DB Manual Work procedures for permanent way maintenance

Size: px

Start display at page:

Download "DB Manual Work procedures for permanent way maintenance"

Jayson Lester
5 years ago
Views:

1 DB Manual Work procedures for permanent way maintenance CONTENTS

2 Contents Preface 19 1 General 21 2 Track equipment General The rails Insulated rails Insulated joints The sleepers The wooden sleepers The steel sleepers The reinforced concrete sleeper Special forms of concrete sleeper The sleepers of the ballastless track system The rail fastening The rail pad The types of rail fastening The ballast bed 41 3 Substructure General Substructure of new tracks Substructure foundation Checking load-bearing capability and rate of compression Measures to prevent embanking settling 47 3

3 3.2.4 Draining the track formation Drainage systems Substructure of old tracks Substructure remediation 50 4 Line layout and routing General Principles of line layout: Discretionary and approval limit values Route elements Fundamentals of routing The curved track Superelevation Lateral acceleration Compensating superelevation Determining superelevation Unbalanced superelevation Excess of superelevation Minimum superelevation Standard superelevation Transition curves and superelevation ramps The transition curve Reverse curve with transition curve Superelevation ramps Ramp forms Longitudinal track pull Slope and gradient change Graduated gradient change 59 5 Maintenance terms 60 4

4 5.1 General Explanation of individual terms and meaning for the permanent way 60 6 Inspection Inspections on foot/inspection runs Track inspections on foot Track inspection runs (see guideline ) Measurement runs Checking the track geometry with track inspection vehicles (see guideline ) Technical driving inspections (see guideline ) Ultrasonic test runs Rail inspection train equipment Manual measurements Switch diagnosis system VAE ROADMASTER Foundation survey General Execution of the geotechnical survey Evaluation of results Construction execution Conclusion Application of ground-penetrating radar Geotechnical survey report for maintenance work Evaluation and measures General Integrated inspection system (IIS) Near-surface defects in rails Planning of measures for track maintenance (see guideline A02) Special inspections with the GeoRail Xpress Servicing 137 5

5 7.1 Weed killing on and alongside railway tracks Weed killing on railway tracks using pesticides Weed killing outside of tracks using mechanical procedures Lubrication of slide base plates Lubrication of slide base plates Switch rollers Switch roller systems Repair work Planning of track maintenance Rail transport Quality assurance when loading rails Rail transport with Robel design type Rail transport with STS design type Mobile continuous welded rail unloading device Geismar design type, model EMD High-speed track renewal machine SUM 315 (Q 3) Track renewal train Matisa Overview of the track renewal train procedure Special features of track renewal trains UM-1, 2 and Special features of track renewal train UM-S 2001 (HENRY THE STRONG) Special features of P UM and UM-P from Schweerbau Track renewal train MATISA P 90 LS from JumboTec Special features of P 95 from Strukton Special features of track renewal train P 95 SR Renewal procedure Matisa P High-speed track renewal machine (SUM-Q 1) RU 800 S track renewal and ballast cleaning in one operation General Description of the working method 215 6

6 9.6 High-performance renewal procedure VFW Track renewal in a two-sleeper cycle with the SUZ 500 UVR Track renewal train SUZ 500 with SVM Preconditions for using the SUZ Preliminary work Organisation Special circumstances Track renewal with SUZ Subsequent operations (not usually by high-speed track renewal train personnel) Unloading and forwarding the continuous welded rails with the rail forwarding machine in combination withhigh-speed track renewal train SUZ Donelli portal crane Track assembly Renewal of switches General Preconditions (unloading, assembly) Revolving cranes Renewal machine unit for switches and tracks Switch renewal with switch renewal machine WM 500-U Switch transport wagon Ready-to-install, fully-assembled large switch parts from the switch supplier Objectives Technical solution Complete assembly in the switch factory Loading and transport 270 7

7 Installation Operations technology advantages Special features of the complete assembly, its transport and installation Summary Switch maintenance Switch inspection Individual replacement of parts of the switch track The locking sleeper Sleeper replacement General Track renewal trains Individual sleeper replacement by hand or with equipment Rail replacement General Rail replacement with rail changers Rail replacement with roller grips Rail replacement with the rail replacement system SR Ballast laying General Classic procedure Ballast bed finisher 311 8

8 14 Installation of tracks General Ballast superstructure Track laying with VFW Track laying with SUZ 500 UVR Niemag track renewal crane Renewal machine unit for switches and tracks Portal crane with integrated single sleeper laying device (PK 1-20/24) Track laying with revolving cranes Track laying with the portal crane (Donelli) Laying of individual sleepers Ballastless track system General The ballastless track system design types Ballastless track system laying procedures Measurement of the ballastless track system with the Hergie system Laying the lean-mixed concrete in ballastless track systems Procedure for laying continuous welded rails in ballastless track systems Switches in ballastless track systems Switches in the RHEDA 2000 design type ballastless track system Requirements on the substructure for ballastless track systems on earthwork foundations Transitions Noise insulation in ballastless track system construction Maintenance and renewal of the ballastless track system Laying of special sleepers Y-steel sleeper superstructure Y/S Twin sleeper Sleeper bed for the ballast superstructure (padded sleeper) 423 9

9 15 Ballast solidification through plastic bonding Product Application areas Required boundary conditions Acceptance, quality control, guarantee Guarantee Work specifications Handling of the bonding during tamping work Ballast cleaning General Ballast cleaning machines RM 80 and Ballast cleaning machine RMW General Ballast bed cleaning with the RMW Rail-mounted ballast cleaning machines RM 800 and RM 800 Super 3S Rail-mounted ballast cleaning machines RM 801 and RM High-performance ballast cleaning machines RM 900 S and RM RM 900 S from SPITZKE AG RM 900 from Schweerbau High-performance ballast cleaning machine RM High-performance ballast cleaning machine RM W

10 16.9 Rail-mounted ballast cleaning machine RM 76 UHR Road-rail ballast cleaning machine ZRM Ballast cleaning using other procedures Loading and unloading systems for waste removal and ballast laying General Material conveyor and hopper unit (MFS 38, 40, 100-S, 250), belt storage device (BSG 60), bulk freight hopper wagon (BSW and 2000) and road-rail MFS Loading belts and systems Unloading systems for laying ballast Formation rehabilitation General Installation with earth-moving machines Formation rehabilitation machine PM 1000-URM General description of the PM 1000-URM work procedure Description of the PM 1000-URM work modules Formation rehabilitation machine PM (BR) General information on PM Addition of an RM ballast cleaning machine to the PM BR Formation rehabilitation machine PM 200-2R General information on PM 200-2R Work procedure Sand distribution and compacting machine (SVV 100) from Joseph Hubert and Schweerbau

11 18.7 Recycling and formation rehabilitation machines RPM 2002 and RPMW Objective of RPM Work procedure Recycling, formation rehabilitation and cleaning machine RPM-RS-900 from SPITZKE AG General Working methods RPM-RS-900 from Schweerbau Möbius soil remediation system Formation rehabilitation with ballast replacement Wiebe system Verification of installation quality Mechanical tamping work in tracks and switches Requirements on track and switch tamping machines and ballast ploughs Measuring work ahead of tamping machines Introduction Measuring work on conventionally marked tracks Measuring work with the EM-SAT track survey system Measuring work with the GEDO CE Measuring work with the Amberg GRP 3000 survey system The satellite-supported track survey during track maintenance Tamping General Compacting First and second stabilisation Creation of the ballast profile Speed regulation after laying Maintenance of the tracks General

12 Preconditions and preliminary work Elimination of long-wave track displacement on high-speed lines (v > 160 km/h) Ballast distribution system (BDS 2000) Maintenance of switches Tamping work with small machines Dynamic track stabilisation Checking execution Creation of the continuous welded rail track General Stress compensation Welded joints (intermediate and final welds) Elimination of individual defects Tracks General Correction of track displacement Gauge correction Bending up retracted insulated joints Sleeper rehabilitation Elimination of individual geometry defects in tracks and switches with individual defect tamping machines UNIMAT-Sprinter individual defect tamping machine Fully mechanised individual defect processing with the ZW Rail processing General

13 22.2 Rail processing machines, type RR Rail grinding trains, types RR 48 M and 32 M Rail grinding machines, type RR 24 M Universal grinding machines, types RR 16 M and RR 24 MC Switch grinding machines, types RR 16 P/D and 16 MS Rail processing machines types RG, SPML, RGM, GWM, SF 03/SM 03, SFU 04/SM 04, SBM Rail grinding machine RG Rail grinding machine SPML Rail grinding machine RGM Track and switch grinding machine GWM Rail milling unit SF 03/SM Rail milling machine SFU 04/SM Rail processing machine SBM Track and switch grinding machine RGH C 20 plus suction and rinsing unit (SuSE) Rail grinding machine SZ Rail milling unit SF 03 FFS-Plus High-speed grinding with grinding machine RC Rail milling train SF 03 W-FFS Hand-held grinding equipment Noise insulation and vibration protection Introduction Noise and vibration caused by railway vehicles Sources of noise Rolling noise Legal framework conditions Vibration Inspection: assessment of the actual status of the rail running table quality

14 Direct measurement processes Indirect continuous measurement processes Maintenance and repair of rail running tables Sound-reducing measures Measures on the rail Absorbent running track coverings Measures in the propagation path Measures at the immission point Vibration-reducing measures Measures in the superstructure system Measures in the propagation path Measures at the immission point Assessment and acceptance of track maintenance Principles General Acceptance Acceptance of new track construction or track renewal General Acceptance following new track construction or track renewal SR 0 values for new track construction or track renewal SR 0 values of the geodetic position of the track and other measurements Checklist for acceptance documents Acceptance of new switch construction and switch renewal General Object of acceptance Acceptance following new switch construction and switch renewal SR 0 values of the switch geometry Acceptance of track maintenance General Acceptance of track maintenance

15 Evaluation of acceptance survey Acceptance of switch maintenance General Acceptance of switch maintenance SR 0 values for switch maintenance Acceptance of welded joints on rails General Principles Tools Acceptance of welded joints on rails Acceptance of rail processing General Acceptance of rail processing Guideline acceptance values following rail processing Guideline acceptance values following the production of special profiles Further developments General SUZW 500 new technology for track renewal in conveyor belt technology, H.F. WIEBE Ballast bed cleaning machine RM900VB Mobile maintenance system ROBEL Ballastless track system DW pre-cast concrete track panels as the track support system System description Routing principles Construction implementation The DURFLEX superstructure system Characteristics of DURFLEX Laying procedure (Durflex installation) Removal procedure and recycling

16 25.7 Drive-on ballastless track system System description Laying procedure on earthworks (rough construction sequence) The ZSX twin sleeper the special pre-stressed concrete sleeper The development objectives of the ZSX twin sleeper Laying procedure DURMINOR, the low noise protection wall New developments in ballastless track system design types New ballastless track system design type Naumburger Bauunion (NBU) design type 744 Annex Abbreviations 746 Units of measurement 747 Advertisers 747 Index 748 Authors

Technology and maintenance of tracks at ÖBB

Technology and maintenance of tracks at ÖBB Dr. Michael Mach ÖBB Infrastructure Head of Railway Construction and Infrastructure Management Dr. Rudolf Schilder Former Head of Maintenance We plan, build,