edilon corkelast® embedded rail system (ers)
DESCRIPTION
edilon)(sedra, with its EDILON Corkelast® Embedded Rail System (ERS), has changed the concept of discretely supported rails by means of sleepers or blocks, into continuously supported rails. This homogeneous elastic support is providing the same dynamic spring and damping behaviour as elg. ballasted track under traffic load, but completely eliminates the influences of individual rail seats or sleepers. Track loads become more evenly spread and dynamic load amplification is getting lower.TRANSCRIPT
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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
www.edilonsedra.com
EDILON Corkelast®
Embedded Rail System
(ERS)
EDILON Corkelast®
Embedded Rail System (ERS)
People are moving, from point A to B, constantly at any
time, any place and any where. Quickly and comfortably
on their way, that is what people want. Public transport is
becoming more and more attractive, in particular com-
bination of railway and tramway (Light Rail) is gaining
popularity. Also High Speed Lines are competing airway
traffi c heavily.
edilon)(sedra develops, produces and installs all kind of
rail systems that contribute to a high quality standard in
public transport. That’s exactly why we call ourselves ‘the
connecting factor’’!
The connecting factorMoving People
The primary characteristics of the EDILON Corkelast®
Embedded Rail System (ERS) is based on EDILON
Corkelast®. This provides elastic bonding to the rail and
the supporting rail channels. The unique, proven, reliable
two component embedding compound assures outstan-
ding position stability over decades – along with simple
installation, reduced construction height, low system
costs, and minimum maintenance.
2 3
For over 130 years tracks for railway traffi c were almost
exclusively based on track panels and cross sleeper sup-
ported on stone ballast. With increasing train loads, higher
speeds, dual use of road traffi c surface and the demand
for more cost-effective track installation methods, this led
to the development of more and sophisticated ballastless
track systems, or slab track.
edilon)(sedra, with its EDILON Corkelast® Embedded
Rail System (ERS), has changed the concept of discre-
tely supported rails by means of sleepers or blocks, into
continuously supported rails. This homogeneous elastic
support is providing the same dynamic spring and dam-
ping behaviour as e.g. ballasted track under traffi c load,
but completely eliminates the infl uences of individual
rail seats or sleepers. Track loads become more evenly
spread and dynamic load amplifi cation is getting lower.
By virtue of the position-stable integration of the rails into
a concrete or steel channel structure, track loads have a
negligible effect on track gauge, position and buckling.
General advantages
• Continuous rail support in vertical and lateral
direction
• Embedded Rail (ERS) is corrosion free
• Easily cleanable and accessible track surface
• Stiffness and damping characteristics are tuneable
• Full integration into engineering structures possible
• Design can be adopted to structure-borne noise
requirements
Cost effectiveness
• Low structural height
• Numerous options for integral design
• Effi cient construction and installation
• Minimum maintenance
• Service life > 30 years
• Low life cycle costs (LCC)
Expertise where it matters
ERS • areas of application
4 5
• Reduction of construction height
• Accessible by emergency vehicles and track maintenance vehicles
• Integration of drainage systems
Tunnels
• 30 m single span in CWR without compensation joints
• Installed on steel, concrete or composite bridges
• Substantial weight reductions
Bridges
• Integrated in EDILON LC designs
• Durable and settlement free rail and road position
• No loose items
• Salt water resistant
Level Crossings
• Easily cleanable
• If applied at stops without platforms, easily accessible
Stations and Stops
• Full green appearance
• Hydration and drainage controlled
• Noise absorbing features
Grass Tracks
• Best integrated in any concrete slab
• Slip-form paved slabs
• In-situ cast slabs
• Combination of in-situ and prefab elements
• Black top surface layer
In street Running Tracks
edilon)(sedra supplies Embedded Rail Systems which meet the standards that are set by the customer. This has led in a period
of more than 30 years to a number of Standardized and Customized ERS solutions. In this brochure the emphasis is put on
ERS solutions for two groups: light rail and heavy rail applications. Roughly speaking this means that focus is put on light rail
traffi c with axle loads till 2,5 tonnes and higher, and much higher operational speeds.
EDILON Corkelast®
Embedded Rail System (ERS):
standardized or customized?
ERS • stiffness categories and noise and vibration characteristics
The EDILON Corkelast® Embedded Rail Systems are designed to meet the requirements for any rail network. Structural en-
gineering design of the ERS allows variation in accordance with the specifi c vehicle load levels and patterns, with respect to
national regulatory frameworks, or company standards (e.g. UIC fi che 700 and 702, BO Strab, etc.)
To enable fl exible adjustment of the track to meet various performance requirements such as ride comfort and structure borne
noise, it is possible to regulate the static spring constant of the EDILON Corkelast® Embedded Rail System in combination
with the EDILON Resilient Strip to match the characteristics of the rail profi le and the channel dimensions. Basically there are
three different categories: Standard Stiffness, Medium Stiffness and Low Stiffness. System parameters are permanently over-
looked by research employees. Material and system properties such as stiffness, strength, stability, fatigue behaviour, impact
resistance, vibration performance, rail-lift resistance and temperature stability form only an outline of the regular survey in
laboratory tests and computer aided design facilities.
6 7
System characteristics
• Permanent and accurate rail position
• Special noise engineering design possible
• Structural integration of design in fl oating slab
• Suitable for any type of grooved and vignole rail profi le
• Any rail inclination possible
• Track circuit current conformity
• Compatibility with any train control systems
The possibility of a customized stiffness of the system, and by consequence a custo-
mized defl ection of the rail, has contributed to a major improvement in noise reduc-
tion. This has e.g. led to a widespread application of the EDILON ERS MS (Medium
Stiffness) on railway bridges for heavy rail. For light rail, numerous steel bridges and
several concrete slab track sections have been equipped with EDILON ERS MS or LS,
in order to control and reduce structure borne and ground borne noise. The seamless
integration of ERS and Floating Slab Track has contributed to effi cient designs e.g. for
tunnels, Floating Slab Track and ERS easily match and supply customized and effec-
tive vibration insulation.
-0.5
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.010 8 6 4 2 0 -2 -4 -6 -8 -10
4 Wheels
Distance (m)
Sta
tic r
ail d
efle
ctio
n (m
m)
ERS HR SS
ERS HR MS
ERS HR LS
UIC60/60E1
25 tonnes axle load
ERS HR SS
ERS HR MS
ERS HR LS
SYSTEM
Standard Stiffness
Medium Stiffness
Low Stiffness
100 kN/mm/m
50 kN/mm/m
25 kN/mm/m
< 1.0 mm
1.0 - 2.0 mm
> 2.0 mm
TYPICAL STATIC
STIFFNESS (rail)
CATEGORY STATIC RAIL
DEFLECTION
ERS LR SS
ERS LR MS
ERS LR LS
SYSTEM
Standard Stiffness
Medium Stiffness
Low Stiffness
60 kN/mm/m
15 kN/mm/m
9 kN/mm/m
< 1.0 mm
1.0 - 2.0 mm
> 2.5 mm
TYPICAL STATIC
STIFFNESS (rail)
CATEGORY STATIC RAIL
DEFLECTION
ERS • system design
The EDILON Corkelast® Embedded Rail System is al-
ways applied in a channel. Depending on the supporting
structure, it is possible to design and construct a type of
channel that meets the requirements of costs, effi ciency,
geometry and structural strength and stability.
Basically there are no restrictions in applying EDILON Corkelast® ERS when the track is in gradient.
And where it concerns switches and crossings, the scale of integration of EDILON Corkelast® ERS can reach a
hundred percent.
• Insulated rail joints and rail expansion joints
• Cable connections, e.g. for earthen and signalling
• Drainage
• Provisions for quick rail access and rail section replacement
• Gradual transition to other types of track
Other track facilities
• Strengthening of the road surface corners
• Application of durable joint fi ller material
• Skid resistant surface treatment
Track in Level Crossings and Road Surfaces
8 9
• No restrictions in track super elevation
• Application of pre-bended rails possible
• Installation with enforced gauge widening
• Special design for increased lateral load risk
• Optional guard rails
• Optional check rails or anti-derailment plinth
Track Curves
ERS • approvals
10 11
System design tests and approvals
As with all products, the EDILON Corkelast® Embedded
Rail System (ERS) must undergo extensive external
system tests to satisfy the strict approval criteria of their
various user organizations. The clients include railway
authorities, and operators of metro, light rail ad tram-
way networks, private clients, e.g. industrial factories or
port authorities. They have formulated approval criteria
for their special application of ERS. For many years our
Research & Development Department has collaborated
closely with research institutes, certifi cation bodies and
several leading technical European universities.
Installation
The installation of EDILON Corkelast® Embedded Rail
System is an important stage on the route between
design and operation. As the underlying structure,
comprising both channels, is fi nished and has been
checked for its correct alignment and level, the installation
of the rail system commences. The partially industrialized
embedding process requires preparation of the bonding
surfaces, accurate positioning of the rails and qualifi ed
conditions. After applying the EDILON Corkelast® mate-
rial, self-levelling and hardening takes place.
Pre-embedding the rail in the channel is possible. The
rail and the channel are then transported to the site and
installed by means of cement grouting or bolted plates.
Full bridge installation with pre-installed Embedded Rail
System has also taken place.
Maintenance and Replacement
Historical track data have indicated that EDILON Corke-
last® Embedded Rail System service life is at least twice
as long as ballasted track systems, designed for simi-
lar rail traffi c, which means several decades. Also in its
service life, EDILON Corkelast® ERS requires only minor
maintenance, e.g. grinding and cleaning where neces-
sary. And conservation of the supporting structure is ne-
cessary, as with any other rail system for Slab Track.
ERS • maintenance and recycling
For repair and replacement of EDILON Corkelast® ERS,
different methods have been developed together with
customers, rail authorities and contractors. Depending
on the type of repair and replacement, time schedules
are produced and special removal and installation equi-
pment for ERS is allocated. Overnight rail replacement is
possible for complete level crossings and for rail sections
up to 50 meters on steel bridges and concrete slabs with
rail replacement provisions (so-called ‘pockets’).
Recycling and Environment
All components used in the Corkelast® Embedded Rail
System (ERS) are fully recyclable. Embedding and pou-
ring compounds are disposed of as domestic waste, in
accordance with the European Waste Catalogue. For
further information please consult the edilon)(sedra Pro-
duct Information Sheets.
• Bottom-up by means of levelling and rail inclination
shims, and alignment wedges.
• Top-down by by means of rail portals
The positioning process of the rails according to
the correct track alignment and track level can be
carried out in two basically different manners: