profile laser/visual/thermal scan processing system - Scan View


Rail surface

16.7.4 Overhead wire recording

Figure 16.49: Real-time diagram of the rail cross-section

Figure 16.50: Overhead wire measuring system of Plasser & Theurer


16.7.7 Track recording cars

High speed track recording cars

Figure 16.51: High speed track recording coach EM 250 of ÖBB

Figure 16.52: Data flow of EM 250

Conference Room

Office Cabin

Operator Room

Conference Room

Office Cabin

Operator Room

16 INSPECTION AND DETECTION SYSTEMS Modern Railway Track

Recording cars for standard speeds

– UFM 120 on Netherlands railways

– EM 130 on Belgium railways

Recording cars for smaller networks

Figure 16.53: Track recording car UFM 120 Figure 16.54: Track recording car EM 130 of SNCB

Figure 16.55: Track recording car EM 130 of SNCB


∞

16.10.3 Dynamic signals

Vertical

Figure 16.77: Principle of an inertial measuring system

λ

..

−++= hctczz 21B −++= hctczz 21B

λ

..

−++= hctczz 21B −++= hctczz 21B

16 INSPECTION AND DETECTION SYSTEMS Modern Railway Track

φ

16.10.4Quasi-static signals

Figure 16.81: Laser system mounted in measuring bogie

Figure 16.82: Principle of galvo control to position laser spot on rail head

√5325)(

H5

1V5

2

b

bb

φΔφ +

=− bφφΔ

bφ

bV

bH

√5325)(

H5

1V5

2

b

bb

φΔφ +

=− bφφΔ

bφ

bV

bH

Δφ φb–Hb

l 5------------–

Vb

½ 5---------------+=

Figure 16.83: Transducer for vertical displacement between axle and bogie frame

5


16.12.3 Track geometry spectra

Table 16.7: Conversion table for track recording car output

Figure 16.101: Psd-functions for vertical track geometry based on BMS measurements carried out for ORE D 161

Modern Railway Track 17 HIGH-SPEED TRACKS

17 HIGH-SPEED TRACKS

17.1 Introduction

17.1.1 Vehicle reactions

Σ

Table 17.1: Safety limits for high-speed operation

17 HIGH-SPEED TRACKS Modern Railway Track

17.2 The Korean High Speed Railway Project

17.2.1 Introduction

17.2.2 Civil Works

Figure 17.3: Seoul-Pusan High Speed Line


17.3.4 Basic design criteria for tunnels

Figure 17.11: Wave forms in tunnel

Δ

Δ


S

SN

NN

S

S

SN

NN

S

Figure 17.18: Levitation principle

N

SN

N

N

N

N

SN

N

N

N

Figure 17.19: Lateral positioning principle

Figure 17.20: Propulsion principle

Z N Z N Z N

ZN ZN N

N Z N Z N ZZN ZN N

- - - - - -

ZN ZN N

Z N Z N Z N

ZN ZN N

N Z N Z N ZZN ZN N

- - - - - -

ZN ZN N

Modern Railway Track 18 TRACK MAINTENANCE MANAGEMENT SYSTEMS

18 TRACK MAINTENANCE MANAGEMENT SYSTEMS

18.1 Introduction

Figure 18.1: Total annual expenditure for maintenance and renewal at NS (price level 2000)

Figure 18.2: Types of data to be col-lected for computer-aided Track Main-tenance Management Systems

InspectionsInspections

TMMSTMMS Work carriedWork carriedoutout

CostsCosts

MeasurementsMeasurements

PlanningPlanning

InfrastructureInfrastructure

18 TRACK MAINTENANCE MANAGEMENT SYSTEMS Modern Railway Track

18.8.3 System functions and process

Level 1 - Initial diagnosis

Level 2 - Detailed diagnosis

Level 3 - Coherence of the elementary M&Rworks

Level 4 - Optimization of resource allocation

Figure 18.8: ECOTRACK Rules

In- situ conditions to which the trackis subjected


Works:- maintenance- renewal


State of track geometryState of track geometry State of track materialState of track materialRULESRULES

RULES

RULESRULES

RULES

RULES

RULESRULES

RULES

DETERIORATIONPROCESS


RESTORATIONPROCESS

RESTORATIONPROCESS





State of track geometryState of track geometry State of track materialState of track materialRULESRULES

RULES

RULESRULES

RULES

RULES

RULESRULES

RULES

RULESRULESRULESRULES

RULES

RULESRULES

RULES RULES

RULES

RULES

RULESRULES

RULES

RULES

RULES

RULES

RULESRULES

RULES RULES

RULES

RULES

RULESRULES

RULES

RULES

RULES



RESTORATIONPROCESS

RESTORATIONPROCESS

Figure 18.9: ECOTRACK - Func-tional Process

INITIAL DIAGNOSIS

COHERENCE

OPTIMISATION

OVERALL MANAGEMENT

DETAILED DIAGNOSIS

RULESTHRESHOLDS

levels1 - 2 - 3 - 4

levels processingINPUT OUTPUT

INITIAL DIAGNOSIS

COHERENCE

OPTIMISATIONOPTIMISATION

OVERALL MANAGEMENTOVERALL MANAGEMENT

DETAILED DIAGNOSIS

RULESTHRESHOLDS

levels1 - 2 - 3 - 4

RULESTHRESHOLDS

levels1 - 2 - 3 - 4

levels processingINPUT OUTPUTlevels processingINPUT OUTPUT

Modern Railway Track 19 RAILWAY ASSET MANAGEMENT SYSTEMS

19 RAILWAY ASSET MANAGEMENT SYSTEMS

Figure 19.1: Core Elements of an AMS

Ware-house

Work-shop

Preventive

Predictive

WorkOrders

MaintenanceSchedule

MaintenancePlan

Maintenance

Materials

PurchaseOrders

InboundLogistics

Human Resources

PersonnelAvailability

Skills &Training

Gen Ledger

CostingPayrollAccounts

ReceivableAccountsPayable

Corrective

19 RAILWAY ASSET MANAGEMENT SYSTEMS Modern Railway Track

19.3.2 Method using laser, video and GPS technology

Figure 19.3: Graphical Presentation of FLI-MAP Data Collection System

Modern Railway Track 19 RAILWAY ASSET MANAGEMENT SYSTEMS

19.4 Integrating a Railway Asset Management System

Figure 19.11: GIS background layout of an AMS [62]

Figure 19.12: GIS background layoutof an AMS (2) [62]

Modern Railway Track 20 LIFE CYCLE COST ANALYSIS

20 LIFE CYCLE COST ANALYSIS

20.1 Life Cycle Costing

'Life cycle management'

'Performance-based contracts'

'Maintenance window scheduling'

in the longterm

20.1.1 Life Cycle Costing principles

Modern Railway Track 20 LIFE CYCLE COST ANALYSIS

2. Maintenance and renewal analysis

3. Impact estimation

4. Financial data

1. Transportation data 2. M&R process data3. Impact estimation

6. Performance analysis5. Total cost estimation4. Financial data

1. Transportation data 2. M&R process data3. Impact estimation

6. Performance analysis5. Total cost estimation

Figure 20.2: Life Cycle Cost DSS model-base

Modern Railway Track INDEX

INDEXNumerics

365364364

364

A93

42286

4943243

459380

30366 368

13 36446

241591 603

465102 104220

279245

608, 605475 591, 603

353517

464336

351 375 553460

69 52655 62 63

B6892, 205

377223 469

224223

223224

551375375

203 231 232 240463

281220

275, 277

114117

71 74 8085

142380

275281

526528123 405

38

8762

476210

470299

18465

527

C102, 591

96, 204529

37 5843

39

279279

796, 204

262494

29275, 118508

22210337

40261

598277

470214

49118, 21

396205

360279388

3144058, 319 514 563

407595301, 304

23027, 29

118, 120301, 305

507333

337, 344341

205205

33135, 540

4164

3564

31 4383, 384

INDEX Modern Railway Track

D329

459257

59351, 374

514

400401, 402, 593

403406

404401, 599

4039

494, 59846525371, 121

366481

482482

116209

366287

37 407 467376

359287, 288

163 166 170260

157108

167527

107375

E595 596 603

284591

91 92247221

75211256

6512

162104, 159, 253, 255, 472

367 368, 552367

297265

46921

80

206, 551597550

496 515297

20490

209209

596

F493

331476

219220

220221220

221221

222221, 252

85 300282

20818

1820

211306, 309

206110258

60632

204379

379, 38192 93

11571 260

122547

300218

112 122109

14340

G386, 387 398

54235

337286

381100

523210

368 60635, 44

4431, 44

379205

353309

352353

206478 479 552

460

Modern Railway Track REFERENCES

REFERENCES

REFERENCES Modern Railway Track

Rail Track Engineerin

Documents

Transcript of Rail Track Engineerin