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edilon)(sedra, with its Corkelast Embedded Block System (EBS), has pursued the concept of elastically supported sleeper blocks. This elastic support providing the same dynamic spring and damping behaviour of ballasted track under traffic loads. As earlier demonstrated by the transition from monoblock to bi-block sleepers in ballasted track systems, the EBS solution is based on individual blocks. By virtue of their position-stable integration in a concrete slab structure, these blocks do not require additional alignment elements such as gauge bars. The primary characteristic of EBS is based on EDILON Corkelast. This provides elastic bonding of the individual blocks and the supporting concrete slab. The unique, proven, reliable, two component embedding compound assures outstanding position stability over decades – along with simple installation, low system costs, and minimum maintenance.
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Solutions that won’t shake the world…
EDILON Corkelast® Embedded Block System(EBS)
www.edilonsedra.comedilon)(sedra bv Nijverheidsweg 23 P.O. Box 1000 T +31 / (0)23 / 531 95 19 [email protected] CN Haarlem NL-2003 RZ Haarlem F +31 / (0)23 / 531 07 51 www.edilonsedra.com
edilon)(sedra bvNijverheidsweg 23NL-2031 CN Haarlem
P.O.Box 1000NL-2003 RZ Haarlem
T +31 / (0)23 531 95 19F +31 / (0)23 531 07 51
edilon)(sedra, with its Corkelast® Embedded Block System
(EBS), has pursued the concept of elastically supported
sleeper blocks. This elastic support providing the same dy-
namic spring and damping behaviour of ballasted track un-
der traffic loads.
As earlier demonstrated by the transition from monoblock to
bi-block sleepers in ballasted track systems, the EBS solu-
tion is based on individual blocks. By virtue of their position-
stable integration in a concrete slab structure, these blocks
do not require additional alignment elements such as gauge
bars.
For over 130 years tracks for mainline rail traffic and urban mass rapid transit
systems were based almost exclusively on track panels and cross sleepers sup-
ported on stone ballast. Increasing train loads, higher speeds and the demand
for more cost effective track installation methods during the 1960’s, led to the
development of ballastless track or slab track systems.
GENERAL ADVANTAGES
• Embedded blocks not subject to wear
• No joint or gap problems
• No moisture, frost or corrosion damage
• No dirt or sludge to foul the block bearing area
• Equivalent spring and damping characteristics
compared to ballasted track
• No need for highly elastic rail fastenings
• Favourable airborne noise behaviour
• Simple concrete slab design
• System design can be adopted to meet
structure-borne noise requirements
• Electrical insulation of the rails
• Free access to the rails
The EDILON Corkelast® Embedded Block System (EBS) has
proved highly effective for more than 30 years of demanding, dai-
ly operations. During 1969 the system was successfully installed
for Netherlands Railways (NS) at the Velim test track in the Czech
Republic. In the same year, edilon)(sedra completed projects in
The Netherlands, for NS at Vlijmen-Empel and in Spain for Ma-
drid Metro. In 1974, EBS was installed on the “Suurhof Bridge” for
NS. Most projects have been carried out with interval blocks, but
NS has always remained a client of row blocks.
COST-EFFECTIVENESS
• Low structural system height
• Simple installation
• Cost-effective, mechanised, large-series production
• Possibility of using all common discrete rail
fastening systems
• Minimum maintenance
• Service life up to 30 years
• Low lifecycle costs (LCC)
The primary characteristic of the EDILON Corkelast® Embed-
ded Block System (EBS) is based on EDILON Corkelast®.
This provides elastic bonding of the individual blocks and
the supporting concrete slab. The unique, proven, reliable,
two component embedding compound assures outstanding
position stability over decades - along with simple installa-
tion, low system costs, and minimum maintenance.
row blocks interval blocks
EDILON Corkelast® Embedded Block System(EBS)
row and interval blocks
2 3
The EDILON Corkelast® Embedded Block System (EBS) is
flexible and can be applied throughout the track. In addition
to being a maintenance free track structure, it also offers the
possibility of reducing structure-borne noise. Embedding
blocks with EDILON Corkelast® also satisfies the strict requi-
rements placed on electrical isolation of the rails.
BRIDGES
• Application on steel and concrete bridges
• Low structural system height
• Reduction in weight
• Possible reductions in cross-sections of
supporting structures
• Surface permanently impervious to liquids
• Simple surface drainage
• Simple adaptation for additional surface
mounted noise abatement systems
• Reduction in structure-borne (bridge) noise
TRACK IN CUTTINGS AND OTHER
CIVIL-ENGINEERING STRUCTURES
• Low structural system height
• Reduction in cross-section of civil engineering
structures possible
• Surface permanently impervious to liquids
• Simple surface drainage
• Simple adaptation for additional surface mounted noise abatement systems
GREEN TRACKS, GRASS TRACKS OR IN-STREET
RUNNING TRACKS
• Grass possible up to the top of rails
• Accessible for road traffic
• Stray-current isolation as stipulated in EN 50122-2
• Use of grooved and vignole rail profiles possible
• No need for gauge bars
• Simple replacement of rails
EBS • areas of application
TUNNELS
• Low structural system height
• Tunnel cross-section reduction
• Stray-current isolation as stipulated in EN 50122-2
• Simple surface drainage
• Simple adaptation for additional surface
mounted noise abatement systems
TRACKS ON EMBANKMENT
• Minimum maintenance
• Simple slab structure
• Simple adaptation for additional surface mounted
noise abatement systems
• Simple surface drainage
• Simple replacement of rails and blocks
4 5
The EDILON Corkelast® Embedded Block System for HR is designed to meet the requirements
of heavy freight passenger and high-speed trains. The structural engineering features of all
EBS HR systems are designed conform to Load Model 71, as stipulated in UIC Code 702. The
EBS HR Systems are generally tested in accordance with Technical Specifications for
Interoperability (TSI) that applies to nowadays European high-speed train traffic.
SYSTEM CHARACTERISTICS
Permanent, accurate track position•
Maximum speed up to 300 km/h•
Maximum track cant: 150 mm (normal gauge)•
Maximum cant deficiency: 40 mm (recommended, normal gauge)•
Exact noise engineering design possible, in accordance with local requirements•
Optional rail fastening elements with vertical and lateral adjustment possibilities•
Use with all commonly applied rail profiles•
Rail inclination of e.g. 1:40 or 1:20•
Track circuit current conformity•
Compatibility with train control systems: e.g. ETCS, ASFA, ATB, LZB, ZUB 121, ZUB 262/•
Integra, Indusi/PZB
EBS HR systemsIt is possible to control the static stiffness of the EDILON Corkelast® Embedded Block System
(EBS) to match the characteristics of the rail profile and the block spacing. This enables adjust-
ment of the track to meet various requirements such as ride comfort or structure-borne noise
behaviour. The following standard stiffness categories of the EBS HR system are available:
The possibility of high static deflection allows the EBS HR system to be optimised to low
frequency structure-borne noise. This is ideally suited for both heavy rail and high-speed
applications. Pads are installed under the block, and by varying the stiffness of these pads
it is possible to modify the low frequency noise and vibration characteristics of the system.
This feature makes it possible to achieve reductions of up to 20 dB, depending on the fre-
quency range involved. The appreciable damping characteristics of the EDILON Corkelast®
Embedded Block Systems (EBS), due to the dead weight of the blocks and the adhesion of
EDILON Corkelast®, offer considerable benefits with respect to noise radiation.
noise and vibration characteristics
SYSTEM CATEGORY TYPICAL STATIC
STIFFNESS
TYPICAL STATIC RAIL
DEFLECTION
EBS HR SS Standard stiffness 60 kN/mm < 1.0 mm
EBS HR MS Medium stiffness 30 kN/mm 1.0 - 2.0 mm
EBS HR LS Low stiffness 15 kN/mm > 2.0 mm
block spacing
EBS HR • for heavy rail and high speed lines
6 7
The EDILON Corkelast® Embedded Block System for LR is designed to meet the requirements
for tram, light rail and metros. Structural engineering design of the EBS LR systems allows varia-
tions in accordance with the specific vehicle load patterns, with respect to national regulatory
frameworks.
SYSTEM CATEGORY TYPICAL STATIC
STIFFNESS
TYPICAL STATIC RAIL
DEFLECTION
EBS LR SS Standard stiffness 60 kN/mm < 1.0 mm
EBS LR MS Medium stiffness 15 kN/mm 1.0 - 2.5 mm
EBS LR LS Low stiffness 9 kN/mm > 2.5 mm
SYSTEM CHARACTERISTICS
Permanent, accurate track position•
Maximum speed up to 150 km/h•
Exact noise engineering design possible, in accordance with local requirements•
Optional rail fastening elements with vertical and lateral adjustment possiblities•
Use with all commonly applied grooved and vignole rail profiles•
Rail inclination of e.g. 1:40 or 1:20•
Complete track circuit current conformity•
Compatibility with train control systems routinely applied on light rail and •
metro networks: e.g. ATB, ZUB 122, CBTC and LZB
The possibility of high static deflection (Low stiffness category) has been developed for the EBS LR systems to a greater extend than for the EBS HR systems. Track systems with good performance in reducing ground- and structure-borne noise and vibration are especially needed in densely populated areas. In above graph the esti-mated insertion loss for EBS HR is displayed (for 60E1 rail, 0.65m block spacing and 22.5 tonnes axle load). The LS category of EBS offers an insertion loss of more than 10 dB at 63 Hz! The MS and SS categories reach significantly lower values at 63 Hz and thus perform worse on vibration insulation. Resonant frequencies of the LS, MS and SS categories are near 20, 31.5 and 50 Hz respectively which is a significant dif-ference in performance.
noise and vibration characteristicsblock spacing
block spacing
EBS LR • for light rail, trams and metros
EBS LR systemsTo enable flexible adjustment of the track to meet various performance requirements such as
ride comfort and structure borne noise behaviour, it is possible to control the static stiffness of
the EDILON Corkelast® Embedded Block System (EBS) to match the characteristics of the rail
profile and the block spacing. The following categories of the EBS LR system are available:
8 9
-30
-20
-10
0
10
20
30
40
50
Estim
ated
inse
rtio
n lo
ss [d
B]
Frequency [Hz]
Estimated insertion loss for EBS PLUS HR 60E1 in 3 categories: SS, MS and LS block spacing: 0.65m
EBS PLUS HR 60E1-LS EBS PLUS HR 60E1-MS EBS PLUS HR 60E1-SS
track in curves The EDILON Corkelast® Embedded Block System (EBS) can be
implemented in curves down to 25 m radius, and with superelevation
up to 150 mm. Beyond a count deficiency of 40 mm, the asymmetric
block is installed at the outside of the curve to limit the lateral railhead
deflection.
rail fastening systemsThe EDILON Corkelast® Embedded Block System (EBS) is available with all commonly used, discrete rail fastening systems.
turnoutsTurnouts in both grooved and vignole rail profiles can be installed in
the EDILON Corkelast® Embedded Block System (EBS). The pre-
assembled turnouts are placed for installation on modified embedded
blocks, or on embedded (monoblock) sleepers. No special compo-
nents are required for the installation of the point drives, the point
control gear, diagnostic systems, heating units, etc.
special track devicesThe blocks of the EDILON Corkelast® Embedded Block System are modified as required for use with special track devices: e.g. with guide rails, check rails, rail expansion joints, etc.
track facilitiesWith the EDILON Corkelast® Embedded Block System (EBS), the integration of special track installations required for heavy
and light rail tracks is simple. These facilities include insulated rail joints, axle counters, signal systems (e.g. track magnets
and balises), hotbox detection units, earthing connections, cable terminal boxes and drainage boxes. The EDILON Corkelast®
Embedded Block System (EBS) is compatible with all train control systems.
Vossloh EDILON Direct Fastening® (EDF) Pandrol
Pandrol Fastclip DE (Deenik-Eisses) Nabla
EBS • system design
10 11
edilon)(sedra, as a matter of course, places great emphasics on the continuous further deve-
lopment and quality control of all components contained in the EDILON Corkelast® Embedded
Block System (EBS). Our goal here is to satisfy the special needs of our customers and to deve-
lop individual solutions. edilon)(sedra bv, with head office in Haarlem, the Netherlands, achieves
this objective by drawing on experience gained in more than 30 years of delivering systems for
rail track operations. It employs comprehensive simulation and test facilities such as:
• climate-testing laboratories
• finite element method (FEM) calculations
• servo hydraulic testing machines for fatigue load testing
In addition to system design from the structural engineering and noise abatement aspects,
edilon)(sedra has concentrated its efforts on the following areas:
• Longitudinal restraint
• Lateral rail stability
• Impact resistance
• Deflection characteristics
• Vibration performance
• Rail-lift resistance
• Temperature stability
system tests and official approvals (homologations)The EDILON Corkelast® Embedded Block System (EBS) must undergo extensive system tests
to satisfy the strict approval requirements of their various customer organizations, railway com-
panies (e.g. NS, SBB-CFF-FFS, RENFE, PKP), metro operators (e.g. Madrid and Rotterdam),
and companies that operate tram and light rail lines (e.g. Bilbao, The Hague, Utrecht and
Dublin). For many years the edilon)(sedra Research and Development Department has col-
laborated closely with research institutes, certification agencies and technical universities
throughout Europe.
productionProduction of all the components used in the EDILON Cor-
kelast® Embedded Block System (EBS) takes place under
factory controlled conditions in fully mechanised production
lines with strict quality assurance procedures.
product versionsIndependently of system specifications, 3 product ver-
sions are supplied for installation of the EDILON Corke-
last® Embedded Block System (EBS):
EBS• Completely prefabricated EBS blocks
• Simple installation
• Embedding, casting and pouring is carried out under
controlled factory conditions
inplace-EBS• Only EBS blocks without tray
• Embedding, casting and pouring is carried out on site
• Suitable for row block installation and for renewal
EBS PLUS• Completely prefabricated EBS blocks
• Simple installation
• Easy handling
• Economical
construction logisticson the siteThe EDILON Corkelast® Embedded Block System (EBS)
offers advantages for materials delivery and for logistics on
the construction site as a result of compact sizes and low
weight. Gauge bars and alignment instruments are only
required during installation.
EBS • system development and production
EBS
inplace-EBS
EBS PLUS
12 13
repair and replacement of blocksBy using rail fastenings that can be adjusted vertically and laterally minor track level
and alignment corrections are simple with the EDILON Corkelast® Embedded Block
System (EBS).
Major corrections, for example, in case of settlement of the supporting concrete slabs,
or replacement of the blocks, is simply carried out by cutting the EBS blocks out of the
block trays. After cleaning the supporting surfaces, embedding can take place once
again. Detailed instructions for maintenance, repair and replacement are available.
recycling and environmentAll components used in the EDILON Corkelast® Embedded Block System (EBS) are
fully recyclable. edilon)(sedra embedding and pouring compounds are disposed of
as domestic waste, in accordance with the European Waste Catalogue. For further
information please consult the edilon)(sedra Product Information Sheets.
EBS • maintenance and recycling
14 15
The top-down method is used for installation of the EDILON Corkelast® Embedded Block System (EBS). This method
allows simple handling and assures high quality track positioning. The selection of the most suitable installation techni-
que details depends on local circumstances and constraints, but the general method is fully described in the General
Installation Instruction EBS.
EBS • installation method
