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INNOVATIVE SLAB
TRACK SOLUTIONS
MARIUSZ KALINOWSKI
STEFAN VONBUN
INNOVATIVE SLAB TRACK SOLUTIONS RHOMBERG SERSA RAIL GROUP
MARIUSZ KALINOWSKI
STEFAN VONBUN
Rail Summit 2024
Copenhagen, Denmark
DO YOU REMEMBER?
DO YOU REMEMBER?
DO YOU REMEMBER?
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SLAB TRACK DEVELOPMENTS
60 YEARS OF INVENTIONS TO INCREASE AVAILABILITY AND REDUCE MAINTENANCE
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DECADES OF SEAMLESS
SLAB TRACK PROJECTS
Project Application System 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Cologne/D •
Lötschberg/CH •
Ingolstadt/DE •
Monterey/MX -
Brenner/AT •
Malmö/SE •
Zurich/CH •
Heitersbergtunnel/CH •
GZU/AT •
Hohenturm/DE •
CEVA/CH •
Ulm – Wendlingen/DE •
Copenhagen/DK •
Stuttgart 21 Lot B/D/DE •
Koralmtunnel/AT •
• Rheda • LVT • Porr
High-speed (HS) Partial HS Tunnel Metro
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Rhomberg Sersa Rail Group | Worldwide
CONSTRUCTION, RECONSTRUCTION AND MAINTENANCE
OF RAILWAY INFRASTRUCTURE
OPERATION AND MAINTENANCE OF RAIL-BOUND
VEHICLES
700 Million Euros
revenue
3,000 Employees
> 230 Rail-bound vehicles
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2
3 4
67 95
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3 CONTINENTS
9 MARKETS
100 BRANCHES
WORLDWIDE
North America
Canada
USA
Europe
Switzerland UK1
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3
4
5 Germany
Austria Ireland
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Australia
Project business: selected locations worldwide
Nordics 8
© Metroselskabet og Hovedhadens Letbane
© Deutsche Bahn © World Travel Images
© Rhomberg Sersa Rail Group
HIGH FIXITY // SLAB TRACK SYSTEMS
MAIN CATEGORIES
Monolithic (e.g. Rheda) Embedded boots (e.g. LVT) Continually supported slab (e.g. IVES)
Pre-fabricated slabs(e.g. PORR STA) Direct fastening (e.g. DFF 300 RS) Embedded rail (e.g. Edilon)
The red colour marks the elastic elements ensuring the stiffness equivalence compared to conventional ballast track.
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IVES SLAB TRACK SYSTEM
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TYPICAL CHALLENGES OF RAILWAY OPERATORS,
ASSET MANAGERS AND DESIGN ENGINEERS
„Our clients are running more trains, so we must plan carefully to ensure a quick return to operations. “
James Cooper, Consulting Engineer
„I have not time for maintenance, but stuff keeps breaking, this is a nightmare! I need a reliable and safe track!“
Sophie Bennett, Track Engineer
*profile pictures & names are AI generatedAutodesk Rail Summit Copenhagen 2024Autodesk Rail Summit 2024
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«As easy as constructing with LEGO!» ─ Hermann Granig (foreman, 20 yrs experience)
about the works at Zierenberg Tunnel (GER)
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AS EASY & FAST AS CONSTRUCTING WITH LEGO BRICKS!
Cementitious:
Epoxy:
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Concrete:
Asphalt:
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COMBINING THE BEST OF BOTH WORLDS:
BOTTOM-UP AND TOP-DOWN APPROACH
Top-Down-Approach
General Characteristics
• High accuracy
• No corrections after casting
• Replacement challenging
• Big, heavy slabs
• In-situ concrete logistics & curing
time
Bottom-Up-Approach
General Characteristics
• Fast installation
• Pre-cast elements with
easy to handle dimensions
• Geometrical corrections
possible
• Easy replacement
of components
Examples
Rheda, LVT, PORR STA
Examples
ATD, Getrac
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IVES CONSTRUCTION PROCESS: ASPHALT LAYER
High-performance wheeled pavers
from road construction
Branxton Weighbridge, NSW, AUS Asfordby Tunnel, Melton RIDC, UK
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OPTIONAL DEPENDING ON ROUTING: SHEAR DOWEL
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IVES CONSTRUCTION PROCESS: PLACING OF IVES ELEMENTS
Zierenberg Tunnel, GER
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IVES CONSTRUCTION PROCESS: PLACING OF DFF
Bruggwald Tunnel, SWI
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IVES CONSTRUCTION PROCESS: ASSEMBLY OF TRACK PANEL
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Bruggwald Tunnel, SWI
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IVES CONSTRUCTION PROCESS: TRACK ALIGNMENT
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CPH Metro, DK
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TRACK ADJUSTMENT SYSTEM: RHOFAS
(FINE ADJUSTMENT SYSTEM)
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IVES CONSTRUCTION PROCESS: CASTING OF DFF 300 RS
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Bruggwald Tunnel, SWI
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IVES CONSTRUCTION PROCESS: FIXATION SYSTEM
VFS DFF 300 RS (Rhomberg Sersa)
grout
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DIFFERENT CROSS-SECTION DESIGNS AVAILABLE
embankment
tunnel invert
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HOW TO TRANSITION FROM SLAB TRACK TO BALLASTED TRACK
V-TRAS VERSATILE TRANSITION MODULE
Elastic pad (blue)
Standard sleepers
(on elastic pads)
Slab track
fix point bearing
for V-TRAS
V-TRAS module
(pre-fabricated steel structure)
Elastoplastic
pad (under steel structure)
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HOW TO TRANSITION FROM SLAB TRACK TO BALLASTED TRACK
V-TRAS VERSATILE TRANSITION MODULE
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AFTER CONSTRUCTION AFTER A PERIOD OF USE
with V-TRAS
Standard Transition
HOW TO TRANSITION FROM SLAB TRACK TO BALLASTED TRACK
V-TRAS VERSATILE TRANSITION MODULE
AFTER CONSTRUCTION AFTER A PERIOD OF USE
GREAT DESIGN…
…BUT DOES IT WORK IN REAL LIFE?
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LONG TERM EXPERIENCE: BRANXTON WEIGHBRIDGE (ARTC, AUS)
▪ installed 2017
▪ epoxy grout: fast curing
▪ 120 MGT p.a.
▪ Total tonnage to date:
800 MGT
800 MGT = 40* years
20 MGT/year
*equivalent operating time in a typical European
mainline track
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LONG TERM EXPERIENCE: ZIERENBERG TUNNEL (GERMANY)
General approval
for network of DB
InfraGO is pending!
Track inspection 11/2023:
no anomalies found!
“HE WHO STOPS BEING BETTER STOPS BEING GOOD.” — attributed to Oliver Cromwell
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PLACEHOLDER FOR ANIMATION VIDEO
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ADDED VALUE OF IVES SLAB TRACK SYSTEM
MAKE THE FUTURE OF RAIL
Stefan Vonbun
Head of Superstructure Products stefan.vonbun@rsrg.com +43 664 629 69 97
Mariusz Kalinowski
Business Development Manager mariusz.kalinowski@rsrg.com +45 31 63 65 10
Folie 1: Innovative slab track solutions Folie 2 Folie 3 Folie 4 Folie 5 Folie 6: SLAB TRACK DEVELOPMENTS 60 yEArs of INVENTIONs to increase availability and reduce maintenance Folie 7 Folie 8 Folie 9 Folie 10 Folie 11 Folie 12 Folie 13: TYPICAL Challenges of railway operators, asset managers and design engineers Folie 14 Folie 15: As easy & fast as constructing with lego bricks! Folie 16 Folie 17: Combining the best of both worlds: bottom-up and top-down approach Folie 18: IVES construction process: asphalt layer Folie 19: optional depending on routing: shear dowel Folie 20: IVES construction process: placing of ives elements Folie 21: IVES construction process: placing of dff Folie 22: IVES construction process: assembly of track panel Folie 23: IVES construction process: track alignment Folie 24: Track adjustment system: rhofas (fine adjustment System) Folie 25: IVES construction process: casting of DFF 300 RS Folie 26: IVES construction process: fixation system Folie 27: different cross-section designs available Folie 28: How to transition from slab track to ballasted track v-tras versatile transition module Folie 29: How to transition from slab track to ballasted track v-tras versatile transition module Folie 30 Folie 31 Folie 32: LONG TERM EXPERIENCE: Branxton weighbridge (ARTC, AUS) Folie 33: LONG TERM EXPERIENCE: Zierenberg tunnel (Germany) Folie 34 Folie 35: Placeholder for animation video Folie 36: Added value of ives slab track system Folie 37