20190319-Rayton PanelRay-R7-5 - Repaired PDF

RAYTON PANELRAY
July 2019
www.yapiray.com.tr
Outline
¾ $VKRUWEULHIRQZKRZHDUH«
¾ Typical Parameters for Rayton PanelRay
¾ Design Summary
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¾ Design -approval Tests

2018-05-15 <DSÕUD\9HULPOLOLN7RSODQWÕODUÕ6XQXP
¾ Production Photos for PST -I and PST-II

¾ <DSÕUD\5HIHUHQFHV
¾ dDWDOFD7XQQHO$SSOLFDWLRQ
¾ <HUN|\-Sivas HSL Project
21/03/2019 z‰fŒÇWvoŒÇôdŒl 3
54 years
of construction
experience
Operating in
13
countries
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More than
500
projects
completed
$ 1.1 billion +10.000

employees
Annual Revenue
YAPI MERKEZI GROUP

78th 9th A global brand for
railway systems
in ENR 201 7 Top 250 in ENR 2017 for
with more than
International Contractors Mass Transit and Rail
2.600 km
approximately
single track
of total
100 km tunnel
and 41
85 k m bridges & viaducts rail transportation
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projects
constructed
used daily by over
2 million
people
in
3
continents
YAPI MERKEZI GROUP

Worldwide Railway Experiences
.DGÕN|\- Kartal Metro (VNLúHKLU/576
øVWDQEXO/576 (VNLúHKLU
- øQ|Q•+6/
øVWDQEXO
Tramway Bozkurt - Dinar Railway
Taksim-.DEDWDú
Funicular Antalya Tramway
Marmaray Irmak-Zonguldak Railway
%H\R÷OX Tramway Ankara - Konya HSL
Bursa LRTS Konya Tramway
ø]PLU0HWUR Kayseri LRTS
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<HUN|\6LYDV+6/
Hasanbey Logistic Center
Casablanca Tramway
Dubai Metro Phase 1 and Phase 2
Zone 1 and Zone 3
Doha Metro Gold Line
Sidi Bel Abbes Tramway CTW 130 Railway

Bir Touta - Zeralda Railway Al Nariyah Workshop
Caroubier Workshop HHR Madinah Station
Light Rail System

Setif Tramway
Awash Kombolcha Hara Gebeya Railway
Metro
High Speed, Interurban, Freight and etc. Dar Es Salam to Makutupora Railway
5DLOZD\%XLOGLQJ:RUNVKRS6WDWLRQ«
‰ YAPIRAY, is an expert Railway Contractor with following skills
‰ Trackwork Construction
‰ Trackwork Rehabilitation
‰ Railway Sleeper and Slab Track Production
Supporting <DSÕ0HUNH]L and other

contractors in all locations
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‰ Sub-contractor
‰ Technical staff
‰ Railway Sleeper and Slab Track Producer
MAIN AREA OF EXPERTIES
&
KEY FIGURES
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™ $50 million turnover ™ 1006 km ongoing project

™ 1.857 km completed railway track ™ 64 % local market share
o 1.033 km high speed line ™ Capacity of yearly 750.000 sleeper
o 403 km conventional railway line ™ 550 + employees
o 177 km metro & LRT line ™ 308 km/h Turkish rail speed record
o 244 km tramway line ™ ,QFRXQWULHVZLWK<$3,0(5.(=ø
MarmarayBosphorusCrossingTrackworkInstallation, 2012
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14 km double track, concrete

slabtrackwith lvt block, high noise & vibration mitigation track
Ankara-Konya High Speed Railway, Turkey 2012

220 km double track
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EthiopiaAwasht Kombolchat Hara GebeyaRailway, 2015 - 2019

400km ballastedtrack conventionalrailway line
YAPIRAY MACHINERY FLEET
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TAMPING MACHINES REGULATORS TRACK LAYING

MACHINES
WELDING MACHINES BALLAST SCREENIGN LOCOMOTIVES

MACHINES
Rayton- Prestressed
Sleeperand SlabTrackFactories, YerkoyU<ŒºlUlR and Soga
Capacity :1.000.000sleepers/year 21.000slabs/ year
¾ RAYTON RAILWAY SLEEPERS

‡B70-L2.6upto 250km/h
‡B58-L2.5upto 160 km/h
‡B70DG-L2.4upto 160 km/hr
‡B70t L2.4upto 200km/h
‡Rayton PSTupto 350km/h
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Turnout Bearers Factory,

Afyon
Capacity : 100.000 linear meter/year
^s]Œšµ}•}]vZ]o^Ç•šu•_
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System references for prefabricated slab track (Capacity for rail, C4R)
Design
PST ± I (Post-tensioned) PST ± II (Reinforced Conc.)
¾ 200mm thickness 4,75m x 2,5m ¾ 200mm thickness 4,75m x 2,5m
¾ 6.25 tonnes of post-tensioned ¾ 6.25 tonnes of reinforced concrete
concrete
¾ C50/60 Concrete acc. to EN 2016-1
¾ C50/60 Concrete acc. to EN 2016-1
¾ S420C acc. to EN 16432
¾ Y1670C acc. to EN 10138
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21/03/2019
z‰fŒÇWvoŒÇôdŒl
15
Design
Design
Fastening System 300

Rail
Screw
Tension
Clamp Angle Guide
Plate
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Elastic Pad
Base Plate Rail Pad
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21/03/2019
Fastening System 300
17
Design
Design
3D View of Rayton PST

Rail Seats
Grouting
Holes
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Adjustment Shear Key

Holes
Design
Plan and Side Views of Rayton PST

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19
21/03/2019 z‰fŒÇWvoŒÇôdŒl
Design
Rebar Plan of Rayton PST (RC Solution)

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20
Design
Rebar Details of Rayton PST (RC Solution)

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21
Design
Rebar Details of Rayton PST (Post -Tensioned)

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22
Design
Shear Key Details of Rayton PST
¾Concrete min. C30/37 according to EN 1992-1-1

¾Rebar: S420 according to EN 10080
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23
Design
Shear Key Details of Rayton PST

RAIL
RAIL SUPPORT
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PANELRAY PANELRAY
CEMENT MORTAR
REINFORCED CONCRETE SLAB

24
Design
Standards and Codes

Design calculations are carried out in accordance with references below:
™ EN 16432-1 Railway applications ± Ballastless track systems ± Part 1: General Requirements
™ EN 16432-2 Railway applications ± Ballastless track systems ± Part 2: Subsystems and
components
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Besides; the recommendation of the referances below are also taken into consideration.
™ Recommendations for Design & Calculations for Ballastless Track, Paris, 2008
™ UIC Norms,
™ EN 13230 series
™ EN 1990, EN 1991 and EN 1992
™ TCDD ± <HUN|\-Sivas High Speed Line Project Technical Specification
Design
According to EN 16432-2 [8], design method is given below.
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26
Design
A typical slab track according to EN 16432

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Design
Design method
Three design method have been carried out for Rayton PanelRay.
LC101: DL Isom
¾ Hand Calculations which is given by EN 16432-1 (Westergaard Method and
Zimmermann Method)
¾ Full 3D Solid Modal
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¾ Full 3D Surface Modal

ZY
X
Design
Design Criteria
¾Typical Design Speed up to 350km/h
¾Typical Design Axle Load up to 280kN
¾Typical Design Load: LM 71 EN 1991-2
¾Fastening System: System 300-1 or System 300 NG
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Load Model 71 acc to EN 1991

-2
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21/03/2019
Hand Calculations
30
Design
Design
Hand Calculations
The following structure interaction system given in Annex B, Section 1.4.2 of EN 16432-2
has been taken into account in the calculations of prefabricated slab superstructure.
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31
Solid Model
CO 2: G + Gq2 Isometric
Loads [kN/m], [kN]
225.000
225.000
225.000
72.000
72.000
72.000
225.000 72.000
150.000
72.000
72.000
72.000
72.000
72.000 48.000
72.000
150.000 48.000
48.000
72.000
72.000 48.000
48.000
48.000
150.000 48.000
48.000
48.000
48.000
48.000
48.000
150.000
72.000
72.000
72.000
72.000
72.000
72.000
72.000
72.000
72.000 48.000
48.000
72.000
72.000 48.000
72.000 48.000
48.000
72.000 48.000
72.000
72.000 48.000
48.000
48.000
48.000
48.000
48.000
48.000
48.000
48.000
Y
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X
In Y-direction
Y X
32
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21/03/2019
Y
Z
Surface Model
In Y-direction
33
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21/03/2019
Design Results
34
Design
Rail Stresses
CO 203: SLS FOR LM 71 x kd x kq Isometric
Solid Stresses Sigma-y
Solid Stresses
Vy [MPa]
92.9
62.7
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32.6
2.5
-27.7
-57.8
-87.9
-118.1
-148.2
Z
-178.3
-208.5
Y
X -238.6
Max : 92.9
Min : -238.6
Max Sigma-y: 92.9, Min Sigma-y: -238.6 MPa
35
Slab Stresses
Solid Stresses Sigma-eqv,Mises
Solid Stresses
Sigma-eqv,Mises
[MPa]
3.9
3.5
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3.2
2.8
2.5
2.1
1.8
1.4
Z 1.1
Y 0.7
X 0.4
0.0
Max : 3.9
Min : 0.0
Max Sigma-eqv,Mises: 3.9, Min Sigma-eqv,Mises: 0.0 MPa

36
Slab Displacement
Global Deformations u-Z
Global Deformations
u Z [mm]
-0.3
-0.4
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-0.5
-0.6
-0.6
-0.7
-0.8
-0.9
-1.0
Z
-1.1
Y
-1.2
X
-1.3
Max : -0.3
Min : -1.3
Max u-Z: -0.3, Min u-Z: -1.3 mm
Factor of deformations: 490.00
37
Design
Rail Displacements
Global Deformations u-Z
Global Deformations
u Z [mm]
-0.4
-0.6
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-0.8
-1.0
-1.2
-1.4
-1.6
Z
-1.8
Y
-2.0
X
-2.2
-2.4
-2.6
Max : -0.4
Min : -2.6
Max u-Z: -0.4, Min u-Z: -2.6 mm
Factor of deformations: 490.00
38
Soil Stresses
Contact Stresses Sigma-z
Z
Y
Contact Stresses
V-z [kPa]
268.24
244.54
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220.84
197.14
173.44
149.74
126.04
102.34
78.64
54.94
31.24
7.54
Max : 268.24
Min : 7.54
Max Sigma-z: 268.24, Min Sigma-z: 7.54 kPa
39
Design Approval Tests (ITU)
Design Approval Tests

Since there is no design approval procedures according to
EN-Norms, the recommendations of ADIF are given in
technical specification ©6,67(0$6 DE VIA SOBRE BASAE
DE HORMIGON Y TACOS 35()$%5,&$'26ª have been
followed.
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Test Setup
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Vertical Static Loading

3 6 L r äwÛ%½ Û3 ÔëßØ
%½ã›•ƒ•‹… ƒ•’Ž‹ˆ‹…ƒ–‹‘• ˆƒ…–‘”

3 ÔëßØãšŽ‡ Ž‘ƒ†
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Test criteria #1: Test criteria #2:

ûPP ¿ ksta < 69 kN/mm ¿
Yükleme kesitinde (Kesit- 5) Yük - <HUGH÷LúWLUPH 80
- ksta(kN/mm)
øOLúNLVL 7HVWSURVHG•U•VÕQÕUGH÷HUL
200 70
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69
'•úH\VWDWLNULMLWOLN
HV #4
Hidrolik Veren Yükü (kN)
HV #1 60
160 7HVWSURVHG•U•VÕQÕUGH÷HUL 63.2 60.5
57.7
50
120
40
80 30
40 20
10
0
0
0 1 2 3 4
HV #1 HV #4 Ortalama
6YH65D\DOWEDúOÕNG•úH\\HUGH÷LúWLUPHOHUL PP
Fatigue Test (3.000.000 load cycle)

3 5 L 3 ÔëßØÛ- ×ìá Û- ½ÜæÛr äw
3 ÔëßØãšŽ‡ Ž‘ƒ†
- ½ìá ã›•ƒ•‹… ˆƒ…–‘”
- ½Üæã‹•–”‹„—–‹‘• ˆƒ…–‘”
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Test criteria #1: Test criteria #2:

ûKRUPP ¿ Variation (ksta) < “ 15% ¿
'•úH\VWDWLNULMLWOLNN1PP
90
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85 83.61
82.39
80.22
80
74.77
75
70
65
60
0 1 2 3
Statik test no
Production
Formwork Preparation for Post-Tensioned Slab

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Production
Formwork Preparation for RC Slab

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21/03/2019
Pouring Concrete
50
Production
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21/03/2019
Demoulding
51
Production
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21/03/2019
Stocking
52
Production
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21/03/2019
Stocking
53
Production
<DS×UD\5HIHUHQFHV
¾ dDWDOFD7XQQHO
Completed
¾ Post-tensioned prefabricated slab track (PST-I)
¾ 3 cm non-shrink grout underneath
¾ 430 m (90 pcs PST-I) track is completed
¾ <HUN|\-Sivas HSL Under Construction

¾ Reinforced concrete prefabricated slab track (PST-II)
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¾ Min. 10 cm self compacting concrete with reinforcement

underneath
¾ ~2000 m (~ 415 pcs PST-II) track is completed.

¾ ~100 km (~20500 pcs PST-II) track is scheduled.
¾ .D\Dú -<HUN|\+6/ Under Construction

¾ Reinforced concrete prefabricated slab track (PST-II)
¾ Min. 10 cm self compacting concrete with reinforcement
underneath
¾ ~45 km (~9000 pcs PST-II) track is scheduled.
&RQVWUXFWLRQLQdDWDOFD7XQQ
Typical Section
Enoughclearence
after slabtrack
application
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Typical Section
Rail 60E1
Rayton Slab Track
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Well compacted Granular backfill

PŒ}µvÀîHíîìDW
Isolation layer installation (subject to design )

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Prefabricated Slab Installation

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Leveling
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Completed Trackwork
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-Sivas
&RQVWUXFWLRQLQ<HUN|\
Typical Section
O
O
O
O
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-Sivas
&RQVWUXFWLRQLQ<HUN|\
Installation of Prefabricated Slab

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RAYTON PANELRAY
July 2019
www.yapiray.com.tr

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RAYTON PANELRAY

¾ Design -approval Tests

¾ Production Photos for PST -I and PST-II

$ 1.1 billion +10.000

YAPI MERKEZI GROUP

used daily by over

YAPI MERKEZI GROUP

Sidi Bel Abbes Tramway CTW 130 Railway

Light Rail System

Supporting <DSÕ0HUNH]L and other

‰ Railway Sleeper and Slab Track Producer

™ $50 million turnover ™ 1006 km ongoing project

™ 1.857 km completed railway track ™ 64 % local market share

o 1.033 km high speed line ™ Capacity of yearly 750.000 sleeper

o 403 km conventional railway line ™ 550 + employees

o 244 km tramway line ™ ,QFRXQWULHVZLWK<$3,0(5.(=ø

14 km double track, concrete

Ankara-Konya High Speed Railway, Turkey 2012

EthiopiaAwasht Kombolchat Hara GebeyaRailway, 2015 - 2019

TAMPING MACHINES REGULATORS TRACK LAYING

WELDING MACHINES BALLAST SCREENIGN LOCOMOTIVES

¾ RAYTON RAILWAY SLEEPERS

Turnout Bearers Factory,

Capacity : 100.000 linear meter/year

Fastening System 300

Base Plate Rail Pad

3D View of Rayton PST

Adjustment Shear Key

Plan and Side Views of Rayton PST

Rebar Plan of Rayton PST (RC Solution)

Rebar Details of Rayton PST (RC Solution)

Rebar Details of Rayton PST (Post -Tensioned)

Shear Key Details of Rayton PST

¾Concrete min. C30/37 according to EN 1992-1-1

Shear Key Details of Rayton PST

REINFORCED CONCRETE SLAB

Standards and Codes

A typical slab track according to EN 16432

¾ Full 3D Surface Modal

Load Model 71 acc to EN 1991

Max Sigma-y: 92.9, Min Sigma-y: -238.6 MPa

Max Sigma-eqv,Mises: 3.9, Min Sigma-eqv,Mises: 0.0 MPa

Max Sigma-z: 268.24, Min Sigma-z: 7.54 kPa

Design Approval Tests

Vertical Static Loading

%½ã›•ƒ•‹… ƒ•’Ž‹ˆ‹…ƒ–‹‘• ˆƒ…–‘”

Vertical Static Loading

Vertical Static Loading

Test criteria #1: Test criteria #2:

Fatigue Test (3.000.000 load cycle)

Fatigue Test (3.000.000 load cycle)

Fatigue Test (3.000.000 load cycle)

Test criteria #1: Test criteria #2:

Formwork Preparation for Post-Tensioned Slab

Formwork Preparation for RC Slab

¾ <HUN|\-Sivas HSL Under Construction

¾ Min. 10 cm self compacting concrete with reinforcement

¾ ~2000 m (~ 415 pcs PST-II) track is completed.

¾ .D\Dú -<HUN|\+6/ Under Construction

Well compacted Granular backfill

Isolation layer installation (subject to design )

Prefabricated Slab Installation

Installation of Prefabricated Slab