Gunther koller


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Gunther koller

  1. 1. FFU synthetic sleeper
  2. 2. SEKISUI Chemical Co., Ltd. Since more than 60 years leading manufacturer of synthetic products Worldwide more than 200 subsidiaries Approx. 20.000 employees Annual Turnover SEKISUI Chemical Co. Ltd. [billions €] 7.628 8.041 8.603 2010 2011 2012
  3. 3. Business Units High Performance Plastics Housing Urban Infrastructure and Environmental
  4. 4. Continuous glass-fibre and Polyurethane durability of plastics light weight and workability like wood Pultrusion process FFU sleepers are manufactured by Pultrusion. Glass fibers are soaked in polyurethane and the linkage is then hardened at a raised temperature. Fibre reinforced Foamed Urethane Form Polyurethane Heat FFU – sleeper Compression Continuous glass-fibre
  5. 5. Best Places at the Track Bridges Steel and Ballast Switches Slim tie
  6. 6. Best Track type Direct Fixation Slab track Ballast track
  7. 7. 1980 Railway Technical Research Institute (RTRI) adopted FFU after laboratorial approval in Japan and started the following field tests: Miomotegawa Bridge of Uetsu Line Kanmon Tunnel of Sanyo Line 1985 very good results of field tests FFU sleeper became a approved standard product of JNR 1991 RTRI reported the results of 10 years field tests, which showed almost no deterioration. Application of FFU by private and municipal railways. 1996 RTRI reported the results of 15 years field tests, which indicated that the strength deterioration of 15 year old wooden sleepers will be equal to the strength deterioration of 50 year old FFU sleepers. 2007 Japanese Industrial Standard JIS 1203 2011 RTRI tested FFU sleeper installed in 1980 positive – announced further use for the next 20 years positive to JR Historical development
  8. 8. Historical development 2004 Austria: First FFU Railway project in Europe, Metro bridge in Vienna 2005 Austria: ÖBB and Wiener Linien installed FFU on further projects 2008 Germany: 16 cm FFU sleeper positive tested by TU Munich First switch on FFU in Germany – Chempark Leverkusen Austria: LCC Analysis of TU Graz for ÖBB - FFU sleepers on open steel bridges, FFU is more economical than wood if bridge life time is longer than 15 years 2009 Germany: Approval of FFU by EBA for German Railway Infrastructure 2010 Germany: Installation of FFU switch in Germany by Hamburger Hochbahn and MVV Austria: Installation of FFU double slip on Vienna main station by ÖBB 2011 Germany: Deutsche Bahn – first Bridge with FFU sleepers on open steel bridge and low height sleepers (12 cm) in ballasted track 2012 Germany: Deutsche Bahn – two switches 70,000 t/day & sleepers & bridges Netherland: Pro Rail installed 3 bridges 2013 Austria: Wiener Linien installed 78 switches with FFU Germany: 12 cm slim tie positive tested by TU Munich for 22,5 t axel load and 200 km/h 2014 Switzerland: approval for FFU sleepers starting by 12 cm height and for tunnels where wooden sleepers are used given by BAV RHB will install first bridge plus slim ties 12 cm BLS will install 2 switches and 1 bridge England: Network Rail will install longitudinal (40/40cm) and regular bridge sleepers World: ISO Standard 12856-1 for synthetic sleepers enters into force
  9. 9. Worldwide approximately 90.000 FFU Synthetic Sleepers are installed annually Accumulated installation amount until 2013 has become more than 2,1 million sleepers 1.300 km of track Historical development
  10. 10. Technical properties property unit beech FFU synthetic wood standard new old 10 years 15 years density [kg/m3] 750 740 740 740 JIS Z 2101 flexural strength [kN/cm2] 8 14,2 12,5 13,1 JIS Z 2101 elastic modulus [kN/cm2] 710 810 800 816 JIS Z 2101 Compressive strength [kN/cm2] 4,0 5,8 6,6 6,3 JIS Z 2101 Shear strength [kN/cm2] 1,2 1,0 0,95 0,96 JIS Z 2101 hardness [kN/cm2] 1,7 2,8 2,5 2,7 JIS Z 2101 Impact flexural strength + 20°C [J/cm2] 20 41 - - JIS Z 2101 - 20°C [J/cm2] 8 41 - - JIS Z 2101 Water absorption [mg/cm2] 137 3,3 - - JIS Z 2101 Insulation resistance dry [Ω] 6,6x107 1,6x1013 2,1x1012 3,6x1012 JIS K 6852 wet [Ω] 5,9x104 1,4x108 5,9x1010 1,9x109 JIS K 6852 Pull-out force dog nail [kN] 25 28 28 23 RTRI Pull-out force screw [kN] 43 65 - - RTRI
  11. 11. EBA (German Railway Authority), following research was conducted: • Sleeper behavior under the impact of vertical and horizontal loads during the effect of repeated loading. Bedding in ballast track according DIN-EN 13481-3 (wooden sleeper) • Tightening torque tests: determine tensile strength of sleeper screws depending on torque moment. • Sleeper screw extraction tests in accordance with DIN EN 13481-2. (concrete sleeper) • Impact tests to simulate derailment in accordance with German railways technical terms of delivery • Electrical resistance in accordance with DIN EN 13146-5 • Static and dynamic tests of sleepers according to DIN EN 13230-2.(concrete sleeper) Effect of repeated loading test TU Munich September 2008 Elastic Rail Head Deflection Constant Rail Head Deflection right support left support right support left support 2.12 mm 1.71 mm 0.42 mm 0.29 mm After 3 million load cycles
  12. 12. Extraction Testing Average extraction force in FFU is 61 kN. Previous extraction tests on sleeper screws on wooden sleepers showed extraction forces of approx. 35 kN. [see Research Report no. 1687, dated June 30.,1997]. Impact Tests A tup (5 kN) with a wheel-flange shaped blade is dropped twice per test from a height of 75 cm onto the impact area. The sleeper is positioned at a slope of 30°. During testing, the sleeper is placed on a 6mm pad. Electrical Resistance Test 1 Test 2 Test 3 Date 10.07.2008 11.07.2008 12.07.2008 Ry [kΩ] 38.9 63.8 57.7 Y [mS/m] 44.4 45.3 44.6 Ky 1.332 1.359 1.338 R33 [kΩ] 51.8 86.7 77.2 Mean value R33 [kΩ] 71,9 Hence, it can be assumed that the required minimum resistance value of R33 ≥ 5 kΩ in accordance with DIN EN 13481-5 was achieved with great certainty. TU Munich September 2008
  13. 13. Static Tests at Sleeper Centre Bearing distance was 1.5 m, load plate width was 100 mm. The initial test force was set at 20 kN. Subsequently, the load was gradually increased by 5 kN, while sleeper deflection was registered by four dial indicator gauges. Up to a load of 240 kN, corresponding to a tensile bending strength of 74 N/mm² on the bottom of the sleeper, no crack was detected within the bending area where flexural tension was applied. TU Munich September 2008
  14. 14. Static Pressure Test Up to a load of 150 kN no plastic deformation was detected Thus, a load of 300 kN (supporting force) below the rib plate shows a plastic deformation of a maximum of 0.8 mm. Generally the support force for an axle load of 250 kN is 150 kN under the most severe conditions. Static Bending at T = RT and T = - 10°C FFU sleepers were stored in a climate-controlled environment at T=-20°C for two days. The average testing temperature is T = - 10°C . The sleeper shows no signs of embrittlement at low temperatures. A comparison of deformation results does not show any significant differences. Test of temperature dependency of sleeper deformation behavior showed no significant bending differences at T=RT and T=10°C. At T= -10°C there is no noticeable brittleness due to temperature variation. Deformation is predominately purely elastic. TU Munich September 2008
  15. 15. Fatigue test on rail seat height 120 mm A load of 150 kN was selected for the fatigue test. This corresponds to an axle load of 250 kN and a train speed V < 200 km/h. A static load of 1.2 x 150 kN = 180 kN was applied before the fatigue test. After the fatigue test the static load was increased to 2 x 150 kN = 300 kN. No damage to the sleeper could be established during the fatigue test. The ribbed plate was subsequently removed. Plastic deformations of approximately 0.85 mm. Extraction tests on FFU height 120 mm The tests were conducted in line with EN 13481-2 attachment A on 12 sleeper screws Ss 8-140 and synthetic wood sleepers with a height of 120 mm. TU Munich September 2013 Sleeper screw Ss-8 – diameter 24 mm Hole diameter / drill tool Mean value [kN] 19 mm / steel drill 56.8 20 mm / steel drill 52.7 20 mm / wood drill 49.6 Slim tie with a height of 100 and 120 mm
  16. 16. Static tests in centre of sleeper (sleeper heights 100 mm and 120 mm) The support spacing was 1.5 m and load plate width was 100 mm. The initial test load was set to 10 kN. Subsequently the load was increased in increments of 10 kN, with sleeper bending registered on four dial gauges. Diagram below shows the values of sleeper bending up to a load of 70 kN, corresponding to a torque of 24.5 kNm TU Munich September 2013 Slim tie with a height of 100 and 120 mm
  17. 17. Manufacturing of FFU
  18. 18. Customized production
  19. 19. Customized production
  20. 20. Easy repair For example: Fastening position may be readjusted by filling nail holes Many possible solutions with FFU ①Removal of rail ②Filling of nail holes with the special filling resin or the plugs ③Tying of rail
  21. 21. Projects in Japan since 1985 Bridges – open steel constructions – concrete
  22. 22. Projects in Japan since 1985 Switches – ballasted track - slab track
  23. 23. Projects international since Japan, Taiwan, China - switches – ballasted track - slab track
  24. 24. Bridge, Switches, 38 t Axel load Projects in Australia since
  25. 25. Bridge – 38 t Axel load - 40 million tonnes the year Projects in USA since 2011
  26. 26. Projects in Austria since 2004 bridges
  27. 27. Projects in Austria since 2004 switches, ballast, slab, direct fixation
  28. 28. Projects in Austria since 2004 bridges, switch
  29. 29. Projects in Germany since ballast, bridge, switches, slim tie
  30. 30. bridges Projects in Germany since
  31. 31. Switche, slim tie, ballast Projects in Germany since
  32. 32. Projects in Netherland since 2012 bridge
  33. 33. Projects in Switzerland since 2014 switch
  34. 34. Handling at the project Drilling, sawing, chiseling
  35. 35. Contact FFU - Ballast
  36. 36. Recycling 100% K-FFU
  37. 37. Experienced Advantages Customized sleepers mm exactly optimizing of design & profile Form retentive always good bearing on construction Easy & fast installation minimizes: installation costs / track closing time Easy care/repair minimizes: installation time/sleeper amount Chemical/oil resistance application in special areas Ecological 100% recyclable Maintenance very little; minimizes maintenance costs/time High availability of track maximizing possible trains on the track Workability/weight like wood, 740 kg/m3 Long life time reduces total cost of track and saves money for further project investments
  38. 38. SEKISUI CHEMICAL GMBH Cantadorstr.3 40211 Düsseldorf Germany TEL: +49-(0)211-36977-0 FAX: +49-(0)211-36977-31 E-Mail: