Page 1
Solutions that
won’t shake the world... www.edilonsedra.com
edilon)(sedra bv
Nijverheidsweg 23
NL-2031 CN Haarlem
P.O.Box 1000
NL-2003 RZ Haarlem
T +31 / (0)23 531 95 19
F +31 / (0)23 531 07 51
[email protected]
www.edilonsedra.com
EDILON Level Crossing
Systems (LC)
Page 2
For over 130 years tracks for mainline rail traffi c and
urban mass rapid transit systems were based almost
exclusively on track panels and cross sleepers
supported on stone ballast. During the 1960’s, increasing
train loads, higher speeds and the demand for more
cost effective track installation methods, resulted in the
development of ballastless track or slab track systems.
Since the introduction of slab track systems edilon)(sedra
evolved as a specialist in this fi eld. Based on 40 years of
experience edilon)(sedra developed specially for road–rail
intersections a range of EDILON Level Crossing Systems,
called EDILON LC.
EDILON LC have given assurance and comfort for more
than 30 years, for both rail and road traffi c. The weight and
stiffness of the EDILON LC enables a good distribution
of forces, which guarantees both a durable as well as a
settlement free system. In addition the EDILON Corkelast®
Embedded Rail System (ERS) also provides signifi cant
noise and vibration reduction opportunities, more and
more important these days in densely populated areas.
The EDILON LC range consists of the following types:
• EDILON LC-H, known as the Dutch “Harmelen”
level crossing, installed since 1976
• EDILON LC-1, known as the German “Stelfundo”
level crossing, installed since 1997
• EDILON LC-L installed since 2002
Naturally edilon)(sedra is ISO 9001 certifi ed.
EDILON LC introduction the history
2 3
GENERAL ADVANTAGES• Proven minimal costs-of-ownership
• Durable long life structure
• Proven technology resulting in a range of technical
approvals
• One structural monolithic unit
• Continuous elastic rail support
• Smooth transition between rail and road
• EDILON LC track elasticity matches elasticity of
adjacent track
• Excellent electrical insulation of the track
COST EFFECTIVENESS• Simple and fast installation
• EDILON LC service life more than 30 years
• Reduction of rail wear and rail corrugation
• Maintenance free
• Low lifecycle costs (LCC)
In EDILON LC the use of mechanical fastening systems, such as clips, anchors and
baseplates, for both the crossing as well as the rail are made completely redundant
because of EDILON Corkelast® ERS.
By using EDILON Corkelast® ERS, the rails are connected to the EDILON LC concrete
slab in a fl exible yet extremely durable way.
Continuous elastic rail support means that horizontal and vertical forces are
more evenly distributed. Furthermore, the chance of rail breaks compared to
traditional level crossing systems based on ballast track, is signifi cantly reduced
and rail corrugation is effectively eliminated.
EDILON Corkelast® ERS also offers maximum electrical insulation.
Page 3
EDILON LC types
All EDILON LC systems meet the various requirements
for heavy rail and high-speed rail. EDILON LC systems
all meet the requirements of UIC load model 71 as speci-
fi ed in UIC code 702. The extremely durable longwearing
surface meets the highest road load class standard of
load class 60. Certain EDILON LC systems are applicable
in heavy loaded level crossings with train axle loads
up to 37 tons and heavy traffi c axle loads up to 90 tons
The top surface of EDILON LC slabs can be prepared in
such a way that high skid resistance values (SRV) can be
obtained. SRV of more than 45 up to 70, are possible with
special concrete mixtures of the top surface.
EDILON LC is applied in all possible kinds of intersections
where road meets rail. There are almost no restrictions.
EDILON LC offers a unique solution, which combines in
an ideal way the track ballast bed, rail fastening and the
paved road into one structural monolithic unit.
By combining EDILON LC concrete slabs, level crossings
from 6 to 50 meters length can be installed in a period
of 8 hours, including the removal of the old crossing as
well!
Quality and installation speed are both very important.
Depending on the condition of the subsoil and the
function of the level crossing in e.g. continuous welded
track a choice can be made between EDILON LC-H and
EDILON LC-L or EDILON LC-1.
Application areas where a road meets rails
EDILON LC-HEDILON LC-H is especially designed for continuous
welded track where the high weight of the slabs is of
major importance to prevent track movement. Because
of the thickness of the EDILON LC-H concrete slabs, the
structural stiffness is high, which allows application in
areas with a subsoil with low foundation coeffi cient, ks =
20 MN/m³, which is equivalent to a subsoil modulus, Ev2
= 35 MN/m².
The installation of EDILON LC-H is done with a “top-down”
approach: the slabs are levelled at the proper Top of Rail
position by using hydraulic jacks and an injection grout
is used to fi x the correct slab position. In this way the
forces of the slab are evenly distributed over the supporting
subsoil. The rail channels are protected and strengthened
by strong steel edge profi les.
EDILON LC-1 and EDILON LC-LEDILON LC-1 and EDILON LC-L are both EDILON LC
systems that offer an optimized slab design which still
meets all rail and road requirements with a slab thickness
of 400 mm.
The installation of EDILON LC-L and EDILON LC-1 is
carried out with a “bottom-up” approach were the slabs
are placed on a smooth and levelled split bed with the
appropriate subsoil foundation stiffness. Application of
these slabs is possible in subsoil areas with a foundation
coeffi cient, ks = 70 MN/m³, which is equivalent to a subsoil
modulus, Ev2 = 120 MN/m².
Protection and strengthening of the rail channels is also
possible. Depending on the channel design all vignole
and grooved rails are accommodated.
All EDILON LC systems include the EDILON Corkelast®
Embedded Rail System (ERS) and offer the following ERS
characteristics:
• Continuous rail support
• Track stiffness tunable following for instance
UIC LM71
• Excellent electrical insulation
• Top-down rail alignment and levelling
Embedded Rail Characteristics
4 5
The fi elds of application of
EDILON LC
• main roads with high density of traffi c
• industrial areas with intensive heavy traffi c
• rural routes
• in city track
• crossing with angles up to 0-180°
• S-shaped roads and horizontal turn movements
Page 4
edilon)(sedra obtained its Dutch product approval for EDILON LC-H concrete level crossing slabs type “Harmelen” in
September 2007 but the principle of the heavy EDILON LC-H system was developed already in 1974 in close co-operation
with Netherlands Railways NS.
Since 1976, more than 1250 level crossings of this type have been installed.
The EDILON LC-H level crossing is available in two standard slab lengths.
Depending on track curvature and rail type the EDILON LC-H slabs can be tapered or wider channels or curved channels can
be applied.
LC-H6 LC-H9
Standard slab type R ≥ 1000m R ≥ 1500m
Tapered slab with straight channels 225m ≤ R ≤ 1000m 500m ≤ R ≤ 1500m
Tapered slab with curved channels R < 225m R < 500m
EDILON LC-H – type “Harmelen”
6 7
Features• Used in heavily loaded road-rail combinations
• Standard asphalt road approach
• Suitable for roads crossing at angles up to and
even exceeding 45 degrees
• Suitable for curved track sections with super elevation
• Intensive heavy road traffi c will not move nor damage
EDILON LC-H
• Standard level crossing drainage solutions
Slab characteristics• Minimal slab settlement and optimal distribution of
forces
• Maintenance free
• Ability to connect slabs to form longer crossings
• Road surface is extremely durable (special dressings
and treatments)
• Edges and channels protected with strong steel
profi les
• Rails fastened securely using EDILON Corkelast®
ERS
• Reduced rail corrugation
• Optimized reinforcement design with C45/55 concrete
• Seamless connection to the road surface
• Rapid installation method maximizes the track
availability
• Motorbike, bicycle and wheelchair friendly
Concrete Slab length Slab width Slab height Weight Radius Vmax
slab type [mm] [mm] [mm] [kg] [m] [km/h]
LC-H6 6.000 2.300 580 20.000 1000 200
LC-H9 9.000 2.300 580 30.000 1500 200
• Maximum train speed V 200 km/h
• Rail traffi c load classes - 150, 250 and 270 kN
• Road traffi c load class - Load class 60
• Maximum superelevation/track cant D 75 mm
• Maximum cant defi ciency I 40 mm
• Maximum cant excess E 40 mm
• Rail inclination - 0 or 1:40 or 1:20 or as required
• High skid resistance value SRV 70 (typical)
• Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements
ProRail Netherlands
Infrabel Belgium
SNCF France
MAV Hungary
Ontario Northland Canada
RENFE / ADIF Spain
REFER EP Portugal
EDILON LC-H track curvature slab range
EDILON LC-H system characteristics
Approvals
Prefab Embedded - Harmelen LC
Page 5
edilon)(sedra obtained its approval for EDILON LC-1 concrete level crossing slabs type
“Stelfundo” from the German Federal Bureau of Railways already in September 2003.
EDILON LC-1 is a logical addition to EDILON LC-H. Developed in the mid 1980’s, these
crossings have also enjoyed worldwide acceptance. Although of lower weight, the reinforcement,
surface treatments and various colours make the slabs also suitable for a wide range of applications.
EDILON LC-1 slabs are installed on a layer of well compacted levelled grit. Crossings of, for instance,
50m length can be installed in track possessions of only eight hours. Again, steel profi les can be
used on the edges of the channels to increase slab durability. It is possible to couple individual slabs
to prevent problems caused by subsoil settlements.
EDILON LC-1 is available in the following slab lengths:
EDILON LC-1 – type “Stelfundo”
Concrete Slab length Slab width Slab height Weight Radius Vmax
slab type [mm] [mm] [mm] [kg] [m] [km/h]
2600 2.600 2.400 400 5.990 85 160
3000 3.000 2.400 400 6.450 100 160
4000 4.000 2.400 400 8.600 200 160
4500 4.500 2.400 400 9.675 255 160
5000 5.000 2.400 400 10.750 315 160
5500 5.500 2.400 400 11.825 380 160
6000 6.000 2.400 400 12.900 450 160
• Maximum train speed V 160 km/h
• Rail traffi c load classes - 150, 250 and 270 kN
• Road traffi c load class - Load class 60
• Rail inclination - 0 or 1:40 or 1:20
• High skid resistance value SRV 45 (typical)
• Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements
8 9
EBA Germany
DB Netz AG Germany
ÖBB Austria
SBB Switserland
Approvals
EDILON LC-1 system characteristics
Features• Suitable for all rail and road traffi c
• Used in all types of road crossings
• Suitable for road crossing angles up to 45 degrees
• Ideal for curved and inclined track
Slab Characteristics• Minimal settlement and optimal distribution of forces
• Various slab lengths available (L codes)
• Available for curves (R codes)
• Highly durable surfacing
• Maintenance free; no rutting, reduced rail corrugation
• C45/55 concrete with optimized reinforcement design
• Increased safety for cyclists, motorbike and wheel
chairs riders
• Minimal installation times
• Slabs can be connected to longer crossings
• Re-adjustability after installation possible
Page 6
Concrete Slab length Slab width Slab height Weight Radius Vmax
slab type [mm] [mm] [mm] [kg] [m] [km/h]
LC-L1,5 1.500 2.400 400 3.300 75 80
LC-L3 3.000 2.400 400 6.500 150 80
LC-L4 4.000 2.400 400 8.600 200 160
LC-L5 5.000 2.400 400 10.725 300 160
LC-L6 6.000 2.400 400 12.850 450 160
EDILON LC-L
10 11
edilon)(sedra obtained approvals for EDILON LC-L
concrete level crossing in several countries i.e. Poland
and France. The principle of EDILON LC-L is based on
the proven concept of EDILON LC-H and EDILON LC-1.
The EDILON LC-L slab design gives freedom to apply
virtually all rail profi les and install track with different gauge
widths.
EDILON LC-L slabs are installed on a well compacted
subgrade with a fi ne split bed top layer. Steel profi les can
be used on the edges of the channels to increase the
slab durability.
EDILON LC-L is available in the following range of slab
lengths:
Features• Used in highly loaded road-rail combinations
• Standard asphalt road approach
• Suitable for roads crossing at angles up to 45
degrees
• Standard level crossing drainage solutions
Slab characteristics• Minimal slab settlement and optimal distribution of
forces
• Maintenance free
• Ability to connect slabs to longer crossings
• Durable road surface, special dressings and
treatments possible
• Edges and channels protected with steel profi les
• Rails fastened securely using EDILON Corkelast® ERS
• Optimized reinforcement design with C45/55 concrete
• Seamless connection to the road surfacing
• Rapid installation method maximizes the track
availability
• Maximum train speed V 160 km/h
• Rail traffi c load classes - 150, 250 and 270 kN
• Road traffi c load class - Load class 60
• Rail inclination - 0 or 1:40 or 1:20 or as required
• High skid resistance value SRV 45 (typical)
• Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements
EDILON LC-L system characteristics
Approvals
SNCF France
RATP France
PKP Poland
Banverket Sweden
DSB Denmark
MAV Hungary
SNCF France
ENR Egypt
APTA Alexandria
MTRC Hong Kong
GVB Amsterdam
Page 7
Design on rail and channelThe forces arising from rail and road traffi c on the slab are
most critical around the rail.
To understand this, extensive modelling and laboratory
tests are performed to analyze and optimize the system.
Rail profi le and mechanical properties, channel dimen-
sions, materials and building tolerances are all included
in the process of fi nding the most durable EDILON LC
system possible.
Depending on its application and the type of EDILON
LC a range of standardized channel designs have been
developed which gives freedom to apply each possible
rail profi le and will also meet the requirements set by road
and rail authorities.
System featuresThe use of slabs means that provisions for cables for
signalling, water drainage and a protection against loose
train couplings, must be made. Standard solutions are
available and can be included in the system design. In
EDILON Corkelast® ERS, multi functional plastic tubes
are applied.
These tubes offer the opportunity to:
• align the rails in the channels and to adjust the width
of the gauge
• reduce the amount of Corkelast® and so the material
costs
• pull cables for signalling through the tubes
EDILON LC system design and installation method
EDILON Corkelast® ERS
installation materials
• EDILON Corkelast®
• EDILON Primer 21
• EDILON Primer U90WB
• EDILON Resilient ERS Strip
• EDILON Dex®-G
• EDILON Fillerblocks and tubes
• EDILON Nylon spacers
• EDILON Polymer wedges
• EDILON Polymer (inclination) shims
On both ends of the crossing, a steel protection plate
is mounted to protect the concrete and/or the drainage
system from impact forces caused by loose couplings,
hanging from passing trains
Geotextile mats are preferred to be applied adjacent to
EDILON LC to provide a long lasting stable ballasted
track. The concrete slab reinforcement is optimized and
together with the applied concrete the electrical insulation
of the slabs is durably secured.
Rail fastening systemEDILON Corkelast® Embedded Rail Systems (ERS)
offers many advantages because of its continuous rail
support. Track stiffness can be tuned by choosing the
appropriate resilient ERS components. edilon)(sedra is
able to perform stiffness analysis using fi nite element
methods (FEM) and is able to test new system designs in
its own laboratory.
edilon)(sedra offers a range of EDILON LC systems optimized for supporting the forces from both rail as well as road traffi c.
A distinction is made in strength and defl ection behaviour between different EDILON LC slabs. A common characteristic
is that the slabs must be installed on stabilized ground. The ground support stiffness plays an important role in the choice
between the different types of EDILON LC systems.
Track facilitiesEDILON LC systems are compatible with all international
train control systems.
EDILON LC systems have been in service in a wide range
of light rail, high-speed and heavy rail applications over a
period of many years.
EDILON LC installation method
For all EDILON LC systems a well consolidated subgrade
is essential. The excavation profi le depends on the type
of installation. In case of a level crossing replacement
the excavation depth can be kept limited, whereas the
bottom of the excavation should be disturbed as little as
possible.
EDILON LC-H allows for a “top-down” approach were the
slabs are levelled with hydraulic jacks and an injection
grout is used to fi x the correct slab position. Because of
the high structural stiffness of EDILON LC-H, a low ground
support stiffness is permitted.
EDILON LC-1 and EDILON LC-L have a reduced slab
thickness, which requires a reduced excavation depth.
The installation of both EDILON LC-1 and EDILON LC-L
is done with a “bottom-up” approach were the slabs are
placed on a compacted smooth and levelled split bed
with the appropriate ground support stiffness.
In all cases the forces of the EDILON LC slabs are evenly
distributed over the supporting subsoil.
Special attention must be paid to the adjacent ballasted
track, which must be sound and stable.
12 13
Page 8
EDILON LC mainten ance and recycling
rail wearIt is well known that a well supported rail as well as one
of good quality will have positive infl uences on the life of
the rail. EDILON LC ensures a well supported rail through
various aspects: the support of the slab, the weight of the
slab, the tight tolerances of the slab, the alignment of the
slab and the exceptionally accurate alignment of the rail
on the slab. Connecting the slabs together also ensures
for better slab support over a longer period of time.
Furthermore, a well documented advantage of EDILON
Corkelast® ERS is a reduction of rail wear. With EDILON
Corkelast® ERS rigid points are omitted. This results in
an improved spreading of the forces and signifi cantly
reducion of high dynamic forces in the rails.
Track with EDILON LC is designed to work exactly how our clients want it to work. Should, for any reason, the track no
longer meets these expectations, either maintenance or rail replacement may be necessary. Height corrections of EDILON
LC concrete slabs can be carried out easily by high pressure injecting a special mortar underneath the slabs and lift them in
this way.
Rail replacement of EDILON Corkelast® ERS is only necessary when rail wear or rail fatigue limits are exceeding the regula-
tions, or in the exceptional case that a rail break did occur. EDILON Corkelast® ERS can be removed completely from both
channels and after cleaning the channels new EDILON Corkelast® ERS can be installed. EDILON Corkelast® ERS installation
can be done in very tight track possession periods.
recycling and environmentAll components used in EDILON LC systems are fully
recyclable. Cured embedding and pouring compounds
can be disposed as domestic waste, in accordance with
the European Waste Catalogue.
14 15
logistics and supplyThe logistic process for EDILON LC track follows a detailed and accurate planning.
Each part, from initial discussions, channel design, production, transport, installation and commissioning, are all included in
the planning. All materials supplied are subject to constant quality control.
partnershipedilon)(sedra supplies EDILON LC as a complete track
system, from initial contacts to system delivery, and from
commissioning to removal. We work with our clients on
questions and advice. EDILON LC delivers the benefi ts
of prefab element quality and rapid installation, and
combines our specialists knowledge of track, concrete
and civil engineering.