MGB Maglev Guideway Bögl Progress is built on ideas.
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Foreword Johann Bögl Stefan Bögl Since more than a decade now, the Max Bögl Group is engaged in trendsetting development and construction of modern guideway-transportation systems. Continuous developments and experiences gained from high speed projects already realized, as well as suggestions, wishes and requirements of customers have led to an extension of our company s know-how and to leading magnetic levitation guideway technologies. Proudly we can say that we are now in a position to offer a complete range of products for all issues and conditions of modern guideways for maglev trains. MGB Maglev Guideway Bögl has combined and optimized the initial standard construction methods of TVE, Lathen, Germany. Consistent further development led to the hybrid guideway system, which was applied in the world s first commercial Transrapid route in a nationalized version in Shanghai, China. The experiences gained from this project were implemented in further developments. Connected with the elaboration of innovative construction methods and experiences with new kinds of concrete mixtures and building materials as well as the most modern manufacturing and machine-technology for concrete processing (drilling, grinding, cutting) in any spatial geometry, they have been the base for securing the future and market leadership. The result is again an economical and qualitatively improved magnetic levitation guideway. Furthermore, the close co-operation with universities and institutes as well as changed requirements of various new projects generated modifications to our systems. Whether construction of an elevated track like in China, or the installation of a guideway system in tunnels and/or as a mass-spring-system: we have risen to the challenges and created solutions for our customers world wide. Economic aspects as well as the experiences gained from our international projects play a superior role in developing new systems. That is why we strongly pay our attention to even more efficient production methods, mechanized and automated assembly processes and the use of more economical construction materials. Operators, public authorities, planners, manufacturers and construction companies worldwide will find a superb partner in the Max Bögl Group who is able to offer fully developed and economic solutions, which will competently advise, assist and guide you in order to implement the required precision and quality of the MGB. With the current brochure we present you our innovative prefabricated systems and give you an overview of the multifaceted range of our products and services. Johann Bögl Partner Stefan Bögl Head of Research and Development 3
Services Because of its versatility, the Max Bögl Group is in the position to offer planning, fabrication, machine technology and turn-key implementation for maglev trackways. For the fabrication of maglev guideways we offer the following specific services: Planning For the MGB Maglev Guideway Bögl the Max Bögl Group developed software that generates from any project s geometric database, all the relevant informations of a track laying plan for all different types of girders. These are the basis for the fabrication and installation of the beams as well as the entire logistics in specific the fabrication and preinstallation steps, the storage and transportation plus on-site construction last but not least the quality assurance and inspection measurement. Manufacturing- and Machine technologies The Max Bögl Group has decades of experience in modern prefabricated construction. We plan, construct and/or operate customer and project-specific manufacturing plants as well as units and equipment for the assembly. We can provide plants and specific assembly equipment for your mobile project from our rental park on request. 4
Know-how transfer A team of experienced experts would advise you on realizing your project with our technology. We supply a complete manual within the frame of a know-how transfer, with workand inspection instructions for the manufacturing of guideway girders and their installation for our product MGB. Our customers receive all necessary informations required for planning, implementation and for the quality control of the MGB in specially adapted training. Our experts escort and advise you during the implementation. Additionally, we also offer the entire technical responsibility of our system and quality supervision. Quality Management Our complete quality management system sets standards for the entire procedure. Defined work procedures appropriate to national standards and inspections ensure continues high quality. Through our support in the selection of national materials we are certainly able to achieve the required quality of the end product. 5
System description of the hybrid guideway The base for the maglev guideway design is the specification of the system industry. For the Transrapid, they are as follows: Very high stiffness, both vertically and horizontally (max fz < L/4.800; max fy < L/18.000) Strong against deformation or rather non deformable Clear away all stimulations by the maglev vehicle Compliance with the system s high tolerance requirements in the functional elements of the guideway Since tolerances of only less than a tenth of a millimeter cannot be realized in the conventional reinforced concrete or prefabricated construction, but with proven record that concrete units are the more economical and low maintenance solution, the idea already occurred to us in 1996 to combine the concrete construction with mechanical engineering. The hybrid modular construction method was born. The hybrid guideway combines the advantages of concrete and steel construction and is produced in the following main groups: 1. A solid, rigid prestressed concrete beam was selected as main structure. Its centric pretensioning & prestressing increases its serviceability. The garland shaped tendon wires allow shape accuracy for the load case dead weight. 2. Within a steel functional module with a length of 3 m the three essential levels for the system were combined: Stator level with stator and winding Side lead level, and Gliding level 3. Prestressed concrete beams and functional modules are connected through consoles anchored in concrete. These consoles are processed mechanically with a computer aided grinding and drilling machine, after creeping and shrinking deformations of the prestressed beam came mainly to its end, in order to keep the project and system specific geometry accurate. Only after precision processing, the functional modules are attached to the consoles and connected to the concrete beam. This module construction method delivers the following advantages compared to previous construction methods: The production and assembling was automated to a large extent. Accurateness in concrete construction was achieved in new dimensions. The modules are exchangeable. 6
System description of the concrete guideway Connecting parts, the so called consoles and the functional modules of the hybrid guideway are made of steel. This design, however, represents costs of approximately 60 % of the hybrid guideway, which still leaves plenty of space for economic optimization regards fabrication as well as maintenance and inspection costs. Therefore steel parts of the hybrid guideway beam which are not mandatory for the operation of the maglev vehicle, were reduced and replaced by concrete. Approximately 75 % of the steel weight was saved. The production costs were reduced by approximately 30 % (base Summer 2006). With newly developed and according to the needs machine technology, drilling for the stator package mounting parts can be accurately manufactured. The new connection is designed for continuous endurance and can be inspected by fully automatic image processing procedures. In specific this results in the following savings: Reduced large-scale welding Reduced intensive corrosion protection Reduction of screws and bolts Reduced inspections Reduction and simplification for maintenance & service Thus this guideway system represents the most economical solution in terms of fabrication, maintenance and operation. The new production procedures guarantee an even more accurate compliance with guideway-tolerances. This results in: Improved travel comfort Energy savings due to reduced gaps Increase in pay load 7
System cross sections MGB Type I 24,8 m The type I girder is optimized with its closed box crosssection to the structural needs, the requirements regarding the trackway evenness as well as production process. The girder is manufactured with fixed bearing pedestal and can be equipped with all maglev guideway innovations of the Max Bögl Group. Curved sections can be realized depending on radius either by adjustment of the top chord or for small radius by bending the entire beam. The transverse slope of up to 12 can be realized by bearing pedestals of variable height. On request and according to project-requirements this type of beam can also be produced in excess length. MGB Type II 12,4 m The MGB Type II girder got the distinctive π-cross section of the type III beam, however with closed beam end-sections. The girder doesn t have garland shaped prestressing but shows similar pedestal bearings like the MGB type I. Curve geometry and transverse gradient are produced likewise the MGB type I. 8
MGB Type III 9,3 m With its 9,3 m long girder Max Bögl has established an optimized beam for the illustration of the most economical track geometry for at-grade guideways. The system consists of standard beams and inclination as well as pedestal bearings are all produced in mass production. This type of girder is implemented without garland shaped prestressing and with π-cross section, that can be realized without a closed end cross section. This leads to further cost-reductions. Concrete-/Steel glide strip In case of settling of the maglev train on its guideway the girder has to provide gliding strips. The Max Bögl Group offers two solutions for that kind of event. A so called steel glide strip integrated in the MGB girders or a coated, highly precision concrete glide strip, which is characterized by cost-effectiveness for equal suitability. Steel glide strip Concrete glide strip 9
Type I Shanghai 2 Type III Type I Air borne sound Because of its material specific characteristics the concrete beam behaves more favorably as hybrid or even steel beams regarding noise emission. The airborne sound emission could be reduced on our all-concrete beams through elimination of the gap between the function level modules, like they are present in hybrid girders. Furthermore the noise can be reduced by external noise insulation elements. Through the choice of the beam s cross-section form, the sound propagation direction can be controlled, too. Vibrations In order to absorb vibrations caused by the vehicles when passing through sensitive zones, so called mass spring systems are used. The entire guideway is placed on elastic support elements, which is implemented either as a steel spring or as PU-material. Through the calculated and chosen spring coefficient the subsidence of the masses of guideway, bearing and pedestal can be defined exactly. In internal tests the mass spring elements were adjusted to interaction of vehicle and guideway. This mass spring system was also tested highly successfully in fall 2008 at the test facility in Emsland (TVE), Germany. 10
Concrete bending switch From the engineer s point of view, the construction and production of a concrete bending switch is a special provocation. The Max Bögl Group has taken on this challenge. 14,4 m long post-tensioned girders are connected to form a switch system, which is bended in transverse direction with rack and pinion drives. The deflection of the switch beams is made possible by constructing slits in the top chord section of the girders. The deformation of the base section is realized with modified concrete, which shows despite its high strength a low E-module. In spring 2009 the Max Bögl Group will carry out different large scale tests of prototype bendable switch-beams on a 1 : 1 scale. 11
Guideway specials Manufacturing of precise track geometry Equip with technical, system modules The key to success, particular for the all-concrete beam lies on the one hand in the adjustable formwork technology being adopted to standardized girders, and on the other hand in special developed machine technology of Max Bögl, which can process concrete parts in highest precision. This allows and enables a series production of the beams, subsequent fine machining is used to adjust the track geometry and to adhere to the required system s technical tolerances. The Max Bögl Group has a leading position in the production of highly precise concrete structures worldwide with its machine technology for concrete processing including the required software. Following the machine processing the girders are already completely equipped in the plant: Coating of the slide strip Assembly of the stator packages and the side guidance plates Assembly of the long stator windings including cable sleeves at the beam joints Assembly of the cable clamps for track cables Quality control and final inspection in the factory Cable sleeves for transportation Pre-assembly of the stator packages 12
Installation (2) Transport (1) Construction of the foundation, piling and if necessary elevated support structures (4) and of the long stator winding (3) Assembly of the girders (5) Start up operation 13
Project TVE 1999 The test and trial track in Emsland (TVE), Germany for the Transrapid exists since beginning of the 80 s. The guideway was made of different beams constructed from different manufacturers. In 1996 the Max Bögl Group begun to develop an alternative, costeffective guideway system for the planned Transrapid project Berlin Hamburg, Germany. For its first guideway structure, Max Bögl developed a hybrid system and manufactured a double-span girder with a total length of 62 m (2 x 31 m). The hollow section tapers trapezoidal downwards. Consoles are concreted by anchor bars laterally into the concrete top chord. Those are oversized and are mechanically milled and bored according to planned geometry. For this reason the connecting faces of the consoles achieve its highly required accuracy. On the machined consoles the function level modules are arranged polygonal. Those combine the three levels in a welded steel construction the glide level, the side guidance level and the stator level which are essential for the operation of the maglev train. The function level modules are manufactured with sufficient precision for the high geometrical requirements. The following points have proven to be advantageous for this guideway system: High accuracy of the individual function level modules and the entire guideway beam The function level modules can be exchanged when damaged. Due to the high dead weight compared to steel guideways, the girder is not endangered through vibration. 14
Project Transrapid Shanghai 2001 In the search of guided ground transportation system for high speeds the Chinese government decided in summer 2000 in favor for the magnetic levitation technology of Germany the Transrapid. The world s first maglev line connects the international airport in Shanghai with the business centre Pudong. For the realization of this track a project company, the Shanghai Maglev Transportation Company (SMT) was established. This company was responsible for the implementation of the entire project. Since there is no experience in China in the construction of guideways for the magnetic levitation system, SMT president Wu Xiangming has assigned the Max Bögl Group as advisor for planning, production and installation as well as the assembly. Opening of the system On 31st December 2002 the ambitious goal to build the 35 km long route in just two years was achieved. On one of the two lanes the first run took place at a planned speed of 430 km/h. After this successful first trip many further test runs were undertaken. At the beginning of 2004 the entire system was officially taken in operation. Decisive for the success in China was the high precision and quality in conjunction with the costumer oriented consulting by the Max Bögl Group. The beam concept of the Max Bögl Group has been proven successfully in the first commercial use. Now up to eight maglev trains sections operate on two lanes every 10 minutes. It is yet a unique system worldwide, which is in use under all operational conditions with speeds up to 501 km/h. 15
Project TVE 2005 and 2008 Since 1996 engineers of the Max Bögl Group continuously advance the guideway. They constantly use experiences gained in China and from high speed railway projects for the technical and economical optimization of the systems. The most important knowledge s gained are: standardization, use of single span beams, precision processing and reduction of steel components. Revised specifications by the system industry and new requirements from planned routes worldwide are likewise cause for adjustments. The results of own advancements are an: in all issues of efficiency, robustness and economically optimized guideway system which is characterized by the following features: Fabrication and Logistics Guideway beams are produced with integrated (MGB type I and II) respectively separated (MGB type III) bearing pedestal as series prefabricated units, and are already equipped with system technical parts in the plant. The cost-intensive and error-prone work procedures are reduced to a minimum. The guideway beams were completely equipped in the factory and delivered to the installation site after successful final inspection. Cost effectiveness Steel parts of the guideway were reduced to the technical necessities as opposed to the preceding versions. Due to the decrease of the steel components, the production costs as well as the maintenance costs of the guideway are minimized. Quality The production of the prestressed beams takes place under defined conditions. The adjustment to the threedimen sional track-curve is done through mechanical processing with a CNC grinding machine with automatic quality record. The beams are equipped in the plant and this allows complete and economic inspections. A very high production accuracy and durability is achieved with this approach. Since August 2005 four all-concrete girders type III are in operation in the south loop of the Transrapid test facility in Emsland (TVE), Germany. In fall 2008 those girders were highly successfully modified with the world s first massspring system. 16
Advantages Production in series Highest accuracy High concrete quality High durability (80 years) Low steel material volume Simple corrosion protection Economical bearings Low maintenance costs Reduced construction time Elimination of accompanying route cable lines 17
Max Bögl Founded by Max Bögl in 1929, Max Bögl Group, headquartered in Neumarkt, Germany, is looking back on a successful company history of more than 80 years. With annual sales of more than 1.5 billion Euro and about 6,000 highly qualified employees, Max Bögl not only ranks among the top 5 of Germany s biggest construction companies: managed by the third generation of the family, Max Bögl Group is Germany s biggest privately owned construction company, too. Thanks to innovations in technology and organisation over the past decades, Max Bögl transformed from a single construction service provider into a technology and service company that operates globally. Today its activities extend across all areas and difficulty levels of the modern construction industry: building and traffic route construction, civil engineering and tunnel construction, steel and plant construction, prefabricated part construction as well as supply and disposal. In the future, Max Bögl s technical know-how will be employed increasingly to make renewable energy even more efficient and attractive. A first step in this direction has been the development and successful launch of the Max Bögl Hybrid Tower System for wind power plants. Without losing sight of its core competence, the traditional construction business, Max Bögl Group remains a trustworthy, results-oriented partner who reliably realises tailor-made individual solutions as well as complex one-stop total packages from planning and financing to realisation and operation. More than 35 locations, production facilities and representative offices all around the world open up new markets for innovative, trendsetting products and highlight our international focus. The know-how that Max Bögl Group has acquired over the course of many years and its skills in construction and innovation are reflected in a plethora of prestigious building projects. For several soccer world cups and European championships, Max Bögl Group demonstrate its capabilities with the construction of several spectacular sports venues. The Group continues to foster its Design & Build competence with the construction of complex and sustainable logistics properties. As a specialist for modern civil engineering and tunnel construction, Max Bögl s technical and logistical solutions have been successfully implemented in many European countries. The Group s leading position in steel construction is reflected especially with the construction of impressive bridges of all sizes. And as one of the leading manufacturers of prefabricated parts Max Bögl produces pre-cast concrete parts of the utmost quality and precision in its own seven stationary plants as well as in a mobile production plant. Max Bögl s innovations such as the development of the Slab Track Bögl or the guideway girder for maglev systems, successfully used in German and Chinese high-speed networks, benefit from decades of experience in the construction and production of precision pre-cast concrete parts. Modern lightrail systems as well as pre-cast slabs for switches & turnouts and concrete sleepers round off the guideway technology portfolio. 18
Max-Bögl-Strasse 1 D-92369 Sengenthal, Germany Postal address: P. O. Box 11 20 D-92301 Neumarkt, Germany Phone +49 9181 909-0 Fax +49 9181 905061 info@max-boegl.com www.max-boegl.com die-jaeger.de böne082011 10/14. Photo credits: Max Bögl Group (title, p. 2, 3, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16); DACHER Design & Technik (p. 11, 12); Nürnberg Luftbild, Hajo Dietz (p. 18); Ingrid Fiebak (p. 14); Kurt Fuchs (title, p. 6); Die Jäger (p. 17); Reinhard Mederer (p. 4, 12); K. Mosch (p. 6); MVP München (p. 14); ThyssenKrupp Stahl (title, p. 7, 13); Transrapid International (p. 4, 17); Fotostudio Weidinger (p. 3)