delivering turnout solutions - rtsa nz - 25052017.pdf · turnout design and integration developing...

DESIGN SUPPLY INSTALL MAINTAIN

Delivering Turnout

Solutions

Introduction

GLOBAL TURNOUT SOLUTIONS

Introduction

BROWNFIELD CONSTRUCTION SOLUTIONS

Introduction

MAJOR PROJECTS

Introduction

CRANE RAIL CONSTRUCTION

▪ Turnout design and integration

▪ Developing turnout technology

▪ Turnout supply management

▪ Critical junctions design and installation

▪ Turnout pre-assembly and installation

▪ Turnout installation staging solutions

▪ Turnout refurbishment and track reconditioning

▪ Crane rail specialist (supply and construct)

▪ Slab track construction

▪ Turnout and track inspections, maintenance and asset

management

Design – Supply – Install – Maintain

Introduction

We specialise in:

▪ Light rail

▪ Metro

▪ Passenger and freight

▪ Heavy haul

▪ High Axle Load Heavy Haul (HAL-HH)

▪ All gauges and rail profiles

Design – Supply – Install – Maintain

Introduction

Turnout range:

Projects

347 TURNOUTS SUPPLIED

SUPPLIED 51 BUFFER STOPS

CONTRACTED FOR THE SUPPLY OF 400+ TURNOUTS

60KM OF TRACK INSTALLED

33KM OF CRANE RAIL INSTALLED

INSTALLED 102 TURNOUTS

WE HAVE BEEN BUSY AT MARTINUS RAIL

Projects

▪ 22.5t axle load

▪ AS60 rail

▪ 200+ tangential turnouts

Kiwi Rail

Projects

Doha Education City – Qatar

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

Projects

Projects

Sydney Ports – Botany third line and yard upgrade

▪ 30t axle load

▪ 60E1 rail

▪ 26 Tangential turnouts

OneSteel – Whyalla – Iron Ore Project

▪ 32t axle load

▪ 60E1 rail

▪ 9 Tangential and conventional turnouts

▪ 54t axle load flangeway running diamond

Projects

ARTC – 30TAL Gunnedah

▪ 30t axle load

▪ AS60 rail

▪ 15 Tangential and conventional turnouts

Projects

ARTC – HRR & LTTSF Hexham

Projects

▪ 32.5t axle load

▪ AS60 rail

▪ 41 Tangential turnouts

▪ swing nose crossings

ARTC – Kooragang Island

32.5t axle loadAS60 rail

8 Tangential turnoutsMonoblock crossings

Projects

ARTC – Upper Hunter Valley

32.5t axle loadAS60 rail12 Tangential turnoutsMonoblock crossings

Projects

MBRL - Brisbane

Projects

• 30km of track• 19 turnouts

ARTC – East/West Productivity works turnout upgrade

Projects

PKCT

Projects

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

Southpine bridge renewals

Projects

• 2 x 700m tracks along two bridges and an embankment, and was undertaken within a 168 hour rail closedown

Webb dock

Projects

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

GCLR Stage 2

Projects

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

Buffer stops

Projects

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

Factories

Manufacturing facility – Century, Australia

Factories

Manufacturing facility – DT, Czech Republic

Global Turnout Solutions

Factories

Manufacturing facility- GWQC, China

Global Turnout Solutions

Factories

Manufacturing facility- CRSBG, China

What is a turnout?

Products

Breakdown of a turnout

Products

1. Switch panel

2. Closure panel

3. Crossing panel


Products


Products

• Bearers

• Switch set

• Infill closure rails

• Crossing

• Check rail unit

• End infill closure rails

• Points machine

• Rodding

• Platework

• Jewellery

Different types of turnout

Products

▪ Similar flexure

▪ Contra flexure

▪ Crossover

▪ Diamond▪ Scissor crossover▪ Single slip▪ Double slip▪ Catchpoints

Conventional vs Tangential

Products


Products

• Tangential = improved technology

– Reduced forces

– Increased speed

– Longer service life

– Improved ride quality

– Concrete bearers

– Asymmetric thick web switch

– Resilient fastened stock rail

– Raised adjustable check rails


Products

Rail Bound Manganese (RBM)

Products

▪ Fully cast manganese insert

▪ Explosively hardened

▪ AS60 Wing rail

▪ CNC machined nose profile to suit

client wheel profile

▪ Life expectancy: 300MGT

Monoblock

Products

▪ Fully cast manganese

▪ Explosively hardened

▪ No bolts

▪ FBW 60kg Legs

▪ CNC machined WR & nose profile to suit

client wheel profile

▪ Life expectancy: 400MGT

Swing nose crossing

Products

▪ Rail type

▪ Frame type

▪ Manganese cradle

- Eliminates impact

- Reduced noise

- Suitable for longer rate

turnout (high speed)

- Life Expectancy: Greater

than 1000 MGT

High axle load (48T) heavy haul turnout

Products

Designs according to axle loads and speed

Products

Temporary Takeoff Turnout

The Temporary turnout creates a

temporary siding allowing track

machines to move on and off track at

will.

▪ Allows safe and easy removal of

track machines with up to 23T axle

loads from mainline

▪ Once the track machine is located

on the temporary siding it is as

simple as removing two switch

ramps and a crossing ramp,

weighing only 350kg each, in order

to restore mainline running

Products

Temporary Takeoff Turnout

PWI Ken EricksonInnovation Award Winners

Products

Points operation rodding

Products

Backdrive Crank

Drive Locking Bars

Detection Bars

Points Motor

Linking rods

Rear Drive Rod

Deflection Plates

Heel of Switch

Points of switch

Hydraulic points machine – Alstom CTS2

Products

Electric points machine - Siemens M3A/20A

Products

Electric points machine - Siemens D84M

Products

Track forms – Concrete bearers

Products

Track forms – Composite bearers

Products

Products

Expansion Switches

▪ Used for thermal and

subsidence management

▪ Moving Stockrail - gauge is

kept within tolerance

▪ Small Expansion – Up to

100mm

▪ Medium Expansion – Up to

330mm

▪ Long Expansion – Up to

600mm

Products

Buffer Stop systems – Friction Hydraulic

R&D

• New product development is key to ensure that Martinus Rail stays at the forefront of turnout technology and meets increasing network and operational demands from the client

• Martinus Rail carries out design validation (can be by an independent third party) to:– Ensure product conformance

– Ensure product suitability

– Ensure product life cycle

• Validation will include:– Engineering reports

– Design review

– Risk analysis review

R&D

• All new crossing designs are verified for performance using finite element analysis (FEA) techniques

• Tested up to 48T for both static and fatigue analysis

• Fatigue life tested for 2.4 x 107 cycles.

R&D

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

R&D

• All products undergo rigorous QA testing and follow up analysis

Install

KR Supply

• Martinus Rail designed brand new tangential turnout design solutions in

collaboration with KiwiRail based around the in track conventional turnouts

currently installed in track. The following table displays current details of turnouts

in use in Kiwi Rail:

• Martinus Rail has reverted to turnout design fundamentals to provide a newly

designed suite of the turnout sizes to incorporate full tangential design and

features that will provide a turnout with an increased life cycle giving Total Cost

of Ownership (TCO) benefits for Kiwi Rail. Martinus Rail has designed the four new

layouts to the following details:

Crossing Rate (Strike) Crossing Angle (°) Speed (km/h)

1 in 7.5 7.59463 25

1 in 9 6.34019 30

1 in 12 4.76364 40

1 in 18 3.17983 60

Radius (m) Crossing Rate (Strike) Crossing Angle (°) Lead Length (m) Divergent Road

Speed (km/h)

R96 1 in 7.5 Straight 7.59463 14.675 28

R140 1 in 9 Straight 6.34019 17.386 33

R250 1 in 12 Straight 4.76364 22.393 42

R560 1 in 18 Straight 3.17983 34.487 66

Kiwi Rail – NZR50 Turnouts

KR Supply

Item Description Reference Document

Turnout Type Tangential – mixed trafficIn accordance with

AS1085 and EN 13232

Turnout

Radius96m, 140m, 250m, 560m

Crossing Rate 1 in 7.5, 1 in 9, 1 in 12, 1 in 18

Gauge 1068mm Kiwi Rail T151

Rail Size NZR50GB 2585-2007 &

Kiwi Rail dwg. 88323/1

Bearers Concrete / CompositeKiwi Rail T151, T160 &

AS1085.14

Turnout

Road SpeedAs per Table 7

Axle Load 22.5T Kiwi Rail T151

Wheel

ProfileNZ A,C & E series

Kiwi Rail dwg. 7604-11,-

13 & -15

Rail Cant in

TurnoutZero

Points

Operation

Suitable for M3A, CTS-2 & Racor

Lever

Yearly

Tonnage18 MGT P.A.


Design Criteria Dimension (mm)

Nominal track gauge 1068

Design wheelset back to back dimension 993 - 998

Check rail effectiveness 1026 - 1032

Crossing Flangeway width 41

Check rail gap 38

Maximum superelevation (cant) deficiency

through diverging track60

Switch rail toe / stock rail open throw

dimension≥ 115

Switch rail throat opening ≥ 50

Check rail flared end opening to gauge ≥ 80

Check rail height above the running rail 0

Flangeway depth clearance 45

KR Supply


Switch assembly – The switch assembly is fabricated from 50AT asymmetric switchblades and NZR50 head

hardened stockrail.

Asymmetric tangential switchblades – The switchblade is manufactured from 50AT rail. The last 500mm of the

switchblade is forged to the NZR50 profile for connection to the infill closure rails.

• Rail type 50AT, U71 V quality according to TB/T 3109-2005. Rail head is post CNC machined factory

pearlitized to produce a head hardened grade material

Stockrail – Manufactured from NZR50 head hardened (to HB 340) rail. Stock rails are drilled for locking device,

anti-creep device and switch stops.

• Rail type NZR50 quality U75V (HT) according to GB2585-2007

• Head of stockrail undercut to 1:3

Monoblock Crossing Assembly – Manufactured from cast austenitic manganese steel manufactured to TB/T

447-2004

• Explosively hardened within range 320 – 350 HB, all running surfaces up to 100mm from ends of

casting, 20mm from top of rail

• FBW Crossing legs NZR50 quality U75V (HT) according to GB2585-2007

KR Supply


Adjustable Check Rail - The check rail unit (two per turnout) comprises the check rail and the check rail

bracket. The check rail is bolted to the bracket using M24 x 80 fasteners. The ends of the check rail are flared to

allow gathering of the wheel flange.

• Check rail type 33C1 (UIC33) to EN 13674-3

• Closure rail clipped to the check rail plate using resilient clips

• Fully adjustable using shim set

Closure Rail - The infill closure rails (rails between the end of the switches and start of the crossing) are supplied

either straight or pre-curved from NZR50 quality U75V (HT) according to GB2585-2007.

Concrete Bearers – Prestressed concrete bearers to AS1085.14 with M24 Screwspike ferrules and Pandrol

shoulders

KR Supply


Quality Management Plans

KR Supply

KR Supply

Risk management

KR Supply

KR Supply

Quality Inspections

• Manufacturing inspection – In process inspection by the manufacturer

• Third party inspection - In process and post production inspection by a

third party expert

• FAT – Factory Acceptance Test carried out by Martinus Rail senior

engineers

• 100% inspection at factory – All products 100% inspected by Martinus

Rail prior to shipping

• 100% inspection on delivery– All products 100% inspected by Martinus

Rail on delivery

• Trial lay – First off article trial lay for KiwiRail proving

KR Supply

Quality Inspections

ITEM No.

PROCESS / OPERATION / DESCRIPTION VERIFYING

DOCUMENTS TARGET ACTUAL TOLERANCE

INSPECTED BY

COMMENTS

1.13

Gauge to Gauge Distance at A/B/C/D/E (Switch closed)

SG.NZR50-7.5-101

122

156

193

232

275

122.4

156.2

193.5

233

275.5

±1 mm (pass)

1<x<1.5mm (note)

x>1.5mm

(adjust with shim)

KJ

1.14 Switch assembly end opening SG.NZR50-7.5-101 427 426 ±1 mm KJ

1.15 Switch tip to end of stock rail SG.NZR50-7.5-101 1090 1090 ±3 mm KJ

1.16 Stockrail Drilling from End of Stockrail (diameter/distance/height from foot)

SG.NZR50-7.5-101 ø22 1500 63

22 1500 64

±0.5 mm ±2 mm ±1 mm

KJ

1.17 Switch Drilling Hole Diameter – Foot SG.NZR50-7.5-101 Ø32 32 ±0.5 mm KJ

1.18 Switch Drilling Hole Diameter – Web SG.NZR50-7.5-101 Ø22 22 ±0.5 mm KJ

1.19 Stock rail head machining clearance to switch tip SG.NZR50-7.5-101 40 39 ±10 mm KJ

1.20 Foot of the rail to the inside edge of the hole - 17 17.5 +2 mm -0 mm

KJ

1.21 From the foot relief to the bottom of the holes - 14 14 +2 mm -1mm

KJ

KR Supply

Quality InspectionsITEM No.

PROCESS / OPERATION / DESCRIPTION VERIFYING DOCUMENTS

TARGET ACTUAL TOLERANCE INSPECTED

BY COMMENTS

1.22

Switch Drilling from Toe of Switch

SG.NZR50-7.5-101

Ø32 Holes: 50, 117, 184, 690, Ø22 Holes: 294 +232 +253 +100 Check M20 Bolt Fit

Ø32 Holes: 49.7, 116.7, 184.5, 690, Ø22 Holes: 294.5 +232 +253 +100

Checked

±1 mm

KJ

1.23 Switch stops correctly positioned (gap between switch stop and rail web)

VISUAL 0 0 +2, -0 mm KJ

1.24

Length of plates under switch: 50-FLAT 50-SW/50-SWH 50-7.5-13-RH-RS/50-7.5-13-LH-LS 50-7.5-14-RH-RS/50-7.5-14-LH-LS 50-7.5-15-RH-RS/50-7.5-15-LH-LS 50-7.5-16-RH-RS/50-7.5-16-LH-LS

-

450

650

790

840

850

906 (Loose)

450

649

790

841

849

±2 mm (OK)

>2 mm (Check Hole to

Hole L-70mm, ±1)

KJ

KR Supply

Quality Inspections

KR Supply

Product Marking

ITEM DESCRIPTION

1 in

7.5

- L

eft

Han

d T

urn

ou

t

1 in

7.5

- R

igh

t H

an

d T

urn

ou

t

1 in

9 -

Le

ft H

and

Tu

rno

ut

1 in

9 -

Rig

ht

Han

d T

urn

ou

t

1 in

12

- L

eft

Han

d T

urn

ou

t

1 in

12

- R

igh

t H

and

Tu

rno

ut

1 in

18

- L

eft

Han

d T

urn

ou

t

1 in

18

- R

igh

t H

and

Tu

rno

ut

1 Left hand side - switch rail + stock rail * I * I * I * I

2 Right hand side - switch rail + stock rail * I * I * I * I

3 Crossing * I * I * I * I

4 Check rails – C * I * I * I * I

5 Check rails – K * I * I * I * I

6 Closure – C * I * I * I * I

7 Closure – K * I * I * I * I

8 Closure – F * I * I * I * I

9 Closure – D * I * I * I * I

10 Closure – A N/A N/A N/A N/A * I * I

11 Closure – H N/A N/A N/A N/A * I * I

12 Loose Items (Box) * I * I * I * I

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Delivery

KR Supply

Logistics

KR Supply

Trial Lay

KR Supply

Installation

KR Supply

Points operation rodding

KR Supply

Teamwork

KR Supply

Summary

• Challenges

• Brand new turnout design

• New manufacturer

• Shipping rail from NZ

• Logistics of moving parts around the world

• Earthquake!

• Successes

• Turnouts on the ground

• Rodding installed

• Working relationships

• Manufacturing quality

delivering turnout solutions - rtsa nz - 25052017.pdf · turnout design and integration developing...

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