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Johann Bgl
Stefan Bgl
Since two decades, Max Bgl is engaged in trendsetting development and construction of advanced, maintenance-free and durable, ballastless tracks made of prefabricated parts for slab track systems. Permanent developments and experiences gained from realized high-speed projects as well as suggestions and wishes of customers have led to an extension of our company know-how and to the completion of our systems. Proudly we can say that we are now in a position to offer a complete range of track solutions accounting for all issues and boundary conditions of modern railway construction. Meanwhile the FFB Slab Track System Bgl has established to become a worldwide known ballastless track system. The initial standard construction method on earth structures according to the Catalogue of Specifications for slab track systems (AKFF) as it was used at the new rail track between Nuremberg and Ingolstadt was further developed and new perceptions were consequently implemented. Furthermore, the close cooperation with universities and institutes as well as sole requirements of various new projects have induced modifications of our system.
Whether it is about the construction of a slab track system (FF) on indefinitely long bridges, as in China, or the installation of high-speed track switches on prefabricated supporting plates made of reinforced concrete, we have risen to the challenges and created solutions for our customers. Operators tend to use the slab track system not only for highspeed tracks. Also routes come into considerations which require a very high availability and which must therefore be as maintenance-free and position-stable as possible over the entire service life. Concepts and new solutions are already available for underground trains, reconstruction lines and routes for lorry traffic. We have also dealt with the topic of reducing sound and vibration, and we have implemented various mass-spring systems on several line sections. Economic aspects as well as the experiences gained from our slab track projects play a superior role in developing new systems. That is why we increasingly turn our attention to even more efficient production methods, mechanised and automated assembly flows and the use of more efficient materials. Homologation of our products in non-European
countries of application is more and more foregrounded. Within Europe, the interoperability of systems has to be proved. Operators, authorities, planners, manufacturers and construction companies worldwide will find in the Max Bgl Group a partner who is able to offer fully developed and economic solutions, who will competently advise, support and guide you in order to enable you to implement the slab track system in the required precision and quality. With the brochure on hand we would like to present to you our innovative prefabricated parts systems and give you an overview of our multi-faceted range of products and services.
Scope of services
Due to its versatility, the Max Bgl Group is able to execute turnkey projects from slab tracks of underground/suburban railways to reconstruction routes to high-speed lines. For the manufacture of the FFB slab track we offer the following services:
Planning
Max Bgl has developed planning software for the FF Bgl system which generates an installation plan from the trackgeometric project containing all relevant data. These are the basis for the entire logistics that is production, stocking, transport and installation as well as for quality assurance and inspection measurement. Adding to this, we also plan special solutions, such as transition areas or construction of prefabricated elements for various types of switches.
Freight traffic
Know-how
E xp e
r t k n ow l e d g e
Technology transfer
We have a team of skilled experts who will assist and advise you in the implementation of your projects by means of our technology. Within the task of a technology transfer we supply for our FFB product a complete compendium with work and test instructions for the manufacture of track slabs and their assembly. In especially adjusted training courses, our customers get all information which they need for the planning, execution and quality control of the FFB. Our practice-oriented experts are glad to accompany and advise you during the execution. In addition we also offer the technical overall responsibility for our system and quality monitoring
Quality management
Our complete quality management system sets standards for the entire process flow. Defined work steps and tests which are adjusted to the national circumstances ensure constant and high quality. Due to our support in selecting national building materials we contribute to unerringly achieve the required quality of the final product.
The high degree of prefabrication of the slab enables short installation times.
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(1) Frost protection layer (FSS) (2) Hydraulically bounded layer (HGT), d = 30 cm (3) Grouting mass (4) Slab Track (5) Design cracking joint (6) Rail support point (7) Opening for grouting mass (8) GEWI steel (9) Prestressed steel Pictured on page 7: (10) Turnbuckles and nuts (11) Construction joints
3 2 1
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Technical data of the FF Bgl System: Construction height (from OK HGT to OK rails): Slab length (System length: nominal 6.5 m): Slab width: Slab height: Rail supports: Prestressing: Longitudinal coupling: 474 mm 6,45 m 2,55 m 0,20 m 10 pairs per slab; spacing 650 mm transversal GEWI steel
The rail support points can be mechanically processed via a computer-controlled grinding machine. This allows an extremely high accuracy of the track bed. The slab production is finished with the assembly of the rail fastenings. All rail A characteristic feature of the fastenings systems which are prefabricated slabs are the predetermined breaking points approved and suitable for that are arranged between the ballastless tracks can be used according to the track requirerail support points. This will ments. prevent an uncontrolled crack development. The slabs are adjusted only on defined measur ing points In order to drain the surface on the rail supporting points water, every slab is manufacwithout the use of a mounting tured with a transverse slope rail. Therefore the main disadof 0.5 % by default. transverse displacement. The longitudinal coupling counteracts the so-called whipping effect, which is a warping of the slab ends due to thermal differences.
vantage due to deformation of a mounting rail as a result of temperature changes during fine adjustment of the slab tracks is solved. Complicated measuring work as well as correction of the track geometry after installation of the rails are unnecessary.
System cross-sections
Typical cross-section for FF Bgl on an earth structure
Line axis
Slab track h = 20 cm Grouting mass h = 3 cm Hydraulically bounded layer or asphalt base course with h = 30 cm Frost protection layer Ev2 120 N/mm2
Edge covering Transverse drainage DN 150 Discharge to the top of the embankment or to deeper drainage
Track axis
Passable slabs for the Bgl system FF Bgl slab track Grouting mass 0.00
2.55
2.55
2.95 Slab track Grouting mass Support panel/Profile concrete Sheeting + fleece 0.00
2.95 Slab track Grouting mass Support panel Sheeting + fleece Styrodur 0.00
Ballast transition area h = 30 cm with full bonding approx. 15 m Base ballast (BB), edge beam (EB), sleeper space (SS) FF Bgl Rails UIC 60
Ballasted track
Slab track h = 20 cm Grouting mass h = 3 cm Hydraulically bounded layer h = 30 cm Frost protection layer
FSS
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and is reinforced. Reinforcement stirrups at the bottom side of the precast slabs for switches & turnouts, which are anchored with the undercast concrete, ensure that their position is secured. Assembly of the precast slabs for switches & turnouts takes place without turnout rails and accessory. Exact fit of the rail fastenings requires no adjustment later on. The complete switch, including all accessory parts, is only mounted after
the precast slabs for switches & turnouts have been undercast. That way, no switch components are soiled or damaged. In contrast to conventional assembly, considerably smaller components can be delivered, reducing costs for transport and assembly cranes. Construction times are considerably shortened. Approval of field testing by Germanys Federal Railway Office (EBA) was the condition for the implementation
within the first FFB high-speed line in China. In 2007, two switches were manufactured as cross-over in the new line between Beijing-Tianjin. In follow-up projects, some further 100 high-speed switches were installed in the new lines WuhanGuangzhou and Beijing-Shanghai. After numerous successful operations in China, this technology will no also be implemented for the German Railway in two overtaking stations of the new line EbensfeldErfurt.
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b d
1 Derailment protection
2 Continuous support
Light mass-spring system In case of low demands on the vibration protection, the FFB system is decoupled via a spa tial support from the constructional environment. The mass Mass-spring system Vibrations generated by wheel- is only generated by the self weight. Flexible mats are glued rail contact can be reduced by means of so-called mass-spring- underneath the slabs. Using variable slab thicknesses and systems in a targeted way. defined spring coefficients of Depending on the relevant the mats, the system can be addegree of efficiency, it is disjusted to the relevant situation. tinguished between light and heavy mass-spring systems.
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Production
Production process
Cleaning and preparing the formwork Installation of the reinforce ment and dowels for the rail fasteners Prestressing Concreting and after treating Cutting through the prestressing wires
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L ifting and storage of the slabs M echanical processing of the rail support points A ssembly of the rail fastenings
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Installation
Installation process
I nstallation of the hydraulically bound base layer (HGT) or reinforced concrete base layer (BTS) A nticipatory pegging out of the track axles and slab joints Transport of the slabs to the building site Depositing and aligning the prefabricated slabs Adjusting and fixing Sealing the longitudinal and transverse joints Underpouring the slab Coupling in longitudinal direction Filling the transverse joints A ssembly of the rails
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New building of the 32 km long high-speed route between Erfurt and Ebensfeld: FF Bgl slab track ensures precise track geometry and best traveling comfort at speeds of 300 km/h.
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Following delivery by rail, the mass-spring plates weighing up to 12.5 t each were lifted and then lowered down the 20-metre deep subsoil using portal cranes.
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In order to meet the safety concept, the newly developed surface cover allows for drivability of the track area for rescue purposes using road vehicles.
Katzenbergtunnel
The roughly 9.4 km long Katzenbergtunnel, Germanys third longest tunnel, with its two one-track tubes is the heart of the extended and new line between Karlsruhe and Basel. In order to achieve highspeeds of up to 250 km/h in the tunnel with high traveling comfort, the FF Bgl slab track was used in both tunnel tubes. As a protection against vibrations and secondary sound, a 500 m long section of the FF Bgl slab track was built as mass-spring system. A considerable novelty for the superstructure in one-track tunnel tubes is the required drivability of the track area by rescue vehicles. The safety concept provides for the installation of special superstructure elements made of prefabricated concrete components in the areas next to the rails and an addition made of in-situ concrete between the rails.
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After installation of the FF Bgl slab track system, the train speed on the new steel frame bridge between Kehl and Strasbourg could be increase from 100 km/h to 160 km/h.
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Beijing Tianjin
Shanghai
1,318 km high-speed experience on the worlds longest high-speed line between Beijing and Shanghai.
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Under normal service conditions, travelling up to 350 km/h: from Beijing to Tianjin in half an hour.
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Thanks to the FF Bgl slab track system, the new ICE line from Nuremberg to Ingolstadt has the highest travelling comfort of all German railway lines, as proved by measurements of the track geometry.
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World record on FF Bgl between Nuremberg and Ingolstadt: In a speed of 357 km/h, the Taurus III locomotive set a new speed record for electric locomotives on a non-prepared track.
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Summary
Service and maintenance-free The FFB Slab Track Bgl which track system is based on prefabricated slabs, High resistance to transverse is the worldwide leading system and longitudinal displacefor high-speed tracks which in ment terms of reliability, availability, Constantly high quality and maintainability, and safety ofaccuracy of manufacture fers a number of advantages: Durable and precise track bed without readjusting High driving comfort Low wear and tear on the rolling stock and the rails Correction options in case of settlements Quick re-commissioning after correction/repair measures Every type of approved rail fastener can be used
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Max Bgl
Founded by Max Bgl in 1929, the Max Bgl Group, headquartered in Neumarkt, Germany, can look back on a successful company history of more than 80 years. With annual sales of Euro 1.6 billion and about 6,000 qualified employees, Max Bgl not only ranks among the top 5 of the biggest German building companies. Today, continued by the third generation, the Max Bgl Group is also Germanys biggest privately-owned construction company. Due to innovations in technology and organisation, Max Bgl has developed in the course of the decades from a provider of mere building services to an internationally operating technology and service company. Today, its activities, certified in accordance with DIN EN ISO 9001:2008 and SCC, range across all areas and levels of difficulty from building construction to traffic projects, civil engineering and tunnel construction to steel engineering and construction, the prefabricated part manufacturing as well as supply and disposal. In future, the technical know-how will be increasingly used for making renewable energies also more efficient and interesting. A first successful step has been taken with hybrid wind turbine plants, the Hybridturm System Max Bgl. Without losing sight of its core competence traditional building activities the Max Bgl Group as a trustworthy, highcapacity partner realises customised individual services as reliably as complex one-stop total solutions from planning and financing to execution and operation. More than 35 locations, production facilities and representations around the globe among others, in the United Arab Emirates and the Peoples Republic of China develop new markets for innovative trendsetting products, substantiating our international orientation. The know-how gained in many years, combined with the competence and innovation of the Max Bgl Group is reflected in a multitude of representative building projects. So the Max Bgl Group confirmed its achievement potential in the building of sport arenas in the course of the 2006 World Cup in Germany. The design & build competence is continued in the construction of a number of stadiums and multi-functional halls in Poland and Romania. As a specialist in modern civil engineering and tunnel construction, Max Bgls technical and logistical solutions have been successfully tried and tested in many European countries. The Groups leading position in steel construction is impressively reflected in bridges of all size. And as one of the leading manufacturers of pre-cast components, Max Bgl produces pre-cast concrete components of the utmost quality and precision in its own six plants and in a mobile production plant. Its own innovations like the development of the Slab Track Bgl or the guideway girder for maglev systems, successfully used in the German and Chinese high-speed network, benefit from decades of experience in construction and production of precision pre-cast concrete components. Modern light-rail systems, but also precast slabs for switches & turnouts and concrete sleepers round off our driveway technology portfolio.
Postal address: P. O. Box 11 20 D-92301 Neumarkt, Germany Phone +49 9181 909-0 Fax +49 9181 905061 info@max-boegl.com www.max-boegl.com