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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

mail@edilonsedra.com

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: