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Delivering Turnout

Solutions

DESIGN SUPPLY INSTALL MAINTAIN

Introduction

GLOBAL TURNOUT SOLUTIONS

Introduction

BROWNFIELD CONSTRUCTION SOLUTIONS

Introduction MAJOR PROJECTS .

Introduction CRANE RAIL CONSTRUCTION .

Introduction We specialise in: ▪ Turnout design and integration ▪ Developing turnout technology ▪ Turnout supply management ▪ Critical junctions design and installation ▪ Turnout pre-assembly and installation ▪ Turnout installation staging solutions ▪ Turnout refurbishment and track reconditioning ▪ Crane rail specialist (supply and construct) ▪ Slab track construction ▪ Turnout and track inspections. maintenance and asset management Design – Supply – Install – Maintain .

Introduction Turnout range: ▪ Light rail ▪ Metro ▪ Passenger and freight ▪ Heavy haul ▪ High Axle Load Heavy Haul (HAL-HH) ▪ All gauges and rail profiles Design – Supply – Install – Maintain .

Projects

WE HAVE BEEN BUSY
AT MARTINUS RAIL

347 TURNOUTS SUPPLIED
SUPPLIED 51 BUFFER STOPS
CONTRACTED FOR THE SUPPLY OF 400+ TURNOUTS
60KM OF TRACK INSTALLED
33KM OF CRANE RAIL INSTALLED
INSTALLED 102 TURNOUTS

Projects
Kiwi Rail

▪ 22.5t axle load
▪ AS60 rail
▪ 200+ tangential turnouts

Projects

Doha Education City – Qatar
▪ 96 Turnouts and Diamonds
▪ 17t axle load
▪ S49, 60R2 rail
▪ Groove and full depth turnouts
▪ Direct fix Vossloh
▪ Edilon Sedra Encapsulation

Projects .

Projects Sydney Ports – Botany third line and yard upgrade ▪ 30t axle load ▪ 60E1 rail ▪ 26 Tangential turnouts .

Projects OneSteel – Whyalla – Iron Ore Project ▪ 32t axle load ▪ 60E1 rail ▪ 9 Tangential and conventional turnouts ▪ 54t axle load flangeway running diamond .

Projects ARTC – 30TAL Gunnedah ▪ 30t axle load ▪ AS60 rail ▪ 15 Tangential and conventional turnouts .

5t axle load ▪ AS60 rail ▪ 41 Tangential turnouts ▪ swing nose crossings . Projects ARTC – HRR & LTTSF Hexham ▪ 32.

Projects ARTC – Kooragang Island 32.5t axle load AS60 rail 8 Tangential turnouts Monoblock crossings .

5t axle load AS60 rail 12 Tangential turnouts Monoblock crossings . Projects ARTC – Upper Hunter Valley 32.

Brisbane • 30km of track • 19 turnouts . Projects MBRL .

Projects ARTC – East/West Productivity works turnout upgrade .

Projects PKCT • Upgrade the 6km of rail system within the 1km long coal stockyard to facilitate the introduction of new stacker and reclaimer equipment in the yard. .

Projects Southpine bridge renewals • 2 x 700m tracks along two bridges and an embankment. and was undertaken within a 168 hour rail closedown .

680m of Gantrex Ballasted – Automatic Stacking Crane (ASC) track .304m of Gantrex Slab Track – Ship to Shore (STS) • 5. Projects Webb dock • 1.

Projects GCLR Stage 2 • Light rail turnouts (49E1 & 51R1) • Diamonds and scissor crossovers • 13km ballast track • 2km embedded track .

Projects Buffer stops • NWRL (NRTIJV) – x23 stops • MBRL – x13 stops • SEQ Yards – x8 stops • Wickham – x5 stops • Perth stadium – x2 stops • Katoomba – x2 stops • MTM – x1 stop • GCLR – x2 stops .

Australia . Factories Manufacturing facility – Century.

Factories Manufacturing facility – DT. Czech Republic .

Factories Global Turnout Solutions Manufacturing facility. China .GWQC.

CRSBG. China . Factories Global Turnout Solutions Manufacturing facility.

Products What is a turnout? .

Closure panel 3. Crossing panel . Products Breakdown of a turnout 1. Switch panel 2.

Products Breakdown of a turnout .

Products Breakdown of a turnout • Bearers • Switch set • Infill closure rails • Crossing • Check rail unit • End infill closure rails • Points machine • Rodding • Platework • Jewellery .

Products Different types of turnout ▪ Similar flexure ▪ Contra flexure ▪ Crossover ▪ Diamond ▪ Scissor crossover ▪ Single slip ▪ Double slip ▪ Catchpoints .

Products Conventional vs Tangential .

Products Conventional vs Tangential .

Products Conventional vs Tangential • Tangential = improved technology – Reduced forces – Increased speed – Longer service life – Improved ride quality – Concrete bearers – Asymmetric thick web switch – Resilient fastened stock rail – Raised adjustable check rails .

Products Conventional vs Tangential .

Products Conventional vs Tangential .

Products Conventional vs Tangential .

Products Conventional vs Tangential .

Products
Rail Bound Manganese (RBM)

▪ Fully cast manganese insert
▪ Explosively hardened
▪ AS60 Wing rail
▪ CNC machined nose profile to suit
client wheel profile
▪ Life expectancy: 300MGT

Products
Monoblock

▪ Fully cast manganese
▪ Explosively hardened
▪ No bolts
▪ FBW 60kg Legs
▪ CNC machined WR & nose profile to suit
client wheel profile
▪ Life expectancy: 400MGT

Products
Swing nose crossing

▪ Rail type
▪ Frame type
▪ Manganese cradle
- Eliminates impact
- Reduced noise
- Suitable for longer rate
turnout (high speed)
- Life Expectancy: Greater
than 1000 MGT

Products High axle load (48T) heavy haul turnout .

Products Designs according to axle loads and speed .

▪ Allows safe and easy removal of track machines with up to 23T axle loads from mainline ▪ Once the track machine is located on the temporary siding it is as simple as removing two switch ramps and a crossing ramp. weighing only 350kg each. in order to restore mainline running . Products Temporary Takeoff Turnout The Temporary turnout creates a temporary siding allowing track machines to move on and off track at will.

Products Temporary Takeoff Turnout PWI Ken Erickson Innovation Award Winners .

Products Points operation rodding Deflection Plates Rear Drive Rod Linking rods Backdrive Crank Heel of Switch Drive Locking Bars Detection Bars Points Motor Points of switch .

Products Hydraulic points machine – Alstom CTS2 .

Siemens M3A/20A . Products Electric points machine .

Siemens D84M . Products Electric points machine .

Products Track forms – Concrete bearers .

Products Track forms – Composite bearers .

gauge is kept within tolerance ▪ Small Expansion – Up to 100mm ▪ Medium Expansion – Up to 330mm ▪ Long Expansion – Up to 600mm . Products Expansion Switches ▪ Used for thermal and subsidence management ▪ Moving Stockrail .

Products Buffer Stop systems – Friction Hydraulic .

R&D • New product development is key to ensure that Martinus Rail stays at the forefront of turnout technology and meets increasing network and operational demands from the client • Martinus Rail carries out design validation (can be by an independent third party) to: – Ensure product conformance – Ensure product suitability – Ensure product life cycle • Validation will include: – Engineering reports – Design review – Risk analysis review .

. R&D • All new crossing designs are verified for performance using finite element analysis (FEA) techniques • Tested up to 48T for both static and fatigue analysis • Fatigue life tested for 2.4 x 107 cycles.

R&D • New crossing designs undergo wheel / rail interface design studies to ensure that new and hollow wheel profiles transfer through the crossing in the most efficient manner without causing impacts. wheel strikes or wear .

R&D • All products undergo rigorous QA testing and follow up analysis .

Install .

675 28 R140 1 in 9 Straight 6.5 7.59463 25 1 in 9 6.34019 30 1 in 12 4.76364 22. Martinus Rail has designed the four new layouts to the following details: Radius (m) Crossing Rate (Strike) Crossing Angle (°) Lead Length (m) Divergent Road Speed (km/h) R96 1 in 7.393 42 R560 1 in 18 Straight 3.487 66 . The following table displays current details of turnouts in use in Kiwi Rail: Crossing Rate (Strike) Crossing Angle (°) Speed (km/h) 1 in 7.59463 14.76364 40 1 in 18 3. KR Supply Kiwi Rail – NZR50 Turnouts • Martinus Rail designed brand new tangential turnout design solutions in collaboration with KiwiRail based around the in track conventional turnouts currently installed in track.17983 34.17983 60 • Martinus Rail has reverted to turnout design fundamentals to provide a newly designed suite of the turnout sizes to incorporate full tangential design and features that will provide a turnout with an increased life cycle giving Total Cost of Ownership (TCO) benefits for Kiwi Rail.34019 17.386 33 R250 1 in 12 Straight 4.5 Straight 7.

250m. T160 & Bearers Concrete / Composite AS1085. KR Supply Kiwi Rail – NZR50 Turnouts Item Description Reference Document In accordance with Turnout Type Tangential – mixed traffic AS1085 and EN 13232 Turnout 96m. 1 in 12. 1 in 9.5.A. 140m.C & E series Profile 13 & -15 Check rail effectiveness 1026 . 1 in 18 Gauge 1068mm Kiwi Rail T151 GB 2585-2007 & Rail Size NZR50 Kiwi Rail dwg. through diverging track Tonnage Switch rail toe / stock rail open throw ≥ 115 dimension Switch rail throat opening ≥ 50 Check rail flared end opening to gauge ≥ 80 Check rail height above the running rail 0 Flangeway depth clearance 45 .998 NZ A.5T Kiwi Rail T151 Wheel Kiwi Rail dwg.. 7604-11. Design wheelset back to back dimension 993 . 560m Radius Crossing Rate 1 in 7.14 Turnout Design Criteria Dimension (mm) As per Table 7 Road Speed Nominal track gauge 1068 Axle Load 22.1032 Rail Cant in Zero Crossing Flangeway width 41 Turnout Points Suitable for M3A. CTS-2 & Racor Check rail gap 38 Operation Lever Maximum superelevation (cant) deficiency Yearly 60 18 MGT P. 88323/1 Kiwi Rail T151.

• Rail type 50AT. The last 500mm of the switchblade is forged to the NZR50 profile for connection to the infill closure rails. 20mm from top of rail • FBW Crossing legs NZR50 quality U75V (HT) according to GB2585-2007 . Stock rails are drilled for locking device. Asymmetric tangential switchblades – The switchblade is manufactured from 50AT rail. KR Supply Kiwi Rail – NZR50 Turnouts Switch assembly – The switch assembly is fabricated from 50AT asymmetric switchblades and NZR50 head hardened stockrail. • Rail type NZR50 quality U75V (HT) according to GB2585-2007 • Head of stockrail undercut to 1:3 Monoblock Crossing Assembly – Manufactured from cast austenitic manganese steel manufactured to TB/T 447-2004 • Explosively hardened within range 320 – 350 HB. all running surfaces up to 100mm from ends of casting. U71 V quality according to TB/T 3109-2005. anti-creep device and switch stops. Rail head is post CNC machined factory pearlitized to produce a head hardened grade material Stockrail – Manufactured from NZR50 head hardened (to HB 340) rail.

The check rail unit (two per turnout) comprises the check rail and the check rail bracket.The infill closure rails (rails between the end of the switches and start of the crossing) are supplied either straight or pre-curved from NZR50 quality U75V (HT) according to GB2585-2007. The ends of the check rail are flared to allow gathering of the wheel flange. KR Supply Kiwi Rail – NZR50 Turnouts Adjustable Check Rail . • Check rail type 33C1 (UIC33) to EN 13674-3 • Closure rail clipped to the check rail plate using resilient clips • Fully adjustable using shim set Closure Rail .14 with M24 Screwspike ferrules and Pandrol shoulders . The check rail is bolted to the bracket using M24 x 80 fasteners. Concrete Bearers – Prestressed concrete bearers to AS1085.

KR Supply Kiwi Rail – NZR50 Turnouts .

KR Supply Kiwi Rail – NZR50 Turnouts .

KR Supply Kiwi Rail – NZR50 Turnouts .

KR Supply Kiwi Rail – NZR50 Turnouts .

KR Supply Kiwi Rail – NZR50 Turnouts .

KR Supply Kiwi Rail – NZR50 Turnouts .

KR Supply Kiwi Rail – NZR50 Turnouts .

KR Supply Quality Management Plans .

KR Supply Risk management .

KR Supply .

In process and post production inspection by a third party expert • FAT – Factory Acceptance Test carried out by Martinus Rail senior engineers • 100% inspection at factory – All products 100% inspected by Martinus Rail prior to shipping • 100% inspection on delivery– All products 100% inspected by Martinus Rail on delivery • Trial lay – First off article trial lay for KiwiRail proving . KR Supply Quality Inspections • Manufacturing inspection – In process inspection by the manufacturer • Third party inspection .

5mm 193.17 Switch Drilling Hole Diameter – Foot SG.NZR50-7.NZR50-7.5-101 193 KJ 233 x>1. 17 17.14 Switch assembly end opening SG.5 mm Stockrail Drilling from End of Stockrail 1.5-101 427 426 ±1 mm KJ 1.NZR50-7.21 From the foot relief to the bottom of the holes .NZR50-7. DOCUMENTS BY Gauge to Gauge Distance at A/B/C/D/E 122.5-101 1090 1090 ±3 mm KJ ø22 22 ±0.NZR50-7.5-101 Ø22 22 ±0.16 SG.2 156 1<x<1.NZR50-7.19 Stock rail head machining clearance to switch tip SG.15 Switch tip to end of stock rail SG.5 mm KJ 1.5mm 232 (adjust with 275.20 Foot of the rail to the inside edge of the hole .NZR50-7.18 Switch Drilling Hole Diameter – Web SG.13 SG.4 122 (Switch closed) ±1 mm (pass) 156. 14 14 KJ -1mm .5 mm KJ 1.5-101 1500 1500 ±2 mm KJ (diameter/distance/height from foot) 63 64 ±1 mm 1.5-101 40 39 ±10 mm KJ +2 mm 1.5 (note) 1. KR Supply Quality Inspections ITEM VERIFYING INSPECTED PROCESS / OPERATION / DESCRIPTION TARGET ACTUAL TOLERANCE COMMENTS No.5 shim) 275 1.5 KJ -0 mm +2 mm 1.5-101 Ø32 32 ±0.

184.5.5-15-LH-LS >2 mm 50-7. -0 mm KJ (gap between switch stop and rail web) 450 450 Length of plates under switch: 650 649 50-FLAT 50-SW/50-SWH 790 790 1.5-14-RH-RS/50-7.5-101 KJ 294 294. KJ ±2 mm (OK) 50-7. KR Supply Quality Inspections ITEM VERIFYING INSPECTED PROCESS / OPERATION / DESCRIPTION TARGET ACTUAL TOLERANCE COMMENTS No.7.NZR50-7.5-14-LH-LS 840 841 50-7. 117.5-16-RH-RS/50-7.5-13-RH-RS/50-7.24 50-7. 690. Ø22 Holes: Ø22 Holes: ±1 mm 1. DOCUMENTS BY Ø32 Holes: Ø32 Holes: Switch Drilling from Toe of Switch 50. 49. 116.5-16-LH-LS 850 849 (Check Hole to Hole 906 (Loose) L-70mm. ±1) . 184.5-15-RH-RS/50-7.22 SG.5 +232 +232 +253 +253 +100 +100 Check M20 Checked Bolt Fit Switch stops correctly positioned 1. 690.23 VISUAL 0 0 +2.7.5-13-LH-LS .

KR Supply Quality Inspections .

Right Hand Turnout 1 in 7.Left Hand Turnout 1 in 9 .Left Hand Turnout 1 in 12 . KR Supply Product Marking 1 in 7.Left Hand Turnout ITEM DESCRIPTION 1 Left hand side .Right Hand Turnout 1 in 18 .5 .switch rail + stock rail * I * I * I * I 2 Right hand side .Left Hand Turnout 1 in 9 .switch rail + stock rail * I * I * I * I 3 Crossing * I * I * I * I 4 Check rails – C * I * I * I * I 5 Check rails – K * I * I * I * I 6 Closure – C * I * I * I * I 7 Closure – K * I * I * I * I 8 Closure – F * I * I * I * I 9 Closure – D * I * I * I * I 10 Closure – A N/A N/A N/A N/A * I * I 11 Closure – H N/A N/A N/A N/A * I * I 12 Loose Items (Box) * I * I * I * I .Right Hand Turnout 1 in 18 .5 .Right Hand Turnout 1 in 12 .

KR Supply Delivery .

KR Supply Logistics .

KR Supply Trial Lay .

KR Supply Trial Lay .

KR Supply Trial Lay .

KR Supply Trial Lay .

KR Supply Installation .

KR Supply Installation .

KR Supply Points operation rodding .

KR Supply Points operation rodding .

KR Supply Teamwork .

KR Supply Teamwork .

KR Supply Summary • Challenges • Brand new turnout design • New manufacturer • Shipping rail from NZ • Logistics of moving parts around the world • Earthquake! • Successes • Turnouts on the ground • Rodding installed • Working relationships • Manufacturing quality .