“StEPS ahead” with the environmentally friendly Engineered Polymer Sleeper (EPS) made of amalentic
Progressive expansion of competencies
Constant product properties
168+ test characteristics were identified & 330 internal tests were carried out for the new, 100% recyclable material mix called amalentic
read more Unique manufacturing process
... whose multifunctional tool concept opens up application possibilities for customers in the track that were previously not feasible, such as the use of direct fasteners.
read more Reason why for an alternative to composite & wooden sleepers
Thanks to amalentic, EPS combines all the positive properties of concrete, wood and plastic sleepers. The innovative amalentic material mix of secondary raw materials in industrial quality and additives forms the basis for ensuring that the most important product requirements, such as high weather resistance, low thermal expansion, high lateral track stability and stable track gauge, are met to a particularly high degree.
Environmentally friendly & 100% recyclable
High compression strength, defined & stable properties
Low thermal expansion coefficient, additional steel reinforcement
Increased safety due to the use of reinforcement
Complete solution with rail fastening systems, usage of direct fasteners
Excessive testing to develop amalentic
Economical & eco-friendly sleeper alternative for tracks, switches & bridges
- 168+ requirements were identified
- About 330 in-house trials were carried out to achieve the optimum material compound that fulfils the standards and customer requirements
- Determination of the influence of temperature on mechanical properties
- Participation in the standardization committee for plastic sleepers ISO and AREMA
International requirements:
- ISO 12856-1:2022-02 material characteristics
- ISO 12856-2:2022-11 product testing
- ISO 12856-3:2022-02 general requirements (Proposal)
National requirements:
- AREMA Chapter 30 Part 5
- Operational capability test (Betriebstauglichkeitsuntersuchung) DB/EBA Version 8
- SPC00298 ProRail
Overview of specifications
Refurbishment & adjustment possibilities
Repair kit for in-track
Our sustainability concept of course also covers refurbishment and adjustment possibilities.
If, for instance, a hole is at the wrong position, this can be easily rectified. Simply clean the hole (blowing out will do the job), fill it with casting compound, let it harden, drill a new hole at the required position, and screw in the screw at the correct location.
Also larger damage can be repaired easily.
Even the gauge can be subsequently adjusted.
If, for instance, a hole is at the wrong position, this can be easily rectified. Simply clean the hole (blowing out will do the job), fill it with casting compound, let it harden, drill a new hole at the required position, and screw in the screw at the correct location.
Also larger damage can be repaired easily.
Even the gauge can be subsequently adjusted.
New series production
- State-of-the-art & largely automated production plant
- Initial capacity of around 100,000 composite sleepers per year (daily capacity approx. 480 units)
- The production process complies with all European energy standards and the topic of sustainability was also a focus from the outset when designing the individual production steps. For example, green electricity is used for production and energy is recovered and reused wherever possible.
- The innovative tool concept enables flexible adaptation of the product design to customer requirements.
- The product portfolio includes track and turnout sleepers as well as special products for railway bridges:
Engineered Polymer Sleeper – Engineered Polymer Sleepers made of amalentic
Material
- New environmentally friendly recyclable composite material in uniform industrial quality
- Consists of filler material, polymer & additives
- Polymer 100% recycled
- Sand 100% natural product no additives
- Rebars approx. 100% scrap steel
Material production
- Polymer is melted and homogeneously mixed with filler & additives
Sleeper production
- Mould preparation and reinforcement positioning
- The prepared compound is poured into the mould; pressed under high load, cooled and then demoulded
Recyclable
- After the product life cycle – in other words after around 50 years on the track –, the EPS is shredded and the material separated. As each sleeper is labeled with a number, the exact material mix is known.
- Before the material is reused, the material is cleaned before processing to ensure quality requirements are met.
Unique Production process
Flexible adaptation of the product design to customer requirements
- Customers can order their EPS without any restrictions concerning design, both the sleeper shape and the positioning and type of reinforcement can be adapted to application-specific requirements.
- A special feature of the EPS and, above all, its manufacturing process is the multifunctional tool concept, which for the first time opens up previously unrealizable application possibilities in the track:
- This means that our sleepers can be supplied with prefabricated, precisely positioned core holes for the sleeper screws – with or without internal threads. This reduces the torque during tensioning, increases the extraction forces and eliminates the need for time-consuming drilling work on the track construction site. Nevertheless, subsequent machining options such as drilling, sawing, milling and grinding are still possible.
The screw axis can also be designed with a precise 5° inclination, as required for direct fastening for pre-assembly.
- This means that our sleepers can be supplied with prefabricated, precisely positioned core holes for the sleeper screws – with or without internal threads. This reduces the torque during tensioning, increases the extraction forces and eliminates the need for time-consuming drilling work on the track construction site. Nevertheless, subsequent machining options such as drilling, sawing, milling and grinding are still possible.
- Customers can choose between different rail fastening solutions – direct or indirect, including safety guard. The prefabrication of beads for a direct fastening is also possible, e.g. to reflect different inclinations in the rail bed. This makes the EPS perfectly suited for W systems with our tension clamps of the new M generation.
- To increase the track stability, lateral profiling as well as corresponding recesses on the bottom side of the sleeper can be provided.
- Instead of prefabricated drill holes or beads for screwed fastening systems, also cast iron shoulders can be embedded in the EPS for the usage of clipped rail fastening systems.
- By incorporating a steel reinforcement, as you know it from concrete sleepers, we ensure an increased safety in the track. By changing the diameter of the reinforcement, the sleeper can be adapted to the various requirements. While the standard sleeper is approved by the EBA for the main line with a diameter of 16 mm, the turnout sleepers with same dimensions are approved for the main line with a diameter of 20 mm in order to improve the coefficient of thermal expansion.
Standard Track sleeper
Covering a wide range of applications
Dimensions
Length: up to 3 m
Height: 100, 140, 150 and 160 mm
Width: 250 and 260 mm
Special features
For the first time with direct fastening
Different inclinations and track gauges without additional machining
Some references
- Bulgaria
- Czech Republic
- Finland
- Germany
- Italy
- Norway
- Romania
- Sweden
- USA
Benefits of direct rail fastening systems
Environmental comparison
- Usage of direct fastening systems as W-systems saves our environment
- Much less weight and less parts lead to lower CO2 equivalent per sleeper
Benefits of direct rail fastening systems
Reduced complexity & quantity of components
Less material & transport costs
Less master data maintenance
Reduced material stock
Lower risk of losing small parts
Benefits of direct rail fastening systems
Reduced assembly & installation time
- Wooden sleepers and other composites always need to be drilled
- The ribbed plate is positioned beforehand for graining
- Alternative: Drilling in the drilling center or in the track
- Additional longer mounting of KS system
1. Graining
2. Drilling
3. Mounting of KS system on wooden sleeper
Mounting of direct fastening system on prefabricated T-groove
Approved integrated solution
Various fastening systems applicable on EPS – System tests realized for different configurations
Indirect Fastening – Heavy Haul:
- Fatigue test according to category E
- Axle load: 35 t
- Test angle: 40°; Test load: 108 kN
Direct Fastening – Conventional Rail:
- Fatigue test according to category C
- Axle load: 26 t
- Test angle: 33°; Test load: 75 kN
Direct Fastening – Heavy Haul:
- Fatigue test according to category E
- Axle load: 35 t
- Test angle: 40°; Test load: 108 kN
Fastening Systems on EPS tested successfully according to DIN EN 13481-3!
EPS PORTFOLIO FOR TURNOUT APPLICATIONS
ADAPTED TO SPECIAL TURNOUT ARRANGEMENTS
With the newly opened series production in Poland, the range of sleeper lengths has been expanded:
- Length: 2.2 – 5 m; in 0.1m increments (can be extended for requirements over 5 m in length)
- Height: 150, 160 mm
- Width: 250, 260 mm
We are also working on an anchor rail solution for flexible fixing with direct fastening solutions – a plus in urban transport.
DB AG / EBA - PERFORMANCE APPROVAL FOR TURNOUT SLEEPERS
Test set-up / results
In the serviceability test for the EBA approval at the Technical University of Munich, the EPS convinced with remarkable results, particularly with regard to thermal expansion, despite the stricter requirements for turnouts.
ADAPTED TO SPECIAL TURNOUT INTERFACES
- Adaptive processing options for turnout assembly:
- Milled recesses for ALD technology (Actuation, Locking & Detection)
- Helpful marking of the reinforcement position for CNC drilling of the core holes and various fastening solutions
- During mechanical treatment such as drilling, sawing, milling, and grinding, no hazardous dust is created (EPS does not contain glass fiber)
- Moreover, subsequent adjustments or repairs of the holes and/or the gauge are possible.
References
- Germany
- Canada
- Turkey
EPS Project in Montreal
A successful one Vossloh story
In a suburb of Montreal, the rail infrastructure of an existing yard was renewed. The previous tracks embedded in asphalt were to be replaced by ballasted tracks. The earlier rail profile 100RA was changed to 115RE.
Additional challenge: turnouts are equipped with precast concrete panels for rubber-tyre vehicles to run on top. Moreover, the tracks will be used by vehicles of very different types with a total of 16 different wheel profiles.
Delivery: six short Tg1/5 turnouts on EPS, each of which required a customized footprint because of the nested arrangement. Tailored floor plans for each turnout and special metal cases were developed that allow a passing with rubber tyres and facilitate the access for maintenance. The cast manganese steel crossings were adapted to the wheel profiles so that even in case of an impaired traffic (flat tire), a safe operation would be ensured.
The first turnout completely fitted to the EPS was accepted by the customer in the factory; the subsequent acceptances were performed via Remote Live Stream. For the transport, the turnouts were fully coated.
The consignment was delivered by ocean freight to the site in Montreal where the installation and commissioning were completed. This marked the successful closure of a truly international Vossloh project. While the EPS for the turnouts came from the Vossloh Skamo factory in Nowe Skalmierzyce in Poland, the manganese steel crossings were cast in the foundry in Outreau, turnouts manufactured in Reichshoffen, and all these components were finally brought together in Fère-en-Tardenois (all in France). The installation in Montreal started mid July 2024 with the assistance of Vossloh Service France. For its customers, Vossloh is a one-stop shop for turnout systems on composite sleepers – a perfect match.
Maximum flexibility
EPS Bridge Beams
Description
- Basic bridge beam with dimensions of 240 x 160 x 2,600 mm
- Integrated guide rail
- Additional height adjustment elements from 20 to 160 mm
- Quick & simple positioning and fixing of vertical elements
- Through-bolts for securing the basic beam with the height adjustment elements
- Weight from 170 to 200 kg possible
Features
- Screw & fixing holes can be realized directly in the EPS
- Bridge beam height adjustable and requiring no or minimal machining
- Sustainability through optimum use of material
DB AG / EBA Performance approval for bridge beams
Test setup / results
The EPS bridge beam also successfully passed the EBA approval test.
bridge beam concept - Exemplary illustration
- Minimum height of the bridge beam incl. height adjustment elements: 180 mm
- Using height adjustment elements, the overall height of the bridge beam can be displayed in 5 mm increments
- Maximum height of the bridge beam 320 mm
- Further heights by processing the height adjustment elements or using intermediate plates
- Simple assembly of the height adjustment elements
| Sleeper width | Basic beam | Height adiustment | Overall height | Overall height incl. relief ≤ 10 mm |
|---|---|---|---|---|
| 240 mm | 160 mm | 20 mm | 180 mm | 170 mm |
| 240 mm | 160 mm | 25 mm | 185 mm | 175 mm |
| 240 mm | 160 mm | 30 mm | 190 mm | 180 mm |
| … | … | … | … | … |
| 240 mm | 160 mm | 155 mm | 315 mm | 305 mm |
| 240 mm | 160 mm | 160 mm | 320 mm | 310 mm |
- The support distance between the bridge girders can be adjusted with the height adjustment elements
- The distance between the supports should be observed considering the maximum eccentricity (≤ 200 mm)
- The maximum distance between the bridge girder supports results from the nominal track gauge / rail support centre and the maximum eccentricity.
Example:
- Rail support center + max. eccentricity = max. distance between bridge girder supports
- 1,500 mm + (2 x) 200 mm = 1,900 mm
Reduced installation time
- Height can be pre-adjusted in mm steps
- Fixing holes for girders can be prefabricated
- Prefabricated screw holes
- Pre-assembled rail fastening
Processing options
Our manufacturing process eliminates many manual operations such as drilling or milling.
European bridge project
With Challenging technical requirements
- Bridge with 308 bridge beams incl. pre-mounted KS fastening system, height adjustment, plus arresting & guiding device
- Delivery: July 2024
- Key challenges: Technical concept with varying heights, fastening to steel girder
