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Under Ballast Mats

1 Functional Principle .

cellular polyurethane materials. 3 . — Resilient layer The resilient layer consists of micro- — Reduction of the emission of second.Under ballast mats made of the Getzner materials Sylomer® and Sylodyn® limit the static and dynamic forces exerted on the ballast bed by railway operations. Depending — Increased track geometry stability on the mat type. each decrease the maintenance costs for with a density specifically selected heavily laden track sections. over the full area and transmitted to ums. hospitals. structures. meaning that no profiles or cavities are required for shaping. muse. vibration-sensitive laboratory. The ary air-borne sound on bridge materials are volume-compressible. testing or measurement equipment. This layer vicinity of buildings. The most important applications Getzner under ballast mats have are: a multi-layer structure: — Isolation of structure-borne noise on — Load distribution layer railway lines in densely populated The top layer of the mats consists regions: local transport railways and of a geotextile or fleece with high standard-gauge railways in the stretch and tear resistance. introduced to the mat are distributed ments such as concert halls. the resilient layer is and reduction of ballast compression comprised of one or two layers. deforms under the load of the ballast. Forces elevated vibration protection require. The ballast rocks are embedded and — Protection of structures and build. historic structures or the underlying resilient layers. to yield the desired overall static and dynamic stiffness. their positions are stabilized by the ings sensitive to vibrations or with increased contact surface.

the actual results. In close cooperation with customers and various research and testing agen- cies. product managers and physicists at Getzner are constantly focused on the rising expectations of the market and of customers. specific calculation models for deter- mining rail deflection. Getzner continuously modifies and tests its product selection. Getzner’s predictions correspond to able vibration reduction. individual on-site construction support or installation instructions for the mats. 4 . Additional examples of the comprehen- sive service offered by Getzner include the creation of CAD installation plans. The engineers. As part of Getzner’s service to its customers. The state-of- the-art testing laboratory helps make this possible. 2 Engineering Service Getzner has developed a specialized ultiple series of tests by various computational model for the installa- tion of under ballast mats that allows M railway operators under a variety of test conditions have shown that for reliable prediction of the achiev. experts generate separate predictions for each application and mat type. Under ballast mats made of Sylomer® and Sylodyn® have proven their quality on operational track sections many times over the past few decades.

Civil Engineer for Technical Physics. Chiari & Partner Ziviltechniker GmbH. Vienna Research and test reports are available upon request.Tests and measurements are available from the following institutes (excerpt): — Chair and Testing Institute for Construction of Transport Routes at the Munich University of Technology — TÜV Rhineland. Testing Institute — Arsenal Research. Vienna — Müller BBM GmbH. Cologne. Bergamo. Berlin University of Technology — Prof. Peter Steinhauser. 5 . Vienna — Ruthishauser Engineering Office for Construction. Italy — Institute for Road and Rail Transportation. Transportation and the Environment. Dübendorf — Fritsch. Federal Materials Testing and Research Institute. Zurich — EMPA. Planegg near Munich — ISMES Spa. Central Department of Vibration Technology and Vibration Protection — Deutsche Bahn.

Getzner determines the actual deflec- tion in the individual case by calculat- ing the bending line of the rails.02 Sylodyn® DN 335 under ballast mat 0 0 1 2 3 4 5 6 7 8 9 10 11 12 Deflection [mm] 6 . it of the substructure are observed.5 mm for high-speed traffic. maximum speed). reduced structure-borne sound level. frequency and amplitude) determining the rail deflection during effectiveness is not determined solely — Vibration resistance (impedance) train passes. The effectiveness of a under ballast The following parameters are pends on the application. If the recommendations by the under ballast mat. the super. 0.15 0. the rail deflection is results from the characteristics of the generally less than 3 mm and less than entire system – from the vehicle to the 1.03 N/mm3 0.10 Cstat=0. The the mat (depends on load. substructure.20 Specific load [N/mm2] 0. given in N/mm3. mat can be seen in the form of a particularly important: structure design (ballast bed height. 3 Technical Product Information Bedding modulus and Effectiveness and static stiffness insertion loss The correct stiffness of a mat de.05 Spring load def lection curve for 0. sleeper area and spacing. T “insertion loss” and is indicated as the difference of 1/3-octave levels of the ballast superstructure exclud- ing the mat he measure of stiffness is the (cumulative level within a 1/3-octave — Dynamic stiffness and damping of T bedding modulus. This value is largely responsible for frequency band) as a function of the 1/3-octave band center frequency. rail type) — Unsprung mass of the bogie and the operating conditions (axle his measure is referred to as — Dynamic stiffness. damping and mass load. rather.

effectiveness of a measure in ad- vance. Depending on the bedding stiffness. a prediction model to calculate the approx. ballast mats (examples: compact elasto- y considering the entire system structure resonance for a superstruc. this is between cavities).03 N/mm2 F' = 0. The for their effectiveness based on under ballast mats are particularly experience and prediction models are Load and frequency dependence of dynamic stiffness (from: Müller- BBM. very strongly stimulated.Prediction model effective in the frequency range not applicable to other types of under corresponding to the wheel/rail super.06 N/mm 2 F' = 0. In most applications.04 0. load and amplitude.06 Load F' = 0. mer mats with profiling or interior B and including the various struc- tural factors. the effectiveness in the frequency range under about The model assumes that the “dynamic 80 Hz is particularly important since stiffness” and the “loss factor” are these low-frequency vibrations are sufficient for a nearly complete descrip.02 0 40 80 120 160 200 Frequency (Hz) 7 . 50 Hz and 80 Hz. Report No. as and frequency range. Getzner is able to apply ture without mats. Buildings and tion of the dynamic properties of the building elements can easily be stimu- under ballast mat in the relevant load lated within this frequency range.01 N/mm2 Under ballast mat: Sylodyn® DN 335 F' = 0. Due to the advanced technology of ness is only minimally dependent on Getzner under ballast mats. can be seen in the natural vibration of ceilings and walls. 32242/12) Dyn. Getzner under ballast mats satisfy this condition because the dynamic stiff. the values frequency. bedding modulus [N/mm3] 0.10 N/mm2 Sample dimensions: 200 x 200 x 35 mm3 0.

fter more than 16 years of opera- A tion and a daily load of roughly 150 000 tons. no contamination was found inside the mats. samples were removed from the superstructure and subjected to various tests. The Sylomer ® B 851 under ballast soiling of the ballast bed with sand or mat superbly withstood the extreme- material worn away from the ballast ly high operating loads totalling over rocks cannot affect the mats. The test results showed that the under ballast mats still exhibited outstanding functionality. In verification measurements on samples that had lain in silty subsoil for over 20 years.. the under ballast mats from Getzner still had an impressive. constant stiffness behavior. Despite more than 16 years of use. 4 Long-Term Behavior Long-term behavior under the harshest conditions Getzner under ballast mats exhibit extremely high effectiveness even after years of exposure to operational loads. This has been proven by a study evaluating the long-term properties of Getzner under ballast mats. Environmental influences such as complete flooding. 760 million tons within a period of more than 16 years. an external testing institute: tions. Getzner under ballast mats retain their Quote from the test report by function even under extreme condi.” 8 . frost or heavy “..


it is delivered directly to with ballast immediately after laying. in all directions.50 m. for this task. they largely adapt to the contour of the subsoil. smoothed to an approximate even- mats in two separately rolled layers to ing water). necessary are performed by inserting fitting blocks or by cutting the mats When existing track sections are to the correct size and shape. 5 Installation Technology and Retrofitting Delivery form Requirements for and installation the subsoil Getzner manufactures under ballast The mat covering is fully functional Getzner under ballast mats lie on the mats in a uniform width of 1. The continuous further development of installation techniques by Getzner has now made it possible to thermally glue the upper layer of the individual mats and the fitting blocks together. the laying may be necessary in the area of surface frequently consists of old curves. it recesses or bumps in the laying the construction site. Con- mat thickness of 35 or 40 millimeters. such as 2-component PUR quired for laying Getzner under ballast adhesives. 10 . fter being cut to size. Any fine adaptations flow or seep to the next drain inlet. sharp-edged on the mat. mats through partial bonding with the crete decking must first be scraped or it is sometimes useful to deliver the subsoil (construction site traffic. The immediately after laying – in other subsoil with full surface contact. incom. the mats are Rubber-tired construction vehicles can A rolled up and packaged. The bonding mats on subsoil of compressed gravel The mat rolls are distributed and laid takes place so that any water that may (sub-grade). Starting from a is useful to secure the position of the surface can damage the mats. which retrofitted with mats. Getzner uses solvent-free ness. mat sheets are cut to the local track words. bonded to the subsoil. even without the mats being Because they are flexible and elastic width before leaving the factory. layer. adhesive. on a cement-paved sup- out at the destination site according to have penetrated under the mats can port layer or on a bitumen support their labeling. After the installation position has been marked drive over the mat covering with no problems. No special measures are re- allow for easier handling. If the mats are not covered S ince the mat optimally adapts to the subsoil beneath.

rail Under ballast mat fastenings and ballast do not have to Peg be replaced. If the mats are subject to constant and clean. extensive water exposure. these can also be elastically supported themselves. instructions as well as the adhesive only short track closure times are required for laying. it is naturally possible to reinstall 00 10 all components. widely available carpet cutters. In this case. Drainage openings drilled on-site Drainage principle: Sylomer® and Sylodyn® under ballast mats 11 . written installation sary to remove the entire track panel. Retroitting existing track sections ballast. The retrofitting procedure from Getzner has been tested frequently in The Getzner under ballast mats practice and ensures rapid construc- delivery program naturally also tion progress. as is the case for other Drainage solution e. Because it is not neces- includes detailed. If the laying surface required for the installation. sleepers. Since it is is coated with plastic (e. drainage nder ballast mats made of Sylom- mats can be laid under the mats in a linear arrangement. however. under ballast mats are to be bonded.g. Rails. If the particularly valued in many retrofit- layer on both sides of the mat. with geotextile vibration-related refurbishment meas- ures. on-site to the exact lengths required. it has proven Sylomer® and Sylodyn® are free of Getzner under ballast mats are effective to provide a load distribution softening agents and other oils. epoxy resin not possible to adapt the size of the for steel bridges). no special measures mats in advance. the grills or grates are protection as well as under extreme covered with perforated under ballast structural conditions. To avoid sound U er® and Sylodyn® have also proven themselves well in sensitive areas with bridges in the area of the water the highest requirements for vibration channels. They can be cut with simple. Profile If the signs of wear on the superstruc- Peg ture are not too extreme after years of operational loads without under ballast m m Side wall mat mats. they must be cut are required. Getzner trumps with economy and efficiency. ting projects due to their low weight the subsoil must first be dry and swept and easy installation. mats.g.

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