For our cliet this is a turout. For us a maufacturig facility cotributig towards our customer s success. voestalpie VAE SA (Pty) Ltd www.voestalpie.com/vaesa
voestalpie VAE Group - Global Presece Preset i more tha 50 coutries as a global leader i the maufacturig, processig, ad developmet of sophisticated steel products, particularly for the techology-itesive sectors, such as the automotive, railway, aerospace, ad eergy idustries. NORTH AMERICA EUROPE ASIA SOUTH AMERICA SOUTH AFRICA AUSTRALIA
With voestalpie VAE SA, Cliets Beefit From a 155 Years of Techical Expertise voestalpie VAE SA (Pty) Ltd is a wholly-owed subsidiary withi voestalpie Austria, a leadig Europea steel producer. The Group has four divisios, Steel, Automotive,Railway Systems ad Profilform, which all ejoy leadig positios i their respective markets. Worldwide, more tha 150 techical experts are employed i egieerig departmets to guaratee optimised desigs, perfect geometry ad outstadig customised solutios. Curretly there are 40 productio cetres across Europe, North ad South America, Australia, Africa, ad Asia. I South Africa, ad across the Africa cotiet, voestalpie VAE SA (Pty) Ltd is the approved ad preferred supplier for all permaet way rail, ragig from high speed mailies, urba traffic, heavy log-distace iro-ore ad coal haulage as well as udergroud miig track. voestalpie VAE SA s commitmet exteds beyod products ad services as it provides complete solutios from site-specific desig, maufacturig ad preassembly through to istallatio. voestalpie VAE SA s guarateed quality is bechmarked agaist worldclass best practices ad backed by ISO 9001:2000 accreditatio ad a five star HASLAC gold star ratig.
Desig, Productio ad Maufacturig Switch rails are maufactured by CAD/CAM systems, usig stadard materials or special wear-resistat materials like HSH (Head Special Hardeed). Switches have a asymmetrical trasitio area, which is heat-treated to guaratee a costat hardess gradiet i the forged area. By lowerig the forces o the rails, wear is reduced, as is maiteace. voestalpie VAE switches are maufactured i accordace with the techical supply specificatios of UIC ad CEN. This is supplemeted by the specific requiremets of the customers ad the vast experiece of VAE. Togue rails ca be maufactured ad delivered i oe-piece legths of 19 meters ad more, with or without forgig. For low, medium or highest loads, rails of the type R350 LHT (S900 HSH) (Head Special Hardeed) are used. These rails are maufactured accordig to a special heat-treatmet procedure. The fie pearlitic structure is particularly suitable for rollig cotact due to its high wear-resistace combied with high tesile stregth ad elogatio. Forgig At the ed of the asymmetrical switch sectio, the required rail sectio is obtaied by forgig. The tools ad equipmet for this essetial techology are desiged ad maufactured at voestalpie VAE factories i order to be able to supply top quality products ad provide safe maufacturig procedures. The weld joit is, i ay case, outside of the trasitio area. Heat Treatmet The decreasig tesile stregth i the heat-affected zoe of the forgig is elimiated by a computer-cotrolled heat-treatmet process, which is a stadard procedure at voestalpie VAE. This pateted procedure reduces the formatio of soft spots o the ruig surface of the switch. After the forgig procedure, the fishig table correspods to the measuremets of the rolled rail. The area of the head ad foot is adjusted to the required measuremets by machiig.
Turouts voestalpie VAE SA has a extesive ivetory of desigs, compliat with iteratioal stadards, ragig from 1:6 turouts to the latest 1:20 swigose uits. Existig desigs are available to suit a variety of rail sectios ad gauges for slab ad ballasted track. These iclude amog others: Sigle Turouts Curved Turouts Equal ad Uequal Split Turouts Sigle ad Double Crossovers Crossovers ad Scissor Crossigs Sigle ad Double Slips Dual-gauge Turouts Various Crossigs Curved Crossigs Stop Blocks A umber of ew iovative turout desigs have bee itroduced sice voestalpie VAE etered the South Africa market. 1:20 Swigose Turout The 1:20 was developed to meet the curret ad future eeds of South Africa s heavy-haul idustry. The desig is suitable for heavy traffic desity, high axle loads ad high logitudial forces i the track. Its ovel features iclude: A crossig frog with a movable vee housed i a robust frame. This gives high stability agaist vertical, horizotal ad torsioal forces A tagetial switch poit etry, which reduces side forces to a miimum I the overru areas, the wig rails are maufactured from cast magaese steel, which forms a uit with the base plate Hollow steel sleepers for housig switch roddig
1:7 Double Slip & Sigle Slip The slips were developed i cojuctio with mai railway operators to meet the future eeds of South Africa s metro lies. The slips are desiged for higher traffic desities ad faster speeds. 1:12 & 1:9 Turouts The desig is suitable for heavy traffic desity, high axle loads ad high rail-expasio forces i the track. Its ovel features iclude: A railboud crossig frog with cast magaese iserts A tagetial switch poit etry, which reduces side forces to a miimum Hollow steel sleepers for housig switch roddig Adjustable check rails 1:4.5 Scissors Crossig The 48kg/m 1:4.5 scissors crossig is built o either uiversalor precast cocrete sleepers or o woode sleepers. 350LHT special head hardeed rails, railboud crossigs ad adjustable UIC33 check rails are used to icrease the product life cycle. The switch areas iclude flexible switch blades ad a techological advacemet through the use of isulated adjustable roddig ad o fish plates required throughout the set. 1:6 Scissors Crossig The 60kg/m 1:6 scissors crossig is desiged o uiversal- ad precast cocrete sleepers. 350LHT special head hardeed 60E1 rails, railboud crossigs ad adjustable UIC33 check rails with cotiuous weldig are used i the set. The turout area ca be either secatial or tagetial geometries. Miig Turouts voestalpie VAE SA is able to supply a wide rage of turouts for udergroud use, to ay agle ad legth varyig from 457 mm to 1 065 mm gauge or i custom specificatios. Narrow gauge turouts ca be supplied to various sectios to eable the splittig up of the switch. This is doe to allow for trasportatio i cofied udergroud eviromets. Switch Devices The divergig path geometry of its switches is optimised accordig to the priciples of vehicle dyamics. This reduces iduced forces ad thereby improves travellig comfort ad service life. The use of highly wear-resistat materials together with most advaced productio techologies facilitates the practical use of the kowledge gaied from EDPsupported simulatio programmes. These products meet the techical specificatios of Traset i South Africa, ad ca also be maufactured accordig to other required iteratioal specificatios. Flexible Switches made from specific asymmetrical or symmetrical togue rail sectios are forged at the ed to match the stadard rail sectio. The trasitio from oe sectio to the other ties mostly i the clamped area at the ed of the switch, which makes weldig i the flexible area superfluous. The legth of the forgig ca be adjusted to the specific coectig system such as weldig, isulated fishplatig or emergecy fishplatig. I order to reduce the settig forces ad to ifluece the elastic lie of the switch, it is possible to mill the base i the flexible area.
Turout Systems Rail switches are made from stadard rail sectios or rails with a reiforced web (thick web rails). Durig the settig process the switch is elastically bet. To reduce the settig forces, a flexible area ca be provided for short rail switches. Fishplatig or weldig to the itermediate rails is possible. Holes are provided for the moutig of operatig ad moitorig rods. Sprig rail switches are prove, low cost switches made from a specific asymmetrical or symmetrical togue rail sectio are forged at the ed to match the stadard rail sectio ad are electrically flashbutt welded to the adjacet stadard rail. The weld is located i the flexible-elastic area of the switch ad is secured with safety fishplates. A flexible area ca be provided for i the stadard rails to reduce the settig forces. This desig allows for high wear with miimal maiteace. voestalpie VAE SA is able to offer a variety of crossigs withi the turout desig: Rail maufactured crossig usig rails to suit light axle loads ad low frequecy lies. Rail boud crossig - rail ad magaese crossigs with a magaese isert i the trasfer or high workig area for a loger life spa. Mooblock crossig (bolted rail joit) - complete magaese steel crossigs for a loger life spa ad miimal maiteace. Mooblock crossig or Cetro crossig (weldable rail joit) - complete magaese crossig with rails welded to each ed through a special process to allow for weldig ito track. voestalpie VAE turout desigs may iclude various forms of switchblades from a semi-curved higed type to a forged tagetial-desig, thick web switchblade. I additio, the compay desigs special products to accommodate oe-off requests from customers. Swigose crossig - a combiatio of rail ad magaese steel, the poit of the vee moves from side-to-side to allow cotiuous support through the crossig for heavy axle loads, or for high speed, high-volume traffic. Switch Poit Rollers voestalpie VAE SA offers a variety of switch rollers optimised for specific requiremets. The switch poit roller offers cosiderable advatages over covetioal slidig baseplates i reducig operatig costs ad maiteace. These rollers reduce the effort eeded to operate the switch. With more secure positioig of the blade, failure rates are lower as reliability has bee ehaced. Lubricatio of the slidig plates is o loger eeded, thereby elimiatig a evirometal cotamiat. These rollers ca be fitted to both ew ad existig switches.
Special Track Compoets Crossigs The advatages of a moveable poit crossig joit is that the cotiuous wheel over-ruig area has o ruig edges ad head surface iterruptios, makig it particularly suitable for high-speed ad heavy haul traffic as well as for mixed operatio. This crossig type elimiates the eed for check rails. Exteded life is achieved, as there are reduced impacts i the wheel trasitios area. These crossigs ca be thermit welded ito the track. Superior stregth AMS high-magaese steel rails are best suited for cast magaese crossigs. This steel with +13% magaese cotet develops a exceptioally wear-resistat surface, makig it suitable for the highest axle loads. The castigs are maufactured by a the voestalpie VAE affiliate, JEZ. voestalpie VAE s pateted flash-butt weldig process permits the coectio of AMS with ormal rail steel allowig magaese steel crossigs to be welded ito the CWR track. UIC 33 Adjustable Check Rail This check rail, which has bee icorporated ito some of voestalpie VAE s turout desigs ad ope track curves, has the advatage of beig easily adjustable. The desig allows for 15 mm of wear ad eeds miimal maiteace. This check rail was desiged for use with either timber, steel or cocrete sleepers. Isulated Rail Joits voestalpie VAE maufactures a variety of workshop-assembled isulated rail joits. The froze joits are all assembled ad epoxied i a cotrolled eviromet ad are maufactured to extremely rigorous toleraces ot obtaiable with field-assembled joits. Six-hole block joits have bee approved ad are commoly used i turouts ad ope track i South Africa.
With predefied import ad hadlig logistics, voestalpie VAE SA is able to provide a most cost-effective service. Rails Various rail profiles are available i multiples of 12 m, 18 m or 60 m legths. New as well as recoditioed rails ca be supplied i legths of up to 240 m accordig to customer requiremets. The ew rail profiles rage from 22 kg/m to 60 kg/m i additio to UIC33 check rail ad special crae rail profiles. Flash-butt weldig of techologically advaced ew rails gives voestalpie VAE SA the edge i the South Africa market with the facilities to hadle up to 240 m legths. Secodhad or used rail ca also be re-coditioed ad ultrasoically tested before they are flash-butt welded ito loger legths uder factory coditios. New rails are supplied i 18 m, 36 m or 60 m legths or multiples thereof, up to a maximum of 240 m legths. Typical rail profiles welded iclude the SAR 48 kg/m, 57 kg/m ad 60E1 profiles. Flash-butt weldig miimises the eed for i-track thermit-weldig ad fish-plated rail joits. The prove processes i flash-butt weldig uder factory coditios esure a higher cosistet quality tha i-track weldig. voestalpie VAE SA is the sole importer of 60 m legths ad supplier of flash-butt welded 240 m legths. The logistical supply process requires accurate ad timeous plaig to esure cost effective delivery. With predefied import ad hadlig logistics, voestalpie VAE SA is able to provide a most cost-effective service. Steel ad Woode Sleepers voestalpie VAE SA is a leader i the desig ad maufacture of steel sleepers, havig supplied may thousads of uits over a period of 50 years. The compay s rage is based o the widely used, well-prove trough sectio. Woode/timber sleepers are imported i various dimesios for turout maufacturig ad ope track. The sleepers are creosoted, tagged ad gag ailed accordig to SABS ad Traset specificatios.
Sigalig As the world leader ad tredsetter i the areas of turout ad drivig, lockig ad moitorig techology, we are committed to our customers ad our success. New challeges ad eeds i passeger ad freight trasportatio require iovative ad sustaiable all-iclusive thikig. This is what drives the Sigalig philosophy, likig together the associated turout systems ad hazard alert systems. To esure that our customers receive the greatest possible beefit icludig appropriate levels of quality, all our products ad system ad service solutios are tailored to the specific eeds of each customer. Further our oe stop service makes material sourcig ad problem solvig all the more simple for our customers. We offer our turouts completely pre-assembled, equipped with all the ecessary sigallig compoets permittig, where required, cotiuous mechaical tampig. Just i time delivery eables our customers to drastically reduce istallatio costs ad time. Our solutios prioritise low life cycle costs ad highest possible asset availability ad reliability for the railway operator, coupled with the greatest possible safety for passegers ad employees. By providig targeted iformatio, our ovel moitorig systems eable early detectio of impedig failures, allowig for efficiet asset utilisatio, icludig the avoidace of uecessary prevetative maiteace. Switch Machies (VAE DLD) SPHEROLOCK a completely sealed lockig system, fully self-cotaied ad largely costructed of tured parts. The lockig system is dirt ad weather-proof. A special lik to the switch makes the system effectively idepedet of switch ad stock rail movemets. Fasteigs ca be specified accordig to customer requiremets. voestalpie VAE i South Africa has combied the SPHEROLOCK with a locally developed hydraulic drive ad detectio system ad applied it to a three operatig poit 1:20 turout. The hydraulic system has a mechaical ad hydraulic retetio device at each of the three hydraulic cyliders for safety purposes. These devices have bee developed to be trailable i emergecy situatios to miimise damage to the other costly compoets.
Switch Machies (Ecostar 4.0) The ECOSTAR is a electro-hydraulic turout drive for moutig outside the gauge of the turout. This machie features a mooblock hydraulic system with itegrated maual pump o a separate level. Positive lockig of the switch blades is achieved by the first safety level (SPHEROLOCK ) ad a fallback level (lockig of detector rods). Both 380VAC ad 110VDC versios ad trailable ad o-trailable machie cofiguratios are available. Itegrated ed positio detectio system comes stadard ad visual ed positio idicators are optioal. Desiged ad approved accordig to CENELEC EN 50126/50129, available i variats for IP54 ad IP67. Switch Machies (Uistar HR NG) The reliable techology ad simple desig of the Uistar HR is settig the bechmark. The Uistar HR NG, desiged for turouts startig with 1000 mm gauge, is so compact it fits betwee the switchblades for this gauge. The CCDrive, prism lockig ad detectig modules are istalled i oe watertight ad dust tight box. Adjustable for switch poit opeig from 60 to 160 mm, all compoets uder mechaical load are made out of iductive hardeed special steel, all exteral parts are made out of corrosio free steel, which are prove sice years. Switch Machies (Uistar RV) The Uistar RV is specifically desiged as a self ormalizig poit mechaism, preferably istalled i cetre of gauge. It is based o the successful ad field prove CONTEC Prism Lock, made of iductive hardeed special steel for virtually maiteace ad wear free service. As a optio, detector rods are available which is locked i the ed positio. The lockig ad detectio system is fulfillig the latest safety requiremets for poit machies. All modules are istalled i a watertight corrosio free housig. Due to the ecapsulated desig, virtually maiteace free service is give. A mechaically idepedet (adjustable) damper is provided smoothig the self ormalizig movemet ad therefore preservig the mechaism ad the set of poits.
Hot Bearig Detector The voestalpie VAE hot bearig ad hot (or cold) wheel detectio system automatically checks the coditio of axle bearigs o movig trais as well as faulty brakig systems o rollig stock, thereby avoidig costly damage as a result of derailmets. This system is istalled i a hollow steel sleeper ad is desiged to measure axle ad wheel temperature. The Phoeix MB uses cotactless, fixed scaers for measurig the temperature of axle bearigs ad wheel sets. Trai speed is ot a limitatio as the system ca measure objects passig at speeds of up to 500 km/h. The purpose-desiged scaig feature follows the directio of the trai. The Phoeix MB hot wheel detectio system ca be istalled as a stad-aloe system that measures wheel set temperatures up to 650 C.
Locatios voestalpie VAE SA s corporate office is i Isado, with maufacturig plats located i Kimberley, Bloemfotei ad Isado. Isado Plat The compay s major customers, amog others are Traset, PRASA/Metrorail, private sidig owers, the miig idustry, railway operators i Africa coutries ad compaies who have maiteace cotracts with various ifrastructure owers. Bloemfotei Plat voestalpie VAE SA corporate office i Isado Kimberley Plat
voestalpie VAE SA (Pty) Ltd 23 Avil Road Isado, 1600 South Africa Tel: +27 11 928 3700 Fax: +27 11 928 3910 Sales.VAESA@voestalpie.com www.voestalpie.com/vaesa