Railway Track Manual Part 1

Content
Preliminary
remark
Preface for the second

edition
Page: 000-01
Preface for second edition

The Railway Track manual is now available, the second edition of it was first published
in December 2004. Completely revised and expanded, this comprehensive reference book
provides up-to-date information about the railway track.
A compendium of the practice for the practice. It focuses on the application and provides empirical
knowledge on types of track systems and materials, especially about
Rails,
Barriers,
Turnouts,
Fasteners as well as
Other accessories
As a Q1-supplier of the Deutschen Bahn AG and as a system provider with a decades
of gathered experience, we hereby put all our expertise on the complete railway track.
We are therefore confident to provide you with Railway Track Manual valuable services for your work.
Without scale/schematic diagram
Date of issue 08/10
Content
Preliminary
remark
Instructions for use
Page: 000-02

The department of Planning and Development of ThyssenKrupp GfT Gleistechnik GmbH
has created a manual for you, which represents the current state of engineering. All
content has been reviewed by our colleague for accuracy and timeliness.
However they do not replace the critical review done by an experienced expert. Therefore
we do not take any responsibility for the issue.
In case you come across with something on our Railway Track Manual that
requires correction or amendment, please contact us. Your contact person at
ThyssenKrupp GfT Gleistechnik GmbH, Dr.-Ing. Siear Qaimi gladly welcomes your
suggestions and contrary comments.
Contact:
Dr.-Ing. Siear Qaimi
Tel.: +49 234 9114-541
Fax: +49 234 9114-316
E-Mail: siear.qaimi@thyssenkrupp.com
We look forward to working with you.
Date of issue 08/10
Content
Preliminary
remark
Addresses, sales offices

and engineering
Page: 000-03
SALES
Regional office
Location of sales
North
Vahrenwalder Str. 205
D-30165 Hannover
Phone: +49 511 6703-25
Fax: +49 511 6703-37
Waidmannstrae 26
D-22769 Hamburg
Phone: +49 40 85340-700
Fax: +49 40 85340-701
West
Hollestr. 7a
D-45127 Essen
Phone: +49 201 844-563745
Fax: +49 201 844-563750
East
Rotherstr. 7
D-10245 Berlin
Phone: +49 30 628901-15
Fax: +49 30 628901-20/-21
An der Kreuzkirche 6
D-01067 Dresden
Phone: +49 351 4902040
Fax: +49 351 4902480
Humboldtstr. 3
D-04105 Leipzig
Phone: +49 341 6017054
Fax: +49 341 6017055
South
Frstenrieder Str. 267
D-81377 Mnchen
Phone: +49 89 7871-300
Telefax: +49 89 7871-343
South-West
Weilimdorfer Str. 74/2
D-70839 Gerlingen
Phone: +49 7156 430730
Fax: +49 7156 430740
Dortmunder Str. 2
D-68219 Mannheim
Phone: +49 621 8906-120/-121
Fax: +49 621 8906-122
EXPORT SALES
MRT Track &
Services Co., Inc.
270 Broad Street
07003 Bloomfield NJ-USA
Phone: +1 973 748-8899
Fax: +1 973 748-9243
ThyssenKrupp
GfT Polska Sp. z o.o.
Al. Slowackiego 66
30-004 Krakw Poland
Phone: +48 12 6204130
Fax: +48 12 2677548
Holzschwellenwerk
Am Bahnhof 2
D-29393 Gro Oesingen
Phone: +49 5838 9905-0
Fax: +49 5838 9905-79
ThyssenKrupp
Weichenbau
Obere Stahlindustrie 4
D-44793 Bochum
Phone: +49 234 9114-343
Fax: +49 234 9114-557
Betrieb
Industrieweichen
Am Wasserturm 3b
D-06869 Coswig/Anhalt
Phone: +49 34903 4741-0
Fax: +49 34903 4741-20
Betrieb Spannmittel
Am Wasserturm 3b
D-06869 Coswig/Anhalt
Phone: +49 34903 4741-0
Fax: +49 34903 4741-24
ThyssenKrupp
Langschienen
Ladestr. 8
D-39175 Knigsborn
Phone: +49 39292 6958-17
Fax: +49 39292 6958-20
Export
Hollestr. 7a
D-45127 Essen
Phone: +49 201 844-563764
Fax: +49 201 844-563757
MANUFACTURING PLANT
Date of issue 08/10
Vertriebsbereich
Waggonausrstung
Rotherstr. 7
D-10245 Berlin
Phone: +49 30 628901-15
Fax: +49 30 628901-22
Content
Preliminary
remark
Information service
Page: 000-04
This information service serves exclusively the function, modifications, amendments and other
important informations on the Railway Track manual if required and to transfer to the interested
individuals and companies in a defined time. It is not used for sending of advertisements, information
sheets or the similar! Of course, your data will be kept confidential and not disclosed to third parties.
Data exchange takes place exclusively via e-mail.
To participate in the information service please fill in the following fields below and send this page by
fax to +49 234 9114-316 or email to gleistechnik@thyssenkrupp.com. The required fields are
marked with *.
Alternatively you may also register under www.tkgftgleistechnik.de and keep yourself updated.
REGISTRATION FOR INFORMATION SERVICE
Company*:
Contact partner*:
Street:
Place:
Tel.No.
E-Mail*:
Date of issue 08/10
Railway Track
Manual
Table of contents
Preface, Table of contents,

Railway Track terms
000-00
Preliminary remark
000-01
000-02
000-03
000-04
Preface for second edition

Addresses of sales office and engineering
Information service
000-10
Table of contents
000-11
000-12
000-13
000-14
000-15
000-16
000-17
Preliminary remark, Table of contents, General terms of tracks

Types of track systems
Vibration-damping rail bedding
Slab track / Crane and depot tracks
Special constructions / Track materials
Turnouts / Crossings / Rail expansion joints
Track accessories
000-20
General Railway Track terms
000-21
000-22
000-23
000-24
000-25
000-26
000-27
000-28
Development, Railway Track, Classification

Gauge of the track, Gauge widening
Track distance
Overview of various standards and regulations
Overview of various standards and regulations (Continued)
Track system abbreviations
Track system abbreviations
Thanks
Date of issue 08/10
Page: 000-11
Railway Track
Manual
Table of contents
Page: 000-12
100-00
110-00
110-01
Standard variants
Overview
111-00
111-01
111-02
Variant W 3 - Concrete sleepers

W 3 - 60E2 made of concrete sleeper
W 3 - Width of the rail flange 125 mm made of concrete sleeper B70/B90
112-00
112-01
112-02
Variant W 14 - Concrete sleepers

W 14 - 60E2 made of concrete sleeper
W 14 - Width of the rail flange 125 mm made of concrete sleeper B70/B90
113-00
113-01
Variant K - Concrete sleeper

K - Width of the rail flange 125 mm made of concrete sleeper
114-00
114-01
114-02
Variant K - Wood sleepers

K - 60E2 made of wood sleepers
K - Width of the rail flange 125 mm made of wood sleeper
115-00
115-01
115-02
Variant KS-H - Wood sleepers

KS-H - 60E2 Wood sleeper
KS-H - Width of the rail flange 125 mm wood sleeper
116-00
116-01
116-02
116-03
116-04
Variant KS-St - Steel sleepers

KS-St - 60E2 made of steel sleeper
KS-St - Width of rail flange 125 mm made of steel sleeper
KS-St-Iso - 60E2 made of steel sleeper
KS-St-Iso - Width of rail flange 125 mm made of steel sleeper
117-00
117-01
Variant Y-Steel sleepers

Rail fastening S15 made of Y-Steel sleeper
118-00
118-01
118-02
118-03
118-04
118-05
Variant grooved rails with guardrail

Installation views 59R1, 59R2, 60R1, 60R2
Installation views 57R1, 67R1, Ph 37N
Guardrail details
Material requirement / 15 m
Indoor track 57R1 made of situ-concrete plate
119-00
119-01
119-02
119-04
119-06
119-08
119-09
119-10
Variants Vossloh / ThyssenKrupp

System W 3 - Standard for Concrete sleepers
System W 14 - Standard for Concrete sleepers
System E14 / E21 - Highly elastic for Concrete sleepers
System 300 - for Slab track
System KS - for ribbed base plates
System W-Tram - with Wedge angle plates
System W97 - for reground concrete sleepers
Date of issue 08/10
Railway Track
Manual
Table of contents
120-00
Vibration-damping rail bedding
120-01
Overview of rail bedding
121-00
121-01
121-02
121-03
121-04
121-05
121-06
121-07
121-08
121-09
Continuous rail bedding

ThyssenKrupp Railflex
ISOLast
ThyssenKrupp Flexpoint
Whisper rail
Railcover
VIBRALast
Highly elastic grooved rail turnouts
Potting material Powerflex
ThyssenKrupp Flattrack
122-00
122-01
122-02
122-03
122-04
122-05
122-06
122-07
122-08
Discrete rail bedding

Delta stock
Krupp ECF-System
EASYLast
TK 99 / TK 99 S
TK07-R
TK 04-R
Ei-attachment
Acoustical Loadmaster
Date of issue 08/10
Vibration-damping
rail bedding
Page: 000-13
Railway Track
Manual
Table of contents
Slab track
Crane and depot tracks
130-00
Slab tracks
131-00
131-01
131-03
131-04
NFF (New slab tracks)

General
Engineering structure
Schematic construction cycle
132-00
132-01
132-02
NBU (Naumburg Bauunion)

Introduction
140-00
Crane and depot tracks
141-00
141-01
141-02
141-03
141-04
141-05
141-06
141-07
141-08
141-09
141-10
141-11
Crane runways
MX-System
MX-System description
MX-System screwed
MX-System welded
MX-System discontinuous rail bedding
MXA-System discontinuous rail bedding
MX-System continuous rail bedding
MXA-System continuous rail bedding
MX-Bottom casting
Surveying System Railcontrol
Crane runway beams
142-00
142-01
142-02
142-03
Railroad depot
Rail support point for side track and wash tracks
Rail fastening on working pits
Rail fastening on steel colum
Date of issue 08/10
Page: 000-14
Railway Track
Manual
Table of contents
Special constructions
Track materials
150-00
Special constructions
151-01
152-01
153-01
Guardrail
Guide rails
Rut rails
200-00
Track materials
210-00
211-01
212-01
213-01
214-01
214-02
214-03
215-01
216-01
217-01
Rails
Overview of commonly used track types
Flange rails
Grooved rails
Crane rails Form A
Crane rail AS 86
Crane rails bevel cuts
Special sections
Rails for crossings and turnouts
Perforation plates Rail perforation
220-00
221-01
222-01
223-01
224-01
225-01
Sleepers
Y-Steel sleepers
Pre stressed concrete sleepers
Wood sleepers
Steel sleepers
Steel bridge sleepers SBS
230-00
231-01
232-01
232-02
233-03
233-01
233-02
234-01
235-01
236-01
Ironmongery and accessories

Fastening clamping plates
Fastening rib based plates
Rib based plates for guide rails
Rib based plates for guide rails and supporting rails
Screw sleeper screws
Screw hook screws
Plastic screw anchor
Plastic spacer plate
Discs and spring lock washer
Date of issue 08/10
Page: 000-15
Railway Track
Manual
Table of contents
Turnouts / crossings /
Rail expansion joints
Page: 000-16
300-00
Turnouts and crossings
300-01
300-02
Preface
General switch description
310-00
311-01
312-01
313-01
314-01
315-01
316-01
317-01
318-01
319-01
Switch
Switch description
Types of switches / Split locking plans for Vignol- and Ph 37a Switch
Tram railed grooves
Tables
Layout plan according to VDV track 1435, system of units C
Turnout definition
Turnout parts
Turnout accessories
Changeover system
320-00
321-01
322-01
Crossings, EKW, DKW

Turnout parts
Crossing variant LSH, Linear slidable centrepiece
330-00
331-01
332-01
Rail expansion joints

Flange rails
Grooved rails
Date of issue 08/10
Railway Track
Manual
Table of contents
Track accessories
400-00
Track accessories
411-00
411-00
411-01
411-04
411-06
411-07
De-watering boxes
Overview
for grooved rail variant "DENA"
for grooved rail variant "RIECKEN"
for vignol rail variant "DENA"
for elastic rail bearings whisper rail
412-00
412-01
412-02
412-03
Track endings
General
Overview of the variants
Buffer stops
413-00
413-01
413-02
Plastic cable channel

DRAE - KA
AU KA
414-00
414-01
414-02
414-04
414-05
414-06
Insulated splicing
MT-Insulated splicing rail foot width 125 mm
MT-Insulated splicing 60E2
MT-Insulated splicing 60E2 increased
MT-Insulated splicing rail foot width 125 mm increased
Transition 49E5 to 54E4
415-00
415-01
415-03
415-04
415-05
415-06
415-07
Railway plates
Other signals
Speed limit signal
Signal for electrical traction
Additional signal at home signal
Signal for shunting operation
Turnout signal
Date of issue 08/10
Page: 000-17
Content
General Railway
Track terms
Development, Railway
Track, Classification
Page: 000-21
Formation of rail forms

The tracks should take the wheel load and transferred to the sleepers. They should also run the
wheel and have a levelled railway. To reach present level, the rail profile has gone through various
stages of development.
From the variety of rail forms, the wide foot rail, today called vignol rails consists of head, base and
foot. The rail is symmetrically shaped in cross section. The rail cross section is designed due to the
extensive experience and detailed considerations on today's valid profiles. The resisting torque and
carrying capacity of the rail is determined primarily by their height and weight as an I-beam. It is the
rolling friction of the wheels of the vehicle and thus exposed to material wear. The rail should remain
only up to a certain degree of wear and tear on the track.
Railway track
The route for railway vehicle is to be understood under railway track. The Railway track includes:
die tracks, turnouts and crossings,

the concrete as well as
the sub-structure
Classification of tracks and turnouts

The tracks and turnouts are divided according to operational and railway track technical aspects.
1. Operational aspects: Differentiation between the tracks and turnouts according to main and side
tracks. Main tracks are scheduled traffic tracks of the trains. Main tracks of the free routes and
continued through the stations are known as continued main tracks. All other tracks are side
tracks.
2. Railway track technical aspects: The tracks and turnouts are divided in 3 orders according to
operating characteristics and specially in
1. Order: strong mode, high travelling speeds and large axle loads
2. Order: moderate strong operation and slower travelling speeds without regard to the
axle loads
3. Order: weak operation, slower travelling speeds.
Date of issue 08/10
Content
General Railway
Track terms
Gauge of the track ,

Gauge of the track
Page: 000-22
Gauge of the track

The gauge of the track is the smallest distance between inner surfaces of the rail heads in the range
of 0-14 mm below rail level.
The basic size of the gauge of the track is 1435 mm.
Deviations from the basic size of the gauge of the track are allowed. Thus, for example turnouts for
non-federal railways (NE-turnouts) can also be prepared with a basic gauge of 1432 mm.
The gauge of the track in any case must not be smaller than 1430 mm and - also including
curve radius of the required extension -not more than 1465 by main line and 1470 mm by loop lines.
The gauge of tracks in rail and turnout curve parts with radius less than 240 m must not fall below
the following values:
Radius of the rail curve parts (m)
The minimum size of the gauge of track (mm)
under 175 to 150
1435
under 150 to 125
1440
under 125 to 100
1445
Gauge widening
A) Federally owned railway capital
manufactured gauge of track (mm)
under 175 to 150
1440
under 150 to 125
1445
under 125 to 100
1450
The gauge of the track in turnouts is set in the control drawings (low).
Standard turnout 54E4 and 60E2 for railway tracks DB AG have no gauge widening.
Turnouts with 49E5 rails and diverging track radius from 150 to 190 m have 6 mm
gauge widening.
B) Non-federally owned railway capital
manufactured gauge of track (mm)
under 190 to 140
1440
under 140 to 100
1445
The gauge widening in rail curve parts is to be produced by impressions of the inner stand in steps of
5 mm. The length of a step in each case is 5 sleeper fields. Before the first stage with a track gauge
from 1440 mm, 5 sleepers with a track gauge of 1435 mm.
Date of issue 08/10
Content
General Railway
Track terms
Railway Track distance
Page: 000-23
Track distance
1.) Standard gauge railway
The usual track distance is according to EBO for new buildings on free routes in curved parts with a
radius of 250 m and in the line of 4, 00 m. This measure applies to speeds > 160 km/h to 200 km/h.
The dimension refers to the distance from rail centre to rail centre.
In rail curves with radius of 250 m, the rail distance must be enlarged according to EBO 10.
Curve radius
Increased distance by:
250 m
0 mm
200 m
115 mm
150 m
300 mm
For existing attachments, the track distance at right operation must be even less than 4.00 m.
The minimum track distance for existing plants according to EBO 10(1) is 3.50 m.
On diverging track routes, the reverse to be driven in right operation and whose tracks have a
distance of 3.50 m, no security space exists for adjacent track. It is just barely a measure for minimum
clearance. During structural alteration works, the desirable track distance for these plants is 4.00 m.
Should this not be possible for compulsory reasons, exceptionally a distance of 3.75 m and 4.00 m
can be permitted.
The distance between track pairs or a track pair and a third track should be minimum 4.50 m. For
better security of rail staff during maintenance work on the inner tracks and possibly to store building
materials on inner tracks, the track distance possible should be 5.40 m.
The required track distance apart from over loaded tracks should be at least 4.50 m, with new
buildings at least 4.75 m and with intermidiate platform at least 6.00 m.
2.) Track distance from narrow gauge lines of general traffic:
A) On the free routes and on loading tracks:
Track gauge 600 mm
2,100 mm Track distance
Track gauge 750 mm
Track gauge 900 mm
Track gauge 1000 mm
B) At stations apart from loading tracks:

Track gauge 600 mm
Track gauge 750 mm
Track gauge 900 mm
Track gauge 1000 mm
For increasing the track distance in curved parts with narrow gauge rails there are special guidelines.
The dimensions are given in the appropriate tables.
Date of issue 08/10
Content
General Railway
Track terms
Overview of different
Standards and regulations
Page: 000-24
Overview of various standards and regulations:

DIN / BN / TL / UIC Kodex / DS/RIL
Name
DIN
Lock washer made of steel for

Railway track
Clamping plates rolled
5906
Crane rails form F
536/2
Crane rails with bottom flange A
536/1
Plastic material for railway tracks

Brief description of the railway track
systems
Tabs for groove less
bottom rails
Fish bolts with
Slotted round head / Oval neck
Fish bolts with
Square head
Railway tracks, basics,
General, guidelines
BN/TL
UIC Kodex
918 006
864-3 V
918 025
918 280
820.0101
5902
5903/1
5903/2
820.0101
Rising height in track curves

Guide rail; Release planned
Standard gauge railways,
Railway track recommended practice
Rails,
Flash butt welded, new
and reground
Rails, General
Rails, bottom rails (old
description) Profile S 10, S 14,
S 18, S 20, 33E1, 41E1, 49E5
Rails, for turnouts and crossings,
in connection with vignol
used from 46 kg/m;
Release planned
820.3030
EN 13674-3
918 255
820.2120
EN 136741
EN 13674-2
20501
Rails, Bus bars made of steel
17122
Rails, use
Rails, Vignol rails 27 kg/m
up to under 46 kg/m;
Release planned
EN 13674-4
Rails, Vignol rails from 46 kg/m
EN 13674-1
Date of issue 08/10
918 168
820.01
Rails, 30E1 and fish plates Fl 30
Rail expansion joints, arrangement of
DS/Ril
918 254
860 V
820.2121
918 254
860 V
820.0134
Content
General Railway
Track terms
Overview of different standards

and regulations (Cont.)
Page: 000-25
Overview of various standards and regulations:

DIN / BN / TL / UIC Kodex / DS/RIL (continuation)
Name
DIN
BN/TL
Rail base plate made of rolled steel
UIC Kodex
864-6 V
Sleepers
820.0105
Sleepers, wood, non-impregnated
918 144
Sleepers, prestressed concrete
918 143
Sleepers, steel
918 123
Sleeper screw
Rail clamps, rail nails
Clamping yoke
Track gauge and rail cant
Structure of rails
918 024-1
Steel upper wall screws
918 024-2
Butt plate made of rolled steel

Turnouts and crossings,
Technical foundation for
complete tracks
Turnouts, crossings and
Crossover made of wood and
steel sleepers
Turnouts, crossings and
Rail expansion joint,
Heat treated components
Intermediate layers of rubber
Driveway
Intermediate layers, elastic
Intermediate layers, under rails
Date of issue 08/10
DS/Ril
863 V
864-1 V
918 127
820.2110
864-4 V
820.0142
918 120
918 142
918 234
918 235
864-5 V
Content
General Railway
Track terms
Railway Track abbreviations
Page: 000-26
Railway track-Abbreviations
ABS
ATD
ATS
Az Obv
B
BN
BTD
BTS
BZA
CEN
DB AG
DIN
DKW
Dann
DS
EBA
EBO
Ei
EN
EW
Fe
FF
Fl
Fsch
FSS
Fz
Grp
Gz
H
HGT
HGV
Hs
ISO
Kp
KS
Ksp
LfB
LIS
MFS
N
NBS
Obv
Ri
Ril
Upgrade of existing line

Asphalt-base course with directly stored sleepers
Asphalt-base course
Appendix additional provision for railway track specifications
Concrete sleeper
Railway standard
Concrete-base course with directly stored sleepers
Concrete base course
Central Office of the German Federal Railways of the former German Federal Railways
European Committee for Standardisation
German National Railway Company
German Institute for Standardisation
Double-slip diamond crossing
Double clamping nail
Leaflet
German federal railway organisation
Railway engineering- and work rules
Insulating insert (in turnouts: Arch support - Ei = Anti-creep device)
Eurocode
Standard turnout
Spring lock washer
Slab tracks
Fish plates
Flexible rail switch-turnout
Anti-freeze layer
Flexible switch-turnout
Base plate
Pivoted heel-turnout
Wood sleeper
Hydraulically bound base course
High speed traffic
Hook screws
International organisation for standardisation
Clamping plate
Crane rail
Clamping track plate
Country representative for rail road supervision
Light industrial sleeper
Mass-Spring-System
Newton (Measuring unit according to English natural scientist)
New upgrade of existing line
Railway track specification for standard gauge railway
Grooved rail
Directive with modules
Date of issue 08/10
Content
General Railway
Track terms
Railway Track abbreviations

(Continuation)
Page: 000-27
Railway Track Abbreviations (Continued)

Rp
Rpb
Rph
Rps
Rsw
Rus
Rz
S
SbS
SBS
Sb
Sd
SO
SO
Sp
Ss
St
TBS
TL
UIC
UIG
Uls
VDV
VOB
WA
WE
Wfp
Yno
Yli
Yre
Zw
Zwp
Ribbed base plate

Ribbed base plate for concrete sleepers
Ribbed base plate for wood sleepers
Ribbed base plate for steel sleepers
Ribbed base track plate
Weldable ribbed base space plate
Control drawing
Rail
City rail road ties
Steel beam bridge sleepers
Clamping yoke
Sleeper anchor
Elastic sole of concrete sleepers
Rail level
Track adjustment plates
Sleeper screw
Steel sleeper
Tramway sleeper
Technical delivery condition
Union Internationale de Chemin de Fer (International Union of Railways)
Unternehmensinterne Genehmigung (Deutsche Bahn AG)
Washer
Association of German Transport Companies
German Construction Contract Procedures
(Before 2002: Contracting rules for award of public works VOB 2000)
Start of turnout
End of turnout
Angular guide plate
Y-Normal rail
Y-Transition rail left
Y-Transition rail right
Intermediate level
Spacer plate
Date of issue 08/10
Content
Thanks
Page: 000-28
For their assistance and support in creating this manual, we heartly thank:
A. Rawie GmbH & Co KG

DENA Stahlbau GmbH & Co
Deutsche Bahn AG
DW Schwellen GmbH
Elektro-Thermit GmbH & Co KG
Gebr. Marmetschke GmbH & Co KG
Hanning & Kahl GmbH & Co KG
Heinrich Krug GmbH & Co KG
H.+ R. Riecken Maschinenbau GmbH
Leonhard Moll Betonwerke GmbH & Co KG
Ortec Gesellschaft fr schienentechnische Systeme mbH
Rail.ONE GmbH
Schilderwerk Beutha GmbH
ThyssenKrupp Weichenbau GmbH
TSTG Schienen Technik GmbH
Vossloh Fastening Systems GmbH
Wirthwein AG
Date of issue 08/10
49090 Osnabrck
49086 Osnabrck
60326 Frankfurt am Main
39317 Gsen
06132 Halle
29393 Gro Oesingen
33813 Oerlinghausen
44145 Dortmund
49565 Bramsche
30629 Hannover
50668 Kln
92318 Neumarkt
09366 Stollberg OT Beutha
44793 Bochum
47166 Duisburg
58778 Werdohl
97993 Creglingen
Date of issue 08/10
Steel sleeper
Ks
Ks
Ks
Ks
Ks-iso
Ks-iso
S 15
E 14/
E 21
Sytem
300
W-Tram
W-Tram
W 97
113-01
114-01
114-02
114-02
115-01
119-08
115-02
119-08
116-01
116-02
116-03
116-04
117-01
119-03
119-09
119-10
1:40
60E2
Rail foot
width 125mm
1:40
without
without
1:40
60E2
59R1 /
60R1
57R1
1:40
60E2
Zw 900180
Zw 900180
Zw 687a*
Zwp104 NT
Zw 692*
Zw E14
Zw 401*
Zw 697*
Zw 697a*
Zw 691*
Zw 664a
Zw 686*
Zw 690*
Zw 672,
Zw 691*
Zw 672,
Zw 691*
Zw 661a
Zw 687*
Zw 664a
Zw 686*
Zw 664a
Zw 686*
Zw 661a
Zw 687*
Zw 700*
Kpo 9
Rph 6**
Wfp 3b 22
Wfp 3b - 28
K-Wfp 14 R
/L
K-Wfp 14 R
/L
Wfp 15a
Wfp E14
Zwp 192**
Rps 8 ia**
Rps 15 ia**
Rps 8**
Rps 15**
Rph 1**
Rph 6**
Rph 1**
Skl 1/97
Skl 14
Skl 14/92v
Skl 14/
Skl 21
Skl 15
Skl 14
Skl 12
Skl 12
Skl 12
Skl 12
Skl 12
Skl 12
Kpo 9
Kpo 6
Kpo 9
Rpb 1
Rph 1**
Kpo 6
Skl 14
Skl 14
Skl 1
Skl 1
Railfastening
Rpb 1
Wfp 14k
Wfp 14k
Wfp 3b
Zw 686a*
Zw 700*
Wfp 3b
Zw 687a*
Plate
Hs 32-55
Hs 32-55
Hs 32-55
Hs 32-55
Hs 32-55
Hs 32-55
Hs 26-65
Hs 26-65
Hs 26-65
Hs 26-65
Hs 26-65
Hookscrews
Uls 7
Uls 7
Uls 7
Uls 7
Uls 7
Uls 7
Uls 6
Uls 6
Uls 6
Uls 6
Uls 6
Uls 6
Uls 7
Uls 7
Uls 7
Uls 7
Disc/
washer
Ss 25
Ss 36
Ss 36
Ss 36
Ss 36-220
Ss 34
Ss 8-150
Ss 8-150
Ss 8-150
Ss 8-150
Ss 8-150
Ss 8-150
Ss 8-150
Ss 35
Ss 35
Ss 25
Ss 25
Sleeperscrew
Fe 6
Fe 6
Fe 6
Fe 6
Fe 6
Fe 6
Springlock
washer
Sd 25
Sd 25
Sd 26
Sd 25
Sd 25
D
S15a
Sd 13
Sd 9a
Sd 9
Sd 9
Sd 9
Sd 9
Anchor
Overview of Standard variants
Slab track with

Upl 180/120
Concrete
sleeper
Concrete
sleeper
1:40
1:40
1:40
Rail foot
width 125mm
Rail foot
width 125mm
60E2
1:40
1:40
1:40
1:40
1:40
1:40
1:40
1:40
1:40
1:40
1:40
1:40
RailIntermediate
gradient
level
Overview
119-09
Concrete
sleeper
Slab track
Y-Steel sleeper
Steel sleeper
with Iw 16
Steel sleeper
with Iw 16
Steel sleeper
Wood sleeper
Rail foot
width 125mm
60E2
Rail foot
width 125mm
Rail foot
width 125mm
60E2
Wood sleeper
Wood sleeper
Rail foot
width 125mm
Rail foot
width 125mm
60E2
Concrete
sleeper
Concrete
sleeper
Wood sleeper
Rail foot
width 125mm
60E2
Rail foot
width 125mm
60E2
Rail
Standard variant
119-06
Wood sleeper
113-01
Concrete
sleeper
W 14
112-02
Concrete
sleeper
Concrete
sleeper
Concrete
sleeper
Storage
W 14
W3
W3
Railway
tracksystem
112-01
119-02
111-01
119-01
111-02
Page
Railway tracks
Page: 110-01
Captive gradient 1:40
Railway track
systems
Standard variant
W3 60E2
Concrete sleeper B70 / B90
Page: 111-01
Tightening torque 200 Nm
Intermediate level
Zw 687a
Plastic dowel
Sd 9
Angular guide plate
Wfp 3b
Rail clamps
Skl 1
Sleeper screws with track
Ss 25 with Uls 7
1
Number/Support
point
Rail
60E2
Designation
Brief description
Pos.
Date of issue 08/10
Railway track
systems
Standard variant
W3 - Width of rail flange

125 mm / Concrete sleeper
Page: 111-02
Intermediate level
Zw 686a
Plastic dowel
Sd 9
Angular guide plate
Wfp 3b
Rail clamps
Skl 1
Ss 25 with Uls 7
1
Number/Support
point
Rail
49E5 or 54E4
Designation
Brief description
Pos.
Date of issue 08/10
Railway track
systems
Standard variant
W 14 - 60E2
Concrete sleeper B70 / B90
Page: 112-01
Intermediate level
Zw 700
Plastic dowel
Sd 9
Angular guide plate
Wfp 14k
Rail clamps
Skl 14
Ss 25 with Uls 7
1
Number/Support
point
Rail
60E2
Designation
Brief description
Pos.
Date of issue 08/10
Railway track
systems
Standard variant
W14 - Width of rail flange

Page: 112-02
Intermediate level
Zw 700
Plastic dowel
Sd 9
Angular guide plate
Wfp 14k
Rail clamps
Skl 14
Ss 25 with Uls 7
1
Number/Support
point
Rail
49E5 or 54E4
Designation
Brief description
Pos.
Date of issue 08/10
Railway track
systems
Standard variant
K - rail flange width

Page: 113-01
Tightening torque 180 - 250 Nm
9
8
7
1
2
2
Intermediate level
Plastic dowel
Hexagonal nut
Clamping plate
5
4
3
2
1
2
1
4
2
1
Number/Support
point
Hook screws
Ribbed base plate
Spring lock washer
Sleeper screws
Rail
Zw 672 or Zw 691
Sd 9a
DB M22
Kpo 6 (49E5)
Kpo 9 (54E3)
Hs 26-65
Rpb 1
Fe 6
Ss 8-150
49E5 or 54E4
Designation
Brief description
Pos.
Date of issue 08/10
Railway track
systems
Standard variant
K - 60E2
made of wood sleeper
Page: 114-01
8
7
6
5
4
3
2
1
Pos.
1
2
2
2
1
6
4
1
Number/Support
point
Date of issue 08/10
Intermediate level
Hexagonal nut
Clamping plate
Hook screws
Ribbed base plate
Spring lock washer
Sleeper screws
Rail
Zw 661a or Zw 687
DB M22
Kpo 9
Hs 26-65
Rpb 6
Fe 6
Ss 8-150
60E2
Designation
Brief description
Railway track
systems
Standard variant
K - Width of rail flange

125 mm made of wood sleeper
Page: 114-02
8
7
1
2
Intermediate level
Hexagonal nut
Clamping plate
5
4
3
2
1
2
1
6
4
1
Number/Support
point
Hook screws
Ribbed base plate
Spring lock washer
Sleeper screws
Rail
Zw 664a or Zw 686
DB M22
Kpo 6 (49E5)
Kpo 9 (54E3)
Hs 26-65
Rpb 1
Fe 6
Ss 8-150
49E5 or 54E4
Designation
Brief description
Pos.
Date of issue 08/10
Railway track
systems
Standard variant
KS - H - 60E2
made of wood sleeper
Page: 115-01
9
8
7
6
5
4
3
2
1
Pos.
1
2
2
2
2
1
4
4
1
Number/Support
point
Date of issue 08/10
Intermediate level
Rail clamps
Washer
Hexagonal nut
Hook screws
Ribbed base plate
Spring lock washer
Sleeper screws
Rail
Zw 661a or Zw 687
Skl 12
Uls 6
DB M22
Hs 32-55
Rpb 6
Fe 6
Ss 8-150
60E2
Designation
Brief description
Railway track
systems
Standard variant
KS - H - Width of rail flange

125 mm made of wood sleeper
Page: 115-02
9
8
7
6
5
4
3
2
1
Pos.
1
2
2
2
2
1
4
4
1
Number/Support
point
Date of issue 08/10
Intermediate level
Rail clamps
Washer
Hexagonal nut
Hook screws
Ribbed base plate
Spring lock washer
Sleeper screws
Rail
Zw 664a or Zw 686
Skl 12
Uls 6
DB M22
Hs 32-55
Rpb 6
Fe 6
Ss 8-150
49E5 or 54E5
Designation
Brief description
Railway track
systems
Standard variant
KS - 60E2
made of Y-Steel sleepers
Page: 116-01
7
6
5
4
3
2
1
Pos.
1
2
2
2
2
1
1
Number/Support
point
Date of issue 08/10
Intermediate level
Rail clamps
Washer
Hexagonal nut
Hook screws
Ribbed base plate
Rail
Zw 690
Skl 12
Uls 6
DB M22
Hs 32-55
Rpb 15
60E2
Designation
Brief description
Railway track
systems
Standard variant
KS - Width of rail flange

125 mm made of steel sleepers
Page: 116-02
7
6
5
4
3
2
1
Pos.
1
2
2
2
2
1
1
Number/Support
point
Date of issue 08/10
Intermediate level
Rail clamps
Washer
Hexagonal nut
Hook screws
Ribbed base plate
Rail
Zw 691
Skl 12
Uls 6
DB M22
Hs 32-55
Rpb 8
49E5 or 54E4
Designation
Brief description
Railway track
systems
Standard variant
KS - St - Iso - 60E2
Page: 116-03
8
7
6
5
4
3
2
1
Pos.
1
2
2
2
2
2
1
1
Number/Support
point
Date of issue 08/10
Intermediate level
Insulating insert
Rail clamps
Washer
Hexagonal nut
Hook screws
Ribbed base plate
Rail
Zw 697a
Iw 16
Skl 12
Uls 6
DB M22
Hs 32-55
Rpb 15 ia
60E2
Designation
Brief description
Railway track
systems
Standard variant
KS -St - Iso - Rail foot width

125 mm made of steel sleeper
Page: 116-04
8
7
6
5
4
3
2
1
Pos.
1
2
2
2
2
2
1
1
Number/Support
point
Date of issue 08/10
Intermediate level
Insulating insert
Rail clamps
Washer
Hexagonal nut
Hook screws
Ribbed base plate
Rail
Zw 697a
Iw 16
Skl 12
Uls 6
DB M22
Hs 32-55
Rpb 8 ia
49E5 or 54E4
Designation
Brief description
Railway track
systems
Standard variant
Rail fastening S15

Page: 117-01
9
8
7
6
5
4
3
2
1
Pos.
1
2
2
1
1
2
2
1
1
Number/Support
point
Date of issue 08/10
Spacer plate
Intermediate level
Clamping dowel
Guide plate (outside)
Guide plate (inside)
Rail clamps
Washer
Sleeper screws
Rail
Zwp 192 (or Zwp 193)

Zw 401
D S 15
Fpa 15
Fpi 15
Skl 14
Uls 7
Ss 34
60E2 (49E5 / 54E4)
Designation
Brief description
Railway track
systems
Grooved rail
with guardrail
Installation views 59R1 /

59R2 / 60 R1 / 60 R2
Page: 118-01
Track 1435/1000
Correction plates
2 and 3 mm thick
End perforation
Splice joint
Welding joint
750 for 15 and 18 m rails
Date of issue 08/10
Guardrail perforation oval

holes only for steel grade 700
Railway track
systems
Grooved rail
with guardrail
Installation views
57R1 / 67R1 / Ph 37N
Page: 118-02
Track 1435
Correction plates
2 and 3 mm thick
End perforation
Guardrail perforation oval

holes only for steel grade 700
Splice joint
Welding joint
937.5 for 15 m rails

(900 for 18 m rails)
H = 75 for 57R1
71 for Ph 37N and 67R1
Date of issue 08/10
h = 65 for 57R1
63 for Ph 37N and 67R1
Railway track
systems
Grooved rail
with guardrail
Guardrail
Details
Page: 118-03
Track
A = Clear width between the bars

L = length of guard rail
Correction plates
2 and 3 mm thick
Guard rails
Fl. 70 x 10 mm
2 or 3
Profile
59R1 - 59R2
60R1 - 60R2
59R1 - 59R2
60R1 - 60R2
59R1 - 59R2*
60R1 - 60R2*
59R1 - 59R2**
60R1 - 60R2**
57R1
Ph 37N
67R1
* Dresden/ ** Leipzig
Date of issue 08/10
Track
1000
1000
1435
1435
1450
1450
1458
1458
1435
1435
1435
Dimensions / Weights
A
1018.5
1018.5
1453.5
1453.5
1468.5
1468.5
1476.5
1476.5
1444
1453.5
1453.5
L
1015
1015
1450
1450
1465
1465
1473
1473
1442
1451
1451
kg / St.
7.233
7.233
9.623
9.623
9.579
9.628
9.628
Railway track
systems
Grooved rail
with guardrail
Material requirement
15 m
Page: 118-04
Material for a 15 m long track length (without tabs)

59R1 / 59R2 track 1435
2
10
10
10
40
Rails 59R1 / 59R2 N

Guard rails
Correction plates (2 mm dick)
Guardrail perforation
59R1 / 59R2 track 1000

2
10
10
10
40
Rails 59R1 / 59R2 N

Guard rails
60R1 / 60R2 track 1435

2
10
10
10
40
Rails 60R1 / 60R2

Guard rails
60R1 / 60R2 track 1000

2
10
10
10
40
Rails 60R1 / 60R2

Guard rails
57R1 / 67R1 / Ph37 N track 1435

2
8
8
8
32
Rails 57R1 / 67R1

Ph 37N
Guard rails
Date of issue 08/10
lg, mm
15000
1450
M22 x 55
lg, mm
15000
1015
M22 x 55
lg, mm
15000
1450
M22 x 55
lg, mm
15000
1015
M22 x 55
lg, mm
15000
1442 / 1451
1451
M22 x 55
kg / pc.
zus. kg
884.55 / 872.10
1769.1 / 1744.2
9.623
96.2
0.135
1.4
0.202
2.0
0.456
18.2
Sum 15 m = 1886.9 / 1862.0
kg / m
kg / pc.
zus. kg
884.55 / 872.10
1769.1 / 1744.2
7.233
72.3
0.135
1.4
0.202
2.0
0.456
18.2
Sum 15 m = 1886.9 / 1862.0
kg / m
kg / pc.
zus. kg
908.85 / 896.25
1817.7 / 1792.5
9.623
96.2
0.135
1.4
0.202
2.0
0.456
18.2
Sum 15 m = 1935.5 / 1910.3
kg / m
kg / pc.
zus. kg
908.85 / 896.25
1817.7 / 1792.5
7.233
72.3
0.135
1.4
0.202
2.0
0.456
18.2
Sum 15 m = 1911.6 / 1886.4
kg / m
kg / pc.
zus. kg
847.50 / 1003.65
1695.0 / 2007.3
988.20
1976.4
9.528 / 9.577
76.2 / 76.6
9.577
76.6
0.135
1.4
0.202
2.0
0.456
18.2
Sum 15 m = 1788.5 / 2101.2
2070.3
kg / m
125.8 / 124.1
124.2 / 122.5
129.0 / 127.4
127.4 / 125.8
119.2 / 140.1
138.0
Railway track
systems
Grooved rail
with guardrail
Indoor track 57R1

made of situ-concrete plate
Page: 118-05
Guard rail with threaded ends M 20

Grooved rail 57R1 / 67R1
Rail grouting MINEY-grout
Indoor track 57R1 / 67R1 made of situ-concrete plate

The usual guard rails made of flat steel are for for grooved rails that are embedded in the final state
are not recommended. Round bar with threaded ends according to the conventional reinforcement.
The site concrete in this case is produced up to 16 cm below SO. For including the width of rail flange,
recesses are provided. The grooved rails are installed with track holders to the rails, laid and aligned
according to location and height. The rails with MINEX-grout to be grouted in the gaps. Subsequently,
the remaining site concrete is introduced, if necessary. with asphalt coating in crossing areas before
the halls or special industrial floors in the hall.
Date of issue 08/10
Railway track
systems
Variant
Vossloh
System W 3 / standard
for concrete sleepers
Page: 119-01
System W 3 for concrete sleepers

Extract from the Technical Communication RO 26 / 05 of DB AG from 08.11.2005: Replacement of the rail
fastening W 3 on site W 14. According to the Directive RiL 820.2010. The rail fastening W 3 with rail clamp Skl 1
and angular guide plate Wfp 3b is to be installed instead of the previously used rail fastening W 14 k made of
concrete sleepers B70 W, B70 W-2.4 and B90.
Rail fastening with rail clamp Skl 1
The rail is placed with the elastic intermediate layer on the concrete sleeper. The lateral position of the rail is
secured by the angular guide plate Wfp 3. The Wfp is made of steel (with insulating insert) or glass fibre
reinforced plastic. They transfer the lateral forces on the concrete body, without claiming the screw to bend and
without effecting adversely for the track gauge formation. The resultant of vertical force and screw clamping
force is directed obliquely. The angular guide plate and the support in the concrete sleeper are shaped in such a
way, so that a tight fit is ensured even with loosened tie screws. The insulating insert between steel angular
guide plate and concrete allows a complete attachment and an electrical insulation. The rail clamp Skl 1 is
supplied with a permanent rust preventive coating.
The non-positive bracing
between rails and sleepers is achieved by using the listed parts.
Advantages
Exact track gauge even by heavy load operation and in curved parts.
High creep distance and torque resistance to prevent fracture gap openings.
High frame rigidity to secure the position of the track.
Low maintenance, no rework after installation.
No route blocking on suspended sleeper screws (stress equalisation). Captive pre-assembly in the
sleeper factory. After installation of the rails, and intermediate layers, the sleeper screw is loosened, the
rail clamp is rotated around 180 and the screw tightened with a torque of approx. 200 Nm. The correct
mounting poition is to be identified so that the intermediate loop touches the angular guide plate. The
clamping force of the spring arm is then approx. 11.5 kN at a deflection of 14.5 mm. There is an air
space of about 1.5 mm between rail clamps intermediate loop and rail flange. The lifting or tilting of the
rail is executed by the intermediate loop and thus excluded overexpanding of the spring arms.
installed
6
5
4
3
2
1
Pos.
1
2
2
2
2
1
Number/Support
point
Date of issue 08/10
pre-installed
Intermediate level
Plastic dowel
Angular guide plate
Rail clamps
Rail
Zw 686a / Zw 687a
Sd 9
Wfp 3b
Skl 1
Ss 25 with Uls 7
49E5 / 54E4 / 60E2
Designation
Brief description
Railway track
systems
Variant
Vossloh
Page: 119-02

Characteristics:
Different rail profile on the the same sleeper
On the same sleeper in same track gauge, the rail profiles 60E2, 54E1 and 49E5 can be used by simply
changing the angular guide plates.
Gauge widening
A gauge widening of +/-10 mm in levels of 2.5 mm is available by default.
Tilting table
Lifting or tilting the track during the way maintenance or while passing through the narrow track curves is braced
after overcoming the small air gap (between intermediate loop of the rail clamp and rail flange) with an
intermediate loop. Thus a permanent deformation of the outer spring arms is excluded.
Track maintenance
The Vossloh rail fastening system requires no regular maintenance.
Rail bracing and creep distance
The rails consistently braced non-positively through the free spring arms in a deflection of approx. 13 mm and a
retaining force of approx. 2 x 10 kN. This will require the high creep resistance of the rail, which prevents
dangerous gap openings in welded rails, as well as a sufficient frame rigidity of the track section is achieved.
Neutralisation
For continuous welding of the rails (CWR), no fastening parts are removed from the sleeper. Only the sleeper
screws are loosened but not removed.
installed
6
5
4
3
2
1
Pos.
1
2
2
2
2
1
Number/Support
point
Date of issue 08/10
pre-installed
Intermediate level
Plastic dowel
Angular guide plate
Rail clamps
Rail
Zw 700
Sd 9
Wfp 14k
Skl 14
Ss 25 with Uls 7
60E2
Designation
Brief description
Railway track
systems
Variant
Vossloh
Page: 119-03
Height adjustment
In Vossloh-rail fastening system W 14, a height adjustment of 8 mm is possible by inserting
height correction plates.
Interchangeability
All components are interchangeable.
Electrical insulation
Since the angular guide plate, the intermediate layer and the anchor screw is made of plastic,
the fastening system W 14 is completely electrically insulated. No additional insulated parts
are required between the rail flange and rail clamps.
Pre-assembly
All the fastening parts can be pre-assembled in the sleeper factory manually or automatically.
Only the rail is inserted at the installation site. Either during transport or during track construction,
the fastening parts are missing.
Mounting
Simple mechanical installation with standard screw machine.
Use of angular guide plates
The Wfp 14 K as a standard railway track, the Wfp 14 S, with Ei and 32 is used only in
exceptional cases depending on the type of earthing.
Installation instructions
Correct
Wrong
The correct installation clamping position is

achieved when the intermediate loop touches
the rib of angular guide plate by tightening the
sleeper screw.
(max. permissible air gap: 0.5 mm).
A tightening torque of
approx. 200 Nm is required.
Intermediate loop does not rest,

air gap is too large.
Desired clamping force is
not reached!
Date of issue 08/10
Railway track
systems
Variant
Vossloh
System 14 / E 21
highly elastic for concrete sleepers
Page: 119-04
System E 14 for concrete sleepers

Railway track E 14 with rail clamps Skl 14 is a highly elastic rail fastening system for concrete
sleepers in gravel tracks.
When upgrading from W 14 to E 14, the sleeper in gravel bed remain stuffed.
Features:
fully compatible to railway track W 14

Improved travelling comfort
improved modulus of grade reaction
lower gravel erosion
It is achieved with the large elastic intermediate plate with surface pressure distribution plate, similar
to the system 300 for slab track, large deflection of the rails. The Skl 14 is also fatigue endurable in
these high vertical dynamic rail movements. All fastening parts can be captively installed in sleeper
factory on the sleeper. Hence mechanised and fully automatic installation in the track is possible.
A possible efficient increase of drive comfort on gravel tracks, equipped with standard railway track W
14, and/or a reduction which takes place under heavy loads gravel destruction can be achieved with
compatible rail fastening system E 14.
Gravel tracks often have insufficient
deflection values when used in high-speed
traffic on new tracks. With EVA
intermediate layers, the maximum of 0.2
mm compressed under rolling wheel,
achieved together with the gravel elasticity
of about 0.6 mm on new tracks of the
highest values of 0.8 mm. Even the use of
so-called "soft" intermediate layers with
static spring digits of
c = 50 - 70 kN/mm brings an improvement
of about 1.0 mm of rail depression.
8
7
6
5
4
3
2
1
Pos.
1
1
1
2
2
2
2
1
Number/Support
point
Date of issue 08/10
installed
pre-installed
Intermediate level
Base plate
Intermediate level
Plastic dowel
Angular guide plate
Rail clamps
Rail
Zwp E 14
Grp E 14
Zw E 14
Sd 25
Wfp E 14
Skl 14 / Skl 21
Ss 36-220 with Uls 7
60E2
Designation
Brief description
Railway track
systems
Variant
Vossloh
System 14 / E 21
highly elastic for concrete sleepers
Page: 119-05
It was therefore the task of finding possible solution by using standard elements that can be achieved
with the desired rail deflection values of 1.5 mm.
The railway track E 14 uses the monoblock concrete sleeper B 70 W 60 with the rail flange Skl 14.
Thus, this railway track system are both on existing routes as well as on new lines to be built for use.
Structure:
The E 14 fastening system is a direct high elastic rail fastener for standard concrete sleepers B70
W60 for the slab track. It is analogously built to the rail fastening system 300. Lateral forces are
transferred via angular guide plates. The rail is still braced with usual elastic rail flange Skl 14 in
ballasted track. The two free spring arms are located on the rail foot. The superior intermediate loop
of the rail foot acts as a tilting table.
Controllability:
The fastening system is designed in such a way that the height adjustments are possible up to 5 mm
as in W 14 railway track, without darning.
If desired, a gauge widening of up to +/- 10 mm are provided even in levels by changing the angular
guide plates, as in systems W 14 and 300.
The System E 14 is available for local public transport under the name 300 UTS with rail flange Skl
21 and adapted intermediate plate.
The Sk 21 in this case replaces the Skl 14 with higher vertical and dynamic fatigue strength.
Date of issue 08/10
Railway track
systems
Variant
Vossloh
System 300 / for Slab

Lane
Page: 119-06
System 300 with rail 60E2 and Skl 15 for the slab track
Slab tracks meet all the requirements for combined high-speed and heavy traffic. The pre-assembled
rail fastening system 300 is suitable for all types of installation of the slab track.
The highly elastic intermediate plate replaces the elasticity of gravel bed. For better load distribution,
a steel pressure distribution plate which rests on the customary interposition of a conventional
interlayer rail. Laterally the rail is held in position by the plastic angular guide plates. The rail flange
Skl 15 is braced non-positively by the long elastic deflection.
The slab track rail fastening system 300 with Skl 15 is analogously built of the fastening W 14.
The lack of gravel elasticity is replaced with the rail fastening system 300 for the slab track by using
the highly elastic intermediate plate. While using a spring constant of 22.5 kN/mm, measured as
secant stiffness between 18-68 kN, a depression of rail is achieved from up to 1.5 mm in the standard
gauge railway (22.5 t axle load).
Construction of the slab track:
Monolithic:
Stored
Special systems
The fastening can be provided on both the sleepers and for individual bases.
Regulatory options:
Height adjustability
Side controllability
Date of issue 08/10
+6
-4
+26
-4
+/- 5
10 mm
30 mm
10 mm
using intermediate levels

using intermediate levels and height balancing
plates
using angular guide plates
Railway track
systems
Variant
Vossloh
System 300 / for Slab

Lane
Page: 119-07
Rail flange Skl 15

Correct
The correct installation clamping position is
achieved when the intermediate loop touches
the rib of angular guide plate by tightening the
sleeper screw. (max. Permissible air gap: 0.5 mm).
A tightening torque of approx. 200 Nm is required.
Wrong
Intermediate loop does not rest, air gap is too large.
Desired clamping force is not reached!
installed
8
7
6
5
4
3
2
1
Pos.
1
1
1
2
2
2
2
1
Number/Support
point
Date of issue 08/10
pre-installed
Intermediate level
Base plate
Intermediate level
Plastic dowel
Angular guide plate
Rail clamps
Rail
Zwp 104 NT
Grp 21
Zw 692
Sd 25
Wfp 15a
Skl 15
Ss 36 with Uls 7
60E2
Designation
Brief description
Railway track
systems
Variant
Vossloh
System KS for rib based plates
Page: 119-08
System KS with rail flange Skl 12 for rib based plates

The rail flange Skl 12 was designed for rail fastening on rib based plates with "hard" intermediate
layers (c 200 kN/m). The rail flange Skl 24 is available as an alternate.
All fastening parts can be captively installed in sleeper factory on the sleeper. Hence mechanised and
fully automatic installation in the track is possible.
With the two free spring arms of the rail flange, a permanently non positively braced rail with approx.
13 kN clamping force is achieved with approx. 14.5 mm deflection per rail flange, whereby the
fastening do not require any maintenance.
The tilting movement of the rail is executed by the intermediate loop of the rail flange. A temperature
stress equalisation of the rails is made easier by only loosening the screws. Any necessary rail
requirement can be done easily, in which the rail flange while installation is pushed back.
1. Loosen hexagonal nut of the screw-hook (approx. 1-2 revolutions)
2. Bring rail flange in installation position (Spring arms must rest on the rail foot)
3. The installation position is achieved when the interediate loop of the rail flange touches by
tightening the screw of the rail foot, or an air gap is up to 2 mm (tightening torque 180-250
Nm).
pre-installed
installed
9
8
7
6
5
4
3
2
1
Pos.
1
2
2
2
2
1
4
4
1
Number/Support
point
Date of issue 08/10
Intermediate level
Rail clamps
Washer
Hexagonal nut
Hook screws
Ribbed base plate
Spring lock washer
Sleeper screws
Rail
Designation
Zw 687
Skl 12
Uls 6
DB M22
Hs 32-55
Rph 6
Fe 6
Ss 8-150
60E2
Zw 687
Skl 12
Uls 6
DB M22
Hs 32-55
Rph 1
Fe 6
Ss 8-150
49E5 / 54E4
Brief description
Railway track
systems
Variant
Vossloh
System W-Tram - with

Wedge angle plates
Page: 119-09
Rail fastening system W-Tram with wedge angular guide lates K-Wfp 14 R and L
With the wedge angular guide plates with a continuous adjustment, the limited rail foot tolerance
related to manufacturing process, above all balanced in grooved rails, and so the track width can be
regulated upto +/-10 mm.
In the slab track, the use of insulated anchor bolts is possible, alternatively the proven anchor screw
combination Sd 26/Ss 36. The lateral forces of the rail is carried on the angular guide plate and the
base plate in the concrete support plate.
Does not have the bending or shear forces on the embedded anchorage system. High power
dissipation by the profiled bottom of the base plate. The sleeper screw / anchor bolts is only subjected
to train. Completely electrically insulated.
For laying the rail grooves on concrete sleepers, the system W is used, for slab track the system WTram is used.
Application examples
W-Tram on slab track
W made of concrete sleepers
installed
Concretesleeper
Slab
track
7
6
5
4
3
2
1
1
2
1
2
2
2
1
Pos.
Number/Support
point
Date of issue 08/10
pre-installed
Intermediate level
Plastic dowel
Base plate
Angular guide plate
Rail clamps
Grooved rail
Designation
Zw 900/180
Sd 26
Upl 180/120
K-Wfp 14
Skl 14
Ss 36 + Uls7
Zw 900/180
Sd 25
K-Wfp 14
Skl 14
Ss 35 + Uls7
W-Tram
W-Sleeper
Brief description
Railway track
systems
Variant
ThyssenKrupp
System W 97 / for 49E5 /
54E4 made of concrete sleepers
Page: 119-10

Characteristics:
The rail fastening W 97 was developed as an adapter solution for using the rails with rail flange width of 125 mm
(rails 49E5, 54E4) on concrete sleepers B 70 W-60 that requires the rail flange width of 150 mm.
Here, specifically, the use of reclaimed sleepers B 70 W-60 is considered (from the year 1974), as standard
equipment of DB.
Tracks with a permissible speed v < 160 km/h

Tracks with a traffic density < 30,000 Lt/d
Routing and marshalling attachments
Authorisation under:
DBS 918127
DIN EN 13481-2
Creep distance in
Rail longitudinal direction
Electrical resistance
F = 10 kN
R33 = 7,11 k
(according to 3.0 Mio. load changes)

(average)
installed
pre-installed
7
6
5
4
3
1
2
1
1
2
Intermediate level
Plastic dowel
Angular guide plate
Special angular guide plate
Rail clamps
1
Number/Support
point
Rail
Zw 686a
Sd 25 (alternatively Sd 9)
Wfp 3b - 22
Wfp 3b - 28
Skl 1 / 97
Ss 25 (alternatively Ss 35) with
Uls 7
49E5 / 54E4
Designation
Brief description
Pos.
Date of issue 08/10
Railway track
systems
Variant
ThyssenKrupp
System W 97 / for 49E5 /
54E4 made of concrete sleepers
Page: 119-11
Resultant track gauge:

Depending on the large sick dimension of the sleeper, there is a resulting theoretical track gauge
when using of rail fastening W 97.
See the below table:
resultant track gauges
gr. sick
dimension
1810
1811
1812
1813
1814
1815
1815.5
Field side
Track gauge
Track gauge
Field side
28
22
22
28
Gauge of the
track
1432
1433
1434
1435
1436
1437
1437.5
Economy:
Compared to the supply of new concrete sleepers, by using the rail fastener W 97 on reclaimed
concrete sleepers B70, W 60 indicates possible savings of about 30%.
(Source: DB, TM 2009-030 I.NVT4 (F) 10.02.2010).
Mounting / Installation:
The following points must be considered in planning and installation:
Providing the right Ironmongery (sleeper screws) depending on the used plastic screw anchor
(Sd 9 / 20 or Sd 25).
Installing two different angular guide plates on the specified positions
Installation instructions after inserting the rails:

1. Release sleeper screw - approx. 1.5 turns.
2. Rail clamps rotate by 180 Spring arms are placed on the rail flange
3. Interlocking the rail fastening as per the Directive 824 5050.
Date of issue 08/10
Elastic
rail bedding
Overview
Road cross section
Operational area (Axle load)

Tram
(up to 100 kN)
Continuous
rail bedding
Discrete
rail bedding
Date of issue 08/10
Page: 120-01
City railway
(up to 135 kN)
Metro
(up to 160 kN)
Rail cover
Standard
gauge railway
(up to 250 kN)
constructive
possible
deflection
(in mm)
up to 1.5
Railflex
up to 1.5
ISOLast
up to 1.5
Flexpoint
up to 1.5
Whisper rail
up to 10
VIBRALast
Highly elastic grooved rail
turnouts
Powerflex
up to 2
variable
Flattrack
up to 1.5
Delta stock
between 2-8
TK 07-R
up to 1.5
up to 4
TK 04-R
up to 5
TK 99
up to 3
EASYLast
up to 3
Krupp ECF-System
up to 3
Ei-attachment
up to 3
up to 4
Elastic
Rail bedding
Continuous
Rail bedding
ThyssenKrupp
Railflex
Page: 121-01
The system RAILFLEX is a continuous elastic rail bending system for city rails and trams. It consists of
the main elastic components, electrically insulating base element, electrical chamber element for inner
and outer side, elastic and electrical insulating coatings for the track holder, rail fastening and
installation base plate. The rail bedding is continuously horizontally and vertically adjustable.
Application for all tracks with asphalt, concrete, paved areas, surface as well as for crossings.
No track geometry limitations, use on bridges and in tunnels. High damping effect for air-borne and
structure-borne sound. Application with all known grooved rails and vignol rail profile. Operational info
systems sice 1993 with approx. 180,000 m rail and 80 crossings.
8
7
6
5
4
3
2
1
Pos.
1
1
1
2
1
2
1
1
Number/Support
point
Date of issue 08/10
Foot coating profile

Chamber element inside
Chamber element outside
Adjustable foot
Support plate with adjusting anchor
Insulation barrel
Hexagon head bolt
Rail
59R1 / 59R2 / 60R1 / 60R2
Designation
Brief description
Elastic
Rail bedding
Continuous
Rail bedding
ISOLast
Page: 121-02
ISOLast stores grooves and vignol rails continuously and elastically, and significantly reduces shocks
and vibrations in railway vehicles by degenerating the entire track of this type (slab track, pavement,
and plantation) from the environment. Due to the installation situation a deflection of more than
1.5 mm is recommendable.
The chamber filling profiles are waterproof. The track should be laid on a situ-concrete plate and
encapsulated with low-shrinkage cement mortar for height adjustment. The width of the chamber
filling profiles is recessed during construction of the surface and later encapsulated to the rail level
with highly elastic compound based on bitumen (Ortec.ESV).
Applications for all tracks and crossings with roofing:
Asphalt
Concrete / Asphalt
Concrete / Natural stone paving
Crossings
9
8
7
6
5
4
3
2
1
Pos.
2
2
1
1
2
2
1
1
1
Number/Support
point
Date of issue 08/10
Clamping plate
Hexagonal nut
Base coat profile
Base plate
Lock-nut
Thread block DIN 976 - M24
Chamber filling profiles outside
Chamber filling profiles inside
Rail
IL-3062-04-A4
DIN 985 - M24
GP-1215-00-A3
IL-3135-00-A3
DIN 7967 - M24
IL-3126-00-A4
IL-2029-03-A1
IL-2028-02-A1
59R1 / 59R2 / 60R1 / 60R2
Designation
Brief description
Elastic
Rail bedding
Continuous
Rail bedding
ThyssenKrupp
Flexpoint
Page: 121-03
The system FLEXPOINT is a discontinuous elastic rail bending system on the basis of rail support
point TK07-R, which is is so provided with an integral elastomer element so that no dynamic gauge
widening is possible under the vehicle. It further consists of both sided elastic chamber elements, the
cover cap on the rail fastenings and the insulating base profile between rail support points.
Application for all tracks with asphalt, concrete, paved areas, crossings. No track geometry limitations,
use on bridges and in tunnels possible.
Application with all known grooved rails and vignol rail profile.
10
9
8
7
6
5
4
3
2
1
Pos.
1
2
2
1
1
1
2
2
2
1
Number/Support
point
Date of issue 08/10
Intermediate level
Chamber element
Anchor
Baseplate with ribbing
Elastic base plate
Support plate
Rail clamps
Washer
Sleeper screws
Rail
Skl 1
Uls 7
Ss 25
59R1 / 59R2 / 60R1 / 60R2
Designation
Brief description
Elastic
Rail bedding
Continuous
Rail bedding
Whisper rail
Page: 121-04
The whisper rail offers the possibility of deflections to reach up to 10 mm due to their construction.
Rail car sound and vibrations are reduced up to 90% in densely built areas especially in trams. The
enclosure profile decouples the inner movement of the rail from the environment. The rail flooring is
not affected by the movement. For open cross-sections, like gravel bed, the whisper rail can be
constructed as a header rail, whereby to stop the enclosure profile below the rail head.
Asphalt
Concrete / Asphalt
Crossings
12
11
10
9
8
7
6
5
4
3
2
1
Pos.
1
1
2
2
2
1
2
1
1
1
2
1
Number/Support
point
Date of issue 08/10
Hexagonal nut
Hexagon head bolt
Lock-nut
Hexagonal nut
Thread block
Base plate
Clamping plate
Base coat profile
Elastomer profile head
Elastomer profile groove
Enclosure profile
Rail
DIN 980 - M20

ISO 4014 - M20 x 160
DIN 7967 - M24
DIN 985 - M24
DIN 976 - M24x240
RI-2754-00-A3
KS-2210-00-A4
GP-1122-03-A3
GP-1160-04-A3
GP-1158-08-A3
RI-2334-01-A3
49E5 / 54E4
Designation
Brief description
Elastic
Rail bedding
Continuous
Rail bedding
Rail cover
Blatt: 121-05
Primarily the system railcover provides the protection against stray current corrosion. For this reason,
the rail is coated with a profile made of plastic. The system design permits a deflection of up to
1.5 mm. The plastic profile is connected on Th rail with a special adhesive. Within the profiles, under
the rail foot, an elastic intermediate layer is inlaid to achieve the desired deflection.
The system is attached to underground guard rail with MX-guide rail clamps. Thus a wheel truing of
+/- 8 mm can be set.
Asphalt
Concrete / Asphalt
Crossings
10
9
8
7
6
5
4
3
2
1
Pos.
2
2
2
1
2
2
2
1
1
1
Number/Support
point
Date of issue 08/10
Washer
Hexagonal nut
Hexagon head bolt
Underfloor steering track rod
Hexagon head bolt
Hexagonal nut
MX-fasteing
Base coat profile
Rail bedding
Rail
ISO 7090-20
ISO 4032 - M16
ISO 4017 - M16 x 120
ER-1001-00-A3
ISO 4017 - M20 x 65
ISO 4032 - M20
MX 2424
GP-1262-03-A3
GP-1269-02-A3
59R1 / 59R2 / 60R1 / 60R2
Designation
Brief description
Elastic
Rail bedding
Continuous
Rail bedding
VIBRALast
Page: 121-06
The system VIBRALast is a channel system that is used with a 2-component material based on
polyurethane. The system can be loaded with grooved rails and also with vignol rails. The rail foot is
furnished with a base coat profile to achieve required deflection of up to 2 mm. All parts are
prefabricated, delivered on the installation site, whereby significantly reducing the installation time.
Asphalt
Concrete / Asphalt
Crossings
7
6
5
4
3
2
1
1
1
1
1
1
Hexagonal nut
Threaded rod
Tightener
Base coat profile
Rail
Pos.
Number/Support
point
Designation
Date of issue 08/10
ISO 4032 - M24

DIN 975 - M24x600
DIN 1480 SP - M24x255
GP-1215-00-A3
IL-2029-03-A1
IL-2028-02-A1
59R1 / 59R2 / 60R1 / 60R2
49E5 / 54E4
Brief description
Elastic
Rail bedding
Continuous
Rail bedding
Highly elastic
Soft grooves
Page: 121-07
standard cross-section
For using within the rail turnouts, system VIBRALast is expanded in view of the deflection. It consists
of the similar components as in VIBRALast, only within the rail foot, modified elastomer elements are
arranged to brace the different rigidity within the crossings and to achieve a uniform deflection of up to
4 mm. The system is suitable for road-aligned cross-sections.
Asphalt
Concrete / Asphalt
Crossings
6
5
4
3
2
1
1
1
1
1
Steel cable coating

Elastomer pad
Foam carpet
Rail
Pos.
Number/Support
point
Designation
Date of issue 08/10
EWL-1025-00-A3
GP-1297-00-A3
EWL-1028-00-A3
IL-2029-03-A1
IL-2028-02-A1
59R1 / 59R2 / 60R1 / 60R2
49E5 / 54E4
Brief description
Elastic
Rail bedding
Continuous
Rail bedding
Potting material
Powerflex
Page: 121-08
Our durable elastic product Powerflex can be used individually in order to grout grooved rails. The
material which sets rapidly after casting can be introduced manually or mechanically. The latter is
suitable for larger projects. The deflection can be varied depending on customer requirements, but
they must not be more than 2 mm. No big actions must be taken for processing; disposal after
decommissioning is possible without any special effort.
Asphalt
Concrete / Asphalt
Crossings
4
3
2
1
1
1
Base coat
Rail
Pos.
Number/Support
point
Designation
Date of issue 08/10
GP-1148-03-A3
IL-2029-03-A1
IL-2028-02-A1
59R1 / 59R2 / 60R1 / 60R2
49E5 / 54E4
Brief description
Elastic
Rail bedding
Continuous
Rail bedding
ThyssenKrupp
Flattrack
Page: 121-09
Joint sealing
The system FLATTRACK is a continuous elastic rail bending system on the basis of the new grooved
rail FLAT RAIL, with the rail height of 100 mm enables a miimum construction height. It further
consists of the elastic; electrically insulating base element, electrical chamber element and rail
fastening and installation support point, so that the rails can be set continuously horizontal and
vertical. By using the adapter elements on the long side of the chamber elemnt, an optial joint design
is possible.
The FAT RAIL is possible with an advantageous wide rail head, the big rail depth und extended head
thickness of an extended service compared to conventional rail service.
9
8
7
6
5
4
3
2
1
Pos.
1
1
2
2
2
1
2
2
1
Number/Support
point
Date of issue 08/10
elastic foot element

Chamber element
Cover cap
Clamping plate
Adjustable foot
Support plate with anchor
Eccentric
Hexagon head bolt
Rail
Flat Rail ( Ri58N)
Designation
Brief description
Elastic
Rail bedding
Discrete
Rail bedding
Delta-Stock
Page: 122-01
The Delta-Lager can be designed in such a way for all local traffic loads, so that a vertical deflection
of 2-8 mm is achieved. The maximum horizontal deflection is < 2 mm. The system is suitable for
concrete sleepers with W-fastening.
When using an additional base plate, the load can be used on concrete or wooden sleepers.
Therefore the Delta-Lager is ideal for slab track.
12
11
10
9
8
7
6
5
4
3
2
1
Pos.
4
4
4
2
2
1
1
2
1
2
2
1
Number/Support
point
Date of issue 08/10
Lock-nut
Hexagonal nut
Thread block
Spring washer
Hexagon head bolt
Base plate
Polyamide plate
Insulating insert
Intermediate level
Spring element
Console
Rail
DIN 7967 - M24

DIN 985 - M24
DIN 976 - M24 x 240
DIN 6796-24
ISO 4017 - M24 x 55
DL-1071-00-A2
DZ-2187-00-A4
DZ-2123-03-A3
DZ-2126-01-A4
GP-1093-11-A3
DL-1104-01-A3
49E5 / 54E4 / 60E2
Designation
Brief description
Elastic
Rail bedding
Discrete
Rail bedding
Krupp ECG-System
Page: 122-02
Alternatively: Screw stay
The developed Krupp ECF-system for the slab track from ThyssenKrupp Gleistechnik is a height and
side adjustable rail support which meets the catalogue of requirements of Deutsche Bahn. Within the
construction, the ribbed base plate has a large hole for eccentric insulating cases, which is inserted by
ribbed base and damping plates and enables a continuous lateral adjustability from 10 mm. By using
slotted correction plates of appropriate thickness, height adjustability from +26 to -4 mm "under
operation" is possible. The Krupp ECF-system is used in precast slabs, concrete sleepers for slab
track and in continuous concrete beam.
11
10
9
8
7
6
5
4
3
2
1
Pos.
1
1
1
2
2
2
2
2/4
2/4
2/4
1
Number/Support
point
Date of issue 08/10
Intermediate level
Ribbed base plate
Spacer plate
Washer
Hook screws
Rail clamps
Hexagonal nut
Spring lock washer
Insulated collar brushing
Hexagon head bolt
Rail
ZW 686 / Zw 687
ERp 1 / ERP 2
Zwp 194 - 125/150
Uls 6
Hs 32-55
Skl 12
DB M22
Fe 31
Fbu 8
ISO 4014 - M22 x 230
49E5 / 54E4 / 60E2
Designation
Brief description
Elastic
Rail bedding
Discrete
Rail bedding
EASYLast
Page: 122-03
The electrically insulating system EASYLast provides a flexible solution for the storage of vignol and
grooved rails. Using the elastic intermediate plate, it also provides an efficient protection from
vibrations, whereby the deflection should be limited to 3 mm.
The system consists of a ribbed base plate, which in addition has an intermediate layer under the rail
foot and also an elastic intermediate plate. The rail fastening is supplied with conventional rail clamps.
While fastening the rib based plate, the pressure springs are arranged to prevent lifting of the rib
based plate. Below the pressure spring, the plastic collar brushes are arranged, which provides the
electrical insulation. The necessary height compensation should be prepared with non-shrinking
cement mortar.
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Pos.
2
1
2
2
2
2
2
2
2
2
1
1
1
1
Number/Support
point
Date of issue 08/10
Protecting cover
Base plate
Thread block
Hexagonal nut
Pressure spring
Washer
Collar brushing
Washer
Hexagonal screw with nut
Rail clamps
Intermediate level
Ribbed base plate
Elastic base
Rail
DZ-2259-00-A4
DZ-2172-00-A4
DIN 976 - M24 x 240
DIN 985 - M24
DZ-2238-01-A4
DZ-2257-00-A4
EA-2033-02-A4
Uls 6
Hs 32 x55
Skl 12
ZW 677
EA-2025-01-A1
DZ-1015-05-A1
49E5 / 54E4
Designation
Brief description
Elastic
Rail bedding
Discrete
Rail bedding
ThyssenKrupp
TK 99 / TK 99 S
Page: 122-04
The TK 99 is an elastic rail support with 2 or 4 anchor bolts with proven construction design of the
system 314 / 336 of the Deutsche Bahn. The elastic deflection is adjustable up to 3 mm. The
optimised sub-structure leads to the improvement of technology and function.
In TK 99 S system, the load around the fastening of guard rail was extended. The system is
constructed as a composite structure made of cast steel for whisper rail and guard rail and is suitable
for all rail profiles. The elastic deflection is adjustable to the complete system.
13
12
11
10
9
8
7
6
5
4
3
2
1
Pos.
1
1
1
1
2
2
2
2
2/4
2/4
2/4
2/4
1
Number/Support
point
Date of issue 08/10
Intermediate level
Support plate
Elastomer base
Ribbed base plate
Rail clamps
Washer
Hexagonal nut
Hook screws
Collar brushing
Helical spring
Hexagonal nut
Anchor bolts
Rail
Skl 12
Uls 6
DB M22
Hs 32 x 55
DIN 985 - M24
54E1
Designation
Brief description
Elastic
Rail bedding
Discrete
Rail bedding
ThyssenKrupp
TK 07-R
Page: 122-05
The TK 07 is a supporting base that has been developed specially for the system Flexpoint.
It consists of 100% plastic and is approved for the use of Metro and tram. The deflection is between
1 and 1.5 mm. The base is available in two versions.
The system is not adjustable in TK 07, in TK 07-R, the horizontal position can be changed even later
via wedge adjustment.
The system is height adjustable and optimised with a special base plate for the use on a site-concrete
construction - also with minimal thicness.
9
8
7
6
5
4
3
2
1
Pos.
1
2
1
1
1
2
2
2
1
Number/Support
point
Date of issue 08/10
Intermediate level
Anchor
Baseplate with ribbing
Elastic base plate
Support plate
Rail clamps
Washer
Sleeper screws
Rail
Skl 1
Uls 7
Ss 25
59R1 / 59R2 / 60R1 / 60R2
Designation
Brief description
Elastic
Rail bedding
Discrete
Rail bedding
ThyssenKrupp
TK 04-R
Page: 122-06
with alternative anchoring
A standard solution developed for Metro and tram rails, the elastic rail support TK 04-R. An innovation
with many technical options. The elastic deflection up to 5 mm ensures driving comfort and low noise
emission. In addition TK 04-R provides a height adjustment between -3 and +10 mm as well as a
lateral adjustment between -10 and +10 mm.
Through extensive use of plastic, the rail is electrically insulated against the concrete construction
optimally. The low dead weight and the possibility of sub-assembly minimise substantially the
installation time on-site.
11
10
9
8
7
6
5
4
3
2
1
Pos.
1
2
1
1
1
1
2
2
2
2
1
Number/Support
point
Date of issue 08/10
Intermediate level
Sliding wedge
Base plate
Elastic base
Spacer plate
Support plate
Rail clamps
Disc/washer
Hexagonal nut
Anchor bolts
Rail
Skl 15
44 / 25x4
M24
49E5 / 54E4
Designation
Brief description
Elastic
Rail bedding
Discrete
Rail bedding
Ei-attachment
Page: 122-07
The Ei-attachment - the name comes from the characteristic oval shape - was originally designed to
reduce the impact sound. Because of the construction, consisting of the ribbed base plate and the
frame, the deflection should be not more than 3 mm.
The rail is mounted on the rib based plate using rail flange or E-clips. The outer side on the frame, the
ears cast integrally, that are provided with bolts for fastening with anchor bolts. Between the rib based
plate and frame, there is a tilted vulcanized elastomer ring, which provides a pressure-/ superimposed
power intake. This results in the excellent acoustical effectiveness of the Ei-attachment. Besides the
track gauge is reliably maintained because of construction. When overloaded, the rib based plate
lowers maximum up to the dead end on the concrete. The elastomer ring dampens not only the
vibrations, but also offers excellent electrical insulation.
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Pos.
11
10
9
8
7
2
2
2
6
5
4
1
1
1
1
Number/Support
point
Date of issue 08/10
Lock-nut
Hexagonal nut
Spring lock washer
Thread block
Cog plate
Washer
Hexagonal nut
Hook screws
Rail clamps
Polyamide plate
Intermediate level
Ribbed base plate
Elastomer ring
Frame
Rail
DIN 7967 - M22

DIN 985 - M22
Fe 7
DIN 976 - M22 x 240
EI-0007-00-A1
Uls 6
DB M22
Hs 32 x 55
Skl 12
DZ-2254-00-A3
Ei-0009-00-A3
EI-0008-00-A1
vulcanised
EI-0002-00-A0
49E5 / 54E4
Designation
Brief description
Elastic
Rail bedding
Discrete
Rail bedding
Page: 122-08
The Acoustical LoadMaster has been developed in order to achieve low stiffness in the rail.
Depending on the axle load, the deflection of the rib based plate as per the construction is designed
up to 4 mm. The system consists of a ribbed base plate and a frame which are connected through a
vulcanised elastomer with each other. As per the requirements, the ribbed base plate are
manufactured straight or inclined (1:20 / 1:40). The frame is so shaped that the ends of the ribbed
base plate protrude. The gap is also filled with an elastomer and provides an elastic lift lock. On the
frame of the load, the fastening points up to 4 are appropriate, which ensures an adequate lateral
adjustability.
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Pos.
1
1
2
2
2
2
2
2
2
2
2
1
1
1
1
Number/Support
point
Date of issue 08/10
Intermediate level
Polyamide plate
Cog plate
Lock-nut
Spring lock washer
Hexagonal nut
Thread block
Washer
Hexagonal nut
Hook screws
Rail clamps
Ribbed base plate
Elastomer
Frame
Rail
LM-1016-02-A4
DIN 7967 - M24
Fe 7
DIN 985 - M24
DIN 976 - M24 x 240
Uls 6
DM M22
Hs 32 x 55
Skl 12
DZ-2200-00-A1
LM-1015-02-A0
DZ-1114-00-A2
60E2
Designation
Brief description
Fixed
Slab track
NFF
General
Page: 131-01
General Information
Gravel construction and conventional fixed slab track as e.g. the system NBU differ in the interface of base /
railway track. Hydraulically Bound Base course (HGT) instead Sub Structure (PSS) and Concrete Base course
(BTS) instead gravel.
Gravel roads can be repaired in limits by considering height and position, in FF-systems, these ratios are
possible in limits in rail fastenings. The gravel roads requires more maintenance and has a shorter life until the
complete reconstruction, FF systems have a long life and requires less maintenance but a more elaborate
preparation of the base (soil stabilisation, compaction, exchange etc.).
The ThyssenKrupp GfT Gleistechnik GmbH comes with two different slab track (FF)-Systems:
System FF NBU
New slab track NFF
New slab track - NFF
In poor soils, the cost for this soil stabilisation increases enormously. Here begins the operational area of NFF.
It accounts to all base course work, that the system NFF loads from the dead weight and rail traffic over deep
foundation (bore piles, micro piles, etc.) directly initiates the bearing capacity of base course The necessary
pickets and associated pile lengths are determined by a ground survey, so that only minimum setting can be
done. Thus, the advantages of the conventional slab tracks (low maintenance cost, long life) are connected to
safe load transfer through deep foundations (small settlements, no complex substructure etc.) the system NFF.
The system "New slab track" (NFF) is looked from a structural point of view as a bridge-like construction with a
railway track part.
Chamber
(cross-fall)
+100mm
Longitudinal support unit

Chamber
(cross-fall)
+100mm
Cross bar
Drilling or micro piles.
Fig. 1: Schematic representation of NFF, here with each 6 pickets per CROSS BAR
Date of issue 08/10
Fixed
Slab track
NFF
General
Page: 131-02
The NFF consists of the rails, the rail fastening of longitudinal support unit (e.g. rail fastening system
Krupp ECF), cross fall and the deep foundation consisting of drilling or micro-piles.
The LTE is stored as a two-span beam on the cross bar which in turn supports the piles.
Fig. 2: NFF longitudinal support unit in track curves with the chamber
Diameter, length, number and inclination of the pickets can be adjusted to the ground conditions, the
reduction requirements and the rail characteristics. The inclination of the pickets in the ground can
absorb both vertical and horizontal forces.
The cross bar is advisable on the pickets. The cross bar in turn serves as a support for LTE. LTE and
cross bar consists of precast concrete element, which are produced under optimal conditions and can
be delivered with consistent quality. Only the connection of the cross bar with the pickets is on the
installation site.
Date of issue 08/10
Fixed
Slab track
NFF
Constructive
construction cycle
Page: 131-03
Constructive construction
The following are the individual modules of the NFF are briefly represented in the real building
process.
Deep foundation
The deep foundation serves the load transfer in subsoil and is therefore dependant on load and soil
conditions. The kind of pickets, lengths and diameters can be selected for each individual case. The
dimensioning and design is carried out according to the picket loads of tested statics and soil
properties per geological survey.
Cross bar
The cross bars are pre-cast reinforced concrete dimensioned and reinforced according to the tested
statics. The 108 m long traversing length at the company Rheinkalk built in Wlfrath, cross bars have
a length of (in the direction of the track) 1.5 m, a width of 3.0 m and a height of 0.5 m.
Longitudinal support units (LTE)
The LTE are composite sections made of steel sections and concrete, which is produced as pre-cast
elements. They consist of two longitudinal sleepers, which are connected like a ladder at the ends
and in the middle.
The dimensioning and reinforcement of steel-concrete-composite sections takes place after tested
statistics. The device on the LTE test track has a length of 10.78 m (dimension between centre lines =
10.80 m), a total width of 2.165 m and a height of 650 mm plus 38 mm bump for the rail fastenings.
The LTE is constructed (dimension between centre lines = 5.40 m) as a two-span beam and lie on an
authorised rubber mat on the cross bar. The LTE are already factory provided equipped with rail
fastenings KRUPP ECF.
Fig. 3: NFF longitudinal beam showing the pickets
Date of issue 08/10
Fixed
Slab track
NFF
Schematic
construction cycle
Page: 131-04

In figure a)
is a track section to toughen up,
still shown in its original state.
a) a track section to toughen up

figure b)
shows track section after setting
The deep foundation 1. The track still remains
boundless for use or drivable
b) Track section after settling the

deep foundation
figure c)
shows the state of track section
after the dismantling of the old tracks and
sleepers. The cross bars are already set
and fixed.
c) Track section with cross bars
Date of issue 08/10
Fixed
Slab track
NFF
Schematic
construction cycle
Page: 131-05
After the cross bars are set and fixed,

the laying of LTE can be started
(see Figure d and e).
d) Longitudinal support unit LTE is set
e) further LTE's are set
In figure f), the complete and approved

tracks are presented. The "voids" of LTE
are filled with gravel.
The stopper is completely eliminated!
f) complete gravel work and approved

tracks
Date of issue 08/10
Fixed
Slab track
NFF
Schematic
construction cycle
An overview of the relevant modules is shown in figure g).
g) NFF Track section showing the three component groups
Date of issue 08/10
Page: 131-06
Fixed
Slab track
NBU
Introduction
Page: 132-01
The slab track "system NBU" is a sleeper free and so monolithic design with individual support on a
concrete base (BTS).
The "System NBU is for application area
Ground construction
Bridges and tunnel (also in trough structures)
applicable without restrictions to gauge railways and mass transit systems In 2008, the road network
of DB AG (route 2600 - Aachen - German border with Belgium), a trial track was successfully tested
and approved for continuous operation.
The railway track construction consisting of the rails, rail fastening system, the concrete base (BTS)
"system NBU" and the hydraulically bound base (HGT) is defined in its deflection and damping state.
It requires a low-deformation support on ground construction, on bridges and in tunnels. The
parameters are defined in rule for bridges and in tunnel.
Introduction
System cross-sectional slab track "System NBU"
Longitudinal groove
fusible
joint tape
Rail 60E2
Rail fastening
Asphalt
Covering
Gravel
Fig. 1: Cross-section "system NBU"
The structural design of the overall system allows unrestricted use up to speeds of 300 km/h.
Date of issue 08/10
Fixed
Slab track
NBU
Schematic
construction cycle
Page: 132-02
In the slab track "system NBU", using a slip form paver, a continuously reinforced concrete layer
(BTS) manufactured with longitudinal grooves for receiving the anchor bolts of a rail fastening.
The pre-installed rails with the rail fastening system Krupp ECF (or similar system) are fixed in
longitudinal grooves of the BTS in precise length and lateral position. Subsequently the anchor bolts
of the rail fastening is grouted and straightened in the longitudinal grooves of BTS.

Manufacturing of HGT (hydraulically bound base). The HGT is a part of railway track and is the lower
bound base. Its quality is equal to the concrete C 12/15 (B 15).
Their installation is done single or multi layered depending on the thickness.
Fig. 2: HGT before the production of concrete base
Date of issue 08/10
Fixed
Slab track
NBU
Schematic
construction cycle
Page: 132-03
The BTS is the upper bound base of the railway track. It is reinforced throughout, and will initially
concreted seamlessly. The reinforced concrete body is made with a C 30/37 (B 35). The seamless
BTS is reinforced longitudinally throughout with 20 pieces 20 mm (construction steel BSt 500 S).
At a distance of 20 cm, in the transverse, construction steel of 14 mm is arranged. Thus the
reinforcement content is provided as 0.84%.
Fig. 3: BTS S with reinforcing elements of BST 500 M or BST 500 S
The picture below shows the applied concrete base with integrated longitudinal grooves by a modified
slip-form. Their installation is done single or multi layered depending on the thickness.
Fig. 4: Modified slip-form paver
Date of issue 08/10
Fixed
Slab track
NBU
Schematic
construction cycle
Page: 132-04
Finishing, installation and completion of the route "system NBU"

This is then followed by concealed joint by chamfering (minimum depth 120 mm), whereby ensuring
the overall design of a crack width limit of < 0.5 mm (controlled cracking).
Fig. 5: BTS with introduced grooves
Concrete base with attached rails.
Fig. 6: BTS with rails and rail fastening system
Date of issue 08/10
Fixed
Slab track
NBU
Schematic
construction cycle
Page: 132-05
Completed track section. The longitudinal grooves are grouted by measurement and fixing
the rail position with the grout.
Fig. 7: Completed and freed track section of the slab track "system NBU"
Date of issue 08/10
Crane- &
Depot track
Crane runways
MX-System
Page: 141-01
Rail supports for conveyor vehicle, e.g. cranes are not common trains they should resist high loads
and low speeds and horizontal forces abrade largely on the frictional resistance of the bearing.
Selecting the suitable rail bedding is to be determined in advance, which loads are acting on the rail
system.
In comparison to the continuous storage cheaper discontinuous rail bedding leads to high stresses
on the attachment and is only partially recommended.
The continuous rail support is the long term economic solution in most applications.
Continuous rail bedding
Discontinuous rail bedding
For the storage of rails on a concrete foundation, the MX-rail bedding has been designed with the
MX-rail fastening.
The MX-rail fastening system is defined by the new VDI-guideline 3576, a guidance system, i.e. the
rail foot is not clamped, but is run free from backlash. Linear expansion, e.g. with the effect of
temperature, does not lead to deflection of terminal screws or ground anchors, but is not effective in
the MX-system.
The MX-rail bedding, continuously or discontinuously includes the entire rail bedding including the
grouting.
Crane rails
Prefabrication of crane rails (planing, milling, drilling, bevel cuts).
MX-crane rail fastening system
Elastic MX-intermediate layer made of special material to prevent the incorporation of rail foot
in the bedding, insulation of driving noise and reduction of stress peaks.
Steel rail bedding
MX-anchoring and fastening material
Precision casting material MINEX Grout and MINEX EP Grout
End delimiter
In addition, we also offer the surveying of your crane rail with automatic crane rail surveying system
railcontrol.
Date of issue 08/10
Crane- &
Depot track
Crane runways
MX-system description
Page: 141-02
The crane rail fastening system from ThyssemKrupp is available as a powerful screw system (MX)
and as welding system (MXA), as simple or highly resilient, dual system.
The outstanding advantage of a designed system by a structural engineer from Hamburg lies in the
principle of the rail guide - the rail is held sideways, but not clamped from the top. The fastening
material is the (shear) loading due to temperature changes and not exposing the braking of vehicle.
The closed, flat design protects it from dirt. The draw-lead connector is a secure screw; the eccentric
allows a step less lateral adjustability.
The system designation comprises of:
the letters MX (screw system) or MXA (welding system)

of 4 or 5 numbers.
The first two digits represent the system height (rail foot thickness + intermediate layer thickness +
minimal air gap). The last two letters stands for the diameter of a bolt (M16, M20 or M24). The middle
number stands for simple or dual system. For historical reasons, this is not implemented consequently
in the simple screwing system. - these are named only with four numbers.
Example MX1820:
Simple screw system with screw bolts M20 for rails 60E2:
MX: Screw system
18:
12.5 mm thicker rail foot + 5 mm thick intermediate layer + 0.5 mm air gap.
20:
Screw M20
max. plus
position
neutral
position
max. minus
position
Rail foot thickness
MX-Intermediate layer thickness

MX-Guide height
Date of issue 08/10
Crane- &
Depot track
Crane runways
Version 1
with screw head
on the top
Version 2
with the screw
on the top
MX-System screwed
Page: 141-03
Version 3
with medium high
Nut
Version 4
with counter sunk
screw V60 / V90
Double system
Simple system
Name
MX1316
MX13216
MX1516
MX15216
MX1520
MX15220
MX1820
MX18220
MX1524
MX15224
MX1524-20
MX15224-20
MX1824
MX18224
MX1824-20
MX18224-20
MX2124
MX21224
MX2124-20
MX21224-20
MX2424
MX24224
MX2424-20
MX24224-20
MX2624
MX26224
MX2624-20
MX26224-20
e [mm]
+/- 5
+/- 6.5
+/- 8
+/- 10
+/- 8
+/- 10
+/- 8
+/- 10
+/- 8
+/- 10
+/- 8
+/- 10
Date of issue 08/10
S [mm]
13
15
15
18
L [mm]
60
60
61
62
65.5
15
93
18
93
21
93
24
93
26
93
System overview
B [mm] H1
H2
[mm] [mm]
44
95
27
39.5
44
95
56
110
32
44.5
56
110
70
140
36
50.5
70
140
70
140
36
50.5
70
140
70
140
36
50.5
70
140
70
140
36
50.5
70
140
70
140
36
50.5
70
140
H3
[mm]
34.5
39.5
H4
[mm]
20
22
23
26
35.5
23
35.5
26
35.5
29
35.5
32
35.5
34
max horizontal
Load [kN]
38
76
38
76
75
150
75
150
125
250
75
150
125
250
75
150
125
250
75
150
125
250
75
150
125
250
75
150
Crane- &
Depot track
Name
MXA13116
MXA13216
MXA13120
MXA13220
MXA15116
MXA15216
MXA15120
MXA15220
MXA18116
MXA18216
MXA18120
MXA18220
MXA21116
MXA21216
MXA21120
MXA21220
MXA24116
MXA24216
MXA24120
MXA24220
Crane runways
MX-System welded
Page: 141-04
Version 1
standard
Version 2
with medium high nut
simple system
double system
S [mm]
13
15
18
21
24
Date of issue 08/10
e [mm]
L [mm]
+/- 5
79
+/- 7.5
95
+/- 5
79
+/- 7.5
95
+/- 5
79
+/- 7.5
95
+/- 5
79
+/- 7.5
95
+/- 5
79
+/- 7.5
95
System overview
B [mm] H1 [mm]
85
46
150
105
54
185
85
46
150
105
54
185
85
46
150
105
54
185
85
46
150
105
54
185
85
46
150
105
54
185
H2 [mm]
41
49
41
49
41
49
41
49
41
49
max horizontal Load [kN]

55
140
125
200
55
140
125
200
55
140
125
200
55
140
125
200
55
140
125
200
Crane- &
Depot track
Crane runways
Discontinued Storage
with MXA-System
Page: 141-05
Version 1
2 Ground anchor
Version 2
4 Ground anchor
9
8
7
6
5
4
3
2
1
Pos.
1
1
4
6
2
4
2
2
2
2
2
2
1
1
1
1
1
1
Version 1
Version 2
Number / Rail bedding
Date of issue 08/10
MINEX Grout / EP Grout

Plastic impact cap
MX-ground anchor with nut and washer
Screw system with nut and washer
Pressure plate
Guide plate
MX-intermediate layer
MX-rail bedding
Vignol rail
Designation
Crane- &
Depot track
Crane runways
Discontinued Storage
with MXA-System
Page: 141-06
Version 1
2 Ground anchor
Version 2
4 Ground anchor
10
9
8
7
6
5
4
3
2
1
Pos.
1
1
4
6
2
4
2
2
2
2
2
2
2
2
1
1
1
1
1
1
Version 1
Version 2
Date of issue 08/10

Plastic impact cap
Base plate
Pressure plate
Guide plate
MX-rail bedding
Vignol rail
Designation
Crane- &
Depot track
Crane runways
Continued Storage
with MXA-System
Page: 141-07
* The adjusting screw are detached according to

the height adjustment.
10
9
8
7
6
5
4
3
2
1
Pos.
6
1
20
10
10
10
10
1
1
1
Date of issue 08/10
Adjustable screws *
Plastic impact cap
Pressure plate
Guide plate
MX-rail bedding
Crane rail
Designation
Crane- &
Depot track
Crane runways
Continued Storage
with MXA-System
Page: 141-08
* The adjusting screw are detached according

to the height adjustment.
11
10
9
8
7
6
5
4
3
2
1
Pos.
6
1
20
10
10
10
10
10
1
1
1
Date of issue 08/10
Adjustable screws *
Plastic impact cap
Base plate
Pressure plate
Guide plate
MX-rail bedding
Crane rail
Designation
Crane- &
Depot track
Crane runways
MX-bottom casting
Page: 141-09
ThyssenKrupp MX Precision casting materials

Our decades of experience have shown that the bottom casting of steel rail support on concrete and
its processing quality is crucial to the longevity of the crane runway. It plays a role especially at a
discontinuous storage, because by the continuous stress, by edge pressure, the material is stressed.
Why to use a bottom casting at all? Due to constant stress to operational and environmental
influences, the steel rail support must be grouted to the entire surface. Is not the case that voids are
present and movement is possible? This leads to a progressive destruction of the lower casting. The
result is a cost associated with downtime and restoration. To avoid this, ThyssenKrupp MX
precession casting materials are avaiable for complete surface grouting. Concrete is not
recommended as a cast - the structure is not suitable and cause additional voids by shrinking. For no
more cross sectional steel profiles, we recommend the elastic MX PUR 880-6.
Designation
Graining
[mm]
Barrel
min. pressure
resistance
[N/mm]
2h
MX
Grout 1
MX
Grout 5
MX
Grout 16
MX
Grout S 1
MX
Grout S 5
MX
Grout S 16
MX Grout
16
reinforced
min. bending
tensile strength
[N/mm]
Bottom
casting
height
[mm]
1d
7d
28 d
28 d
0 -1
40
60
80
10
10 - 25
0 -5
40
70
83
10
20 - 100
0-8
40
70
85
10
50 - 200
0-1
0-5
25 kg
Sacks
0-8
0-8
MX EP
Grout
MX PUR
880-6
Date of issue 08/10
15 kg
Combined
metal sheet
bucket
2 kg
15
30
75
10 - 25
15
30
80
20 - 100
15
30
85
50 - 200
Note
Precision grout
Very high
Early strength;
recommended
for winter
construction
sites
With steel fibres
At scheduling
high pressure,
flexural and
shear loads
45
75
81
11
50 - 200
40
70
90
45
20 - 80
2-component
Reactionplastic grout
30
to balance
of not more
scatter
cross-section
Steel beams
Shore hardness = 85-95 at 20 to 7d

mechanically fully resilient after 24h
Crane- &
Depot track
Crane runways
Surveying system
Railcontrol
Page: 141-10
Automatic crane rail surveying system RailControl

Whatever (rail) profile, regardless of inclination your crane runway has, we can measure them threedimensionally - quickly and competently. The system RailControl was designed for automated
surveys for crane runways (Crane lifts, gantry crane lifts, sloped runways, etc.). With a vehicle,
travelling along the rail on its own, a continuous and fast measurement of rails (e.g. crane rails, vignol
rails, rectangular profiles) is possible. Measuring with an engineering tachymeter, you get an exact
size, highest accuracy and special software:
Gauge of the track

Position of a rail
Height of the track
Max. run out tolerance
Inclination of a rail
3D Data
millimetre accurate All the figures are according to VDI 3576, and ISO 12488-1. The position will be
automatically registered in close succession and then evaluated. Furthermore, there is a possibility to
hang test coach on the crane (crawl operation) and perform a measurement with heavily loaded crane
runway. In the analysis it can be determined how the crane runway acts as compared to the unloaded
state.
Possible reasons and advantages for the measurement of RailControl:
Short downtime of your system / crane runway

Before commissioning new cranes on existing runways
To document the location and height of new runways
Damage analysis / damage assessment
As part of predictive maintenance
Assessment of the utilization of a hall construction
Quality assurance / minimising of abrasion
Health and safety / occupational safety
The usual scaffolding not applicable in crane lifts.
We measure for you - quickly and competently. In Germany and world wide.
Date of issue 08/10
Crane- &
Depot track
Crane runways
Crane runwy beams
Page: 141-11
The ThyssenKrupp crane runway beams is a precast concrete element, which is laid on flat
foundation and results a monolithic slab track for gantry cranes. It was designed for the requirements
of settling areas, as they can be found for example in port areas. The crane runway beams boasts
outstanding economy over the entire service life (Life Cycle) and enormously rapid laying
compatibility. Through the latter it is particularly suitable for the modernisation (retrofit) of container
terminals, which will be converted to automatic operation.
To react to the settlements, there is a possibility to correct the entire slab track in position and
height. In height they are at least 30 cm!
The system is completely free in its dimensioning and can be adapted to the local conditions and
loading images.
ThyssenKrupp GfT Gleistechnik has designed this innovative product in collaboration with the HHLA
CT civil engineering and comes world wide for the first time in use on the automatic container terminal
Burchardkai in Hamburg.
MX-fastening
Date of issue 08/10
Crane &
Depot tracks
Depot tracks
Rail supports
Storage track- and wash tracks
Page: 142-01
Support points on utility and laundry tracks have special requirements on the electrical insulation.
Furthermore, at times highly aggressive special attention should be paid to the corrosion resistance.
The present design meets all these requirements. It is completely insulated electrically coupled with
optimum corrosion resistance.
Self understood, that the production of large cross-falls of the track surface is used to drain the used
fluids and use of common rail profiles is readily available.
7
6
5
4
3
2
1
Pos.
2
2
2
1
2
1
1
Date of issue 08/10
Protective cap
Spring washer
Anchors with screws
Support plate
Rail clamps
Intermediate level
Rail
Designation
Crane &
Depot tracks
Depot tracks
Rail fastening
Working pits
Page: 142-02
For optimal functionality of working pits as few distractions in the work area are required. With the
represented construction, maximum internal diameters for all gauges and thus minimum disturbing
elements can be achieved. The rail fastening has a small width and allows - if necessary - to insulate
the rail electricity. The execution is possible with each rail section.
8
7
6
5
4
3
2
1
Pos.
1
2
2
2
1
2
1
1
Date of issue 08/10
Chamber filling
Countersunk screw
Sleeper screws
Anchor
Hooked tie plate
Rail clamps
Insulating sheath rail
Rail
Designation
Crane &
Depot tracks
Depot tracks
Rail fastening
Steel supports
Page: 142-03
The illustrated rail fastening on a steel support is infinitely adjustable for height and elevation. Here,
too, if necessary, the rail can be electrically insulated. The execution is possible with each rail profile.
7
6
5
4
3
2
1
Pos.
2
2
2
2
1
1
1
Date of issue 08/10
Pipe supports
Hexagonal nut
Fastening screw
MX-fastening, laterally adjustable
Support plate
Insulating sheath rail
Rail
Designation
Specialconstructions
Guard rails
Guard rail tracks

R = 100 m mit RL 1-60
Page: 151-01
Guard rail track with running rail 54E4 and guard rail Rl1-60 to support analog Rp 71/241,
Level surface SO, groove width 60 mm.
Date of issue 08/10
Guide rails
Krupp ECF 49E5 / 54E4

Concrete with TK-DENA
Page: 152-01
The vibration damping rail bedding Krupp ECF is laid on the concrete slab, designed, powered and
sealed with MINEX-Grout.
The groove width of the guide is set according to on-site requirements and considered in the
construction and arrangement of the support.
The accuracy of the concrete slab is standard for the construction and design of the system.
Special grout MINEX-grout
Date of issue 08/10
Base plate
Guide rails
60E2 made of concrete

(B 355 W60M-S)
Page: 152-02
Guide rail layout on dual-block sleeper B 355 W60M-S track system Krupp GfT DENA
Dual block sleepers

B 355 W60M-S
7
6
5
4
3
2
1
Pos.
1
2
1
1
1
1
1
Number / Support point
Date of issue 08/10
Sealing plug
GPN 300 F 37
Bolt connection
Hexagonal nut
M24
Hexagon head bolt
M24 x 60
Spacer plate
Zwp 80 - Stp F
Baffle mounting plate
100 x 50
Guide support point

Designation
Stp F355
Brief description
Guide rails
60E2 made of concrete

(B 93)
Page: 152-03
Guide rail layout on concrete sleeper B 93 track system Krupp GfT DENA
* rail fastening is represented according lowa 10,0018

* applies for rail fastening according to lowa 10,0012: 195 mm
Concrete sleeper B 93
7
6
5
4
3
2
1
Pos.
1
2
1
1
1
1
1
Date of issue 08/10
Sealing plug
GPN 300 F 37
Bolt connection
Hexagonal nut
M24
Hexagon head bolt
M24 x 60
Spacer plate
Zwp 80 - Stp F 93
Baffle mounting plate
100 x 50
Guide support point
Stp F93
Brief description
Designation
Rail grooves
tracks
Heinrich Krug - Form 49

for 49E5 / 54E4 / 60E2
Page: 153-01
The rut rails are suitable as asphalt, concrete and plaster protected for vignol rails ranging from
depots, assembly halls and road crossings.
Through processing or use of adapters, the combination with the most vignol rails is possible.
Rail 60E2
Dual washer Fe6

Rut rail screws
Rail 49E5
Rail 54E4
Dual washer Fe6

Rut rail screws
Date of issue 08/10
Rut rail screws
Date of issue 08/10
Page: 211-01
Special forms of crane rails
Overview of commonly
used rail types
Crane rails
Rails
Grooved rails
Vignol tracks
Track materials
Track materials
Rails
European standards
DIN EN 13674-1:2008-01
Page: 211-02
The European standard DIN EN 13674-1 existing since year 2003. The following changes to the basic
standard UIC-Kodex 860 V have been made:
a.
b.
c.
d.
e.
f.
g.
h.
i.
k.
Rail designations from e.g. UIC 60 in 60E1.

Rail designations "Vignol rails" instead "flange rail.
Rails affiliated only from 46 kg/m.
All types of steel designations have been changed, wherein serves as a scale basis no longer
the tensile strength, but the minimum hardness of the runway.
The steel grade R0550 (1.0422) is removed.
In a slightly different chemical composition steel grade was maintained:
f.1.
700 (1.0521) - replaced by the grade R200
f.2.
900A (1.0623) - replaced by the grade R260
f.3.
900B (1.0624) - replaced by R260Mn (variant of the grade R260 with lower
C-content higher Mn-content)
f.4.
1100 (1.0915) - replaced by grade R320Cr
f.5.
1200 (1.0631) - replaced by R350HT
Additionally the steel grades affiliated were R220 (tensile strength 770 MPa) and R350LHT
Determining the mechanical properties and identification of heat treated rails.
Qualification tests for the manufacturer's approval were determined.
Extensive illustrations intended to sampling and testing, on rail profiles and gauges.
The document DIN EN 13674-1:2008-01 was designed by a technical committee CEN/TC256

"Railway track engineering products" and supports requirements of EU directives. According to the
national standards bodies, the decisions are kept to implement this European standard.
The European standard DI EN 13674 covers for railway applications - railway track - rails the
following parts:
Part 1: Vignol rails from 46 kg/m
Part 2: Rails for turnouts and crossings, which are used in connection with vignol rails from 46 kg/m
Part 3: Check rails
Part 4: Vignol rails with a linear mass between 27 kg/m and under 46 kg/m
Parts 2, 3 and 4 have validity since August 2006. The Standard for grooved rails and associated
construction section (DIN EN 14811) was adopted in October 2006.
The DIN EN 13674-1 refers to the European quality management standard DIN EN ISO 9001 and
includes amongst others:
1. Qualification test
2. Specification test
Date of issue 08/10
Track materials
Rails
Differences
UIC-K 860 E - DIN EN 13674-1
Page: 211-03
Difference between UIC-Kodex 860 E and DIN EN 13674-1:2008-01

The European Standard 13674-1
includes the following qualification tests for steel rails:

- Fracture toughness (KIc), Paragraph 8.2
- Assessment of crack growth rate, Paragraph 8.3
- Dynamic fatigue test, Paragraph 8.4
- Determination of the residual stresses in the rail foot, Paragraph 8.5
- Profile of the surface hardness on the runway at HH - rails, Paragraph 8.6
- Determination of tensile strength and elongation using a regression formula, Paragraph 8.7
regulates the hydrogen and oxygen content and also the accompanying elements such as
amongst Al, V, N, Cu, Sn etc.- Table 4, Paragraph 9.1.2
regulates surface decarburisation - Table 4, Paragraph 9.1.4
regulates efficiency of the rails - Table 4, Paragraph 9.1.5
contains sulphur prints, Paragraph 9.1.6 (Appendix D)
allows tensile test only once every 2000 t under the condition of a regression formula
refer to the rails after the minimum hardness, such as R260, instead of its minimum strength,
such as 9000A according to UIC-Kodex 860 E
refer the new rail sections (60E1 instead UIC 60), Appendix A, Page 43
includes the profile drawings (which were earlier included in UIC 861)
allows two profile classes (X,Y) and two straightness classes (A,B) and on the contrary defines
UIC-Kodex 860 E also the straightness between the ends, paragraph 9.2
defines the criteria for testing gauge as well as the methods of measurement, Paragraph 9.3
defines the test criteria for Us-audit, Paragraph 9.4.1
specifies criteria/tolerances and surface finish, paragraph 9.4.2
regulates the procedure for interoperability EU-Directives, Paragraph ZA
is a pure material and testing standards
no more includes the impact test (see Paragraph 2.6, UIC-Kodex 860 E)
Date of issue 08/10
Track materials
Rails
Old and new

Rail designations
Page: 211-04
Overview of old and new rail designations
Vignol and grooved rails

Vignol rails according to
DIN EN 13674-4:2008-01
new
old
30E1
S 30
33E1
S 33
40E1
S41 R14
41E1
S41 R10
Vignol rails according to
DIN EN 13674-1:2006-08
new
old
49E1
S 49
49E5
50E4
UIC 50
54E3
S 54
54E4
54E1
UIC 54
60E1
UIC 60
60E2
60E2-40
-
grooved rails, RI-special section

according to DIN EN 14811:2006-10/12
new
old
53R1
Ri 53N
Ri 55N
59R1
Ri 59
59R2
Ri 59N
60R1
Ri 60
60R2
Ri 60N
57R1
Ph 37
67R1
Ph 37a
Ph 37N
52R1
Ri Ir
56R1
Ri Ic
75C1
BA 75
76C1
VK Ri 60
105C1
D 180/105
310C1
BL180/260
Rails for crossings and turnouts

Switch rail according to
DIN EN 13674-2:2006-08
new
old
49E1A1
Zu 2-49
54E1A2
Zu 1-54
54E1A1
ZuUIC54B
60E1A1
Zu 1-60
Zu60E2-40
Check rail according to
DIN EN 13674-3:2006-08
new
old
36C1
48C1
33C1
RL1-49
RL1-54
RL1-60
Date of issue 08/10
Full-web rails according to

DIN EN 13674-2:2006-08
new
old
49E1F1
54E3F1
54E1F1
Vo60E2-40
60E1F1
60E2A2
60E2A3
Vo1-49
Vo1-54
Vo1-UIC54
Vo1-60
Zu60E2-40
60E2A1-20
Track materials
Rail steels
Rails
Chem. composition
and mechanical values
Chemical composition %
C
Si
Mn
0.15 0.58
0.20 0.60
0.15 0.58
0.15 0.60
0.50 1.10
0.15 0.58
0.15 0.58
0.70 1.20
1.00 1.25
0.70 1.20
1.30 1.70
0.80 1.20
0.70 1.20
0.70 1.20
Cr
Tensile
strength
Rm
MPa and
N/mm2
0.15
0.030
680
14
200 - 240
0.15
0.030
770
12
220 - 260
0.15
0.030
880
10
260 - 300
0.15
0.030
880
10
260 - 300
0.80 1.20
0.18
1080
320 - 360
0.15
0.030
1175
350 - 390
0.30
0.030
1175
350 - 390
1)
Page: 211-05
Stretching
A5 %
Hardness
HBW
Steel grades
2)
according to DIN EN 13674-1
R200
R220
R260
R260Mn
R320CR
R350HT
R350LHT
0.40 0.60
0.50 0.60
0.62 0.80
0.55 0.75
0.60 0.80
0.72 0.80
0.72 0.80
0.035
0.025
0.025
0.025
0.020
0.020
0.020
0.008 0.035
0.008 0.025
0.008 0.025
0.008 0.025
0.008 0.025
0.008 0.025
0.008 0.025
according to UIC-Kodex 860 E (2008-01) )

700
900 A
900 B
1100
0.40 0.60
0.60 0.80
0.55 0.75
0.60 0.82
according to AREMA (2009)

Standard steel
0.74 0.86
grades
5
according BS 11 (1985) )
normal
A
B
0.45 0.60
0.65 0.80
0.55 0.75
4)
0.05 0.35
0.10 0.50
0.10 0.50
0.30 0.90
0.80 1.25
0.80 1.30
1.30 1.70
0.80 1.30
0.10 0.60
0.75 1.25
0.05 0.35
0.10 0.50
0.10 0.50
0.95 1.25
0.80 1.30
1.30 1.70
0.050
0.050
680 - 830
14
0.040
0.040
880 - 1030
10
0.040
0.040
880 - 1030
10
0.030
0.030
1080
0.020
0.020
980
10
0.040
0.040
710
0.040
0.040
880
0.040
0.040
880
Steel grades for grooved rails and Ri-special section (DIN EN 14811)
R200
R220G1
R260
R260GHT
R290GHT
R340GHT
0.40 0.60
0.50 0.65
0.62 0.80
0.40 0.60
0.50 0.65
0.62 0.80
0.15 0.58
0.15 0.58
0.15 0.58
0.15 0.58
0.15 0.58
0.15 0.58
0.70 1.20
1.00 1.25
0.70 1.20
0.70 1.20
1.00 1.25
0.70 1.20
0.80 1.30
0.20
6)
0.035
0.035
680
14
200 - 240
0.025
0.025
780
12
220 - 260
0.025
0.025
880
10
260 - 300
0.035
0.035
880
12
260 - 300
0.025
0.025
960
10
290 - 330
0.025
0.025
1175
340 - 390
1) Check analysis deviant

2) Delivery specifications of the European Committee for Standardisation
3) Delivery specifications of the Internal Union of Railways
4) Delivery specifications of the American Railway Engineering Association and Maintenance-of-Way Association
5) Delivery specifications of the British Standards Institution
6) Delivery specifications of the European Committee for Standardisation
Date of issue 08/10
310
Track materials
Rails
Mechanical and
electrical properties
Page: 211-06
Yield point (Rp0,2) [N/mm2]
Yield ratio for different rail grades
Tensile strength [N/mm2]
The electrical conductivity is dependent on the chemical compositions of the rail steels, in particular
the Si-content. In the rail steels R200, R220, R260, R260Mn and R320Cr, the following values for the
electrical conductivity can be observed:
R200
R220
R260/Mn
R320 Cr
4.6 - 4.8 Sm/mm

4.4 - 4.7 Sm/mm
4.3 - 4.6 Sm/mm
3.0 - 3.3 Sm/mm
Continuous welded rail: Rails were formerly connected with tabs. There must be an expansion gap
considered for the thermal expansion. Today, modern rail track systems are welded. They are called
completely welded rails. The forces generated by the thermal expansion are taken up by the rail
fastening and discharged over the threshold into the gravel track.
Change in rail length L due to temperature change:
L = L0 x T x
L0
T
= Rail length in mm
= Temperature change in C
= Expansion coefficient for steel: approx. 0.000012 [-]
Example:
L0 = 120,000 mm
T = 60 C
L = 120,000 x 60 x 0.000012 = 86.4 mm
Date of issue 08/10
Track materials
Rails
Bearing marks according to

DIN EN 13674-1
Page: 211-07
The European Standard DIN EN 13674-1:2008-01 determines the labelling of rails.

The bearing marks are raised on a rail side at a distance of more than 4 m to roll on. The bearing
marks must be clearly readable on the rails and have a font size of 20 mm to 25 mm and raised to 0.6
mm to 1.3 mm. The distinguishing bearing marks of the steel grades must have a length of 50 mm for
the long labelling line and from 25 mm for the short labelling line.
The bearing mark must contain the following information:
Features of a manufacturer
steel grades
the last digits of the year of manufacture
Designation of the rail section
Steel grades
Description
Type of bearing marks
R200
R220
Hardness range
HBW
200 to 240
220 to 260
Carbon-manganese (C-Mn)-steel
without bearing marks
R260
260 to 300
R260Mn
260 to 300
R320Cr
320 to 360
alloy steel (1% Cr)
R350HT
350 to 390
R350LHT
350 to 390
steel grades
thermally annealed
Low-alloy steel, thermally
annealed
Example for a bearing mark:
In addition to the bearing mark, each rail must be characterised with a numeric and/or alphabetical
code, which is on the opposite side of the bearing mark of the base, continuously inculcate at least
once every 5 meters. In line with the current version of the standard, the distance of 10 m has been
set.
Date of issue 08/10
Track materials
Rails
Bearing marks according to

UIC-Kodex 860 E
Page: 211-08
The UIC-Kodex 860 E still exist parallel to the EN 13674-1 and is described in Paragraph 1.3
of the identification of rails. The bearing marks are raised on a rail side, according to the choice
of manufacturer between 20 and 30 mm, to be rolled with a relief height of minimum 0.8 mm.
The bearing mark must contain the following information:
features of a manufacturer
the last digits of the year of manufacture
designation of the rail section
steel grades
Steel grades
Symbol for the melting process
Quality
Type of bearing marks
Method
700
900 A
900 B
without bearing marks
On the basis of open

hearth process
1100
Example for a bearing mark:
Date of issue 08/10
Electric process
Basic oxygen steelmaking
Sign
Track materials
Rails
Profile tolerances and

Rectitude for vignol rails
Page: 211-09
Profile limit deviations (tolerances) and straightness for vignol rails from 46 kg/m
The profile classes X and Y define according to DIN EN 13674:2008-01 the profile limit deviations.
As per the requirements of high-speed rail line (> 160 km/h) refers to the profile class X,
while the class Y is tangent to the normal rail lines.
Rail height
< 165 mm
165 mm
Width of the rail head

Rail symmetry
Web thickness
Width of rail foot
Rail foot thickness
Concavity on the rail foot
Profile class
(measurement in mm)
X
Y
0.5
+ 0.5 / - 1.0
0.6
+ 0.6 / -1.1
0.5
+ 0.6 / - 0.5
1.2
1.2
+ 1.0/ - 0.5
+ 1.0 / - 0.5
1.0
+ 1.5 / - 1.0
+ 0.75/ - 0.5
+ 0.75/ - 0.5
max. 0.3
max. 0.3
For straightness the classes A and B are fixed. A for the high-speed rail lines (> 160 km/h),
B for the normal rail lines. Then the straightness of the rail body (between the ends) is for the
classes A to 0.3 mm < 3 m, for class B to 0.4 mm < 3 m.
Perpendicularity of the rail ends

(0.6 mm in all directions)
Length tolerance of the rails

Length drilled on both sides
L 24 m
L > 24 m
L 40 m
3 mm
4 mm
4 mm
For other lengths (without holes) or with holes at one end of 1 mm/m rail (max. 30 mm
on the rail length).
The limit deviations in rails are for particular applications without holes up to 24 m long 6 mm, in
rails greater than 24 m length 10 mm.
The specified rail lengths apply to +15 C. If measurements are performed at different temperatures,
expansions or contractions are to be considered by corrections.
Date of issue 08/10
Track materials
Rails
Rail lengths
Page: 211-10
Rail lengths
Guideline 820.2120 Para. 3 (1) Fundamentals of tracks, design of tracks and turnouts; rails;
here: Rail lengths.
With the known guideline the use of rail lengths is provided as follows:
Complete tracks - basically rails > 100 m length (the theme bearing length and so the delivery
here is not tangent; only the installation length is provided).
v > 230 km/h - exclusive tracks of bearing lengths > 100 m
200 v 230 km/h - means already at v > 160 km/h exclusive tracks of bearing lengths 60
m lengths
The current status of the particular welding technique (see "Influence of different welding processes")
allows the following rule (put into effect 31.07.2002):
for the range of v > 230 km/h an opening for the use of factory-welded 60 m rails
for the range up to 200 km/h an opening for the use of factory-welded 30 m rails
With reference to an increasing freedom at the planning and execution of a site, an opening
for use of rail lengths under 100 m (overall length, not bearing length).
Depending on the area of application, however at the same time, to provide additional requirements
on the geometric quality compared to the previously approved additional welds / rail ends.
Influence of different welding processes:
The quality of welds is influenced by applying next welding process, i.e.:
stationary flash butt welds as factory welds (qualitative high quality welding);
mobile flash butt welds as construction welding (metallurgical similar to the stationary welding;
however smears with reference to geometric quality, similar to aluminothermy welds)
aluminothermy construction welding (standard welding construction sites, which has reached
in terms of welding portions and process technology a standard of quality that approaches the
flash butt welding.)
Manual metal arc welds are not considered as not relevant here.
Date of issue 08/10
Track materials
Rails
New rules for the

use of rail lengths
Page: 211-11
New regulations for the use of rail lengths

Bearing length 30 m
V max
RA(5)
(Factory)
160 km/h
160 < v 200
km/h
200 < v 230
km/h
v > 230 km/h
Yes
Bearing length 60 m
RA(5)
(Installation
AS(6)
location)
Yes
No
(Factory)
Yes
RA(5)
(Installation
AS(6)
location)
Yes
(1)
No
RA(5)
(Factory)
RA(5)
(Installation
AS(6)
location)
Yes
Yes
Yes
No
No
Yes
(2)
Yes
(4)
No
(1)
Yes
Yes
Yes
No
No
No
Yes
(2)
Yes
(4)
No
(1)
Yes
Yes
Yes
No
No
No
Yes
(3)
No
Yes
Yes
Yes
(2)
(1)
RA(5)
Bearing length 120 m
No
No
(except SS)
Explanations:
1) Opening against the previous default of Ril. 820,2120, 3 (1): "For complete tracks, rails usually in
lengths > 100 m to deliver on the site."
The values below "d" are to be observed in the entire range of 3 m in front and behind the
weld!
2) News of rail ends and weld joint in the production with the following requirements:
vertical flatness*:
horizontal flatness*:
d 0,4 mm at L = 3.0 m and d 0.3 mm at L = 1.0 m

d 0,6 mm at L = 1.5 m
3) News of rail ends and weld joint in the production with the following requirements:
vertical flatness*:

d 0,45 mm at L = 1.5 m
4) News of rail ends and weld joint in the production with the following requirements on the
construction site:
vertical flatness*:

d 0,6 mm at L = 1.5 m
(5) RA = Flash butt welding

(6) AS = aluminothermy welds
* matched to the design CEN - Standard Pr 13674-1 Table 9
Significant changes
Date of issue 08/10
Track materials
Rails
Minimum length of rails

High support the Welds
Page: 211-12
Rails minimum lengths and maximum numbers of welds according to Ril. 820.0120 (new rails)
Rail lengths
80
5
m
30
> 30 to 60
> 60 to 90
> 90 to 120
> 120 to 180
4
8
12
16
24
4
5
Rails
All rails
Conductor speed (km/h)
120
160
230
Rails minimum lengths (m)
10
12
15
Maximum number of welds (piece)
2
1
1
5
2
2
7
4
3
9
6
4
14
9
6
300
30
0
0
1
1
2
Minimum rail lengths may not exist at the end of the finished rail.
For the minimum lengths replacement, pass, transition connecting bars apply Ril 820 01 04
and Ril 820 03 18.
For high-speed rail lines (v > 160 km/h) only welded rails which are removed according to DBS 918
254-1 These tracks are labelled from the manufacturing factory marked on the bearing side at each
rail end, the brush stroke in green oil paint about 20 cm long and 3 cm wide.
Approved only for installation in NBS according to Ril 820 01 04.
New rails with bearing lengths 100 m or

180 m long units, to be welded for 60 m long new rails.
Date of issue 08/10
Date of issue 08/10
[mm]
108.00
134.00
138.00
138.00
149.00
154.00
152.00
159.00
172.00
33E1 (S 33)
41E1 (S41 R10)
40E1 (S41 R14)
49E1 (S 49)
54E4 (S 54)
50E4 (UIC 50)
54E1 (UIC 54)
60E1 (UIC 60)
150.00
140.00
125.00
72.00
70.00
70.00
67.00
67.00
67.00
67.00
58.00
60.30
[mm]
Head
width
C1
74.30
72.20
72.20
70.00
70.00
67.00
67.00
58.00
60.30
[mm]
Head width
below
C2
16.50
16.00
15.00
16.00
14.00
12.00
12.00
11.00
12.30
[mm]
Base
thicknes
51.00
49.40
49.40
55.00
51.50
43.00
43.00
39.00
31.00
[mm]
Head height
in total
11.50
11.00
10.00
12.00
10.50
9.48
9.48
9.50
7.04
[mm]
Foot
thicknes
7670.00
6977.00
6428.00
6948.00
6292.00
5217.00
5253.00
4264.00
3839.00
[mm ]
Cross
section
60.21
54.77
50.46
54.54
49.39
40.95
41.24
33.47
30.13
[kg/m]
Weight
3038.30
2337.90
1934.00
2074.00
1816.00
1366.90
1382.10
1040.30
608.20
[cm ]
Inertia
moment
JX
333.60
278.70
252.30
262.70
240.30
195.90
199.30
156.00
108.50
[cm ]
Resistance
moment
Wx
Vignol rails
125.00
125.00
125.00
125.00
105.00
108.00
[mm]
Foot
width
Rail
height
30E1 (S 30)
Rail forms
Rails
Railway track bearing sections vignol rails
Track materials
Page: 212-01
Date of issue 08/10
[mm]
50.00
58.00
70.00
82.00
82.00
90.00
65.00
70.00
80.00
93.00
100.00
115.00
S7
S 10
S 14
S 18
S 20
S 24
Foot
width
Rail
height
[mm]
Rail forms
53.00
44.00
43.00
10.00
10.00
10.00
9.00
6.00
5.00
[mm]
Base
thicknes
30.50
27.00
25.40
22.00
21.30
15.60
[mm]
Head height
in total
7.00
6.00
5.00
4.80
4.00
3.20
[mm]
Foot
thicknes
3110.00
2520.00
2330.00
1780.00
1270.00
859.41
[mm ]
Cross
section
24.43
19.80
18.30
14.00
10.00
6.75
[kg/m]
Weight
569.00
346.00
278.00
154.00
85.70
51.60
[cm ]
Inertia
moment
JX
97.30
66.80
58.10
36.90
24.40
15.20
[cm ]
Resistance
moment
Wx
Vignol rails
Narrow-gauge railways
38.00
32.00
25.00
[mm]
Head
width
Rails
Railway track bearing sections vignol rails

Light rails / light rail profiles
Track materials
Page: 212-02
Date of issue 08/10
150.00
180.00
180.00
180.00
180.00
180.00
150.00
180.00
180.00
180.00
180.00
180.00
Ri 55N
59R1 (Ri 59)
59R2 (Ri 59N)
60R1 (Ri 60)
60R2 (Ri 60N)
Ri 60 N/L
150.00
180.00
180.00
182.00
180.00
180.00
57R1 (Ph 37)
67R1 (Ph 37A)
Ph 37N
133.75
135.00
127.00
60.02
60.00
51.92
56.00
55.83
113.00
113.00
56.00
55.83
113.00
113.00
56.00
56.00
113.00
113.00
55.83
[mm]
Driving
head width
C2
113.00
[mm]
Head
width
total
C1
58.21
60.60
60.46
36.00
36.34
36.00
42.52
42.00
36.00
36.34
Grooved
width
C3
13.00
13.00
11.00
12.00
12.00
12.00
12.00
12.00
12.00
12.00
[mm]
Base
thickness
43.85
43.85
43.50
41.15
41.15
41.15
41.15
41.15
41.15
41.15
[mm]
Head
height
in total
9.00
9.00
8.50
8.00
8.00
8.00
8.00
8.00
9.50
9.50
[mm]
Foot
thickness
8392.00
8524.00
7202.00
7725.00
7611.00
7719.00
7407.00
7512.00
7064.00
6748.00
[mm2]
Cross
section
65.88
66.91
56.54
60.64
59.75
60.59
58.14
58.97
55.45
52.97
[kg/m]
Weight
3501.00
3564.00
3030.40
3377.00
3298.10
3352.90
3210.60
3266.80
1976.38
1326.00
[cm4]
Inertia
moment
JX
404.00
416.40
363.60
395.40
380.60
391.40
363.10
373.80
248.79
208.30
[cm3]
Resistance
moment
Wx
grooved rails
Industry
150.00
[mm]
130.00
[mm]
Foot
width
53R1 (Ri 53N)
Rail
height
Industry - grooved rail
Rails
Transport
Rail forms
Transport - grooved rail
Railway track sections grooved rails

Track materials
Page: 213-01
Date of issue 08/10
[mm]
180.00
180.00
180.00
260.00
180.00
180.00
180.00
184.00
75C1 (BA 75)
76C1 (VK Ri 60)
105C1 (DST 180/105)
310C1 (BL 180/260)
Foot
width
Rail
height
[mm]
Rail forms
130.00
260.00
56.00
[mm]
Driving
head
width
C2
114.00
113.00
[mm]
Head
width
in total
C1
40.00
12.00
32.00
162.00
[mm]
Base
thicknes
s
36.00
Groove
d
width
C3
56.00
68.25
41.25
41.15
[mm]
Head
height
in total
30.00
9.00
10.00
8.00
[mm]
Foot
thickn
ess
39450.00
13405.00
9643.00
9584.00
[mm ]
Cross
section
309.69
105.23
75.70
75.23
[kg/m]
Weight
12786.00
4945.00
4237.60
3596.00
[cm ]
Inertia
moment
JX
1430.00
643.05
546.40
398.30
[cm ]
Resistance
moment
Wx
Rails
Railway track bearing sections Ri-special section

Track materials
RI-Special section
Page: 213-02
Track materials
Schienen
Bridge section
Block grooved rails
Grooved rail B1
Grooved rail B3
Grooved rail LK1
Date of issue 08/10
Page: 213-03
Date of issue 08/10
[mm]
125.00
150.00
175.00
200.00
200.00
220.00
220.00
55.00
65.00
75.00
85.00
95.00
105.00
150.00
A 45
A 55
A 65
A 75
A 100
A 120
A 150
Foot
width
Rail
height
[mm]
Rail forms
150.00
120.00
100.00
75.00
80.00
72.00
60.00
45.00
38.00
31.00
24.00
[mm]
Base
thicknes
50.00
47.00
40.00
35.00
30.00
25.00
20.00
[mm]
Head height
14.00
14.00
12.00
11.00
10.00
9.00
8.00
[mm]
Foot
thicknes
19140.00
12740.00
9470.00
7160.00
5490.00
4050.00
2820.00
[mm ]
Cross
section
151.60
100.00
74.30
56.20
43.10
31.80
22.10
[kg/m]
Weight
4373.00
1361.00
856.00
531.00
319.00
178.00
90.00
[cm ]
Inertia
moment
JX
565.70
235.10
161.80
105.40
71.40
45.60
27.00
[cm ]
Resistance
moment
Wx
Crane rails Form A
65.00
55.00
45.00
[mm]
Head
width
Rails
Railway track bearing section crane rails
Track materials
Page: 214-01
Track materials
Rails
Crane rails AS 86
Page: 214-02
The crane rails of form MRS used commonly are increasing. Disadvantage of the commercially
available crane rails that form the flat tread. The least deviation of the parallelism leads to the direct
edge pressure.
Crane wheel
Edge pressure
Crane rail MRS 87A
ThyssenKrupp Gleistechnik has therefore given a change in the tread. The new crane rail AS 86
corresponds in the main dimensions of MRS 86 A, has a similar rounded head as in crane rail A 100.
Thus, the wheel force is transferred to the back axle crane rails. The stress on the bearing surface
and the wear behaviour is considerably reduced.
Crane wheel
approx. axial loading

Crane rail AS 86
Date of issue 08/10
Track materials
Rails
Crane rails
Bevel cut
Page: 214-03
Bevel cuts on crane rails are required, if the rails on the components are clamped or riveted.
In this antiqued track system, an increased deterioration of the crane rail system pre-programmed.
The economic solution is the use of straight-cut rails and welding of the rails on the entire length.
Applies for the attachment: not CLAMPING rather OPERATING
See page 134-01 ff.: MX-rail support with MX-rail fastening
Example for bevel cut-versions

1. Cut direction
Version a
Version b
Version c
2a. Length information measured in the middle of the head
2b. Length measured from tip to tip
3. Degree setting for the cutting angle
Date of issue 08/10
Date of issue 08/10
120.00
80.00
F120
131.80
131.80
152.40
152.40
152.40
150.00
180.00
220.00
131.80
146.10
152.40
152.40
152.40
152.46
180.00
160.00
MRS 52
MRS 67
MRS 85
MRS 87B
MRS 87A
AS 86
MRS 125
MRS 221
120.00
120.00
80.00
120.00
140.00
105.00
Q 120
R 120
STR 40
35.00
40.00
145.00
101.60
120.00
220.00
18.00
34.93
101.60
80.00
38.10
102.40
80.00
31.75
101.60
80.00
31.80
76.20
120.00
23.80
65.10
120.00
25.40
90.00
120.00
63.50
70.00
100.00
[mm]
Base
thicknes
Head
width
[mm]
11.80
104.00
91.00
40.00
64.80
50.80
50.80
44.50
50.80
47.60
45.20
38.10
42.00
42.00
[mm]
Head
height
33.00
24.00
17.00
17.50
21.00
15.40
15.90
12.70
15.60
31.80
10.40
12.20
17.00
17.00
[mm]
Foot
thicknes
5130.00
15600.00
13080.00
28210.00
16030.00
10940.00
11130.00
11050.00
10850.00
8590.00
6650.00
6640.00
8920.00
40.37
122.40
102.70
221.40
125.00
85.88
86.80
86.80
84.83
66.97
52.09
51.59
70.10
57.50
[kg/m]
[mm2]
7320.00
Weight
Cross
section
626.70
2625.00
1632.00
6862.00
6225.00
2968.00
3068.00
2922.00
3055.00
2105.00
1432.00
1242.00
499.00
414.00
[cm4]
Inertia
moment
JX
135.10
364.00
261.50
829.00
681.00
394.00
400.00
344.00
400.00
282.00
203.00
175.00
123.00
101.00
[cm3]
Resistance
moment
Wx
Special section
Special forms
127.00
127.00
MRS 51
Thick web rails
100.00
80.00
[mm]
Foot
width
F100
[mm]
Rail
height
Rails
Form F according DIN 536 - 2
Rail forms
Railway track bearing section special section

Track materials
Page: 215-01
Date of issue 08/10
140.00
147.00
140.00
121.00
129.00
134.00
54E1A2 (ZU1-54)
54E1A1 (ZU-UIC54 B)
60E1A1 (ZU1-60)
125.00
140.00
150.00
154.00
159.00
172.00
54E3F1 (Vo1-54)
54E1F1 (Vo1-UIC 54)
60E1F 1 (Vo1-60)
75.00
75.00
40.00
168.00
199.00
93.00
36C1 (Rl1-49)
48C1 (Rl1-54)
33C1 (Rl1-60)
78.50
22.00
19.00
72.00
70.00
67.00
67.00
72.00
70.00
67.00
67.00
[mm]
Head width
up
C1
80.00
76.00
74.00
72.00
70.00
74.50
72.20
70.18
70.20
[mm]
Head width
below
C2
20.00
20.00
18.00
76.00
74.00
72.00
85.00
44.00
40.00
40.00
40.00
[mm]
Base
thicknes
37.50-54.70
54.30
> 50,00
39.80
53.00
49.40
57.50
53.50
[mm]
Head height
in total
12.00
12.00
10.50
11.50
11.00
12.00
10.50
20.00
20.00
20.00
20.00
[mm]
Foot
thickness
4202.00
6154.00
4604.00
14171.00
12484.00
11556.00
12300.000
9295.00
8783.00
8385.00
8043.00
[mm2]
Cross
section
32.99
48.31
36.14
111.24
98.00
90.72
96.55
72.97
68.95
65.82
63.14
[kg/m]
Weight
297.00
2330.50
1312.30
3737.30
2818.00
2389.00
2234.00
1726.90
1544.00
1244.30
1098.40
[cm4]
Inertia
moment
JX
83.70
218.30
137.60
394.30
385.30
286.10
274.30
229.70
208.40
181.10
165.30
[cm3]
Resistance
moment
Wx
Construction rails
Check rails
125.00
149.00
49E1F 1 (Vo1-49)
Complete rails
140.00
116.00
[mm]
Foot
width
49E1A1 (ZU2-49)
[mm]
Rail
height
Rails
Switch rails
Rail forms
Railway track section construction rails

Track materials
Page: 216-01
Date of issue 08/10
Rail perforation
Perforation plates
Rail perforation
Flat plate FL 14a, 25,.16 kg / pair
Perforation plates
Flat plate FL 41/49, 17.44 kg / pair
Perforation plates
Rails
Hole diameter 33 mm for rail lengths 30, 45 and 60 m
Rail perforation
Track materials
Page: 217-01
Track materials
Rails
Y-Steel Sleeper
Page: 221-01
Y-steel sleepers St 98 Y with rail fastening S 15

Special advantages of Y-railway track
Highly economical due to the comparatively low gravel requirement and the low transport
weight.
Due to the frame stiffness of the system and the high track resistance, the tracks are also at
very small radii welded gaps.
Long life.
Excellent recycling properties.
Lower maintenance costs due to long intervals in the elaboration.
Applicable for all common rail sections and rail inclinations.
Due to the versatile design possibilities of the material steel, an optimum adjustment of the
construction of Y-shaped steel sleeper on the individual parameter of infrastructural manager
is relatively easy to implement.
The used rail support point S 15 ensures the complete electrical insulation of the rail against
the sleeper on the Y-shaped steel sleeper.
Fields of application
General gravel railway track:
Especially here the major advantages in the field of machine

track reconstruction should be mentioned.
High-speed railway tracks
Special sleepers with ra fastening Typ A 8 on asphalt bases

with anchor slot.
Cogwheel tracks
Supplement the sleeper construction to hold a cograil, which

is welded in any position on the sleeper, can be pinned or
screwed. By adjusting the rail clamping grids with the cograil
lengths follows a further optimisation of railway tracks.
Multi and broad gauge track
By welding technique facility, all types are feasible.
Railroad crossing
Similar track coverings can be realised on the Y-steel sleeper

rail. Furthermore, the installations of LST-systems are
unproblematic.
Tracks with safety guard

and guiding device
These special solutions on Y-steel sleepers are standard

designs of DB AG (180 mm groove width, one and two
sided). Deviating from other groove widths already been
realized.
Tunnel run
Due to the low height of the sleeper proves that Y-steel

sleeper rail currently the reorganisation measures in old
stock to be very beneficial. In individual cases a design as a
slab track with an overall height of only 440 mm (SO to OK
tunnel floor, rail 49E5) is possible.
Date of issue 08/10
Track materials
Rails
Y-Steel Sleeper
Page: 221-02
Y-shaped normal sleeper
Type selection and dimensions

Support
distance A
in mm
B in
mm
Weight /
Pc. in kg
Track
in
mm
Comments
Rail 46E1
Y-S15D-No-650-FO
650
1210
122.6
1000
Regular narrow gauge

track sleeper
Rail 49E5
Y-FT-No-990-BRB
990
1510
122.1
800
Rail 54E4
Y-S15D-No-600-BAM-SE
600
1160
119.5
1000
Rail 60E2
St98-Y-No-600-60
600
1160
142.3
1435
Date of issue 08/10
large deflection with cograil

and uninsulated support
base
Base with the possibility of
additional track expansion
< + 20 mm
Control sleeper DB AG
Track materials
Rails
Y-Steel Sleeper
Page: 221-03
Y-Changeover sleeper
Type selection and dimensions

Support
distance A
in mm
B in
mm
Weight /
Pc. in kg
Track in
mm
Comments
Rail 46E1
Y-S15D-li-650-FO
210
770
119.2
1000
Regular narrow gauge track

sleeper
Rail 49E5
Y-FT-li-990-BRB
990
440
1510
169.1
800
Rail 54E4
Y-S15D-li-600-BAM-SE
185
745
117.1
1000
Rail 60E2
St98-Y-re-600-60
St98-Y-li-600-60
185
185
745
745
139.3
139.3
1435
Date of issue 08/10
large deflection with cograil

and support base
Anchoring possibility
Base with the possibility of
additional track expansion
< + 20 mm
Control sleeper DB AG
Track materials
Rails
Y-Steel Sleeper
Page: 221-04
Special section IB 100 S-1

Sleeper body made of steel profile
IB-100-S, all around welded to the upper
Crossbars ( 25 x 150) and the
lower cross-bars (L 50x50x6) made of
material EN10025-2-S235JR+AR.
Compound in inert gas welding process,
Welding quality as per
DIN EN ISO 5817 Kl. C,
seam strength 4mm.
Y-axis
Z-Axis
F=
G=
ly =
W y=
26.4 cm2
20.8 kg/m
432.0 cm4
91.0 cm3
iy =
lz =
W z=
iz =
installed
Rail support distance
Date of issue 08/10
4.04 cm
276.0 cm4
39.5 cm3
3.23 cm
pre-installed
On delivery, the fastening parts are

pre-assembled.
After inserting the rail, the sleeper screw to
be freed for approx. one turn. The rail
clamps can be brought in locking position to
the rail centre. The screws are tightened
until the middle bend of the clamps rest on
the guide plate.
Torque according to RiL 824.5050 of DB
AG: until the distance between middle bend
of the clamp and bearing surface of the
guide plate is 0.5 mm,
and torque 200 Nm
Track materials
Rails
Y-Steel Sleeper
Page: 221-05
General product details of the Y-Steel Sleeper

Compared to conventional cross sleeper made of wood, concrete or steel, the Y-sleeper has the
following key features:
The sleeper body made of special rolled steel profile IB 100 S with a low, favourable height of 95 mm.
The Y-shaped fork.
Three rail supporting points per sleeper.
Each base serves the rail a dual bearing.
The patented rail support S15 is fully electrically isolated and enables unrestricted use of the Y-steel
sleeper in the network of electrified railways. The installation of equipment of control technology and
defence electronics is likewise unproblematic.
The rail support S15

The patented rail support S15 enables the rail two bearing surfaces per base. The rail is thus
mounted at a distance of 230 mm on elastic intermediate layers and in the middle between these two
supports held down by the tension clamp in combination with a threshold, and a screw plug. The
corresponding inclination is produced by the intermediate plate, on which the elastic intermediate
layers are locked. The guide rail is carried out by the inner and outer guide plate. By pair wise
exchange of the guide plates can also be retrofitted on certain types of sleepers also subsequently
the track can be adjusted, e.g. at a subsequent desired track extension in tight curves. The guide
plates ablate the ensuing horizontal forces on the welded upper crossbar in the emerging body. The
lower cross bar from L-sections allow significantly to the high lateral resistance of the Y-steel sleeper
track.
Date of issue 08/10
Track materials
8
7
6
5
4
3
2
1
Pos.
Rails
1
2
2
1
1
2
2
1
Date of issue 08/10
Y-Steel Sleeper
Spacer plate
Intermediate level
Clamping dowel
Guide plate (outside)
Guide plate (inside)
Rail clamps
Sleeper screws
Rail
Designation
Page: 221-06
Zwp 192
Zw 401
D S 15
Fpa 15
Fpi 15
Skl 14
Ss 34 with Uls 7
60E2
Brief description
Track materials
Rails
Y-Steel Sleeper
Page: 221-07
Sleeper requirement
The sleeper requirement for conventional cross sleeper with a rail support distance of 600 mm
is 1667 sleepers per 1000 m track.
Y-Steel sleeper requirement
A = Rail support distance
Number of Y-Steel sleepers n =
Length of the track section in meters

(Supporting distance in meters + 0.23) * 1.5
Example of supporting distance A = 600 mm and a track section of 1000 m

1000 m
(0.6 + 0.23) m * 1.5
= 803 piece per 1000 m rail
Example of a supporting distance from A = 650 mm and a track section of 1000 m

1000 m
(0.65 + 0.23) m * 1.5
Date of issue 08/10
= 758 piece per 1000 m rail
Track materials
Rails
Y-Steel Sleeper
Page: 221-08
Gravel requirement
Safety space
according to
DS 132
Minimum clearance
Safety space
according to
DS 132
Edge away
Edge away
1)
Danger zone at v=120 km/h
Gravel requirement of 1.42 m / m rail

Single line track
Elevation 0 mm
V max 120 km/h
Front and head gravel 30 cm
This value is around ~ 30% lower than the comparable railway track with bar sleeper.
Date of issue 08/10
Track materials
Rails
Y-Steel Sleeper
Page: 221-09
Applications and installation criteria in the track network of DB AG
Authorisation document of Federal Railway Authority from 30.12.1997

Certificate No.: 1221/11101/21AZ2/0244/97
Approved area for use according to the approval of former Central Office of the German Federal
Railways from 30.12.1993 - VIII.8301 Io:
Vmax = 120 km/h
Load: 20,000 Lt/d in continuous main tracks of 2nd rule and 30,000 Lt/d in other main and side
tracks
Minimum radius: 190 m
Approval of a standard design NEF (0). - Iosb 17.01.2000
Approval series of track detector FSSB construction forum (protective device EbT 80) for
railway track with Y-steel sleepers
EBA from 08.04.1995, Approval number 75 025/5
Licence for field test for Y-steel sleeper with rail fastening S 15 ballast substructure
for v = 160 km/h
EBA 21.61 Iozb (274/98) from 04.01.2000
Identification mark: 1221 / 11101 / 21AZ2 / 8274 / 9
Licence for field test for Y-steel sleeper with rail fastening S 15 heavy duty in ballast
substructure
EBA 21.61 Iozb (575/00) from 04.01.2000
Identification mark: 1221 / 11101 / 21AZ2 / 0575 / 0
Authorisation for guiding mechanism and safety gear on Y-steel sleepers

EBA 21.61 Iozb (575/01) from 04.01.2001
Identification mark: 1221 / 1110 / 21ZEN2 / 0557 / 01
Release as a standard design: TZF 61.Da. K0 20/2003
User declaration of DB AG - TZF63 from 04.03.2002

LeBODAN, System BODAN 2 and BODAN-Y-Platte
Date of issue 08/10
Track materials
Sleepers
Pre stressed concrete sleepers

Technical data
Page: 222-01
Pre-stressed concrete sleepers

are being produced since beginning of 50s with continuous technical development. While
manufacturing, it is differentiated between immediate and delayed stripping. For receiving the rail
fastening plastic plugs are required to be fitted in front of the vibrating of the concrete into the form
work. On the surface of pre-stressed concrete sleepers is to be placed clearly visible:
The identifying mark of the manufacturer

the last two digits of the year of manufacture
the rail foot width in mm
the classification mark (e. g. B70)
The sleepers are manufactured of a concrete with high compressive strength w 28 of 60 N/mm,
i.e. a test cube from the production must have setting time after 28 days of this compressive strength
For more information on the nature of the concrete:
Compressive strength
wv
Bending tensile strength
B 7
Cement mortar
w7
Cement grade CEM 42.5 and CEM 52.5
= 45.0 N/mm
= 6.5 N/mm
= 30.0 N/mm
Generic information:
As a standard railway structure currently the sleeper B 70 W 60 can be considered. The sleeper sole
is thus used to reduce the gravel load, especially in elasticity jumps as well as for increasing the
railway track elasticity (e.g. bridges and in tunnel areas) and for impact sound reduction. It is used in
DB AG currently with UIG under operational tests.
For the slab track with the rail fastening system 300-1, pre-stressed concrete sleepers B 301-W 60
and B 302-W 60 are used. Depending on the manufacturer, names may be different.
For the gravel crossing / slab tracks, the sleepers B 303-W60 are used.
Classification: e.g.:
Concrete sleeper
Categor
soled
rail 60E2
W-fastening
Requirements for producing pre-stressed concrete sleepers

1. Principles of design, construction and approval procedures
2. Technical specifications of concrete sleepers according to DBS 918 143
3. European Standard EN 13230 1-5, Edition 2009
Railway applications, railway track, track and turnout sleepers made of
concrete
4. As VDV railway track guidelines apply OR 13.3,
Technical specifications for pre-stressed concrete in each valid copy.
Date of issue 08/10
Edition
January 1982
November 2008
valid from 2009
Track materials
Sleepers
Concrete sleepers B70 W60

Immediate limit switch
Page: 222-02
Width of rail foot
Sd 25 (alternatively Sd 9)
for 60E2 track gauge 1435 mm
Classification mark
Identifying mark
Date
Production week
Trough designation
Number forms
Axle load
Concrete volume
Concrete mass incl. concrete
reinforcement
Attaching part
Total weight
Date of issue 08/10
250 kN
114 L
280kg
8kg
288kg
Track materials
Sleepers
View: B
Dimensions Rail support 60E2
Date of issue 08/10
Concrete sleepers B70 W60
Immediate limit switch (Details)
A-A
Page:.222-03
Track materials
Sleepers
Concrete sleepers
Overview Part 1
Page: 222-04
Nominal gauge 1435 mm
Gravel railway track

B70 W54

B70 W-2,4-54

B70 W60

B70 W2,4-69
Date of issue 08/10
Track materials
Sleepers
Concrete sleepers
Overview Part 2
Page: 222-05

B58 W54
Date of issue 08/10
Track materials
Sleepers
Concrete sleepers
Overview Part 3
Page: 222-06

B90 W54

B90 W60

B07 W60

Pre-stressed sleeper
Concrete pre-stressed sleepers are manufactured in each required length

The distance of the fastening (L to Z) resulting from the associated pre-stressed design.
Date of issue 08/10
Track materials
Sleepers
Concrete sleepers
Overview Part 4
Page: 222-07
Gravel railway track PNVW49
Gravel railway track PNV W Ri 180
Gravel railway track PNVW 41E1
Gravel railway track PNVW59R1 / 60R1
Date of issue 08/10
Track materials
Sleepers
Page: 222-08
Concrete sleeper railway track

Track system W 3
The construction W 3 (with angled guide plates and Skl 1) is the standard railway track design for
concrete sleepers in gravel track.
Position
Brief description /
Construction
W 3 K-60
W 3 K-54
Date of issue 08/10
Ss 35 Uls 7
Skl 1
Wfp 3b
Sd 25
Zw 686a
ZW 687a
4
4
4
4
4
4
4
4
2
2
Track materials
Sleepers
Page: 222-09

Track system W 14
The construction W 14 (with angled guide plates and Skl 14) for elastic railway track.
Position
Brief description /
Construction
W 14 K-60
W 14 S-60
W 14 K-54
W 14 S-54
W 14 K900-60 on
B70
W 14 K900-60 on
B 90
1
Ss 35
Uls 7
4
4
4
4
Date of issue 08/10
2
Skl 14
4
4
4
4
Wfp14
K-12
4
3
Wfp14
S-12
Ei 31
Ei 32
Wfp14
K900
6
Sd
25
4
4
4
4
7
Zw
700
2
2
2
2
Zw
900
Track materials
Sleepers

Track system FF 300
Page: 222-10
The railway track design FF 300 (with elastic rail bedding and Skl 15) is the standard-railway track
design for the slab track.
pre-installed
installed
Position
Brief description
/ Construction
System 300-1
1
Ss 36
Uls 7
4
Date of issue 08/10
Skl 15
Wfp 15a
Sd 26
Zw 692-6
Grp 21
7
Zwp 104 NT
c = 22.5 kN/mm
Track materials
Sleepers
Page: 222-11

for grooved rails, W 14
The track design W 14 with wedge angular guide plates for gauge widening and Skl 14 is the
standard-railway construction for grooved rails with W-fastening.
installed
pre-installed
Concretesleeper
Position
Brief description /
Construction
W 14 with
Wedge angle guide plate
Date of issue 08/10
Ss 35 Uls 9
Skl 14
Wfp 14R
Wfp 14L
Sd 25
ZW 180
Track materials
Sleepers
Wooden sleepers
Page: 223-01
Wood sleepers
For over 150 years, tracks are laid on wooden sleepers. Types of wood, dimension, stacking,
planning and drilling, pre-assembly, emerging head sleeper etc. have been explored over decades of
work and implemented the research result in production.
The wooden track sleepers of the Deutsche Bahn are exclusively made of beech wood. Turnout
sleepers exclusively of oak tree. In northern European countries such as Sweden, Norway and
Finland, as well as in some German private railways, track and pre-stressed sleepers made of
pinewood are used.
To avoid that the wood comes from a disputed or illegal logging, a "Programme for Endorsement of
Forest Certification Schemes" (German: Certification system for sustainable forest management
PEFC) was shortly brought into life PEFC in year 1999. PEFC is an international forest certification
system and until today the world's largest independent organization to ensure continuous
improvement of sustainable forest management, ensuring environmental, social and economic
standards. Wood processing firms can be certified under this standard and ensures their customers
that for every felled tree, a new will be replanted and thus causing no harm to the environment.
The wooden sleepers are impregnated with the remains of coal tar. This is a very complex mixture of
substances, which consists of approximately 10,000 individual compounds. Under the terms of
Western European Institute for impregnation - W.E.I. It is classified into two classes, A, B and C
according to the content of Benzopyrene. In the meanwhile these W.E.I.-classes have been
transferred to the European Standard DIN EN 13991. Today, for wooden sleepers in Deutsche Bahn
coal tar oils of W.E.I.-type C are used with a benzopyrene content of < 50 ppm.
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-02
Requirements of Creosote oil of type A, B and C

Parameter
Type A
Type A
Type A
Test procedures
Density at 20 C (kg/m)
1.04 to 1.15
1.02 to 1.15
1.03 to 1.17
BS 144:1997, Annexe B
Moisture content in % (m/m)
max. 1
max. 1
max. 1
ISO 760*
Crystallisation temperature (C)
max. 23
max. 23
max. 50
Annexe A
Moisture extractable phenols in % (m/m)
max. 3
max. 3
max. 3
EN 1014-4
Toluene insoluble in % (m/m)
max. 0.4
max. 0.4
max. 0.4
BS 144:1997, Annexe G
Annex B
Boiling curve (Vol.-%)

Distillate up to 235 C
max. 10
max. 20
20 to 40
40 to 60
max. 10
55 to 75
max. 70
max. 65
Benzopyrene content (mg/kg)
max. 500
max. 50
max. 50
EN 1014-3
Burning point (C)
max. 61
max. 61
max. 61
EN ISO 2719
*Alternatively, the distillation process is used according to ISO 3733.
Comment 1: Type A should be used for the pressure impregnation of wood.

Type B is also suitable for pressure impregnation, but has a more defined boiling curve and a more
limited residue as Type A. It is particularly suitable for the treatment of masts for power lines and
telecommunications where the tar oil constituent parts can be flushed during the use.
Type C is suitable for the pressure treatment of wood at temperatures in excess of 100 C. In this
type, the low-boiling fraction is excluded, which is allowed in the other creosote oil types. Hereby
lowering the odour is achieved.
Comment 2: All types of creosote oil should not contain more than 3% water.
Comment 3: Used creosote oil should not contain more than 3% water.
Comment 4: The density is determined at a temperature above the crystallization temperature. For
every degree Celsius above 20 C, a fixed value of 0.7 kg/m density to the read is added.
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-03
Wooden sleepers are impregnated in the pressure process. The impregnating profiles and intakes for
wooden sleepers are defined in DIN 68811 and in the DBS 918144. Generally it is to be noted that for
a best possible impregnating result, the wooden sleepers must be settled. I.e. for example, beech
sleepers must have a gross weight of < 750 kg/m and oak sleepers of < 900 kg/m before
impregnation.
The approved shapes of wooden sleepers, dimensions, details on acceptance, manufacturing and
acceptance conditions are listed in UIC-Kodex 863 V, the DBS 918144 and in the DIN EN 13145. The
impregnation of railway sleepers of wood with coal tar is defined in the DIN 68811 as well as the DBS
918144.
Impregnating diagram for beech sleepers
Impregnating diagram for oak sleepers
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-04
Drying and cracking

Wood is a natural material, which is in contrast to synthetic materials not constructed homogeneously.
This creates the diversity of appearance, which is particularly appreciated in this ecological material.
This inhomogeneity exists both in the structure, as well as in the properties. Wood is a swellable,
anisotropic material. Anisotropy means that the behaviour in the three main anatomical directions
(longitudinal, radial, and tangential) is not equal.
Swelling and shrinkage depends on the moisture change, wherein humilities above the so-called fibre
saturation point are of about 28-30% without the influence. Wood changes its moisture content mainly
by the relative humidity. As long as the moisture content is above the fibre saturation point, do not
change in drying of the freshly cut wood dimensions. With the below this point is where the shrinkage,
which results in a change in the output size and the formation of cracks.
On the drying ground the rough sleepers are stacked until they mature in an expedient manner.
Impregnating is a wood whose cells do not contain "free" water anymore, so that the introduction of
the preservative can pass freely by pressure impregnation. External characteristic for these physical
processes is a severe weight loss of the sleeper, connection with a natural drying crack growth due to
oscillation processes.
The cracking is therefore biologically based and therefore inevitable, but also quite desirable. Cracks
facilitate impregnation, promote a better distribution of coal tar oil in wood and enable an optimal
protection of wood. To request the delivery of crack-free wooden sleepers contradicts the
impregnating technical knowledge. Such wooden sleepers are not because of the excessive moisture
impregnated properly, would later form drying cracks in the track and so to expose the unprotected
wood biological pests with the result of early failure.
Excessive cracking is determined by quality control, with frontal cracking can be effectively limited by
the prescribed means of security. Cracks, unless they go through the entire threshold not weaken the
strength of the wood sleeper.
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-05
In the European standard DIN EN 13145:2001 the regarding shapes, dimensions and tolerances are
specified requirements set below:
Group
1
260
2
260
3
260
4
240
5
240
6
240
7
240
8
220
9
250
10
305
11
305
12
250
13
300
14
200
*
Minimum size
Dimensions of track sleepers (mm)

d*
r*
e
Form E1 Form E2
Form E1+E2
160
160
200
80
150
160
200
80
130
130
170
60
150
160
180
70
160
160
180
80
140
160
180
70
130
130
170
60
130
130
160
50
125
205
230
100
125
255
280
100
150
255
280
125
130
200
225
105
130
250
275
105
120
110
140
40
Dimensions of turnout sleepers (mm)

Group
I
e
d*
r*
1
300
150
240
120
2
280
140
220
120
3
260
160
200
100
4
260
150
210
120
5
240
150
200
90
6
240
160
160
80
7
240
140
200
80
8
300
130
200
80
*
Minimum size
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-06
Forms:
Rail sleepers:
Turnout sleepers:
Dimensions:
While ordering, the customer must define the actually required dimensions I, e and d. This also
applies to the length. These dimensions are for track and pre-stressed sleepers, ready for use or for
impregnation.
Tolerances: The following tolerances find applications ready to use or for impregnation in all tracks
and pre-stressed sleepers:
Length:
Width:
Strength (Height):
Cross-section:
30 mm;
+ 10 mm / - 3 mm;
+ 10 mm / - 3 mm;
maximum deviation from right angle is 3".
Note: The length tolerance is limited due to both sided rectangular truncation of tracks and prestressed sleepers. Deviating tolerance for rail and pre-stressed sleepers shall be provided which are
installed under specially justified conditions.
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-07
In UIC-Kodex 863 V respective shapes, dimensions and tolerances specified below are the following
guidelines:
Track sleepers
The shapes of the track sleeper cross-section are shown in the following diagrams (they are also
made sharp-edged):
Form I:
Form II:
Form III:
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-08
In addition, the track sleepers are divided into seven groups accordance to the following in
compilation of the dimensions (according to UIC 863 V) listed. The normal track sleeper length is set
at 2600 mm. Where tracks with other gauges than 1435 mm, the length of the sleepers in the
tendering process is agreed.
Group
1
2
3
4
5
6
7
I
(cm)
26
26
26
24
24
24
22
e
(cm)
16
15
13
15
14
13
13
d (cm)
Form I and III
16
17
13
16
16
13
13
Form II
20
20
17
18
18
17
16
r (cm)
Form I and II
8
8
6
7
7
6
5
The dimensions in any case should not exceed from a width of 30 cm and a thickness of 17 cm. The
dimensions for d and r are minimum values.
Dimensional deviation:
The permissible dimensional deviations are as follows:
in the lengths:
+3 cm / -3 cm;
in the widths:
- in the rail support surface: no dimensional deviations towards

downwards;
- outside this range: -2 cm;
in the thickness:
- This must be exactly equal to 0.5 cm in the two rail supports;

- in the rail surface area: no dimensional deviations downwards;
- outside this area: -1 cm;
in the ceiling beam
- in the rail surface area: no dimensional deviations downwards.
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-09
Turnout sleepers
The shapes of pre-stressed sleepers given are in the following descriptions
Form I:
Form II:
Form IIa:
Form IIb
The pre-stressed sleepers are divided in four groups according to the following compilation transverse
dimensions.
Date of issue 08/10
Track materials
Sleepers
Wooden sleepers
Page: 223-10
The expressed dimensions required in cm from a distance of 25 cm to the sleeper ends (according to
UIC 863 V) over the entire length. The dimensions for d and r are minimum values.
Group
I (cm)
e (cm)
d (cm)
r (cm)
1. Group
30
15
Form I
Form II
Form IIa
Form IIb
24
21
22
27
12
8
8
12
2. Group
28
14
Form I
Form II
Form IIa
22
19
20
12
8
8
3. Group
26
16
Form I
20
10
4. Group
26
15
Form I
Form II
Form IIa
Form IIb
21
18
20
23
12
5
5
12
Dimensional deviation:
The following dimensional deviations are permitted in the dimensions:
in the lengths:
+3 cm / -3 cm
in the widths:
+2 cm / -1 cm for the groups 1 and 2

+1 cm / -0.5 cm for the groups 3 and 4
in the thickness:
- 0.5 cm with all 4 groups, provided the ceiling width

around 1 cm is larger than for the group in question.
is required:
- Greatest thickness 17 cm
of the ceiling width:
no dimensional deviations towards lower
level of the lateral processing:
no dimensional deviations towards lower
Date of issue 08/10
Track materials
Sleepers
Steel sleepers
Page: 224-01
Steel sleepers
Steel sleepers Sw 82 according to UIC-Codex 865-1 V, 3. Paragraph 1.1.1983, with welded ribbed
plates Rps 8 (49E5.54E4 for rail foot 125 mm) or Rps 15 (60 E2 for rail foot 150 mm). Also deliverable
in pre-assembled design and insulated one-sided and two-sided.
Approach of the accounting measure see detail X
I (e.g. 1674, see table)
Detail X
Spot
Accounting measure
Check point
with onesided
insulation
without
insulation
49E5 /
54E4
Date of issue 08/10
Railway track KS Ioarg 322
without
insulation
60E20
Railway
track
Railway track KS Ioarg 322
without,
with
insulation
with onesided
insulation
Rail
Pre assembly with
track gauge
in mm
Measurement
in mm +2/-1
Number of
Spot
Rps 15 - Iotkp 44 and

Rps 15-ia - Iotkp 112U
1450
1445
1440
1435
1689
1684
1679
1674
4
3
2
-
Rps 15 - Iotkp 44
1450
1445
1440
1435
1682
1677
1672
1667
4
3
2
-
Rps 8-Iotkp 47 and

Rps 8-ia - Iotkp 12U
1450
1445
1440
1435
1658
1653
1648
1643
4
3
2
-
1450
1445
1440
1435
1651
1646
1641
1636
4
3
2
-
Rps 8 - Iotkp 47 and
Track materials
Sleepers
Steel sleepers
Page: 224-02
Profile
Profile
shapes
Pr 51
UIC 28
SW
82/54
H
Total
height
in mm
75
90
B
Upper
width
in mm
120
150
C
Lower
width
in mm
232
260
D
Ceiling
thickness
in mm
9
12
F
Side
thickness
in mm
7
7
A
Crosssection
in mm
2590
3625
100
145
260
3070
20.33
28.46
XH
Neutral
axis
in mm
50.31
63.10
JX
Inertia
moment
4
in cm
148
277
WX
resistance
moment
3
in cm
29.4
44
24.10
68.10
313
45.8
Weight
in kg/m
X = Axis for torque of inertia

Technical values:
Cross-section:
Stretched length L = 2400 mm:
Weight of SW L = 2400 mm *):
*) without ribbed plates
F = 30.7 cm
L = 2581.0 mm
L = 2681.0 mm
L = 2781.0 mm
W = 62.20 kg
W = 64.61 kg
W = 67.02 kg
Detail Y
- Bearing marks -
SW 82
Profile
Manufacturer
Date of issue 08/10
Mark
04
the last two digits of the year of manufacture
bold font
DIN 1451
2.5 mm
1-2 mm embossed
rolled
Track materials
Sleepers
Steel beam bridge sleeper
Page: 225-01
The SteelBridgeSleeper, developed by ThyssenKrupp GfT Gleistechnik,

also known as SBS, is designed for railway bridges with open rail track as an alternative to the
traditional wood bridge sleepers.
The fatigue test at TU Mnchen has been cleared successfully at an elevation of 130 mm,
22.5 t axle load at 3 million load change.
In 1999, the steel bridge sleeper was emerging on behalf of DB AG installed on a bridge in Dortmund
Wickede for the first time. Up to the current period, the DB AG as well as other transport operators,
SBS have been installed in numerous construction projects.
The experience gained in the past years, the findings were incorporated into SBS built an established
structural standards.
The static type meets the requirements of the Directives, thereby eliminates complex individual
evidence and the conclusions to be applied for approval by the Federal Railway Authority.
Following requirements are met from the steel bridge sleepers:
Directive of DB AG 804, 805, 820, 897.02 with DIN EN 50122-1,
DBS 918002-2 in connection to DIN EN 10204,
DIN 18800, DIN 18800 part 7, DIN FB 101 and 103
DIN 18800 part 7 :2208-11, DIN EN ISO 14555
Technical specialist report of DB Systemtechnik VTZ 115
Functional requirements of DB Systemtechnik etc.
Date of issue 08/10
Track materials
Sleepers
Page: 225-02
Nut
Spring washer
Insulated collar brushing
Ribbed base plate
Elastic intermediate plates
Krupp ECF-correction plates
Zero position (chamfer)
Rail support system:

The elastically mounted rail fastening system from ThyssenKrupp ECF, is used as a rail bed.
For vibration damping, a 12 mm thick elastomer plate is used as per the
dynamic requirements.
For ribbed plate fastening weld-on threaded bolts can be used by means of drawn arc or DIN screws
by plug connection.
A height compensation under Krupp ECF-System is through height compensation plates
up to + 26 mm / - 4 mm possible,
a side adjustment by the eccentric insulating sleeve of +/- 5 mm.
Impact sound:
The steel bridge sleeper in connection with the elastomer plate from Krupp ECF-System
reduces the impact sound over wooden bridge sleepers by up to 6 dB.
Date of issue 08/10
Track materials
Sleepers
Page: 225-03
Carrier section:
For steel bridge sleeper the wide flange beams of the series HEA, HEB and HEM are used
in accordance with the DBS 918002-2.
The grider depth and weights are derived from the static requirements as well as height requirements
of the survey.
Coating:
The steel bridge sleepers and attachments are coated according to the requirements of ZTV-Ing. and
the local corrosivity.
The add-on parts, such as cross bars, hooks and front panels get an anti-slip grip coating
according to DIN 18800 part 7 and DIN FB 103, quality standard B.
Environmental protection:
All used construction materials are ecological and completely recyclable.
Height structures:
The height structures are made according to the individual requirements and specifications, either
welded beneath the sheet or conventionally edged with EVA base plate as a site assurance and
EVA-height compensation boards.
The under welded plates are designed by aligning tracks in elevation as wedges and designed in
non-elevated track.
Height between
plates
Sleeper shoe
Base plate
Date of issue 08/10
Track materials
Sleepers
Page: 225-04
Guiding device:
In guiding devices on the bridges RIL 820 and 804 may be required, angle brackets are welded on
the top flange of SBS.
In the locality, an L-corner on the angle brackets are placed, drilled and installed.
L-Corner
Angle bracket
Rail cover:
For track cover on SBS GFK-grating, a laminated cover plate to be installed.
For securing the position, mounting bracket and bracket from ThyssenKrupp are installed, which are
screwed on the welded thread bolts.
As a sleeper space cover to protect against falling parts, the edged glass plates or aluminium plates
designed by TK are used.
Mounting bracket
GFK-cover
Sleeper
space cover
Mounting bracket
Date of issue 08/10
Track materials
Ironmongery
and accessories
Fastenings
clamping plates
Page: 231-01
Kpo 6 (49E5)
0.648 kg/Pc.
Kpo 6 i (Steel sleepers)

0.570 kg/Pc.
Kpo 9 (54E4 / 60E2)

0.649 kg/Pc.
Kpo B (for bridges with slipper)

approx. 0.53 kg/Pc.
Designation Rail
B7
B8
B9
B 10
B 11
60E2
54E4
49E5
49E5
(iso)
60E2
(iso)
Dimension
h in mm
7.5
7
8.5
2.5
Inclination
1.5
1:7.8
1:14
1:7.8
1:7.9
1:14
The bridge clamping plates are used in connection

with plastic railpad.
Date of issue 08/10
Track materials
Ironmongery
and accessories
Fastenings
Rib based plates
Page: 232-01
Inclination
Name
La
la
LB
lb
D1
D2
Inclination
Comment
kg/Pc.
Rph 1 - 150
Rph 1 - 160
Rph 1 - 180
Rph 1 - 210
Rph 6 - 160
Rph 6 - 180
Rph 6 - 210
Rpo 5a-210
Rpo 5 - 160
Rp 01/01 160
Ps 60 - 160
PT 180-160
PT 180-115
Rpb 1 - 110
Rp 16 h
Rps 8
Rps 15
Rus 26 a
Rp 16 g
345
345
345
345
370
370
370
345
345
285
285
285
285
310
310
310
285
285
30
30
30
30
30
30
30
30
30
150
160
180
210
160
180
210
210
160
90
90
90
90
90
90
90
90
90
30
35
45
60
35
45
60
60
35
127
127
127
127
152
152
152
127
127
13
13
13
13
13
13
13
13
15
15
15
15
15
15
15
15
15
17
1:40
1:40
1:40
1:40
1:40
1:40
1:40
01:20
01:20
49E5 / 54E4, Wooden sleepers
7.328
7.857
8.950
10.549
8.440
9.500
11.316
11.690
9.540
345
285
30
160
94
33
127
15
15
without
7.770
375
400
400
345
345
240
265
235
293
310
340
340
285
285
32.5
30
30
30
30
160
160
115
110
160
110
110
110
160
90
94
0
0
90
35
33
57.5
55
35
152
183
183
127
127
127
152
127
127
16
15
15
14
16
7.5
7.5
15
16
16
15
15
14
16
13.5
14.1
15
16
without
without
without
without
without
1:40
1:40
without
without
60E2, Concrete sleepers
8.800
8.600
6.250
4.836
8.150
3.005
3.390
3.860
7.357
Date of issue 08/10

Bridge sleepers
Bridge sleepers
60E2, Wooden sleepers
49E5 / 54E4, Steel sleepers
60E2, Bridge sleepers
67R1, 59R1, 60R1

67R1, 59R1, 60R1
49E5 / 54E4, Concrete sleepers
60E2, Steel sleepers
Track materials
Ironmongery
and accessories
Rib based plates

for guide rails
Page: 232-02
Guide rails, grooved width 180 mm, are used on bridges with more than 50 meters in length. They
should keep derailed vehicles as close to the track, so that they can not parallel on bridge piers.
Before and after the bridge, gripping device is installed. Here the splice rails converge towards the
track axis in such a way, so that the wheels of incoming derailed vehicles driven into the groove.
Used ribbed plates
Name
Rph 11
Rph 12
Rph 13
Rph 14
Date of issue 08/10
manufactured from
Rph 1 / Rpo 5
Rph 1-210 / Rpo 5
Rph 6 / Rph 6
Rph 6-210 / Rph 6 - 160
Width of rail foot

54E4
54E4
60E2
60E2
Weight kg / piece
15.373
17.843
15.268
17.859
Track materials
Ironmongery
and accessories
Rib based plates for

guide rails and supporting rails
Page: 232-03
Guide rails can be use in curved parts of R < 300m to protect the outside running rail. The groove
width is 50 mm, at R < 150m 60 mm. The guard rails are approx. 15 m long, are not welded and are
bent at the beginning and at the end to 100 mm, grooved width, 400 mm length. At 60 mm groove
width also for ways transitions track type Lindau.
Name
Rph 7
Rph 8
Rph 9
Used ribbed plates

manufactured from
Width of rail foot
Rph 6 / Rph 1
60E4
Rph 1 / Rph 1
49 E5 / 54 E4
Rph 1 / Rpo 5
49 E5 / 54 E4
Weight kg / piece
12.727
11.915
13.293
Protection rails are arranged with 80 mm groove width on the inner sides of both the running rails,
when a particular reinforcement of the track frame is required; also serve as a derailment.
Name
Rph 15
Rph 16
Date of issue 08/10
Used ribbed plates

manufactured from
Width of rail foot
Rph 6 / Rph 1
60E2
Rph 6 210 / Rph 6
60E2
Weight kg / piece
1.839
15.321
Track materials
Ironmongery
and accessories
Screws
sleeper screws
Page: 233-01
Ss 35 with rounded thread
pre-assembled Uls
Name
Ss 8-140
Ss 8-150
Ss 8-160
Ss 23
Ss 25
Ss 30-230
Ss 30-240
Ss 33
Ss 34
Ss 35
Ss 36
Ss 36
Ss 36
Ss 36
Ss 36
Ss 36
132
142
152
152
161
195
205
195
125
161
195
205
215
220
225
235
35
35
35
38
35
35
35
35
35
35
35
35
35
35
35
35
0
0
0
6
0
0
0
0
0
0
0
0
0
0
0
0
Date of issue 08/10
Weight
in kg
0.528
0.548
0.568
0.594
0.625
0.703
0.739
0.689
0.530
0.656
0.732
0.769
0.807
0.826
0.844
0.882
Use
K-Support, wood and concrete sleeper
K-structure
K-structure
Track system W 14 (replaceable by Ss 35)
Track system W 14 with Uls 7 (replaceable by Ss 35)
B 93 with Uls 6
Track system 15 with captive Uls 7
Track system W 14 with captive Uls 7
System 300 with captive Uls 7
Track materials
Ironmongery
and accessories
Screws
Hook screws
Page: 233-02
Name
kg
Use
Hs 26-55
Hs 26-65
Hs 32-55
Hs 32-65
Hs 32-75
Hs 32-90
55
65
55
65
75
90
0.45
0.475
0.469
0.503
0.517
0.577
Railway track K
Railway track K
Railway track KS, turnouts 54E4 / 60E2
Turnouts 49E5
Turnouts 60E2
Turnouts 49E5
Date of issue 08/10
Track materials
Ironmongery
and accessories
Plastic screw
anchor
Page: 234-01
The plastic screw anchor always received different forms in their development, which are adapted to
the respective used sleeper screw.
As an example of Sd 25 is represented here.
Name
D1
D2
D3
kg
Use
Sd 9a
Sd 9b
Sd 25
Sd 26
Sd 27
135
155
141
141
141
39
39
36
36
36
25
24
25.5
25.5
25.5
31
31
29
29.4
29.4
0.051
0.062
0.033
0.033
0.037
Concrete sleepers
Concrete sleepers
Concrete sleepers, gravel
Concrete sleepers, slab track
Concrete sleepers, slab track
Date of issue 08/10
Track materials
Ironmongery
and accessories
Plastic screw
intermediate layers
Page: 235-01
Angular deviation <12
Pre-assembly securing
Name
a
b
c
d*
e
Zw 661 a
165
180
12
6
148
Zw 664 a
165
180
12
6
123
Zw 676
215
230
12
6
148
Zw 677
215
230
12
6
123
Zw 686
165
180
12
6
123
Zw 686 a
165
180
12
6
123
Zw 687
165
180
12
6
148
Zw 687 a
165
180
12
6
148
Zw 690
119
134
12
6
148
Zw 691
119
134
12
6
123
Zw 692
175
190
12
6
148
Zw 900
165
180
15
6
148
* Strengths possible according to the customer's wish.
Date of issue 08/10
Width of rail foot

60E2
49E5 / 54E4
60E2
49E5 / 54E4
49E5 / 54E4
49E5 / 54E4
60E2
60E2
60E2
49E5 / 54E4
60E2
60E2
Bearing
Rph 6-160
Rph 1-160
Rph 6-210
Rph 1-210
Rph 1-160
W-fastening
Rph 6-160
W-fastening
Rps 15
Rpb 1 / Rps 8
W 300-60
W 14 - K900 - 60
Track materials
Ironmongery
and accessories
Discs and
lock washer
Page: 236-01
washer Uls
simpler washer Fe
dual washer Fe
three fold washer Fe
Name
H
t
b
D1
D2
Fe 6
19
6
10
25
45
Fe 7
11
6
10
26
45
Fe 8
16
5
9
21
39
Fe 15
19
6
12
28
52
Fe 19
25.5
6
10
26
46
Uls 6
4
12
23
47
Uls 7*
4
12.5
25
50
Uls 8*
4
12.5
25
50
* Adjustment of Uls 7 and the Uls 9 to reduce the diversity
Date of issue 08/10
Type
doubled
simple
doubled
doubled
three fold
kg
0.09
0.05
0.058
0.126
0.145
0.042
0.047
0.047

Railway Track Manual Part 1

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Content

Preface for the second

Preface for second edition

Without scale/schematic diagram

Date of issue 08/10

Instructions for use

Instructions for use

Without scale/schematic diagram

Date of issue 08/10

Addresses, sales offices

Without scale/schematic diagram

Date of issue 08/10

REGISTRATION FOR INFORMATION SERVICE

Without scale/schematic diagram

Date of issue 08/10

Preface, Table of contents,

Preface for second edition

Preliminary remark, Table of contents, General terms of tracks

General Railway Track terms

Development, Railway Track, Classification

Without scale/schematic diagram

Date of issue 08/10

Types of track systems

Types of track systems

Variant W 3 - Concrete sleepers

Variant W 14 - Concrete sleepers

Variant K - Concrete sleeper

Variant K - Wood sleepers

Variant KS-H - Wood sleepers

Variant KS-St - Steel sleepers

Variant Y-Steel sleepers

Variant grooved rails with guardrail

Variants Vossloh / ThyssenKrupp

Without scale/schematic diagram

Date of issue 08/10

Vibration-damping rail bedding

Overview of rail bedding

Continuous rail bedding

Discrete rail bedding

Without scale/schematic diagram

Date of issue 08/10

NFF (New slab tracks)

NBU (Naumburg Bauunion)

Crane and depot tracks

Without scale/schematic diagram

Date of issue 08/10

Ironmongery and accessories

Without scale/schematic diagram

Date of issue 08/10

Turnouts and crossings

Crossings, EKW, DKW

Rail expansion joints

Without scale/schematic diagram

Date of issue 08/10

Plastic cable channel

Without scale/schematic diagram

Date of issue 08/10

Formation of rail forms

die tracks, turnouts and crossings,