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 SCHWIHAG RAIL FASTENING SYSTEMS

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SCHWIHAG‘S PRODUCTS  4

INNOVATIVE RAIL DEVELOPMENT  8

FASTENING PRODUCTION10

SYSTEMS QUALITY ASSURANCE 12

TECHNICAL INNOVATIONS  13

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 SCHWIHAG RAIL FASTENING SYSTEMS

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MODERN
TECHNOLOGY
FOR THE TRACK
The rail fastenings supplied by SCHWIHAG are
based on systems which have been put to the test
in practice for decades. SCHWIHAG has technically
and economically optimised these systems.

SCHWIHAG provides consulting, development,

design, production, delivery and service for rail
fastenings and the following applications:

:: Standard railway lines

:: High-speed lines
:: Heavy freight transport
:: Underground railways SCHWIHAG rail fastening systems offer many Other advantages:
:: Commuter railways advantages for assembly and installation:
:: Tramways :: Tension clamps are produced free of surface decar-
:: Industrial railways :: Can be completely preassembled in the burisation (see page 13 of the brochure) > maximum
sleeper factory dynamic fatigue strength
and in the following types of track construction: :: D
 ue to sorted delivery, completely automated :: H igh-quality long-term corrosion protection availa-
preassembly is also possible in the sleeper factory ble (see page 14 of the brochure) > The dynamic
:: Ballast track with concrete sleepers :: Q
 uick, automated, mechanical final assembly on the properties are maintained for the complete life
:: Ballast track with wooden sleepers construction site possible with assembly speed :: H igh elasticity > Results in improved load distribution
:: Ballast track with steel sleepers of > 400 m/h track (deflection curve) along the rail, therefore, associated
:: Slab track significant reduction in point loading on all track
:: Bridge beams (beams on steel bridges) components such as the rail, rail fastening system,
:: Transition areas sleeper and ballast
:: I ntegral anti-tilt protection > prevents overloading of
with regard to: the tension clamp in extreme load situations
:: I ntegral electrical insulation > is achieved by using
:: Rail profile and cant the insulating plastic fastening components: angle
:: Sleeper geometry guide plate, rail pad and dowels
:: Line layout SCHWIHAG rail fastening systems are: :: Modularity > enables universal usability for all railway
(e.g. tight radii, large gradients) applications from the tramway, underground railway,
:: Proven standard systems and heavy load through to high speed traffic
(standard KS-track or W-track) :: P recise batch marking > Lettering is made using laser
:: New developments to customer requirements Tension clamp Skl 14 in preassembly position technology and enables exact dating of the produc-
:: Adaptations with optimised components, e.g. new tion date of each batch (see page 14 of the brochure)
tension clamps for existing sleepers for retrofitting :: H eavy-duty dowels > Special design of the dowel
or conversion geometry in conjunction with optimised material
:: Special designs for difficult installation situations selection enables high pull-out forces and safety
:: Systems with special surface protection for the against excessive torques (see page 14/15 of the
RFS components to customer requirements for brochure)
critical environmental conditions
:: Systems with highly effective sound insulation
(structure-borne sound/vibrations)
:: Systems for transition areas, e.g. at tunnel/bridge
with large relative movements between the rail
and support Tension clamp 14 tensioned

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 SCHWIHAG RAIL FASTENING SYSTEMS

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RAIL FASTENINGS FOR CONCRETE SLEEPERS RAIL FASTENINGS FOR

AND SLAB TRACK WOODEN SLEEPERS

Tension clamp Skl 14 on concrete sleeper (W-fastening) Tension clamp Skl 12 on wooden sleeper (KS-fastening)

RAIL FASTENINGS FOR

TRANSITION AREAS

Tension clamp Skl 15 for System 300-1 for slab track

System BSP-FF-B1 with Skl SL1, concrete

Tension clamp Skl 12 on elastically supported baseplate System BSP-FF-B2 with Skl SL1, steel
as single support point for slab track

RAIL FASTENINGS FOR SWITCHES

Tension clamp Skl 14 and Skl 12

as well as spring clip SSb2 for
slide baseplate URg 57 on
W switch bearer

Tension clamp Skl SL 1 for heavy-haul systems on concrete sleeper

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 SCHWIHAG RAIL FASTENING SYSTEMS

::::::::::::::::::: DEVELOPMENT ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

SCHWIHAG

DEVELOPS, TESTS
AND PRODUCES RAIL
FASTENING SYSTEMS

Targeted research and product development play an

important role in SCHWIHAG. The requirements for
forward-looking track components are determined
through continuous dialogue with the railway engi-
neers of the railway companies.

The 3D CAD system Pro Engineer is used to develop

new products and to adapt or optimise products that
have already proven their worth. The necessary FEM
analyses are then performed on the basis of this CAD
data. Prototypes are examined in our own test labo-
ratory to determine their general technical properties
and their suitability for use in railway operations.
Continuous load (endurance) tests can be performed
according to the test conditions of international
standards and/or the specifications of the railway
companies.
In addition to the static and dynamic load tests, the
following material tests can also be performed:
:: Hardness test
:: Tensile/compressive strength test
:: Grinding preparation and microstructural analyses
(optical microscopy)
:: Polymer tests (melting point, heat of fusion, glass
transition point)
:: Optical 3D measurement of components
SCHWIHAG AG‘s jig construction department enables
the production of customer-specific adapters and test
apparatus, which ensures optimum position adjust-
ment and clamping of the components to be tested
during the tests.
SCHWIHAG AG in Tägerwilen (CH) with research and
development facilities
Development and design laboratory of SCHWIHAG AG in Tägerwilen
SCHWIHAG GmbH, Radefeld near Leipzig Test machine for strength tests
(tensile test) on material samples
SCHWIHAG gmbh manufactures
schwihag ag inhouse developed
products. SCHWIHAG GMBH HAS
STATE OF THE ART PROCESS
TECHNOLOGY FOR TENSION
CLAMP PRODUCTION.
Biaxial, static and dynamic tests can be performed
in the test laboratory. The max. vertical test force is
400 kN and the max. horizontal test force is 100 kN.
Test laboratory with test equipment for continuous load (endurance) tests
The components can be tested, among other things,
in a horizontal position (biaxial) or in an inclined test
(mono-axial).
Based on this development concept, our customers‘
specific requirements can be implemented in new
products or new product variants.

Following successful testing in the SCHWIHAG labo-

ratory, the components and systems are subjected to
further testing by an independent test institute as part
of the approval procedure. Here SCHWIHAG works
closely with renowned test and research facilities, e.g.
the University of Technology of Munich or Dresden. Test machine for recording spring characteristic curves

Selected variants or fail fastening tension clamps produced by SCHWIHAG

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 SCHWIHAG RAIL FASTENING SYSTEMS

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FROM THE WIRE TO THE

FINISHED TENSION CLAMP:
SCHWIHAG PRODUCES IN A FULLY
AUTOMATED PRODUCTION PROCESS

1 WIRE ROLL MADE OF 2 BENDING LINE 3 SORTED TRANSPORT TO 4 QUENCHING AND HARDE-
SPRING STEEL QUENCHING AND HARDENING NING LINE

5 SORTED PACKAGING OF 6 AUTOMATIC TRANSPORT 7 INDOOR STORES - WAREHOUSE 8 OUTDOOR STORES

THE FINISHED PRODUCT INTO THE WAREHOUSE PRODUCTS ARE READY FOR DISPATCH

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 SCHWIHAG RAIL FASTENING SYSTEMS

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:

Example of the microstructural change in metals caused by the

heat treatment process: acicular martensitic microstructure

NO SURFACE
DECARBURISATION
SCHWIHAG tension clamps can be produced free of
surface decarburisation thanks to a special heat treat-
ment method in closed chambers.
Following the heat treatment of the spring steel the
fine acicular, martensitic microstructure forms. If
classical heat treatment methods are used with open
processes, surface decarburisation forms all around
of this surface decarburisation the material is brittle
and tends to form cracks, especially under dynamic
loading. These cracks or incipient cracks produce a
notch effect and propagate in the quenched and har-
dened material and can cause a component to break.
This process is also accelerated by increased formation
of rust, which can occur especially in the area of the
surface decarburisation.
The tension clamps produced using the SCHWIHAG
method do not have any surface decarburisation

HIGH TECH the perimeter of a wire with circular cross-section:

these are the starting points for cracking. In the area
zones and therefore achieve high dynamic fatigue
strength.
IN THE TEST LAB
We guarantee our customers that SCHWIHAG products
are produced according to the following criteria:

:: Careful selection of suitable heavy-duty materials

:: Selection of the optimum production method under
the aspects of product quality, flexibility and use of
resources (manpower, material, energy consumption)
:: Continuous monitoring of the production processes
and the product data through material and dimen-
sional checks according to national, international
standards or those specified by our customers.

Schwihag has a quality management system certified

to ISO 9001-2008 and for many years has been a Q1
supplier of Deutsche Bahn AG and a certified supplier
of numerous other railway companies (including SNCF,
Network Rail, RFI).

The SCHWIHAG production concept in conjunction

with the SCHWIHAG logistics concept enables us to
respond to customers‘ special wishes at short notice
and to deliver standard products or special designs Measuring the tension clamp geometry by means No surface decarburisation, free of incipient cracks All-round surface decarburisation with formation of incipient cracks
worldwide and on-schedule. of 3 dimensional digitising

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::::::::::::::::::: TECHNICAL
technIScheINNOVATIONS ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
InnovatIonen ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

LONG-TERM
langzeit-
CORROSION
korroSionSSchutz
PROTECTION
schwihag
SCHWIHAG bietet
offers new,
für spannklemmen
high-quality long-term
aus Federstahl
corro-
einen
sion protection
neuen hochwertigen
for tension clamps
langzeit-korrosionsschutz
made from spring
an.
steel.
MitWith
diesem
this new
neuartigen
type ofkorrosionsschutz
corrosion protection,
kann
die
rusting
rostbildung
can be verifiably
nachweislich
and significantly
über die gesamte
reduced over
lebensdauer
the entire life unter
underoperativen
operative conditions.
Bedingungen In this
deutlich
way
reduziert
the fatigue
werden.
strengthdamit
properties
bleibenofdie
thedauerfestigkeits-
tension clamps
eigenschaften
remain virtuallyderconstant
spannklemmen
over very nahezu
long usekonstant
cycles.
über sehr lange einsatzzyklen.

PRECISE
chargengenaue
BATCH
LABELLING
kennzeichnung
schwihag plastic
SCHWIHAG kunststoffschraubdübel
anchor dowel Sdüsdü-s3
S3

schwihag spannklemmen
In future, each werdentension
batch of SCHWIHAG zukünfig chargen-
clamps will
genau markiert.
be marked die Beschriftung
precisely. The labellingerfolgt mittels
is carried hoch-
out using
moderner lasertechnik
highly modern und ermöglicht
laser technology die exakte
and enables exact
datierbarkeit des Produktionsdatums
dating of the production date of each jeder
batch.charge. The development objective was achieved in design
terms by the geometrical formation of the dowel‘s
external (male) thread and the allocation of the
corresponding dowel internal (female) thread. In

hochbelaStbarer addition, different wall thicknesses were implemented

in the design of the dowel‘s thread area. This material
dübel distribution causes any stress peaks occurring due to
HEAVY-DUTY dowels elastic and plastic deformation of the dowel material
to be absorbed and therefore prevents damage to the
der dübel ist eine wesentliche komponente für surrounding concrete contour.
The dowel is an essential component
schienenbefestigungssysteme for rail fastening
auf Betonschwellen.
systems
damit on concrete
kommt sleepers.
dem dübel The
als im dowel,
Beton as a compo-
eingegossenes The newly developed plastic anchor dowel Sdü S3 can
nent cast
Bauteil in the
hohe concrete,für
Bedeutung is therefore very important
die Funktionalität der for be used not only with the sleeper screw Ss 25 but also
the function of the railzu.
schienenbefestigung fastening. The loading
die Belastbarkeit voncapacity
dübel- with the sleeper screw Ss 35. Damage to the internal
of dowel constructions
konstruktionen can mainly be
kann hauptsächlich determined
anhand by its
ihres kon- thread of the dowel caused by incorrect positioning of
skl 14 without
Skl ohne (links)
(left)und
and(rechts) mit neuem
with (right) langzeit-korrosionsschutz
new long-term corrosion protection design failure.
struktiven This can
versagens not only bewerden.
festgemacht loss of the connec-
dieses kann the sleeper screw Ss 25 with pointed thread is preven-
tion or keying
sowohl of the
ein verlust derdowel with thebzw.
verbindung sleeper body, e.g.
verzahnung ted by special design of the internal thread runout.
pulling
des out of
dübels mitthe
demdowel from the sleeper
schwellenkörper, z.B.or damage to
herausreißen
the surrounding
des dübels aus der concrete,
schwelle but alsoBeschädigung
bzw. failure of the internal
des Within the scope of qualification tests it was estab-
plug construction,
umgebenden e.g.als
Betons, pulling
auch out of the screw
ein versagen deror bolt
inneren lished that the new SCHWIHAG plastic anchor dowel
from the plug.
dübelkonstruktion, z.B. auszug der schraube aus dem Sdü S3 has a factor of safety of up to 4 for the pull-out
dübel, sein. force. The SCHWIHAG design also has a 3-fold factor of
The objective of the development of the new safety for the tightening torque, which is introduced
SCHWIHAG
Ziel plastic anchor
der entwicklung dowelschwihag
des neuen Sdü S3 waskunst-to reduce into the dowel when tightening the sleeper screw.
the tensile stresses in
stoffschraubdübels thes3concrete
sdü war, diebody
aus derresulting
schraube-from Apart from laboratory tests, this was also verified by
the screw-dowel combination.
dübel-kombination resultierenden In critical loading situa-
Zugspannungen im practical tests on the track panel. When the sleeper
tions, which occur
Betonkörper especiallydadurch
zu reduzieren. during laying
soll in of the track
kritischen screw was tightened and undone 10 times, no move-
and the tightening of the
Belastungssituationen, dierail fastening, this
insbesondere beishould
der Mon-en- ment in the dowel crown was found and the bonding
Test sample after screwing in ten times using
sure
tage ades
reserve against
gleises und der failure of the dowel
verspannung der construction
schienen- between the sleeper concrete and the dowel was a power assembly tool in the screw in tests
kennzeichnung
Labelling von clamps
of tension spannklemmen
by meansmittels
of laserlasertechnik
technology and the bonding
befestigung with the
auftreten, einesleeper
reserve concrete.
gegen versagen completely intact. under practical conditions.

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Schwihag AG
Track and Switch Technology
Lebernstrasse 3, CH-8274 Tägerwilen
Tel +41(0)71 666 88 00 Fax +41(0)71 666 88 01
info@schwihag.com www.schwihag.com