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This DB manual provides specialists and managers who plan and execute work on the permanent way with knowledge concerning the interaction of personnel, machines, devices and track equipment during permanent way maintenance
This DB manual provides specialists and managers who plan and execute work on the permanent way with knowledge concerning the interaction of personnel, machines, devices and track equipment during permanent way maintenance. The authors clearly describe the work procedures involved in the repair and installation of tracks and switches, including ballast cleaning and mechanical tamping work. Both formation rehabilitation methods and day-to-day maintenance are dealt with. The reader is familiarised with inspection and maintenance work as well as the acceptance of permanent way services. The authors also deal with the relatively new topic of „ballastless permanent way systems“ (ballastless track system) and provide an outlook concerning further developments in track maintenance machines and working procedures.
Contents
Preface
1 General
2 Track equipment
- 2.1 General
- 2.2 The rails
- 2.2.1 Insulated rails
- 2.2.2 Insulated joints
- 2.3 The sleepers
- 2.3.1 The wooden sleepers
- 2.3.2 The steel sleepers
- 2.3.3 The reinforced concrete sleeper
- 2.3.4 Special forms of concrete sleeper
- 2.4 The sleepers of the ballastless track system
- 2.5 The rail fastening
- 2.5.1 The rail pad
- 2.5.2 The types of rail fastening
- 2.6 The ballast bed
3 Substructure
- 3.1 General
- 3.2 Substructure of new tracks
- 3.2.1 Substructure foundation
- 3.2.2 Checking load-bearing capability and rate of compression
- 3.2.3 Measures to prevent embanking settling
- 3.2.4 Draining the track formation
- 3.2.5 Drainage systems
- 3.3 Substructure of old tracks
- 3.3.1Substructure redevelopment
4 Line layout and routing
- 4.1 General
- 4.2 Principles of line layout: Discretionary and approval limit values
- 4.3 Route elements
- 4.4 Fundamentals of routing
- 4.4.1 The curved track
- 4.4.2 Superelevation
- 4.4.3 Lateral acceleration
- 4.4.4 Compensating superelevation
- 4.4.5 Determining superelevation
- 4.4.6 Unbalanced superelevation
- 4.4.7 Excess of superelevation
- 4.4.8 Minimum superelevation
- 4.4.9 Standard superelevation
- 4.5 Transition curves and superelevation ramps
- 4.5.1 The transition curve
- 4.5.2 Reverse curve with transition curve
- 4.5.3 Superelevation ramps
- 4.5.4 Ramp forms
- 4.6 Longitudinal track pull
- 4.7 Slope and gradient change
- 4.7.1 Graduated gradient change
5 Maintenance terms
- 5.1 General
- 5.2 Explanation of individual terms and meaning for the permanent way
6 Inspection
- 6.1 Inspections on foot/inspection runs
- 6.1.1 Track inspections on foot
- 6.1.2 Track inspection runs (see guideline 821.2004)
- 6.2 Measurement runs
- 6.2.1 Checking the track geometry with track inspection vehicles (see guideline 821.2001)
- 6.2.2 Technical driving inspections (see guideline 821.2002)
- 6.2.3 Ultrasonic test runs
- 6.2.4 Rail inspection train equipment
- 6.3 Manual measurements
- 6.3.1 Switch diagnosis system VAE ROADMASTER 2000
- 6.4 Foundation survey
- 6.4.1 General
- 6.4.2 Execution of the geotechnical survey
- 6.4.3 Evaluation of results
- 6.4.4 Construction execution
- 6.4.5 Conclusion
- 6.4.6 Application of the ground-penetrating radar
- 6.4.7 Geotechnical survey report for maintenance work
- 6.5 Evaluation and measures
- 6.5.1 General
- 6.5.2 Integrated inspection system (IIS)
- 6.5.3 Near-surface defects in rails
- 6.5.4 Planning of measures for track maintenance (see guideline 823.0100A02)
- 6.5.5 Special inspections with the GeoRail Xpress
7 Maintenance
- 7.1 Weed killing on and alongside railway tracks
- 7.1.1 Weed killing on railway tracks using pesticides
- 7.1.2 Weed killing outside of tracks using mechanical procedures
- 7.2 Lubrication of slide base plates
- 7.2.1 Lubrication of slide base plates
- 7.2.2 Switch rollers
- 7.2.3 Switch roller systems
8 Repair work
9 Planning of track maintenance
- 9.1 Rail transport
- 9.1.1 Quality assurance when loading rails
- 9.1.2 Rail transport with Robel design type
- 9.1.3 Rail transport with STS design type
- 9.1.4 Mobile continuous welded rail unloading device, Geismar design type, model EMD
- 9.2 High-speed track renewal machine SUM 315 (Q 3)
- 9.3 Track renewal train Matisa (UM)
- 9.3.1 Overview of the track renewal train procedure UM
- 9.3.2 Special features of track renewal trains UM-1, 2 and 3
- 9.3.3 Special features of track renewal train UM-S 2001 (HENRY THE STRONG)
- 9.3.4 Special features of P 95-2008 UM and UM-P from Schweerbau
- 9.3.5 Track renewal train MATISA P 90 LS from JumboTec
- 9.3.6 Special features of P 95 from Strukton
- 9.3.7 Special features of track renewal train P 95 SR
- 9.3.8 Renewal procedure Matisa P 100
- 9.4 High-speed track renewal machine (SUM-Q 1)
- 9.5 RU 800 S track renewal and ballast cleaning in one operation
- 9.5.1 General
- 9.5.2 Description of the working method
- 9.6 High-performance renewal procedure VFW 2001
- 9.7 Track renewal in a two-sleeper cycle with the SUZ 500 UVR 229
- 9.8 Track renewal train SUZ 500 with SVM 98
- 9.8.1 Preconditions for using the SUZ 500
- 9.8.2 Preliminary work
- 9.8.4 Special features
- 9.8.5 Track renewal with UZ 500
- 9.8.6 Subsequent operations (not usually by SUZ personnel)
- 9.8.7 Unloading and forwarding the continuous welded rails with the rail forwarding machine (SVM) in combination with
high-speed track renewal machine SUZ 500
- 9.9 Donelli gantry crane
- 9.10 Track assembly
10 Renewal of switches
- 10.1 General
- 10.2 Preconditions (unloading, assembly)
- 10.3 Revolving cranes (Sk)
- 10.4 Renewal machine unit for switches and tracks (UWG)
- 10.5 Switch renewal with switch renewal machine WM 500-U
-10.6 Switch transport wagon
- 10.7 Ready-to-install, fully-assembled large switch parts from the switch supplier
- 10.7.1 Goal setting
- 10.7.2 Technical solution
- 10.7.3 Complete assembly in the switch factory
- 10.7.4 Loading and transport
- 10.7.5 Installation
- 10.7.6 Operations technology advantages
- 10.7.7 Special features of the complete assembly, its transport and installation
- 10.7.8 Summary
- 10.8 Switch maintenance
- 10.8.1 Switch inspection
- 10.8.2 Individual replacement of parts of the switch track
- 10.9 The locking sleeper
11 Sleeper replacement
- 11.1 General
- 11.2 Track renewal trains
- 11.3 Individual sleeper replacement by hand or with equipment
12 Rail replacement
- 12.1 General
- 12.2 Rail replacement with rail changers
- 12.3 Rail replacement with roller grips
- 12.4 Rail replacement with the rail replacement system SR
13 Ballast laying
- 13.1 General
- 13.2 Classic procedure
- 13.3 Ballast bed finisher
14 Installation of tracks
- 14.1 General
- 14.2 Ballast superstructure
- 14.2.1 Track laying with VFW 2001
- 14.2.2 Track laying with SUZ 500 UVR
- 14.2.3 Niemag track renewal crane (UN)
- 14.2.4 Renewal machine unit for switches and tracks (UWG)
- 14.2.5 Gantry crane with integrated individual sleeper laying device
- 14.2.6 Track laying with revolving cranes (Sk)
- 14.2.7 Track laying with the gantry crane (Donelli)
- 14.2.8 Laying of individual sleepers
- 14.3 Ballastless track system
- 14.3.1 General
- 14.3.2 The ballastless track system design types
- 14.3.3 Ballastless track system laying procedures
- 14.3.4 Measurement of the ballastless track system with the Hergie system
- 14.3.5 Laying the lean-mixed concrete in ballastless track systems
- 14.3.6 Procedure for laying continuous welded rails in ballastless track systems
- 14.4 Switches in ballastless track systems
14.4.1 Switches in the RHEDA 2000® design type ballastless track system
- 14.5 Requirements on the substructure for ballastless track systems on earthwork foundations
- 14.6 Transitions
- 14.7 Noise insulation in ballastless track system construction
- 14.8 Maintenance and renewal of the ballastless track system
- 14.9 Laying of special sleepers
- 14.9.1 Y-steel sleeper superstructure Y/S15
- 14.9.2 Twin sleeper (BS)
- 14.9.3 Sleeper bed for the ballast superstructure (padded sleeper)
15 Ballast solidification through plastic bonding
- 15.1 Product
- 15.2 Application areas
- 15.3 Required boundary conditions
- 15.4 Acceptance, quality control, guarantee
- 15.5 Guarantee
- 15.6 Work specifications
- 15.7 Handling of the bonding during tamping work
16 Ballast cleaning
- 16.1 General
- 16.2 Ballast cleaning machines RM 80 and 80-92
- 16.3 Ballast cleaning machine RMW 1500
- 16.3.1 General
- 16.3.2 Ballast bed cleaning with the RMW 1500
- 16.4 Rail-mounted ballast cleaning machines RM 800 and RM 800 Super 3S
- 16.5 Rail-mounted ballast cleaning machines RM 801 and RM 801-2
- 16.6 High-performance ballast cleaning machines RM 900 S and RM 900
- 16.6.1 RM 900 S from SPITZKE AG
- 16.6.2 RM 900 from Schweerbau
- 16.7 High-performance ballast cleaning machine RM 95-700
- 16.8 High-performance ballast cleaning machine RM 95-800
- 16.9 Rail-mounted ballast cleaning machine RM 76 UHR
- 16.10 Road-rail ballast cleaning machine ZRM 79
- 16.11 Ballast cleaning using other procedures
17 Loading and unloading systems for waste removal and ballast laying
- 17.1 General
- 17.2 Material conveyor and hopper unit (MFS 38, 40, 100-S, 250), belt storage device (BSG 60), bulk freight hopper wagon (BSW 11000 and 2000) and road-rail MFS
- 17.3 Loading belts and systems
- 17.4 Unloading systems for laying ballast
18 Formation rehabilitation
- 18.1 General
- 18.2 Laying with earth moving equipment
- 18.3 Formation rehabilitation machine PM 1000-URM
- 18.3.1 General description of the PM 1000-URM work procedure
- 18.3.2 Description of the PM 1000-URM work modules
- 18.4 Formation rehabilitation machine PM 200-1 (BR)
- 18.4.1 General information on PM 200-1
- 18.4.2 Addition of an RM 80-92 ballast cleaning machine to the PM 200-1 BR
- 18.5 Formation rehabilitation machine PM 200-2R
- 18.5.1 General information on PM 200-2R
- 18.5.2 Work procedure
- 18.6 Sand distribution and compacting machine (SVV 100) from Joseph Hubert and Schweerbau
- 18.7 Recycling and formation rehabilitation machines RPM 2002 and RPMW 2002-2
- 18.7.1 Objective of RPM 2002
- 18.7.2 Work procedure
- 18.8 Recycling, formation rehabilitation and cleaning machine RPM-RS-900 from SPITZKE AG
- 18.8.1 General
- 18.8.2 Working methods
- 18.8.3 RPM-RS-900 from Schweerbau
- 18.9 Möbius soil remediation system
- 18.10 Formation rehabilitation with Wiebe ballast replacement system
- 18.11 Verification of installation quality
19 Mechanical tamping work in tracks and switches
- 19.1 Requirements on track and switch tamping machines and ballast ploughs
- 19.2 Measuring work ahead of tamping machines
- 19.2.1 Introduction
- 19.2.2 Measuring work on conventionally marked tracks
- 19.2.3 Measuring work with the EM-SAT track survey system
- 19.2.4 Measuring work with the GEDO CE
- 19.2.5 Measuring work with the Amberg GRP 3000 survey system
- 19.2.6 The satellite-supported track survey during track maintenance
- 19.3 Tamping
- 19.3.1 General
- 19.3.2 Compacting
- 19.3.3 First and second stabilisation
- 19.3.4 Creation of the ballast profile
- 19.3.5 Speed regulation after laying
- 19.4 Maintenance of the tracks
- 19.4.1 General
- 19.4.2 Preconditions and preliminary work
- 19.4.3 Elimination of long-wave track displacement on high-speed lines (v > 160 km/h)
- 19.4.4 Ballast distribution system (BDS 2000)
- 19.5 Maintenance of switches
- 19.6 Tamping work with small machines
- 19.7 Dynamic track stabilisation (DGS)
- 19.8 Checking execution
20 Creation of the continuous welded rail track
- 20.1 General
- 20.2 Stress compensation
- 20.3 Welded joints (intermediate and end welds)
21 Elimination of individual defects
- 21.1 Tracks
- 21.1.1 General
- 21.1.2 Correction of track displacement
- 21.1.3 Gauge correction
- 21.1.4 Bending up retracted insulated joints
- 21.1.5 Sleeper rehabilitation
- 21.2 Elimination of individual geometry faults in tracks and switches with individual defect tamping machines
- 21.2.1 Individual defect tamping machine UNIMAT-Sprinter
- 21.2.2 Fully-mechanised individual defect processing with the 08-275 4ZW 67
22 Rail processing
- 22.1 General
- 22.2 Rail processing machines, type RR
- 22.2.1 Rail grinding trains (Ssz), types RR 48 M and 32 M
- 22.2.2 Rail grinding machines (Ssm), type RR 24 M
- 22.2.3 Universal grinding machines (Usm), types RR 16 M and RR 24 MC
- 22.2.4 Switch grinding machines (Wsm), types RR 16 P/D and 16 MS
- 22.3 Rail processing machines, types RG, SPML, RGM, GWM, SF 03/SM 03, SFU 04/SM 04, SBM
- 22.3.1 Rail grinding machine RG 48
- 22.3.2 Rail grinding machine SPML 16-2
- 22.3.3 Rail grinding machine RGM
- 22.3.4 Track and switch grinding machine GWM 550
- 22.3.5 Rail milling unit SF 03/SM 03
- 22.3.6 Rail milling machine SFU 04/SM 04
- 22.3.7 Rail processing machine SBM 250
- 22.4 Track and switch grinding machine RGH C 20 plus suction and rinsing unit (SuSE)
- 22.5 Rail grinding machine SZ 2000
- 22.6 Rail milling unit SF 03 FFS-Plus
- 22.7 High-speed grinding with grinding machine RC 01
- 22.8 The rail milling train SF 03 W-FFS
- 22.9 Hand-held grinding equipment
23 Noise insulation and vibration protection
- 23.1 Introduction
- 23.1.1 Noises and vibrations caused by railway vehicles
- 23.1.2 Sources of noise
- 23.1.3 Rolling noise
- 23.1.4 Legal boundary conditions
- 23.1.5 Vibrations
- 23.2 Inspection: assessment of the actual status of the rail running table quality
- 23.2.1 Direct measurement processes
- 23.2.2 Indirect continuous measurement processes
- 23.3 Maintenance and repair of the rail running tables
- 23.4 Sound-reducing measures
- 23.4.1 Measures on the rail
- 23.4.2 Absorbent running track coverings
- 23.4.3 Measures in the propagation path
- 23.4.4 Measures at the immission point
- 23.5 Vibration-reducing measures
- 23.5.1 Measures in the superstructure system
- 23.5.2 Measures in the propagation path
- 23.5.3 Measures at the immission point
24 Assessment and acceptance of track maintenance
- 24.1 Principles
- 2.4.1.1 General
- 2.4.1.2 Acceptance
- 24.2 Acceptance of new track construction or track renewal
- 24.2.1 General
- 24.2.2 Acceptance following new track construction or track renewal
- 24.2.3 SR values for new track construction or track renewal
- 24.2.4 SR values of the geodetic location of the track and other measurements
- 24.2.5 Checklist for acceptance documents
- 24.3 Acceptance of new switch construction and switch renewal
- 24.3.1 General
- 24.3.2 Object of acceptance
- 24.3.3 Acceptance following new switch construction and switch renewal
- 24.3.4 SR 0 values of the switch geometry
-24.4 Acceptance of track maintenance
-24.4.1 General
-24.4.2 Acceptance of track maintenance
-24.4.3 Evaluation of the acceptance survey
- 24.5 Acceptance of switch maintenance
- 24.5.1 General
- 24.5.2 Acceptance of switch maintenance
- 24.5.3 SR 0 values for switch maintenance
-24.6 Acceptance of welded joints on rails
- 24.6.1 General
- 24.6.2 Principles
- 24.6.3 Working equipment
- 24.6.4 Acceptance of welded joints on rails
- 24.7 Acceptance of rail processing
- 24.7.1 General
- 24.7.2 Acceptance of rail processing
- 24.7.3 Guideline acceptance values following rail processing
- 24.7.4 Guideline acceptance values following the creation of special profiles
25 Further developments
- 25.1 General
- 25.2 SUZW 500 – new technology for track renewal in conveyor belt technology, H.F. WIEBE
- 25.3 Ballast bed cleaning machine RM900VB
- 25.4 Mobile maintenance system ROBEL 69.70
- 25.5 Ballastless track system DW prefabricated concrete track panels as the rail support system
- 25.5.1 System description
- 25.5.2 Routing principles
- 25.5.3 Construction implementation
-25.6 The DURFLEX superstructure system
