Dependency between super- and substructure in ballastless track systems. PCM RAIL.ONE AG October 16 Wojciech Nawrat

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1 Dependency between super- and substructure in ballastless track systems PCM RAIL.ONE AG PCM RAIL.ONE AG October 16 Wojciech Nawrat 1

2 Topics Ballastless track systems Requirements and Interfaces Ballastless track systems on different substructures Substructure settlements and other deformations Project Cases PCM RAIL.ONE AG October 16 2

3 What are the requirements on the (high speed) track? PCM RAIL.ONE AG October 16 3

4 What are the interfaces determining the track design? Rolling Stock Rolling Stock! Diversity of rolling stock! Static and dynamic interaction! Air-borne noise TRACK Track equipment! Installation compatibility! Electro-magnetic interaction! Power supply Substructure Track equipment Substructure! Loading and bearing capacity! Expected settlements and other deformations! Structure-borne noise PCM RAIL.ONE AG October 16 4

5 Characteristics of ballastless track! Low maintenance! High availability! Increased service life! Reduced life cycle costs! Low structure height! Low weight of track system! High lateral track resistance which allows future speed increases e.g. in combination with tilting technology! Very good and stable track alignment Can we be sure about this? PCM RAIL.ONE AG October 16 5

6 Track quality comparison - ballasted vs. ballastless track PCM RAIL.ONE AG October 16 6

7 BALLASTLESS TRACK ON DIFFERENT SUBSTRUCTURES PCM RAIL.ONE AG October 16 7

8 Types of ballastless track systems Directly supported ballastless track system (e.g. GETRAC A3) Monolithic ballastless track system (e.g. RHEDA 2000 ) PCM RAIL.ONE AG October 16 8

9 Ballastless track on bridge PCM RAIL.ONE AG October 16 9

10 Ballastless track on bridge PCM RAIL.ONE AG October 16 10

11 Ballastless track in tunnel PCM RAIL.ONE AG October 16 11

12 Ballastless track in tunnel PCM RAIL.ONE AG October 16 12

13 Ballastless track on embankment PCM RAIL.ONE AG October 16 13

14 Ballastless track on embankment PCM RAIL.ONE AG October 16 14

15 BALLASTLESS TRACK SETTLEMENTS AND DEFORMATIONS PCM RAIL.ONE AG October 16 15

16 Substructure risk PCM RAIL.ONE AG October 16 16

17 Requirements on the substructure for ballastless track Bearing resistance and dynamic stability Limited settlements and other deformations Homogeneity PCM RAIL.ONE AG October 16 17

18 Total settlements on new embankments Total settlements s tot = s S + s E + s T settlements s S of subsoil [cm-dm] settlements s E of embankment/substructure [cm-dm] settlements s T due to dynamic track loading [mm] Settlements during construction (and waiting time) S tot,con = s S,con + s E,con Residual settlements after start of operation S tot,res = s S,res + s E,res + s T,res PCM RAIL.ONE AG October 16 18

19 Deformations on new constructed lines cutting culvert dam bridge cutting on tunnel front tunnel st = settlements due to traffic loads se = embankment settlements ss = subsoil settlements heave measurement settlement stot = ss + se + st PCM RAIL.ONE AG October 16 19

20 Overall Integrated Deformation Consideration (OIDC) Design stage (settlement calculation, proof, dimensioning) Construction of earth/engineering structure and waiting time (measurement > evaluation > improved settlement prediction) Proof of deformation conditions predicted s R s R,pre Counter measure Construction of ballastless track PCM RAIL.ONE AG October 16

21 Overall Integrated Deformation Consideration (OIDC) cutting culvert dam bridge cutting on tunnel front tunnel Controlling sections along overall line (interface/transition zones) PCM RAIL.ONE AG October 16

22 Overall Integrated Deformation Consideration (OIDC) Earth structures (embankment, cutting) Settlement/heave calculation for all controlling sections ( monitoring sections) at controlling time points under consideration of construction schedule) Check/proof of fulfillment of requirement on residual settlement after ballastless track installation Transition zones/backfill Analogously as for earth structures Consideration of construction sequence on settlement (e.g. dragging settlement of abutment due to subsequent embankment construction) Foundation of engineering structures (e.g. bridge foundations) Analogously as for earth structures Interaction of foundations (e.g. short bridge: two abutments within same settlement trough) Engineering structures (e.g. bridges) Dividing deformation into those from foundation and from structures time-dependent deformation development: elastic deformation under loading, deformation due to temperature, creep, shrinkage, load distribution and delayed elastic deformation PCM RAIL.ONE AG October 16

23 Time depending settlement observation settlement-levelling gauge each m PCM RAIL.ONE AG October 16

24 Time depending settlement observation ,00 Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez 2,00 4,00 s [mm] 6,00 8,00 Time depending settlement at so called white dam (high speed line from Cologne to Frankfurt/Main, km 121, ,070) 10,00 12,00 14,00 Source: Baugrund Dresden PCM RAIL.ONE AG October 16

25 Requirements for residual settlements s res s res,req = 1.5 cm s res s res,req = 6.0 cm and R a 0.4 v² e R a =36,000 m for v e =300 km/h R a - radius of the rounding curve of the gradient v e - design maximum train velocity PCM RAIL.ONE AG October 16

26 Compensation possibilities in the fastening system (ex. Pandrol VIPA DFC) Static stiffness (main lines) kn/mm Adjustability +/- 5 mm horizontal +20 mm vertical PCM RAIL.ONE AG October 16 26

27 Compensation possibilities in the fastening system (ex. Pandrol VIPA DFC) PCM RAIL.ONE AG October 16 27

28 Compensation of residual settlements cutting settlement ex. 1.5 cm dam heave ex. 1.0 cm existing gradient heave, settlement new gradient underlay with compensation plates PCM RAIL.ONE AG October 16

29 Compensation of residual settlements cutting settlement ex. 1.5 cm heave ex. 1.0 cm dam existing gradient heave, settlement new gradient Take-off compensation plates underlay with compensation plates PCM RAIL.ONE AG October 16

30 PROJECT CASES DISPLACEMANTS PCM RAIL.ONE AG October 16 30

31 Special Case - Lateral displacement of substructure (HSL Zuid, NL) Displacement now > 10 mm expected app. 30 mm PCM RAIL.ONE AG October 16

32 Special Case Dilative Subsoil PCM RAIL.ONE AG October 16 (HSL Nuremberg-Ingolstadt, DE)

33 Special Case - Dilative Subsoil (HSL Nuremberg-Ingolstadt, DE) HBL frost protection layer 5 % HBL asphalt protection layer th = 8 cm soil exchange 0,5 m th 2,3 m 5 % subsoil PCM RAIL.ONE AG October 16

34 Special Case - Cutting stabilisation Auer Mountain (HSL Nuremberg-Ingolstadt, DE) PCM RAIL.ONE AG October 16

35 Special Case - Cutting stabilisation Auer Mountain (HSL Nuremberg-Ingolstadt, DE) Motorway A 9 piles 90 cm PCM RAIL.ONE AG October 16

36 Special Case - Karstified Regions (HSL Nuremberg-Ingolstadt, DE) PCM RAIL.ONE AG October 16

37 Special Case - Karstified Regions (HSL Nuremberg-Ingolstadt, DE) Geo-grid S max = 11 mm Cavity 4x4 m PCM RAIL.ONE AG October 16

38 Contact Wojciech Nawrat Head of R&D and Machinery Engineering PCM RAIL.ONE AG Dammstrasse Neumarkt Germany PCM RAIL.ONE AG October 16 Tel Fax wojciech.nawrat@railone.com 38

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