Professional Documents
Culture Documents
Bahn Fachverlag
www.bahn-fachverlag.de
ISBN: 978-3-943214-03-1
DB Manual
EX
TR A
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Work procedures
for permanent way
maintenance
7th revised and
extended edition
Lothar Marx
Dietmar Momann
In co-operation with:
EX
TR A
Published by Bahn FachverlagC
T!
DB Manual
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TR A
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Contents
Preface
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19
General
21
Track equipment
25
2.1
General
25
2.2
The rails
25
2.2.1
Insulated rails
26
2.2.2
Insulated joints
26
2.3
The sleepers
28
2.3.1
28
2.3.2
28
2.3.3
30
2.3.4
31
2.4
32
2.5
35
2.5.1
35
2.5.2
36
2.6
41
Substructure
42
3.1
General
42
3.2
44
3.2.1
Substructure foundation
45
3.2.2
46
3.2.3
46
3.2.4
47
3.2.5
Drainage systems
47
3.3
48
3.3.1
Substructure redevelopment
49
50
4.1
General
50
4.2
50
4.3
Route elements
51
4.4
Fundamentals of routing
52
4.4.1
52
4.4.2
Superelevation
52
4.4.3
Lateral acceleration
53
4.4.4
Compensating superelevation
53
4.4.5
Determining superelevation
53
4.4.6
Unbalanced superelevation
54
4.4.7
Excess of superelevation
55
4.4.8
Minimum superelevation
55
4.4.9
Standard superelevation
55
4.5
56
4.5.1
56
4.5.2
56
4.5.3
Superelevation ramps
57
4.5.4
Ramp forms
57
4.6
58
4.7
58
4.7.1
58
Maintenance terms
60
EX
5.1
General
5.2
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60
60
Inspection
63
6.1
63
6.1.1
63
6.1.2
64
6.2
Measurement runs
65
6.2.1
65
6.2.2
71
6.2.3
73
6.2.4
80
6.3
Manual measurements
83
6.3.1
85
6.4
Foundation survey
88
6.4.1
General
88
6.4.2
89
6.4.3
Evaluation of results
97
6.4.4
Construction execution
99
6.4.5
Conclusion
99
6.4.6
100
6.4.7
111
6.5
117
6.5.1
General
117
6.5.2
117
6.5.3
126
6.5.4
130
6.5.5
136
Maintenance
142
7.1
142
7.1.1
143
7.1.2
146
7.2
148
7.2.1
148
7.2.2
Switch rollers
148
7.2.3
148
Repair work
152
154
9.1
Rail transport
164
9.1.1
164
9.1.2
168
9.1.3
170
9.1.4
172
9.2
174
9.3
182
9.3.1
182
9.3.2
190
9.3.3
192
9.3.4
197
9.3.5
200
9.3.6
205
9.3.7
207
9.3.8
212
9.4
218
9.5
221
9.5.1
General
221
9.5.2
223
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9.6
9.7
9.8
234
9.8.1
234
9.8.2
Preliminary work
235
9.8.3
Organisation
235
9.8.4
Special features
236
9.8.5
236
9.8.6
238
9.8.7
239
9.9
239
9.10
Track assembly
242
10
Renewal of switches
248
10.1
General
248
10.2
251
10.3
259
10.4
269
10.5
272
10.6
276
10.7
278
10.7.1
Goal setting
278
10.7.2
Technical solution
278
10.7.3
280
10.7.4
280
10.7.5
Installation
282
225
229
10.7.6
283
10.7.7
283
10.7.8
Summary
286
10.8
Switch maintenance
287
10.8.1
Switch inspection
289
10.8.2
297
10.9
302
11
Sleeper replacement
305
11.1
General
305
11.2
305
11.3
306
12
Rail replacement
311
12.1
General
311
12.2
312
12.3
314
12.4
315
13
Ballast laying
317
13.1
General
317
13.2
Classic procedure
321
13.3
323
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14
Installation of tracks
14.1
General
14.2
Ballast superstructure
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324
324
324
14.2.1
324
14.2.2
325
14.2.3
326
14.2.4
327
14.2.5
329
14.2.6
331
14.2.7
331
14.2.8
331
14.3
335
14.3.1
General
335
14.3.2
336
14.3.3
365
14.3.4
404
14.3.5
411
14.3.6
415
14.4
417
14.4.1
424
14.5
428
14.6
Transitions
428
14.7
428
14.8
431
14.9
433
14.9.1
433
14.9.2
437
14.9.3
442
15
444
15.1
Product
444
15.2
Application areas
445
15.3
449
15.4
450
15.5
Guarantee
450
15.6
Work specifications
450
15.7
450
16
Ballast cleaning
451
16.1
General
451
16.2
454
16.3
460
16.3.1
General
460
16.3.2
461
16.4
465
16.5
471
16.6
476
10
16.6.1
476
16.6.2
480
16.7
483
16.8
488
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16.9
493
16.10
16.11
495
17
496
17.1
General
496
17.2
Material conveyor and hopper unit (MFS 38, 40, 100-S, 250),
belt storage device (BSG 60), bulk freight hopper wagon
(BSW 11000 and 2000) and road-rail MFS
496
17.3
501
17.4
503
18
Formation rehabilitation
505
18.1
General
505
18.2
505
18.3
506
18.3.1
506
18.3.2
513
18.4
516
18.4.1
516
18.4.2
Addition of an RM 80-92
ballast cleaning machine to the PM 200-1 BR
522
494
18.5
523
18.5.1
523
18.5.2
Work procedure
526
11
18.6
531
18.7
538
18.7.1
538
18.7.2
Work procedure
539
18.8
544
18.8.1
General
544
18.8.2
Working methods
546
18.8.3
550
18.9
554
18.10
18.11
559
19
562
19.1
562
19.2
574
19.2.1
Introduction
574
19.2.2
575
19.2.3
577
19.2.4
584
19.2.5
590
19.2.6
595
Tamping
603
19.3
12
19.3.1
General
603
19.3.2
Compacting
614
19.3.3
615
19.3.4
616
19.3.5
616
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19.4
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618
19.4.1
General
19.4.2
19.4.3
621
621
19.5
Maintenance of switches
625
19.6
626
19.7
631
19.8
Checking execution
635
20
636
20.1
General
636
20.2
Stress compensation
636
20.3
639
21
650
21.1
Tracks
650
21.1.1
General
650
21.1.2
650
21.1.3
Gauge correction
653
21.1.4
655
21.1.5
Sleeper rehabilitation
656
21.2
665
21.2.1
665
21.2.2
670
19.4.4
618
620
13
22
Rail processing
673
22.1
General
673
22.2
676
22.2.1
678
22.2.2
678
22.2.3
679
22.2.4
679
22.3
682
14
22.3.1
682
22.3.2
684
22.3.3
685
22.3.4
686
22.3.5
688
22.3.6
689
22.3.7
691
22.4
693
22.5
698
22.6
701
22.7
703
22.8
706
22.9
710
23
711
23.1
Introduction
711
23.1.1
711
23.1.2
Sources of noise
712
23.1.3
Rolling noise
713
23.1.4
714
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23.1.5
Vibrations
715
23.2
23.2.1
717
23.2.2
718
23.3
719
23.4
Sound-reducing measures
720
23.4.1
720
23.4.2
720
23.4.3
720
23.4.4
721
23.5
Vibration-reducing measures
721
717
23.5.1
721
23.5.2
722
23.5.3
722
24
723
24.1
Principles
723
24.1.1
General
723
24.1.2
Acceptance
723
24.2
727
24.2.1
General
727
24.2.2
727
24.2.3
730
24.2.4
732
24.2.5
733
24.3
734
24.3.1
General
734
24.3.2
Object of acceptance
734
24.3.3
734
24.3.4
736
15
24.4
16
738
24.4.1
General
738
24.4.2
738
24.4.3
739
24.5
740
24.5.1
General
740
24.5.2
740
24.5.3
741
24.6
742
24.6.1
General
742
24.6.2
Principles
743
24.6.3
Working equipment
743
24.6.4
743
24.7
748
24.7.1
General
748
24.7.2
748
24.7.3
750
24.7.4
25
Further developments
754
25.1
General
754
25.2
754
25.3
759
25.4
763
25.5
768
25.5.1
System description
769
25.5.2
Routing principles
769
25.5.3
Construction implementation
769
25.6
771
EX
25.6.1
Characteristics of DURFLEX
25.6.2
25.6.3
25.7
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771
772
774
774
25.7.1
System description
774
25.7.2
776
25.8
776
25.8.1
776
25.8.2
Laying procedure
777
25.9
780
25.10
784
25.10.1
784
25.10.2
785
Annex
Abbreviations
787
Units of measurement
788
Advertisers
789
790
Index
792
Authors
796
17
Ihre Anzeige
Your Advertisement
18
EX
Preface
TR A
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19
Preliminary remarks
The maintenance of tracks and switches to guarantee operational safety necessitates
knowledge of the work procedures, the relevant working methods and the individual track
machinery and equipment. The authors' task was therefore to clearly and understandably
convey the process technology applied at DB Netz AG to all interested parties.
This new edition of the manual is intended to be used as a training and advanced training
document and to provide knowledge regarding the interaction of personnel, machines and
track equipment in permanent way maintenance.
Changes have particularly arisen due to the inclusion of:
track renewal train RU 800 S,
track renewal train SUM 315,
the P 95-SR track renewal trains,
track renewal train P 100,
ballast cleaning machines RM 95-700 and RM 95-800 W,
the new tamping machines for tracks (09-4X) and switches 09-475 Unimat 4S,
the survey procedures EM-SAT, GEDO and GRP,
the switch transport wagon WTW,
the new formation rehabilitation machine PM 1000,
rail milling machine SF 03,
track renewal train SUZW 500.
VO
R
WO
R
New chapters dealing with the following topics have also been added:
Track equipment,
Substructure,
Line layout and routing,
Ballast bonding,
Noise insulation.
The installation and maintenance of the ballastless track system (FF) are additionally
described. The ballastless track systems have also been further developed, particularly
the RHEDA, Zblin, Bgl and Infundo design types.
The technical status of the work procedures is documented up to September 2010.
At this point, we would like to thank all of our expert colleagues for their friendly
assistance and helpful advice. We would also like to thank the track maintenance
companies and the manufacturers of the machines, equipment and materials required
for maintenance for their valuable support and for providing us with documents which
contributed towards making this manual a success. We would particularly like to thank
Messrs. Armbruster, Dietrich, Dr. Hetzel, Knfel, Dr. Kratochwille, LeDosquet, Rausch
and Zck of DB for their kind co-operation. Additional thanks go to Mr. J. Rauch
(IBES Baugrundinstitut GmbH) and Dr. Stefan Lutzenberger (Mller-BBM GmbH) for
their supporting preliminary work.
Mainz, September 2010
The authors
20
EX
1
General
TR A
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The task of permanent way maintenance is to provide the user (passenger and goods
transport) with an infrastructure which meets the requirements in terms of speed, load
and safety according to technical and economic aspects. The DB Netz AG infrastructure
encompasses around 64,000 km of track and around 67,000 switch units (Fig. 11).
Abb XXX 1_en.pdf
14.06.12
15:34
Schematic portrayal
Priority network
High-performance network
Abb. 11: DB Netz AG railway network showing the priority and high-performance network
21
represented milestones in the high-speed network (v > 160 km/h), which now covers a
track length of around 5,000 km, whereby the permissible speed on the new lines (NBS) is
300km/h with the ICE3 (Fig. 12).
It has also been possible to increase the speed throughout the existing network, whilst
retaining the route parameters, thanks to higher-performance vehicles in passenger and
goods transport (Figs. 13 and 14).
22
EX
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In addition to the classic superstructure components (rail, sleeper and ballast), the
installation of ballastless track system constructions (see Chapter 14.3) will also be
described. Maintenance costs are to be reduced even further through innovative track
constructions.
Each year, DB Netz AG spends considerable amounts of money on track maintenance
and renewal. Performance of this work often under dicult operational conditions
23
24
EX
2
Track equipment
2.1
General
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The permanent way, consisting of the track and switch constructions including crossings
and rail expansion joints, is generally the most highly-stressed part of the infrastructure.
Since railways came into being, the ballast superstructure and its components, the rail, rail
fastening, sleeper and ballast, have undergone significant technical development, up to and
including the currently familiar forms of the cross sleeper track and the ballastless track
system design types. The superstructure products, design types or construction procedures
may only be used if they have been certified by the Federal Railway Oce and/or approved
by DB Netz AG's headquarters.
This chapter will only deal with the currently conventional superstructure components.
2.2
The rails
Today, form 60 E2, 54 E4 and 49 E5 rails are generally used by Deutsche Bahn (Fig. 21).
The rails are usually supplied in what is referred to as their naturally hard condition
(pearlitic rails). As a rule, the rails used by Deutsche Bahn have a minimum strength of
700 N/mm, whilst wear-resistant rails have a minimum strength of 900 N/mm (the tensile
strength of the rail steel is used as rail strength fracture [N/mm]). To achieve higher rail
strengths, pearlitic, naturally hard rails are additionally heat treated (e.g. head-hardened
rails).
Abb. 2.2 - 1_en.pdf
14.06.12
15:42
The rail's identification includes the following data such as manufacturer, year of rolling,
profile and steel grade.
Today, a continuous welded rail track is usually produced. The rails are prefabricated in
the factory and delivered to the installation location in lengths up to 120 m. Thanks to the
lower number of welds, higher productivity during neutralisation, clamping and welding is
25
achieved on the worksite. Joint gap rails are manufactured from rails with standard lengths
of 30 m, 45 m or 60 m.
Profile transition rails are installed in tracks with different rail base widths and/or rails
with height differences of >5mm. For example, form 54 E4 rails must be fitted between
form 60 E2 and form 49 E5 rails. Profile transition rails are usually prefabricated in the
welding factory.
Rails have to meet requirements including the following:
2.2.1
Insulated rails
Insulated rails are as long as the largest wheel-base which occurs (30 m) and are insulated
from the opposite rail. To achieve this, both ends of the insulated rail are joined to the
neighbouring rails by means of an insulated joint.
2.2.2
Insulated joints
Due to safety reasons, insulated joints which prevent the passage of electrical current have
to be installed in the track.
The production of insulated joints in the track has not proved worthwhile, and is therefore
usually carried out in the factory. To do this, 3 to 5 m long rail sections are bonded using
adapted fish plates and tensioned with high-strength bolts. A distinction is made between
design type S and IVB 30 insulated joints manufactured in the factory and design type MT
insulated joints produced in the track. Design type IVB 30 insulated joints currently have
to be used as standard in tracks and switches. Design type MT insulated joints are only
permissible if design type IVB 30 insulated joints manufactured in the factory cannot be
used (e.g. structural joints of switches and crossings).
The finished insulated joints are welded into the track at the work site (see Figures 22
to 25).
26
14.06.12
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Abb.
IVB 30
Hauptfahrrichtung_en.pdf
Concrete sleeper
with 2.2 - 3 Isoliersto
Wooden
sleeper
with
superstructure W (Skl 1K)
superstructure K (Kpo 9)
Abb. 22: Insulated joint design type S
15:47
27
14.06.1
2.3
The sleepers
Wood, concrete or steel can be used as construction materials for sleepers. The sleepers'
tasks include:
2.3.1
Wooden sleepers are produced using oak, red beech, pine or larch, among other woods.
The standard types of wood currently used in Europe are beech for dancing sleepers
and oak for crossing timbers. All wooden sleepers are impregnated to protect them from
rotting. The service life of an impregnated wooden sleeper is 30 to 45 years. They are
unsuitable for high-speed lines with speeds in excess of 160 km/h, as they exhibit
15percent lower lateral displacement resistance.
2.3.2
The steel sleepers are manufactured in trough form (Fig. 26). The material which is used
is steel S235JR. They have a service life of between 40 and 60 years.
Advantages:
Low weight, so easier to handle,
Low installed height, so less ballast required,
Long service life.
28
EX
Disadvantages:
Lateral displacement resistance is lower in comparison with concrete sleepers,
More complex track insulation,
Increased ballast wear.
2.3.2.1
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Graphic: DB AG
Y-steel sleeper St 98
The Y-steel sleepers consist of two hot-rolled IB 100S broad-flanged girders bent in an s
shape and two straight girder sections with the same profiles. The steel profiles are joined
at each end of the sleeper by means of two upper and two lower locks, which are welded
to the girder flanges (Fig. 27). The insulated support point S15 with tension clamp S14 is
used as the rail fastening.
The Y-steel sleepers are used in both the ballast superstructure and the ballastless track
system (FF) in combination with an asphalt base layer (ATS) (also see Chapter 14.3
"Ballastless track system"). In contrast to the "standard" steel sleeper, the Y-steel sleeper
exhibits high lateral and longitudinal displacement resistance. Its disadvantages include
more complex maintenance and tamping with switch tamping machines.
Installation of the Y-steel sleeper is carried out according to guideline 824.2060 and can be
accomplished using all conventional procedures (e.g. with UM1, SUZ 500).
The Y-steel sleeper is not installed on earthwork foundations in high-speed lines.
29
2.3.3
Today, reinforced concrete sleepers are the standard design type for standard-gauge railway tracks (Figs. 28, 29 and 210). The prestressed concrete sleepers most commonly
used by Deutsche Bahn are the B 70 W-60, B 70 W-54, B70 W-24 and B 90 W-60/54. The
significant advantages of reinforced concrete sleepers include their extensive prevention
of track buckling caused by high weight, good gauge maintenance and long service life.
Each concrete sleeper must show the following identification:
Year of manufacture,
Rail base width,
Design series symbol,
Formwork number,
Factory symbol.
In addition to the static test, the dynamic bending test in which shock load in the track is
simulated also has to be performed as part of the certification test for concrete sleepers.
The fatigue test also forms part of the certification test, as does the measurement of
electrical sleeper resistance (minimum ballast resistance = 3 ohm/km).
30
EX
Form number
Graphic: DB AG
Manufacturing date
Form number
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Manufacturing date
2.3.4
2.3.4.1
The conceptual design of the twin sleeper is based on the features of the B-70 sleeper. The
sleeper width (57 cm) is doubled and its length is shortened by 20 cm. The sleeper height,
fastening and support points are identical. Water channels are located on the outer side.
31
These channels are raised in the centre so that the water is able to drain off outwards. The
3 cm laying gap between the sleepers is sealed using a soft PVC cover. This prevents the
ingress of dirty water and surface water (Fig. 211).
Sleeper centre
Abb. 211: Prestressed concrete twin sleeper BBS 1 W (60 and 54)
2.3.4.2
Graphic: DB AG
In this system, the concrete sleepers are "padded" with an elastic material on the underside of the sleeper. Sylomer and Sylodyn have proved to be suitable materials for this (also
see Chapter 14.9 "Installation of special sleepers"). As part of track or sleeper renewal or new
track construction, sleepers with elastic bases or sub-ballast mats have to be installed in the area
of man-made structures (e.g. bridges, tunnels, trough structures, passages) in order to reduce
ballast stress.
Padded concrete sleepers offer advantages including the following:
The requirements on sub-ballast mats and sleepers with elastic soles are regulated in
DB standards DBS 918 071, DBS 918 145-1 and DBS 918 145-2 (technical terms of delivery).
2.4
The sleepers for constructing the ballastless track system have been developed on the
basis of the classic ballast superstructure (cross sleeper superstructure). This is the
simplest method for ensuring the required track geometry (including the track gauge) in
the ballastless track system. In this case, the sleepers may be concreted into the slab in
combination with the rails (track panel) or individually.
32
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Abb. 213: ATD design type with twin-block concrete sleeper B 350 W-60
Vossloh 300-1
rail fastening
Recess for
dowel block
Nonwoven
cloth
3 mm
Abb. 214: Getrac design type with monobloc concrete sleeper B 316 W-60
33
Abb. 215: Twin concrete sleeper BBS 3 W-60, Getrac design type
Abb. 216: Twin-block concrete sleeper B 355.3 W60M for RHEDA 2000 design type
34
Graphic: DB AG
EX
2.5
5
6
7
8
9
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Graphic: DB AG
The rail fastening is used to securely tension the rails on the sleepers and therefore ensures
that forces are reliably conducted away, the rail is mounted with sucient elasticity and
adequate resistance to longitudinal displacement is achieved.
One of the essential functions of the fastening system in the case of concrete sleepers is
electrical insulation of the rail from the rest of the track panel. This is necessary to minimise track circuit signal losses which occur due to poor rail insulation from the foundation.
The forces acting vertically on the rail fastening are reduced by elastic rail pads beneath
the base of the rail and by accompanying spring elements.
Some of the horizontal forces transverse to the rail are absorbed by the elastic rail pads,
whilst the remainder are transferred directly onto the sleepers, e.g. through angled guide
plates.
The forces in the track's longitudinal direction (starting, braking and temperature forces)
are absorbed by the elastic rail pads and the tensioning element.
In an elastic rail fastening, the bolts are tightened in such a way that initial tension is
achieved through the elastic clip or the spring rings. The fastening is constantly subject
to the influence of force due to this initial tension. This leads to a constantly effective
fastening even under the various forces induced by the train's wheel load. The hold-down
force extensively determines the resistance to longitudinal displacement between the rail
and the sleeper.
2.5.1
The rail pad beneath the base of the rail acts to distribute load and serves as an elastically
damping element to isolate vibrations. Due to the elasticity of the rail pads and the related
35
sinking-in of the rails, the load is distributed over several sleepers. For elastic rail pads,
DB AG demands static stiffness of 40 kN/mm to 70 kN/mm and dynamic stiffness of
50 kN/mm to 130 kN/mm.
Rigid rail pads have a static stiffness of approximately 600 kN/mm.
2.5.2
The rail fastenings described in the following are limited to the most common fastenings
used by DB AG.
2.5.2.1
This rail fastening is a typical representative of a separate or indirect fastening. The rail
is fastened onto the sleeper with the "ribbed plate/rail clip/T-head bolt" components (see
Figure 219). This separation of the fastening has proved appropriate in both design and
technical construction terms. The sleeper screws' bending stress is disadvantageous.
(or Kpo 6)
2.5.2.2
Frictional tensioning of the rail is achieved using two tension clamps, each offering a tensioning force of approximately 13 kN through the spring arms. The centre loop of tension
clamp Skl12 (Fig. 220) serves to protect the rail against tipping. The rail fastenings can
be pre-assembled on the sleeper at the sleeper factory.
The superstructure with tension clamps (KS) is applied on steel sleepers by welding the
ribbed plates onto the sleeper.
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EX
Rail
TR A
C T!
Hexagon Nut
Washer Uls
T-Head Bolt Hs
Sleeper Screw Ss
Wooden Sleeper
Spring Washer Fe
Rail Pad Zw
Ribbed Plate Rph
2.5.2.3
As in the case of the KS superstructure, frictional tensioning of the rail is achieved using
two tension clamps, each offering a tensioning force of approximately 10 kN through the
spring arms. The centre loop of tension clamp Skl 14 serves to protect the rail against
tipping (Fig. 221).
Sleeper Screw Ss
Rail
Rail Pad Zw
Concrete Sleeper
Plastic Dowel Sd
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2.5.2.4
Supporting point S 15
Sleeper screw
Tension clamp
Clamp dowel
Intermediate plate
Rail pad
Guide plate (inner)
Guide plate (outer)
Steel sleeper
Item
Units
Designation
Abbreviated form
2.5.2.5
Drawing No.
Material No.
This fastening system is suitable for all ballastless track system laying methods.
The highly-elastic intermediate plate replaces the elasticity of the ballast bed. A steel
pressure distribution plate with corresponding rail pads is used to achieve better load
distribution on the elastic intermediate plate.
The rail rests on this and is held in position laterally by plastic angled guide plates.
The long elastic spring travel of tension clamp Skl 15 provides the rail with permanent
frictional tension. The height and track gauge of rail fastening system 300 can be adjusted
by -4 mm/+76 mm and 8 mm respectively. With spring travel of approximately 15 mm and
a hold-down force of around 2 x 9 kN, the two free spring arms frictionally tension the rail
with the concrete sleeper.
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All fastening parts can be pre-assembled at the sleeper factory (Fig. 223).
The DFF 300 system with tension clamp Skl 15, which can be regulated by at least 60 mm
and 46 mm in terms of height and track gauge respectively, can also be used for repair and
redevelopment purposes (Fig. 224).
Sleeper Screw Ss
Rail
Rail Pad Zw
Concrete Sleeper
Abb. 224: Rail fastening system DFF 300 with Skl 15
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EX
2.6
The ballast forms part of the superstructure and has the following tasks:
TR A
C T!
Transferring and distributing vertical forces from the sleeper into the subgrade,
Securing the position of the track in the lateral and longitudinal direction,
Keeping the superstructure dry thanks to water and air permeability,
Adjustability of the track bed.
The ballast bed consists of crushed natural stone with a coarse grain size of 22.4 mm to
63 mm. Hard stones such as granite, basalt, diabase, etc. are most suitable.
DB distinguishes between new ballast and reprocessed ballast. New track ballast has to be
produced using rock found in quarries. Reprocessed ballast also called recycled ballast
is old ballast which has been treated in reprocessing plants after removal from the track.
The requirements on new and recycled ballast are regulated in DB standard DBS 918 061
"Technical terms of delivery, track ballast". It specifies geometrical and physical requirements as well as requirements relating to purity and the characteristics of the stone.
Ballast class "S" is a special type of ballast. This is installed along track sections with
speeds of v > 230 km/h. Particularly high requirements are therefore made on ballast
class "S".
When working on the ballast bed, the ballast embankment should be created with an
inclination of 1 : 1.25. When designing the ballast profile, a ballast embankment inclination
of 1 : 1.5 must be used as the basis.
The ballast embankment inclination of 1 : 1.5 is used to determine the base point of the
ballast embankment on the subgrade. The 1 : 1.25 inclination (natural angle of repose of
ballast) ensures adherence to the track bench width in the event that the track is raised
due to tamping work. A calculation programme for determining the embankment base point
and the volume of ballast required is available in guideline 823.0100Z08.
The required track bed thickness is dependent on the sleeper spacing, the sleeper width
and the ballast's angle of repose, and is at least 30 cm beneath the lower edge of the
sleeper (measured as of the lower edge of the sleeper beneath the non-superelevated rail).
A thickness of 35 cm is required for high-speed lines as of a speed of v > 230 km/h.
The standard track bed thickness must be produced in accordance with annexes 04 06
of guideline 820.2010. In addition, the thickness of the track bed beneath the rail support
should not exceed 60 cm.
To prevent the track from slipping to the side, a ballast width of 30 to 50 cm is required up
to the ends of the sleepers. In addition to the ballast in the space between the sleepers
and beneath the sleepers, the ballast up to the ends of the sleepers contributes significantly towards lateral displacement resistance.
41