Heavy Haul. We put heavy loads on the rail safely

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1 Heavy Haul We put heavy loads on the rail safely

2 High axle loads under extreme conditions... Heavy Haul heavy loads safely driven Axle loads of more than 26 t mean extreme loads for the railway track. Resistant fastening systems ensure safe and durable connections and simultaneously allow fast and easy maintenance. Robust rail long-lived and low-maintenance In freight traffic, the track must be able to withstand higher and higher weights. Axle loads of 35 tons have long stopped being the exception in mining. At large raw material handling harbors, up to 72 tons are required at times under the extreme conditions of the aggressive salty sea air. Our weatherresistant special fastenings for heavy haul applications not only protect the rail, but also the entire track superstructure from material fatigue and ensure stability even under the highest loads and in the narrowest curves. Thanks to easy installation and flexible subsequent equipment options, they minimize initial investments as well as current operating and maintenance costs.

3 ... Challenges that we are up to Certificated product quality for safety and durability in heavy haul traffic Vossloh has certified system solutions for secure rail fastening on heavy haul routes in almost every region and climate zone of the world. Complex rail fastening systems can only withstand the permanent load in heavy haul traffic permanently if the quality of every single component is ensured. Therefore, Vossloh checks, e.g., the fatigue strength of tension clamps with a dedicated test procedure that by far exceeds the prescribed parameters: In our labs, not only vertical forces but also loads in the lengthwise and lateral directions are simulated. We perform comprehensive combination examinations to safely exclude undesired tilting of the rail and thus increase rail safety. Our knowhow enables us to always create the perfect balance between safety, durability and resource protection. Heavy haul under control properties and benefits of the Vossloh rail fastening: Property Coordinated combinations of force-absorbing rail bearings with dedicated clamping and angle guidance elements Market-specific further developments of tried and tested fastening components Easy-to-install fastening systems... Simultaneously optimized retention forces in the horizontal and vertical directions Advantage manage the split between economic efficiency and increasing safety requirements. permit safe heavy haul traffic even under extreme climate conditions. offer a particularly cost-efficient option for retrofitting of railway routes. sustainably extend the usage duration and reduce the maintenance effort across the life cycle. Around the world, robust fastening solutions by Vossloh are keeping the rails on track in 16 countries and on a total of 4,300 km of heavy haul routes. Both ballasted track systems with concrete and wooden sleepers and solutions for slab tracks are used.

4 Rail fastening systems for heavy haul traffic overview Function / criteria Vossloh KS 12 Vossloh W 14 HH Vossloh W 30 HH ballasted track with concrete sleeper (CS) ballasted track with wooden sleeper (WS) slab track WS CS CS Maximum Axle Load (up to) 30 t 35 t 35 t* Minimum Curve Radius 400 m 1000 m 400 m Maximum Speed (up to) 80 km/h 160 km/h 160 km/h* Assembly Clip Skl 12 Skl 14 R Skl 30 Toe load / clamping force (per clip) 12 kn 12 kn 12.5 kn Vertical fatigue strength (per clip) 1.4 mm 1.8 mm 2.2 mm Track adjustment (range gauge adjustment) limited ± 10 mm ± 10mm Height adjustment optional optional optional Switch solution possible Insulation (EN 13146) 5 kω 5 kω 5 kω Rail creep resistance (EN 13146) 9 kn 9 kn 9 kn Static stiffness of the rail pad > 400 kn/mm > 400 kn/mm > 400 kn/mm* Tilting protection / tipping protection Maintenance intervals (frequency) Handling during track maintenance / destressing Possibility and easiness to replace all fastening components (e. g. after train derailment) Prefabrication / pre-assembly level Easiness of construction steps and mechanized construction / overstess possible System requirements to the sleeper No systems requirements W-rail support W-rail support Compatibility with other systems (up-/down grading) PA = pre-assembly / M = montage Rail foot adjustment Riding comfort / protection of train materials Resistance against temperature fluctuations Stress for system (components) Maintenance-, service-, labor costs; costs for operating complications Life cycle / reuse (components and sleeper) (PA) Skl 30 (M) Skl 30 / 40 (PA) Skl 14 (M) Skl 14R / 40 Remark Contents, figures and technical data in this brochure display exemplarily the performance of the fastening system, however, they always depend on external conditions. Please contact us to enable us to develop a solution for you that will be customized to your requirements. The information presented corresponds to the technical state at the time of printing; in the meantime, continuous research and development programmes at Vossloh could have caused adaptations of the product.

5 Vossloh W 40 HH Vossloh 300 HH Comparison Vossloh DFF 30 HH Standard shoulder solution with clip CS CS CS 35 t 35 t* 35 t 72 t 150 m 300 m 150 m 300 m 160 km/h 160 km/h* 80 km/h 80 km/h Skl 40 Skl 15 Clip Skl kn 9 kn 12.5 kn 12.5 kn 3.2 mm 3.0 mm 1.0 mm 2.2 mm ± 10mm ± 16 mm limited 10mm / + 70 mm optional 4mm / + 26 mm optional + 80 mm 5 kω 5 kω 5 kω 5 kω 9 kn 9 kn 9 kn 9 kn > 400 kn/mm > 37.5 kn/mm > 400 kn/mm > 400 kn/mm W-rail support 300 rail support Shoulder W-rail support (M) Skl 14R / 30 (M) other clips (PA) Skl 14 R (M) Skl 14R / 40 Level of performance (0 4): 0 = 1 = 2 = 3 = 4 = 0 = 1 = 2 = 3 = 4 = * The System is also suitable for tracks that serve both heavy haul and passenger traffic (W 30 HH: By the use of a more elastic railpad (160 kn).

6 In service around the world Milelong trains and tight curves We developed the W 40 HH AP system specifically for the extreme heavy haul traffic in the USA. The tension clamp Skl 40 with backwards bent spring arm ends achieves a high toe load and fatigue strength. The new shape also ensures a secure support on the rail base, improving lateral and vertical retention forces. The result: high fatigue limits for a long usage duration and thus low lifecycle costs. The system particularly meets the extreme mechanical loads on heavy haul tracks and there mostly in the curve areas: wider angle guide plates on the field side make it possible to take up higher loads. An abrasion plate (AP) of fiberglass-reinforced polyamide is located between the rail pad and the rail seat to protect them both: It is abrasion-proof and can be stressed with high contact pressings. Its special design also makes penetration of sand more difficult. Permanent load tests performed according to the provisions of the US directive AREMA Chapter 30 at temperature changes and with a sand-water mixture have proven this. Crane rails at container harbours In answer to the enormous track loads in container ports, we developed the DFF 30 HH system based on the tried and tested W 30 HH and DFF 300 solutions. This slab track system is used among others in the huge crane systems of Port Botany in Sidney, where axle loads of up to 72 tons are required. Angled guide plates and rail pads are made of high-tech materials that are perfectly resistant against the moist and salty sea air. Transportation of raw materials through deserts and lowlands Mauretania s only railway route connects the iron ore mines inland with the Atlantic harbor town of Nouadhibou, leading mostly through the Western Sahara desert. Since 2005, Vossloh has been equipping this heavy-load route with its KS-System, a wooden sleeper solution for ballasted tracks more than 1.7 M fastening systems have since been installed. This corresponds to a track length in excess of 500 km. The fastenings must resist extreme loads: Every year, freight trains transport up to 17 M tons of iron ore at temperatures up to + 60 C. In Venezuela, as well, more than 600,000 support points of W 14 HH system across a track length of 200 km have ensured safe transport from the iron ore mines to the country s ports since 2006.

7 Heavy haul systems at a glance System KS 12 System W 14 HH System W 30 HH System W 40 HH System 300 HH System DFF 30 HH System W31 RS I

8 Vossloh Fastening Systems GmbH Vosslohstraße 4 D Werdohl Phone +49 (0) Fax +49 (0) info@vfs.vossloh.com Published The trademarks Vossloh,, and cellentic are registered trademarks of the Vossloh group, which are internationally protected in many countries. These trademarks may only be used with prior consent by Vossloh AG. This publication may also contain trademarks of third parties. The use of those trademarks is subject to the terms of use of the respective owner.