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| Rai lways


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Railways


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>>

Your objective is our challenge

RAIL.ONE delivers innovative products for rail-

ways and urban trafc in Germany and through-

out the world. We offer engineering, production,

supply, logistics, and quality management -- all

on a one-stop basis. Our systems require a min-

imum of maintenance over decades, and assurestable track geometry and outstanding riding

comfort even at top speeds and with extreme

loads. And since each track should be optimized

for its special application area, RAIL.ONE places

great emphasis on close collaboration with cus-

tomers and business partners. With its extensive

sales and distribution network, as well as loca-

tions in Germany, Hungary, Korea, the Nether-

lands, P. R. China, Romania, and Spain, RAIL.ONE

holds a leading position in track technology and in

the production of concrete sleepers. Continuous

research and ongoing development guarantee our

technological leadership.

We develop innovative track systems, to help you get ahead

fast and safely. And what are your plans?

RAIL.ONE the way to go

>>

RAIL.ONE your one-stop provider

RAIL.ONE GmbH known until now as Peiderer

track systems conducts business with the goal

of providing comprehensively oriented systems and

engineering for the entire eld of railway tracks and

their many and varied requirements. In this area,

RAIL.ONE GmbH in close collaboration with itscustomers and partners carries out as one-stop

supplier all activities involved in product develop-

ment, manufacture, and application of concrete

sleepers: beginning with engineering; including

production, supply, and logistics; and extending to

quality management.


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Railways


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Track systems represent the future way to go. But markets are

changing, and new concepts are in urgent demand. The rst step

involves communication so lets talk about what you need.

We are ready

>>

On the right track

When it comes to economy, reliability, and envi-

ronmental compatibility, railways are miles ahead

of their competitors on the highways, on water,

and in the air. And as far as speed is concerned,even air travel can hardly compete now with the

new offerings in rail transport. Road transporta-

tion has long since reached the limits of its capac-

ity despite ongoing high investment. Especial-

ly with a view to future European cargo trafc,

railways obviously offer the only escape. Europe,

after all, presents promising chances: unication

in the EU has opened up completely new possibil-

ities for international construction and joint devel-

opment projects for passenger and cargo trans-

portation.

>>

With new concepts toward new horizons

A revolution in railway culture was necessary to

move it successfully into the future. Liberalization

of technical standards and new forms of awarding

contracts have quickly led to new quality in cus-tomer-provider relationships. Communications

plays a key role here and this is where RAIL.ONE

comes into action. Track systems and infrastruc-

ture must now as before and, in the future, even

more extensively be designed for advanced

transportation systems. And a great deal remains

to be done. Transportation networks are still not

fully compatible at borders between countries.

Research for innovative products and manu-

facturing techniques must be continuously and

vigorously promoted. Planning and implementa-

tion work must be more closely merged and coor-

dinated. The key to successful project work lies

in the integration of the system provider into the

engineering and construction processes.

>>

We have grasped what is required

As system provider, RAIL.ONE is at the interface

between planners, general contractors, and con-

struction companies. A complex construction

project - such as the new high-speed lines from

Nuremberg to Ingolstadt, from Amsterdam toBrussels (HSL Zuid), and from Taipei to Kaohsiung

in Taiwan - demands far more than mere delivery

of hardware. RAIL.ONE accordingly understands

its mission as a service and competence provid-

er. Leadership in technology is assured not only

through advanced production facilities and inno-

vative process technology, but primarily through

experience and know-how in engineering. The

strict quality criteria of railway authorities play a

key role here and with respect to safety, inno-

vation, reliability, protability, aesthetics, comfort,

and environmental friendliness, RAIL.ONE is readyindeed for the rail market of the future.


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Railways


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Engineering

When the ground is broken for a

construction project, half the work

is already nished. The more pre-

dictive the planning, of course, theless problematic the actual execu-

tion. RAIL.ONE provides engineering

services to construction companies

as early as the bid-invitation and

tendering phase. A complete detail

design is the basis for all following

steps which enables precise calcu-

lation of costs. From rough to detail

planning, RAIL.ONE is actively inte-

grated into the design process. The

track system is modied if neces-

sary, collaboration between the part-

ner companies is coordinated, the

site is examined, materials tests are

conducted, and the logistics con-

cepts and installation processes are

tailored to the specic project.

Complex projects demand clarity in control. After all: rail transport

involves great responsibility. As system providers, we are

well accustomed to working systematically. Try us and see!

Your capable partner

>>

Production Supply Logistics

RAIL.ONE prots from more than 50

years of experience in the manufac-

ture of concrete sleepers. Supply of

complete track systems, however,demands far more: the entire pro-

cess chain starting with planning;

including production, delivery, and

logistics; and extending to quality

management must be holistically

understood and effectively support-

ed. For example, it can be advisable

from logistics or cost-effectiveness

standpoints to set up a sleeper pro-

duction plant near the track construc-

tion site or to award manufacturers

licenses to local partner companies.

RAIL.ONE remains responsible for

the coordination: because effective

supervision makes sure that every-

thing properly rolls.

>>

Quality Management

Safety of course enjoys absolute

top priority, especially where pas-

senger transport is involved. RAIL.

ONE provides the entire perfor-mance spectrum from supervi-

sion to quality management in

its work with owners and partners.

Comprehensive documentation

assures that the installed systems

satisfy the required quality crite-

ria in all stages of production and

installation. Although it is precise-

ly ballastless track systems that

are extensively maintenance -free,

RAIL.ONE together with customers

and partners develops concepts for

long-term quality assurance. In addi-

tion, a RAMS analysis was conduct-

ed in accordance with international

standards for the RHEDA 2000 bal-

lastless track with verication of

RAIL.ONE quality.


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Railways


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All systems at a glance

When requirements go beyond conventional ballasted systems, RAIL.ONE has the appropriate solution for all require-

ments of railway transportation. In addition to operating speed and axle load, many additional factors are essential

in selection of rail systems. Among these factors, long-term availability and maintenance costs play increasingly

signicant roles.

Systematically toward success

>>

Many roads lead to Rome

Every new project poses new challenges for engi-

neers and planners. With respect to long service

life, top speed, comfort, and load-carrying capa-

bility, ballastless track basically has a lot to speakfor it especially in the construction of new rail

lines. Where refurbishment of existing lines is

involved, however, a system that allows trafc

to continue, even during construction, offers key

benets. In many applications, conventional bal-

lasted tracks fully satisfy all requirements. Wide

sleepers on a ballast substructure can offer signif-

icant benets where availability counts. Life-cycle

costs have also become increasingly important in

planning a track route. It is essential to consid-

er whether a virtually maintenance-free track is

the most favourable long-term solution, or wheth-

er the choice should go to a system that can be

installed on a exible and cost-reducing basis,

without trafc interruption.

>>

The route follows the terrain, and not vice-versa

A track system by RAIL.ONE is always a tailored

solution, in which systems are adapted to special

requirements. Curves, bridges, ll sections, tun-

nels, and turnouts place the strictest of require-

ments on the route. Certain track sections such ascurves, bridges, embankments, tunnels, and turn-

outs place strict requirements on route design.

What physical forces and environmental inu-

ences can be expected? How will the soil react to

operational loads over the long run? And - what

logistics requirements must be considered during

construction? After all: optimization of the pro-

cess chain is our primary goal, and this includes

construction-site access, transport paths, and

material supply.

>>

From the environmental standpoint

As future-oriented means of transport, rail sys-

tems are eminently capable of fullling their

responsibilities to the environment. Where strict

limit values for airborne noise and vibration apply,especially in densely populated areas, innova-

tive mass-spring systems and noise-absorbing

products assure good neighbourliness. Increas-

ingly, aesthetic criteria are applied to track sys-

tems, particularly in urban environments. Para-

sitic current must be dissipated below stipulated

limits, and intelligent disposal of waste water

and other liquids must be guaranteed. RAIL.

ONE places high importance on these problems.

Careful selection of the system consequently

determines the service and maintenance expenses

of a track system: foresight in planning eventually

amounts to considerable money savings.

Which track system is the best for you? Sometimes, a simple application will

solve your problem faster but sometimes a sophisticated solution actually

represents the simplest alternative. Whatever, well help you nd the best way.

40 100 200 300

URBAN TRAFFIC

High-speed trafc

RAILWAYS

Commuter traffic

Underground

Trams/commuter

Speed in km/h

HEAVY FREIGHT TRAFFIC

250

200

150

100

A

xle

load

in

kN

500

Trunk lines

Standard ballasted track system

Special ballasted track system

RHEDA 2000 ballastless track system

GETRAC ballastless track system

RHEDA CITY ballastless track system

RHEDA MRT ballastless track system

The Green Tracks(ATD-G and RHEDA CITY GREEN)


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The B70 concrete sleeper: a clear-cut solution

Highly convenient and cost-effective production and installa-

tion possibilities, long service life, and no impregnating with

agents such as creosote: all this makes the concrete sleeper

an environmentally friendly and cost-effective solution over

the long run.

Turnout sleepers: sturdy and safe

With their great weight, concrete turnout sleepers

assure optimal position permanence and stability

even for turnouts that take trafc at high speed.

Railways

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n High performance capability, even under conditions of great operational loadsn Cost-effective optimization of the track system, together with full maintenance of long-term technical and

safety characteristics

n Guarantee of operational continuityn Standardization of operational and maintenance work sequencesn Possibility of fully mechanical installation of sleepers on the building siten Adaptation of track elasticity to special trafc conditions by the use of elastic intermediate layers

>>

Type B70 concrete sleepers are the simplest way

to a complete railway track. Their chief advantage

of course is their great exibility. These sleep-

ers are a fast and reliable solution for almost

any application: whether for a newly construct-ed route or for refurbishment of existing lines, for

railways or urban trafc, for trunk or secondary

lines, and for freight or passenger trafc. And their

simple installation ensures high availability levels.

The B70 concrete sleeper can also be produced

and delivered in great numbers within a short peri-

od of time. From four production plants, RAIL.ONE

annually delivers in Germany up to 1,500,000

concrete sleepers for main tracks: the majority

of them are the standard B70 sleepers. The inter-

national plants currently in Spain, Hungary, and

Romania produce approx. 1,000,000 sleepers

annually, primarily in the models favoured for use

in the respective countries.

Our classical track: simple and exible

Now as before, concrete sleepers on ballast represent the classical, fundamental

version of track systems: in Germany and around the world. The general opinion is

that these sleepers could not possibly be improved: but were working on it.

BALLASTED TRACK SYSTEMS

The B70 concrete sleeper

>>

For turnouts as well, concrete sleepers have

become widely and successfully accepted. Their

economic and technical advantages are the

results of longer life cycles, less maintenance, and

mechanized installation techniques. Production ofthese sleepers in different plants, with output of

up to 500,000 linear metres annually, takes place

in close technical and logistical coordination with

the manufacturers of the turnouts with which they

will be installed. Only in this way is it possible to

guarantee dependable support of track construc-

tion sites at the superior quality levels character-

istic of RAIL.ONE.


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Pressure compensation below the sleepers

The benets of wide sleepers are also quite evident at grade

crossings: all loads acting at the surface are transferred

uniformly into the ballast layer. The ballast, in turn, remains in

stable and unchanged position as a result of the use of wide

sleepers.

Sleepers with elastic footing top performance

on quiet feet

Use of an elastic footing can considerably upgrade a system

with concrete sleepers on ballast. Maintenance costs are

reduced, and track positioning is improved for the long term.

Railways


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n Simple installation with conventional track-construction technologyn Constant quality and stability, and avoidance of continuous displacements in the ballast structuren Up to 70% greater resistance to lateral displacement, in addition to less settlementn Signicantly increased track availabilityn Great safety factor from the large mass of the sleepers and from continuous bearing-surface supportn Simple vegetation control and minimal cleaning work, as a result of the closed surface of the track;

no need for herbicides

n Systematic drainage of surface water and other liquidsn Considerably reduced emission of vibrations into the soil foundation, owing to the greater mass of

the sleepers

>>

Wide sleepers are used in urban and commuter

trafc applications. The system is suitable for

all gauges, for tilting technology, and for either

freight or passenger trafc. As a result of its

appealing design and ease of maintenance for itssurface, it is also well suited for tracks in train sta-

tions. Wide sleepers enable considerable reduc-

tion of loads applied to the ballast: the larger sup-

port area ensures uniform distribution of applied

loads. The wide sleeper solution furthermore low-

ers vibration values, lengthens maintenance inter-

vals, and extends the service life of the track sys-

tem. Wide-sleeper track systems enhance riding

comfort, environmental compatibility, and the

cost effectiveness of railway operations.

Wider, faster: more sophisticated

Wide-sleeper track systems combine the benets of ballastless track with

conventional ballasted systems. As a result, this sleeper system satises the most

demanding of requirements and it manages to look good at the same time.

SPECIAL TRACK SYSTEMS ON BALLAST

Wide sleepers

>>

Provision of elastic footing for concrete sleep-

ers represents a further measure for upgrading

classical ballasted track systems. Emplacement

of the elastic footing into the fresh concrete cre-

ates a direct bond to the sleeper. This techniqueprotects the ballast and achieves enhanced track

elasticity. Concrete sleepers with elastic footing

are especially effective for installation on highly

stressed track sections or in vibration-sensitive

areas. Applications that have proven especially

effective include high-performance track systems,

rail facilities in urban areas, as well as vibration-

and settlement-sensitive transitions of rail lines

between embankments and tunnels or bridges.


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Greater convenience over the long run

Ballastless track systems require practically no main-

tenance. Once in place, they ensure system availability

of almost 100%. As the supporting layer, asphalt

offers the unique advantage that geometry can further

improve with time.

Optimal cost-benet ratio

In assessment of the service life of such track systems, it

has become increasingly plain that overall system costs

i.e., life-cycle costs have become a widely accepted and es-

sential criterion. In addition to the long-term savings that they

offer in maintenance costs, GETRAC systems are especially

cost-friendly as a result of the high productivity they enable

in track installation, and in the very short overall construction

times required for their emplacement.

Railways


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n Long-term stability of the required track geometry, through elastic bonding of the track panel to the asphaltn Short construction timen Capability of using conventional road and track-construction equipmentn High degree of mechanization and small number of work steps in track constructionn Pre-assembly of the anchor blocks and the rail-fastening elements in the production plantn Long life cycle with little maintenancen Possibility of track cant up to 180 mmn Great stabilityn Unrestrained drainage of water from the trackn Fast availability of the track after repairs

>>

The chief component of GETRAC track systems

consists of asphalt supporting layers on which

concrete sleepers directly rest. The sleepers are

elastically connected to the asphalt layer by spe-

cial concrete anchor blocks, which contribute tothe transfer of horizontal forces from the track

panel into the asphalt, and which provide long-

term stability for track geometry. A major advan-

tage of this product is its fast and simple instal-

lation techniques with conventional track-laying

technology, and with high daily track-laying out-

put. In recent years, the GETRAC A1 system var-

iation has become well known in our segment,

for its outstanding operational characteristics.

The GETRAC A3 ballastless track system is the

newest and highest-performance product in the

GETRAC line. The wide sleepers, an intrinsic part

of this system, enable signicant reduction in

track structural height.

Asphalt in top form

Asphalt track systems offer all the advantages of a ballastless system they are

fast and uncomplicated to install. A precondition, however, is highly developed

asphalt technology and we are quite proud of our engineering expertise here.

BALLASTLESS TRACK SYSTEMS: GETRAC

The GETRAC system

>>

In 2004, the German Federal Bureau of Railways

(EBA) provided ofcial approvals, without speed

limitation, for various track innovations in the

form of GETRAC model variations. This approv-

al accordingly signies clearance of GETRAC forhigh-speed track applications as well.


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The exible way for every application

The RHEDA 2000 ballastless track system is ideal for

application on embankments, on bridges, in tunnels, for

turnouts, as well as with vibration-attenuating mass-spring

systems. Installation of noise absorbers dampens wheel

and propulsion noise.

The modular principle

Uniform track concrete layers with low structural height

ensure simplied structural design and installation. The

lightweight mode of construction, with the possibility of

installation by pre-assembled track sections, enables

optimization of construction schedules. Fastening of the

track to the substructure, and track regulation, with a high

degree of mechanization: this saves time and money.

Railways


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>>

The monolithic, ballastless RHEDA 2000 system

represents the most advanced stage of develop-

ment in the RHEDA family. This system is espe-

cially used for railway tracks, on high-speed lines.

Chief characteristics of the supporting concreteslab include its lack of a trough, and its use of

a modied bi-block sleeper with a lattice truss.

The development of special turnout sleepers for

the RHEDA 2000 system means that track and

turnout are totally compatible: the low structur-

al height and the reduced weight enable signi-

cant time and cost benets in project engineer-

ing and installation. As a result of the monolithic

structure of the track concrete layer, and the low

overall structural height, this system is outstand-

ingly suited for applications for embankment sys-

tems, tunnels, and bridges also at speeds over

300 km/h.

High speed to perfection

Our contribution to ICE technology: the RHEDA 2000 system

is the direct way into the future. For top operational loads.

For extremely high speed. For safetys sake.

BALLASTLESS TRACK SYSTEMS: THE RHEDA 2000

n Capability of modication to suit all standards for international high-speed trafcn Perfect track positioningn Great precision of gauge and track geometry owing to the sleepers usedn No need to waste compensation tolerances in rail fastenings during the construction periodn No periodic occurrence of waves in the railsn No special tolerance requirements placed on individual componentsn No longitudinal joints in the track concrete layer, as a result of elimination of the troughn Good homogenous quality, owing to system design featuring modied bi-block sleepers, as well as

optimized reinforced-concrete characteristics

n Good concrete properties as a result of requirement-oriented concrete technologyn Favourable rescue and emergency access owing to the smooth track surfacen High daily track-laying capability

The RHEDA 2000 system

>>

Rail trafc causes vibrations. RHEDA2000 can

also be executed as a mass-spring system for

application in areas sensitive to noise and vibra-

tions. Elastic elements installed between the track

system and a tunnel absorb vibrations to such anextent that they are imperceptible to persons in

adjacent buildings. The mass-spring system can

be effectively adapted to the various local require-

ments.


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Industrial solutions

For industrial companies RAIL.ONE offers

optimal possibilities for the construction and

expansion of private track systems in any

required gauge. RAIL.ONE provides complete

designs and key components:

RAIL.ONE your one-stop provider

We offer a broad portfolio of products and services involving all aspects

of railways and infrastructure, tailored to individual requirements.

In addition to its broad spectrum of track

systems for railway transport, RAIL.ONE

also provides systems for urban trafc.

RHEDA systems are available, for exam-

ple, especially for application with trams,

underground trains, and surface commuter

trains.

Urban trafc

The product ATD-G Green Track is in-deed

quite special: similar to the GETRAC systems,

this system is based on an asphalt supporting

layer that supports concrete sleepers. Plant-

ing turf or sedum creates a very attractive opti-

cal impression.

Railways


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Plant construction

RAIL.ONE exports its experience, logistics,

and technology. Standardized models for sleep-

er construction plants can be quickly and sim-

ply built at any location that offers the required

infrastructure.

Such plants enable production of up to

600,000 concrete sleepers per year: in man-

ual, semi-automatic, or fully automatic modes

of production, and in accordance with the cus-

tomers requirements.

tarting from simple solutions such as modi-

cation of an urban trafc system, but also

ncluding ballastless track systems for extreme

xle loads, and extending to infrastructure

roducts for expansion of existing facilities.


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RAIL.ONE GmbH Pfleiderer track systems | Ingolstaedter Strasse 51 | D-92318 NeumarktTel +49 9181 28-136 | Fax +49 9181 [email protected] | www.railone.com

June2007/V8-werbeagentur.de/

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