Conductor Rail Documents

Railtech Alu SingenRailtech International and Alcan Singen GmbH:

A COMBINATION OF STRENGTHSCOMBINATION OF STRENGTHSfor the benefit of the customer...

RailtechRailtech International:International:- leader in rail technology- worldwide flexibility-core business: insulators and third rail components

- strong references formass transit electrificationsystems & composites

3rd rail system

AlcanAlcan Singen GmbH:Singen GmbH:- leader in aluminium technology- large group + resources- core business: conductor rail- strong references forsupply of coextruded 3rd rail

1. References1.1 References for coextruded conductor rail1.2 References for insulators1.3 References for 3rd rail systems

2. Conductor rail

3. 3rd Rail ComponentsSplice joint assemblies - Expansion jointsAnchor assemblies - General arrangementLow speed ramp cable terminals - covers

4. Testing of 3rd

TABLE OFTABLE OFCONTENTS:CONTENTS:

1.1 REFERENCES: COEXTRUDED CONDUCTOR RAIL1.1 REFERENCES: COEXTRUDED CONDUCTOR RAILTransit System: Year: Quantity:Berlin Underground 1978 - 1995 20.480 mHamburg Rapid Transit 1978 - 1984 3.300 mOsaka South Port - Town Line 1979 34.000 mMetro Barcelona 1980 - 1982 8.000 mLondon Docklands Light Railway 1984 - 1995 89.500 mVienna Underground 1984 - 2000 49.050 mSMRT Singapore 1985 - 2001 223.150 mMetro North New York 1985 - 1999 8.400 mBerlin Rapid Transit 1986 - 2001 401.000 mTokyo Monorail 1986 4.000 mBritish Rail Portsmouth 1988 8.000 mMunich Underground 1992 - 1998 39.100 mTRTC Taipei 1992 - 1999 66.350 mLRTS Kuala Lumpur 1994 - 1996 41.200 mBTS Bangkok 1996 - 1998 60.870 mNuremberg Underground 1997 - 1998 9.100 mPeople Mover Turin 1999 3.400 m

1.068.900 m

1.2 REFERENCES: INSULATORS1.2 REFERENCES: INSULATORSTransit System: Year: Quantity:A) Railway TrackSNCF Paris since 1936 92.000 pcs.RATP Paris since 1972 95.000 pcs.Tunis since 1933 18.000 pcs.Barcelona 1973 - 1978 25.000 pcs.Caracas 1980 - 2001 78.500 pcs.London 1985 - 1986 11.500 pcs.Lisboa 1995 4.500 pcs.Kuala Lumpur 1996 - 1999 24.000 pcs.MRTS Bangkok 2001 11.000 pcs.Athenes 2003 2004 7000 pcs.B) Special Track for TyresRATP Paris 1961 - 2001 74.000 pcs.Marseille 1977 - 1998 46.000 pcs.Lyon 1977 - 1998 67.500 pcs.Santiago de Chile 1976 - 1999 67.500 pcs.Mexico 1986 - 1993 7.500 pcsMontreal 2003 - 2004 8000 pcs.

617.500 pcs.approx. 2.000.000 m

1.3 REFERENCES: 3rd RAIL SYSTEM1.3 REFERENCES: 3rd RAIL SYSTEMTransit System: Year: Length:Disney Monorail 1970 11.000 mBART San Francisco 1977 14.000 mBarcelona Metro 1973 - 1978 50.000 mCaracas Metro 1980, 1992, 2001 187.000 mBC Transit Vancouver 1987 - 1992 128.000 mToronto Transit 1986, 1999 32.000 mDetroit Transit 1986, 1999 20.000 mKuala Lumpur 1997 120.000 mMRTA Bangkok 2001 56.000 mWuhan (China) 2003Athenes 2003 2004 36.000 mTransRapid (test track) 2003

2. COEXTRUDED CONDUCTOR RAIL:2. COEXTRUDED CONDUCTOR RAIL:ManufacturingManufacturing processprocess

High temperatures, high pressure: metallic bondLowest interface resistance, longterm stability (-> comperative testing)

Stainless steel coilDie

Press

Aluminium billet

Extrusion stamp

The stainless steel strip is rolled on a coil and feed to the extrusion press. Twocoils are used, one on the left side andone on the right side of the extrusion press since a duplex profile is extruded. The aluminium billet (pushed by theextrusion stamp) and both stainless steelstrips are extruded through the tooling(die) which gives the shape for theconductor rail.

2. COEXTRUDED CONDUCTOR RAIL:2. COEXTRUDED CONDUCTOR RAIL:Design Design featuresfeatures of of steelsteel stripstrip

Bent and punched stainless steel strip;X6Cr17 = high chromium steel (17%)thickness 4,5mm minimum.

Lateral punchings; filled withaluminium during extrusion process.Steel strip is one piece & not subjectof delamination due to wear.

Cross-section of conductor rail;showing detail of interlocking.

2. COEXTRUDED CONDUCTOR RAIL:2. COEXTRUDED CONDUCTOR RAIL:ExampleExample and design and design detailsdetails

Detail: Steel strip and interlockingConductor rail Metro North New York

3. :33. :3rdrd RailRail ComponentsComponentsSpliceSplice jointjoint assembliesassemblies ((examplesexamples))

Splices Berlin UndergroundSplices MRTA Bangkok

3. :33. :3rdrd RailRail ComponentsComponentsExpansion Joint (Expansion Joint (examplesexamples))

Expansion joint - MRTA Bangkok Expansion joint cover MRTA Bangkok

3. :33. :3rdrd RailRail ComponentsComponentsExpansion Joint (Expansion Joint (examplesexamples))EJ BTS Bangkok

EJ - TransRapid

3. :33. :3rdrd RailRail ComponentsComponentsExpansion Joint (Expansion Joint (examplesexamples))

EJ - Athens

3. :33. :3rdrd RailRail ComponentsComponentsAnchorAnchor AssemblyAssembly ((examplesexamples))

Anchor design for MRTA Bangkok

3. :33. :3rdrd RailRail ComponentsComponentsAnchorAnchor AssemblyAssembly ((examplesexamples))

Anchor design BTS Bangkok

3. 3. 3rd 3rd RailRail ComponentsComponentsGeneral General arrangementarrangement, , bracketbracket & & insulatorinsulator

3. 3. 3rd 3rd RailRail ComponentsComponentsExampleExample MRTA Bangkok,MRTA Bangkok, mechanicalmechanical analysisanalysis

3. 3. 3rd 3rd RailRail ComponentsComponentsLowLow speedspeed rampramp, high , high speedspeed rampramp, , applicationsapplications

Ramp design BTS Bangkok

3. 3. 3rd 3rd RailRail ComponentsComponentsCABLE TERMINALSCABLE TERMINALS

Power feed Berlin Rapid Transit

3. 3. 3rd 3rd RailRail ComponentsComponentsExamplesExamples of of existingexisting applicationsapplications

Power feed MRTA Bangkok

3. 3. 3rd 3rd RailRail ComponentsComponentsStandard cover, distance holder, Standard cover, distance holder, specialspecial partsparts

Cover design MRTA Bangkok

4. TESTING OF 3rd RAIL:4. TESTING OF 3rd RAIL:LongitudinallyLongitudinally cuttingcutting & & TensileTensile testtest

Result:Metallic bond breaksat 15 kN.Interlocking ok 22-24 kN.Delamination at 25 kN.-> very good results

4. TESTING OF 3rd RAIL SYSTEM:4. TESTING OF 3rd RAIL SYSTEM:Short Short circuitcircuit testtest

Result:100 kA for 1 s successfully passed!

4. TESTING OF 3rd RAIL SYSTEM:4. TESTING OF 3rd RAIL SYSTEM:InsulatorInsulator TestingTesting

Tests usually performed on the insulators:

Mechanical tests

High voltage test

Non propagation of flame

A high experience in Railway application with the most exacting customers

A design department to propose you a complete third rail solution adapted atyour needs

A world wide flexibility

The guarantee of two major companies :

Strong references in third rail application

1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...

Berlin Rapid Transit

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Vienna Underground

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Nuremberg Underground Munich Underground

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LRTS Kuala LumpurSMRT Singapore

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BTS Bangkok

TRTC Taipei

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1.3 REFERENCES: THIRD RAIL SYSTEM1.3 REFERENCES: THIRD RAIL SYSTEM

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Athenes Athenes

Athenes

1.3 REFERENCES:1.3 REFERENCES: THIRD RAIL SYSTEMTHIRD RAIL SYSTEM

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Trans Rapid

Trans Rapid

1.2 REFERENCES:1.2 REFERENCES: INSULATORSINSULATORS

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Athenes Trans Rapid