One system crossing the boundaries

ERS - Embedded Rail System for optimum integration into tunnel, station and

bridge structures

How can you improve safety and accessibility in tunnels and stations? How can you accurately

integrate a rail track in a bridge design and save on installation time? These are only some of the

questions that are central in the design process of railway tracks, whether they are designed for

tunnels, stations or bridges. The answers can be found in the solutions for which edilon)(sedra

received its recognition : technology for embedded rail fastening systems.

edilon)(sedra is an international manufacturer and supplier of rail fastening systems. The company

cooperates in turnkey rail infra projects throughout Europe, Asia, Australia, North America and the

Middle East. An important activity of the company is to provide technical rail track solutions for

tunnels, stations and bridges. The basis of these solutions is the edilon)(sedra ERS (Embedded Rail

System). This robust and proven ballast free system has flexible application options for both heavy

and light rail.

Embedded Rail System (ERS)

ERS has radically changed the concept of how rails can be supported. The use of a homogeneous

continual elastic support along the full length of the rail provides the required support, resilience and

electrical isolation. Moreover it eliminates the logistical problems and costs associated with ballast,

sleepers, base plates, fasteners and their subsequent inspection and maintenance. The system can

be installed quickly and is adaptable to all rail profiles.

The main product in the ERS rail fastening system results from enclosing and bonding the rails with

the 2 component edilon)(sedra Corkelast® in a concrete or steel channel. This unique, long-life

material ensures that the rails have homogeneous support throughout, with specifically determined

elasticity, in accordance with specified conditions. Corkelast® is a polymer embedding compound

with a defined stiffness through the unique mixture of filling material that depend on the product

type. Resilient ERS Strip controls the rail deflection for ERS rail fastening systems, under the

prevailing loads.

These and many more features make edilon)(sedra ERS perfectly applicable for heavy and light rail

tracks in tunnels, stations and on bridges.

edilon)(sedra ERS (vignol rail)

Optimal longitudinal performance

ERS is fully compliant to EN 13481-5:2012 on longitudinal performance. Requirements on

longitudinal rail restraint are important criteria for safety in case of braking and acceleration of

trains. The longitudinal rail restraint is much higher for edilon)(sedra ERS than for most other

mechanical rail fasting systems. The longitudinal rail restraint of ERS is tested indirectly, namely by

means of the longitudinal stiffness test. For 7 mm longitudinal rail displacement, the required force is

usually 50kN per 0.6m ERS, which is 7 times more than the longitudinal rail restraint of most other

mechanical rail fastenings.

ERS for tunnels

Tunnel projects (new tunnels or refurbishment of old ballast tunnels) are often complex, time

consuming and costly because of the issues concerning the limited height of the tunnel, strict safety

requirements, water drainage, the need to combine train/tram/metro traffic with car traffic and the

need to save installation and future maintenance costs.

edilon)(sedra ERS provides a solution for each of these issues. The system offers optimum reduction

of tunnel construction height and therefore is an ideal solution for tunnel projects that have to deal

with strict installation requirements. Besides being robust and durable, the system creates optimal

accessibility for emergency vehicles. A very important consideration for contractors or tunnel

operators which have to deal with strict safety requirements!

edilon)(sedra ERS can operate in extreme climatological circumstances, from the very hot to the very

cold or wet situations. ERS can be installed to accommodate all kinds of gauges and rail profiles: both

standard and non-standard gauges but also for example a tunnel gauge of 1000 mm.

Eurotunnel from Franceto England. Eurotunnel Plc chose edilon)(sedra ERS for a diamond crossing

refurbishment because of the low maintenance aspect and highest degree of serviceability and

longevity .

Technical features of edilon)(sedra ERS for tunnels

Mixed crossing traffic solution (trains/trams and heavy trucks, busses, cars, rescue and

service vehicles)

Savings in construction height & weight*(see below)

Optimum electrical insulation

Optional prefabricated solution for short installation time

Multiple water drainage construction

Highly durable

Easy to clean

French Tunnel de Montets: unique mixed traffic solution

Railway tunnel ‘Tunnel de Montets’ located in the European mountain area The Alps celebrates its

first year of exploitation. In July 2014 the tunnel opened its doors after completing a full

refurbishment with edilon)(sedra ERS Embedded Rail System. Four seasons, including extreme cold

and a winter with heavy snow falls, later, the experiences and reactions in the local media are

overwhelmingly positive.

Located in a mountain valley, the Tunnel des Montets has a double feature, unique in France and

elsewhere: The tunnel has been converted to a dual purpose railway tunnel which can also be used

by cars and trucks when the mountain pass ‘Col des Montets’ is closed to traffic due to winter

weather conditions.

The refurbishment with edilon)(sedra ERS Embedded Rail System was an important part of the

modernization of the Tunnel de Montets (line St. Gervais – Chamonix). The installed Embedded Rail

System not only improved the accessibility, safety and environment, it also offers (local) economic

advantages because of the efficient use of the tunnel.

Dual purpose railway Tunnel de Montets which can also be used by cars and trucks

ERS for stations

Expansion and modernisation of railway stations influence the development of rail tracks.

edilon)(sedra can build on more than 40 years of experience in developing state-of-the-art rail tracks

or tram, train, metro and high speed train stations.

ERS provides optimal contribution to vibration attenuation in station buildings. An important aspect

in cases of iconic buildings and residential areas. Due to the Corkelast® material, the system has a

high performance in electrical insulation. Furthermore the flat surface of the ERS track allows easy &

effective station cleaning, and very important: easy access for rescue services from the platforms to

the station tracks. Visual inspection of tracks searching for unauthorized items is facilitated! The

modern design of the system contributes to a perfect aesthetic integration into the station building

and railway platform. A very important aspect for architects!

Easy access for emergency road vehicles

Technical features of edilon)(sedra ERS for stations

Free accessible escape routes for passengers

Accessible for rescue and service vehicles

Reduction of station construction height

Optimal electrical insulation

Short track possession times during installation

Prefabricated solutions for a short installation time

Prefabricated ERS slab track solution (logistics)

Renovation of tracks in Atocha HSL station,Madrid after more than 20 years in service

edilon)(sedra recently renovated part of the rail track in Platform 5 of railway station Madrid-Puerta

de Atocha in Spain. Since the construction in 1992 the ERS-track (Embedded Rail System) did not

require any maintenance. The rails at the tight curved approach and straight platform tracks needed

to be renewed. The 1st phase of renovating 15 tracks started in June 2015 at Platform 5. The total

track renovation was completed in a short Sunday shift, without any nuisance for the public or

timetable.

Maintenance free system

The old station ‘Estación de Atocha’ (now called ‘Estación de Madrid-Puerta de Atocha’) is one of the

most beautiful architectural complexes in Spain. The first high-speed line in Spain was built in 1992

by edilon)(sedra and connected the cities of Seville and Madrid.

Only after more than 20 years in service, ADIF had to renew rails, which proves the extended lifetime

which ERS is offering to rails and its maintenance-free feature. For more information please

download the case Renovation Platform 5 Estación de Madrid-Puerta de Atocha.

‘Estación de Madrid-Puerta de Atocha’

ERS for bridges

An important activity for edilon)(sedra is to provide technical railway solutions for bridges based on

ERS. Integrating durable and safe rail tracks in all kinds of new, old or monumental bridges is a

challenging task. That is why edilon)(sedra created a state-of-the art rail track solution for bridges

based on ERS (Embedded Rail System), with an integrated guard rail structure.

ERS designs for bridges with integrated guard rail:

Steel channels on a steel bridge

Steel channels on a concrete bridge (deck)

Steel channels integrated in a steel bridge (deck), including Silent Bridge (full integration)

Concrete channels integrated in a concrete bridge (deck)

Some of the unique technical features of edilon)(sedra ERS bridge application, starts with the

capable and accomplished accurate integration in bridge designs, the free accessible escape routes

and short track possession times. Moreover this system has an aesthetic design without interfering

beams - an important feature in case of monumental bridges.

Silent Bridge system

In the past decades edilon)(sedra successfully completed several large rail bridge projects. Such as

the Moerdijk bridge in The Netherlands. For this bridge edilon)(sedra successfully installed 1,026

meter of double track based on ERS for steel bridges. This ‘Silent Bridge system’ has a quick

installation time and an integrated guard rail structure to minimize the risk of derailment.

Furthermore the construction will result in low maintenance costs for the duration of its long

lifecycle.

edilon)(sedra ERS Silent Bridge system with integrated guard rail, Moerdijk bridge, The Netherlands

Technical features of edilon)(sedra ERS for bridges with integrated guard rail:

Bridge deck curvatures can be easily followed

Short track possession times: fast & accurate installation

Reduction of noise & vibration

Electrical isolation against stray current

Full corrosion protection

Virtually maintenance free also with regard to corrugation failures

Rail tracks accessible by emergency vehicles

Due to the track construction and the integrated guard rail structure – there are no

additional costs for steel fixing support, steel guard rail with traverse beams

One system crossing the boundaries

The comprehensive application possibilities of edilon)(sedra ERS makes it a very flexible and durable

rail system. Whether a light or heavy rail system is required, or whether the system is to be installed

in densely populated urban areas or even in unfavourable rural areas, ERS offers the best system for

different worlds.

About edilon)(sedra

edilon)(sedra is an international manufacturer and supplier of track systems, insulating rail systems and noise and vibration reduction systems for: )( heavy rail )( high speed rail )( metro )( tram )( light rail )( crane applications edilon)(sedra believes that project support for the installation of our systems is a journey best travelled in close partnership with our customers. That’s why the company supplies a complete package of services including but not limited to: system designs, application development, construction support, maintenance advice, consultation and supervision. edilon)(sedra rail solutions stand for low construction height and weight, maximum electrical insulation, short installation times and a minimum of maintenance required. It is foreseeable that during the next decades, not only rail transport standards will increase, but also the requirements for sustainable rail track systems. In order to help fulfilling the needs for tomorrow, edilon)(sedra is working responsibly today. The company is contributing to a more sustainable rail infra future, by using both recycled and recyclable materials, investing in green technologies and by collaborating with customers on global rail infra challenges. The ballastless rail track systems of edilon)(sedra have been a well-known standard in the international rail market since the early 1970’s. The patented systems are fully compatible with leading quality and safety requirements. Over many years edilon)(sedra has researched and tested rail track systems, in own laboratories and other independent facilities. edilon)(sedra entities are ISO 9001:2008 certified.