You are on page 1of 24

Presentation to STC Metro de Mexico March 2004

SATEBA EXPERIENCE IN THE FIELD OF Under Sleeper Pads

UIC 17th October 2006

Presentation

Presentation to STC Metro de Mexico March 2004

PART 1: PRA PADS FOR REDUCTION OF BALLAST WEAR PART 2: USP FOR VIBRATION MITIGATION

Part 1 - The PRA system

Presentation to STC Metro de Mexico March 2004

The polyurethan interface (history) Purpose of the PRA system Design of the PRA system PRA Quality Advantages of the system Scope of using Technical presentation of the PRA References

Part 1 -The polyurethan interface (history)

1989 SNCF laboratory


Presentation to STC Metro de Mexico March 2004

First tests on concrete cubes covered with polyurethane Test : Los Angeles test Result : no mark of erosion on the surface

SNCF : application on concrete sleepers


Idea : reduce ballast and sleeper erosion Test : Vibrogir test : 200 hours under load Result : no mark of erosion on ballast and sleeper Specification of thickness and quality of polyurethane

Part 1 - The polyurethan interface (history)

1990 Patent SNCF / SERP


Presentation to STC Metro de Mexico March 2004

Principle : spray of polyurethane under sleeper, polyurethane supplied by SERP Result : the polyurethane is sprayed at the base of the sleeper once dry (after production)

1995 Patent SATEBA


Principle : propose a more industrial process Result : polyurethane pad (PRA) to be embedded at the base of the sleeper during production

Part 1 - Purpose of the PRA system


Reduce the erosion of ballast and concrete sleeper
This involves

1
Presentation to STC Metro de Mexico March 2004

2 Reduction of Reduction of thickness of ballast thickness of ballast under the sleeper under the sleeper Reduction of the maintenance Reduction of the maintenance of the track with conservation of the track with conservation of track geometry of track geometry

Up to 10 cm

Proven by Mauzin recording

Part 1 - Design of the PRA system

One single design of PRA pad for PU hardness, thickness, etc


Presentation to STC Metro de Mexico March 2004

Geometry of PRA pad is adapted to the geometry of the sleeper/bearer with recess all around the sleeper edge Fits for twin block sleepers, monoblock sleepers as well for bearers Fits for every concrete sleeper manufacturing process: Long line, single moulds, instant demoulding and late demoulding

Part 1 - Design of the PRA system

Presentation to STC Metro de Mexico March 2004

No weakening of sleeper strength due to PRA pad This is checked with many static and dynamic tests on sleepers according to EN 13230 standard No reduction of concrete cover on steel inside the sleeper due to PRA pad

Part 1 PRA Quality

On PRA pads before use Quality of polyurethane is checked with Shore A hardness, tensile strength , etc
Presentation to STC Metro de Mexico March 2004

On sleepers with PRA pad after manufacturing Position of the embedded PRA pad in the sleeper Pull out test on PRA pad On sleepers after years in track SNCF has taken sleepers out of track for checking general appearance and quality of PRA pads

Presentation to STC Metro de Mexico March 2004

Part 1 PRA Quality Part 1 PRA Quality

Part 1 - Advantages of the PRA system


1. 2.
Presentation to STC Metro de Mexico March 2004

3. 4.

The thickness of the ballast can be reduced (up to 10 cm) The conservation of the initial track geometry is improved The lateral stability of the track is increased by 9% (SNCF data) Noise level equivalent with or without polyurethane

Part 1 - Scope of using


Concrete sleepers with PRA pads are used :
In order to reduce maintenance in the track by extending the initial geometry In order to reduce the thickness of the ballast :
In case of height issues (tunnels, bridges) in addition with shallow monoblock sleepers, In case of weight issues (viaducs), Where the stiffness of the concrete basement induces very heavy stresses in the ballast in comparison with ordinary track

Presentation to STC Metro de Mexico March 2004

Presentation to STC Metro de Mexico March 2004

Part 1 - Scope of using Part 1 - Scope of using

Presentation to STC Metro de Mexico March 2004

Part 1- Mauzin recording Part 1- Mauzin recording

Technical presentation of the PRA


Gravel layer

Monobloc sleeper

PRA pad
Presentation to STC Metro de Mexico March 2004

Polyurethan layer

Part 1 - References
Some figures

35000 concrete sleepers with sprayed polyurethane 210000 concrete sleepers with PRA system
Networks
Presentation to STC Metro de Mexico March 2004

SNCF (France) High speed lines SNCF (France) Regular tracks RATP (France) Paris metro GIF (Spain) High speed line CTRL Project (UK) High speed line

Approx. 120.000 twinblock and monoblock sleepers laid with PRA

Approx. 83.000 sleepers laid with PRA system since 2001

Part 2 USP FOR VIBRATION MITIGATION

LYON LEA new LRT line requires high vibration mitigation on ballast tracks close to housing
Presentation to STC Metro de Mexico March 2004

2 technical ways for achieving the requiremen Well known solution with ballast mat SATEBA innovative solution with USP on monoblock standard sleepers

Part 2 USP FOR VIBRATION MITIGATION

Step 1 SATEBA design for USP on ballast tracks in the field of vibration mitigation
Presentation to STC Metro de Mexico March 2004

USP covers the total bottom surface of the sleeper with a recess all around USP binding to the sleeper has to be deep in the concrete USP is 10 to 20mm thick USP material is soft to mid-soft according to the rolling stock axle load and mitigation requirement Material is PU foam

Part 2 USP FOR VIBRATION MITIGATION

Step 2 Checking SATEBA sleeper design with laboratory tests


Presentation to STC Metro de Mexico March 2004

Vibration mitigation level Sleeper with USP is set in a ballast box Sleeper is loaded to 25kN then 50 kN Vibrating pot provides vibration on 8-250 Hz range Vibration mitigation is measured with accelerators

Best quality/thickness of USP determined

Part 2 USP FOR VIBRATION MITIGATION

Step 2 Checking SATEBA sleeper design with laboratory tests


Presentation to STC Metro de Mexico March 2004

Mechanical behaviour of USP VIBROGIR test on sleeper with 50000000 load cycles No deterioration of USP No change of binding between USP and concrete sleeper

Part 2 USP FOR VIBRATION MITIGATION

Presentation to STC Metro de Mexico March 2004

Step 3 LYON LEA track construction 6000 monoblock sleepers with USP provided by SATEBA for LYON LEA new LRT line

Part 2 USP FOR VIBRATION MITIGATION

Presentation to STC Metro de Mexico March 2004

Step 4 Measurement of vibration mitigation in track Measurement in track when rolling stock runs show vibration mitigation of 12dB at 63Hz with regard to track with no USP

Part 2 USP FOR VIBRATION MITIGATION

Conclusion of part 2
Presentation to STC Metro de Mexico March 2004

New SATEBA development with USP has shown efficiency of the design for vibration mitigation on ballast tracks Next step will be 850 monoblock bearers with USP for SNCF to be laid on RER viaduc

CONCLUSION

SATEBA experience in the field of USP for more than 15 years:


Presentation to STC Metro de Mexico March 2004

Hard and thin USP for ballast thickness reduction/ ballast wear reduction/sleepers submitted to shocks Soft and thick USP for vibration mitigation