SP3 Design and implementation of solutions at test sites WP 3.9 – Karlsruhe New installation methods for prefabricated track operator: VBK presented by Thomas Rupp Verkehrsbetriebe Karlsruhe (VBK), construction department M48 Final Assembly June 25, 2010, Prague
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SP3 Design and implementation of solutions at test sites
WP 3.9 – Karlsruhe New installation methods for prefabricated track
operator: VBK
presented by Thomas Rupp Verkehrsbetriebe Karlsruhe (VBK), construction department
M48 Final Assembly June 25, 2010, Prague
Final Conference - June 25, 2010 - Prague 2
Contents
Objectives
Initial position
Description of test site
Technical requirements on track modules
Description of activities
Engineering, technical details
Constructing process
Final activities
Experiences
Perspectives
Final Conference - June 25, 2010 - Prague 3
Initial positionNeed of renewing
Final Conference - June 25, 2010 - Prague 4
Initial position
Superstructure has to be replaced urgently
Karlsruhe is constructing a tram tunnel under the pedestrian district, construction has begun in may 2010
Re-Modulix : removable prefabricated track modules
Final Conference - June 25, 2010 - Prague 5
Description of test site
installation location
Final Conference - June 25, 2010 - Prague 6
Description of test site
Length: 375 m, double track
The chosen section is the track section with the most rail traffic in the entire rail network of the VBK
7 lines of the light rail system (a tram train vehicle crosses every 85 seconds per direction)
Extract of network diagram
Final Conference - June 25, 2010 - Prague 7
Technical requirements on track modules
Surface of red pavement stones – like the sand-stone building of the University of Karlsruhe (KIT)
Prefabricated concrete pavement stones as integrated parts of the modules
Maintenance free surface of the pavement stones
Load: trams (11 to axle load) and busses (only at nights)
Noise and vibration reduction (slab track!)
Stable position and level of the track
Integrated rail drainage system
Fast construction process
Completion of all works on test site within 3 weeks
Removable track modules to use elsewhere in the VBK-network
Final Conference - June 25, 2010 - Prague 8
Engineering process
Application of anti-adhering coating allowing future module removal
Realisation of all plans for modules and panels
18 Re-Modulix out of 42 prefab modules
Development of embedded hoisting anchors
Production and transport
Production & transport from Belgium to Karlsruhe
Final Conference - June 25, 2010 - Prague 10
Delivery of prefabricated slabs in Karlsruhe harbour
Production and transport
Final Conference - June 25, 2010 - Prague 11
Technical details
Quantity: 247 slab elements (42 + 205)
Weight: 32.000 kg
Length: 18 metres
Concrete quality: C30/37
Special vehicles for installing (existing catenary!)
Final Conference - June 25, 2010 - Prague 12
Construction process
Works: Monday, August 10, 2009 until Friday, August 28, 2009
Six days a week (no works on sundays)
Daily working time: 6 a.m. to 10. p.m. (two shifts)
Detouring diagram for tram lines (3 tram lines replaced by busses)
Final Conference - June 25, 2010 - Prague 13
Construction process
Removal of superstructure
Production of track modules, transport to test site, cranes, installation: CDM, Brussels
(Other) construction works: Heilit+Wörner, MunichConstruction supervision: VBK, construction department
Final Conference - June 25, 2010 - Prague 14
Construction process
Module positioning Rail welding Concreting
Panel assembly
FinishingInstallation of the great elements within 3 days (average of 2 modules/hour)750 m of rail Ri 59 N (59 Ri 2)88 rail welds210 fill-in panels 400 m³ of concrete (in 4 days)
Final Conference - June 25, 2010 - Prague 15
rail underpour with concrete, assembly of small slabs in the centre and in the welding zones
Constructing process
Final Conference - June 25, 2010 - Prague 16
Works are finished
Final Conference - June 25, 2010 - Prague 17
Experiences: noise & vibration reductionMeasurement and analysis by Karlsruhe Institute of Technology (KIT)
(former University of Karlsruhe), department for railroading:
Maximum amplitude of acceleration lower than before (see below)
Amplitude more continuous, but a little stronger
before after
4 bogies visible not visible
Final Conference - June 25, 2010 - Prague 18
Experiences+ stable, quiet track, good visual appearance,
fast and successful construction process,track used by trams and busses (bus only at night)
+/- expensive (but: long transport distance, long engineering time...)
-- Severe damages after only 9 months (!) at several pointsremoval of pavement stones from the prefabricated concrete
7 cm
Joint between elements
Final Conference - June 25, 2010 - Prague 19
ExperiencesReasons (possibly):• failure in the production process during the underpooring of the pavement stones: deficient ahesion!
Solution (probably):• Elastic joints in the pavement level (8 cm) between the elements
• Close open joints (frost damage!) • Fix pavement stones on concrete
5 years of contractual warranty!
Consequences:• Significant reduction in expected LCC-Savings
Final Conference - June 25, 2010 - Prague 20
Perspectives
Implementation of Modulix-system in Karlsruhe in the existing form not successful
Re-use of Re-Modulix elements because of pavementdamages doubtful or: only without pavement stone filling
Room for improvement:• quality level, tolerances (accuracy)• elastic, closed joints• adhesion between pavement stones and concrete• assembly only with cross beam along the element• production near the installation site
Good chance for a better quality, durability, price level Competitive system!
Final Conference - June 25, 2010 - Prague 21
Thank You for attention
SP3 Design and implementation of solutions at test sites
WP 3.9 – Karlsruhe New installation methods for prefabricated track
operator: VBK
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