Modern Railway Track - Esveld · 2017-08-18 · Modern Railway Track PREFACE xi PREFACE After the success of Modern Railway Track this Second Edition is an extension and complete
Post on 02-Jan-2020
15 Views
Preview:
Transcript
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: mrt@esveld.comInternet: 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
xi
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
xii
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
xiii
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
TABLE OF CONTENTS Modern Railway Track
xiv
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
Modern Railway Track TABLE OF CONTENTS
xv
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
TABLE OF CONTENTS Modern Railway Track
xvi
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
Modern Railway Track TABLE OF CONTENTS
xvii
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
TABLE OF CONTENTS Modern Railway Track
xviii
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
Modern Railway Track TABLE OF CONTENTS
xix
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
TABLE OF CONTENTS Modern Railway Track
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
Modern Railway Track TABLE OF CONTENTS
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
TABLE OF CONTENTS Modern Railway Track
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
Modern Railway Track TABLE OF CONTENTS
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
TABLE OF CONTENTS Modern Railway Track
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
Modern Railway Track TABLE OF CONTENTS
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
TABLE OF CONTENTS Modern Railway Track
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
Modern Railway Track 10 THE RAIL
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
Modern Railway Track 10 THE RAIL
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
Maintenance & 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
Maintenance & Renewal
Surface welding
Switches
Level crossings
Manual Mechanical
Maintenance
Manual Mechanical
Renewal
Maintenance & 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
Modern Railway Track 12 TRACK MAINTENANCE AND RENEWAL
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 TRACK MAINTENANCE AND RENEWAL Modern Railway Track
12.7.2 Measuring philosophy used for the stone blower
Figure 12.44: Stoneblower operated at RAILTRACK
Modern Railway Track 12 TRACK MAINTENANCE AND RENEWAL
12.10 Mechanised track maintenance train
12.11 Ballast cleaner
Figure 12.56: Mechanised track maintenance train MDZ 2000
12 TRACK MAINTENANCE AND RENEWAL Modern Railway Track
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–
Modern Railway Track 13 NUMERICAL OPTIMIZATION OF RAILWAY TRACK
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,
Modern Railway Track 13 NUMERICAL OPTIMIZATION OF RAILWAY TRACK
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
Modern Railway Track 16 INSPECTION AND DETECTION SYSTEMS
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
Modern Railway Track 16 INSPECTION AND DETECTION SYSTEMS
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
Modern Railway Track 16 INSPECTION AND DETECTION SYSTEMS
∞
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
Modern Railway Track 16 INSPECTION AND DETECTION SYSTEMS
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
Modern Railway Track 17 HIGH-SPEED TRACKS
17.3.4 Basic design criteria for tunnels
Figure 17.11: Wave forms in tunnel
Δ
Δ
Modern Railway Track 17 HIGH-SPEED TRACKS
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
In- situ conditions to which the trackis subjected
Works:- maintenance- renewal
Works:- maintenance- renewal
State of track geometryState of track geometry State of track materialState of track materialRULESRULES
RULES
RULESRULES
RULES
RULES
RULESRULES
RULES
DETERIORATIONPROCESS
DETERIORATIONPROCESS
RESTORATIONPROCESS
RESTORATIONPROCESS
In- situ conditions to which the trackis subjected
In- situ conditions to which the trackis subjected
Works:- maintenance- renewal
Works:- maintenance- renewal
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
DETERIORATIONPROCESS
DETERIORATIONPROCESS
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
top related