Railway applications - Ballastless track systems - Part 3: Acceptance

This part of EN 16432 specifies the methods for the implementation of ballastless track system designs and the criteria for the acceptance of works concerning construction of ballastless track systems. It does not include any criteria for inspecting, maintaining, repairing and replacing ballastless track systems during operation.

Bahnanwendungen - Feste Fahrbahn-Systeme - Teil 3: Annahme

Dieses Dokument legt die Implementierung von FF-Systementwürfen und die Kriterien für die Abnahme von Arbeiten bezüglich der Ausführung von FF-Systemen fest. Es beinhaltet keine Kriterien für die Inspektion, Instandhaltung, Reparatur und den Austausch von FF-Systemen während des Betriebs.

Applications ferroviaires - Systèmes de voie sans ballast - Partie 3 : Réception

Le présent document spécifie la mise en œuvre des systèmes de voie sans ballast et les critères de réception des travaux concernant la construction de systèmes de voie sans ballast. Il n'inclut aucun critère lié au contrôle, à la maintenance, à la réparation et au remplacement des systèmes de voie sans ballast en exploitation.

Železniške naprave - Progovni sistemi z utrjenimi tirnicami - 3. del: Prevzem

General Information

Status
Published
Public Enquiry End Date
09-Sep-2020
Publication Date
23-Nov-2021
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
11-Nov-2021
Due Date
16-Jan-2022
Completion Date
24-Nov-2021

Buy Standard

Standard
SIST EN 16432-3:2022 - BARVE na PDF-str 26
English language
26 pages
sale 10% off
Preview
sale 10% off
Preview
e-Library read for
1 day
Draft
oSIST prEN 16432-3:2020 - BARVE na PDF-str 27
English language
29 pages
sale 10% off
Preview
sale 10% off
Preview
e-Library read for
1 day

Standards Content (sample)

SLOVENSKI STANDARD
SIST EN 16432-3:2022
01-januar-2022
Železniške naprave - Progovni sistemi z utrjenimi tirnicami - 3. del: Prevzem
Railway applications - Ballastless track systems - Part 3: Acceptance
Bahnanwendungen - Feste Fahrbahn-Systeme - Teil 3: Annahme
Applications ferroviaires - Systèmes de voie sans ballast - Partie 3 : Réception
Ta slovenski standard je istoveten z: EN 16432-3:2021
ICS:
45.080 Tračnice in železniški deli Rails and railway
components
93.100 Gradnja železnic Construction of railways
SIST EN 16432-3:2022 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

---------------------- Page: 1 ----------------------
SIST EN 16432-3:2022
---------------------- Page: 2 ----------------------
SIST EN 16432-3:2022
EN 16432-3
EUROPEAN STANDARD
NORME EUROPÉENNE
November 2021
EUROPÄISCHE NORM
ICS 93.100
English Version
Railway applications - Ballastless track systems - Part 3:
Acceptance

Applications ferroviaires - Systèmes de voies sans Bahnanwendungen - Feste Fahrbahn - Teil 3: Abnahme

ballast - Partie 3 : Réception
This European Standard was approved by CEN on 13 September 2021.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this

European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references

concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN

member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by

translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management

Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,

Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,

Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and

United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels

© 2021 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 16432-3:2021 E

worldwide for CEN national Members.
---------------------- Page: 3 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)
Contents Page

European foreword ....................................................................................................................................................... 3

1 Scope .................................................................................................................................................................... 4

2 Normative references .................................................................................................................................... 4

3 Terms and definitions ................................................................................................................................... 4

4 Symbols and abbreviations ......................................................................................................................... 5

5 General ................................................................................................................................................................ 6

5.1 Overview ............................................................................................................................................................ 6

5.2 Validation of fitness for construction of a novel ballastless track system design ................... 6

5.3 Establishing the criteria for acceptance of work ................................................................................. 7

5.4 Integration in the assurance process/Works Acceptance Plan (WAP) ....................................... 7

6 Acceptance of works ...................................................................................................................................... 8

6.1 Track geometry and position ...................................................................................................................... 8

6.2 Track stiffness .................................................................................................................................................. 9

6.3 Track stability ............................................................................................................................................... 10

6.4 Durability ........................................................................................................................................................ 10

6.5 Drainage .......................................................................................................................................................... 11

7 Acceptance of substructure and subsystems ..................................................................................... 11

7.1 General ............................................................................................................................................................. 11

7.2 Acceptance of substructures .................................................................................................................... 11

7.3 Acceptance of pavements .......................................................................................................................... 13

7.4 Acceptance of intermediate layer .......................................................................................................... 17

7.5 Acceptance of prefabricated element (sleeper, block, slab, frame) .......................................... 18

7.6 Acceptance of fastening systems ............................................................................................................ 18

7.7 Acceptance of rails ....................................................................................................................................... 18

7.8 Specific measures for switches and crossings and rail expansion devices ............................. 19

8 Acceptance of system specific installation methods ....................................................................... 19

8.1 Ballastless track system with continuously supported or embedded rails ............................ 19

8.2 Ballastless track system with discrete rail seats on prefabricated element,

supported by a pavement .......................................................................................................................... 20

8.3 Ballastless track system with discrete rail seats on prefabricated element,

independent from the surrounding concrete filling layer or pavement .................................. 21

8.4 Ballastless track system with discrete rail seats on prefabricated element,

monolithically integrated in a pavement ............................................................................................ 22

8.5 Ballastless track system with discrete rail seats on a concrete pavement ............................. 22

Annex A (informative) Risk assessment of novelty in a proposed ballastless track system

design ............................................................................................................................................................... 24

Annex B (informative) Material acceptance tests for intermediate layers .......................................... 25

Bibliography ................................................................................................................................................................. 26

---------------------- Page: 4 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)
European foreword

This document (EN 16432-3:2021) has been prepared by Technical Committee CEN/TC 256 “Railway

applications”, the secretariat of which is held by DIN.

This European Standard shall be given the status of a national standard, either by publication of an

identical text or by endorsement, at the latest by May 2022, and conflicting national standards shall be

withdrawn at the latest by May 2022.

Attention is drawn to the possibility that some of the elements of this document may be the subject of

patent rights. CEN shall not be held responsible for identifying any or all such patent rights.

Any feedback and questions on this document should be directed to the users’ national standards body.

A complete listing of these bodies can be found on the CEN website.

According to the CEN-CENELEC Internal Regulations, the national standards organisations of the

following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia,

Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland,

Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North

Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United

Kingdom.
---------------------- Page: 5 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)
1 Scope

This document specifies the implementation of ballastless track system designs and the criteria for the

acceptance of works concerning construction of ballastless track systems. It does not include any criteria

for inspecting, maintaining, repairing and replacing ballastless track systems during operation.

2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. For dated references, only the edition cited applies. For

undated references, the latest edition of the referenced document (including any amendments) applies.

EN 206, Concrete — Specification, performance, production and conformity

EN 12390-5, Testing hardened concrete — Part 5: Flexural strength of test specimens

EN 13231-1:2013, Railway applications — Track — Acceptance of works — Part 1: Works on ballasted

track — Plain line, switches and crossings

EN 13848-2, Railway applications — Track — Track geometry quality — Part 2: Measuring systems —

Track recording vehicles

EN 13848-6:2014+A1:2020, Railway applications — Track — Track geometry quality — Part 6:

Characterisation of track geometry quality

EN 13877-2, Concrete pavements — Part 2: Functional requirements for concrete pavements

EN 14587 (all parts), Railway applications — Infrastructure — Flash butt welding of new rails

EN 14730 (all parts), Railway applications — Track — Aluminothermic welding of rails

EN 16432-1:2017, Railway applications — Ballastless track systems — Part 1: General requirements

EN 16432-2:2017, Railway applications — Ballastless track systems — Part 2: System design, subsystems

and components
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at https://www.electropedia.org/
3.1
tolerance
permissible deviation from reference or specified value
3.2
relative track geometry

group of parameters defining the position of the rails, usually the following: track gauge, alignment,

longitudinal level, twist and cross level
---------------------- Page: 6 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)
Note 1 to entry: As described in EN 13848 series.
3.3
absolute track position
position of the track when measured from external absolute references
EXAMPLE Network of geodetic reference points
3.4
alignment

horizontal position of the rail or the track in relative or absolute co-ordinate system

3.5
longitudinal level

vertical position of the rail or the track in relative or absolute co-ordinate system

3.6
design

calculations, drawings, evidence and specifications relating to the materials and configuration of

ballastless track for a specific project or location within the project
3.7
system design

process of applying a systematic approach to ensure that all elements specified will work together to fulfil

the performance requirements
3.8
ballastless track system

entire structure of a ballastless track from rail to substructure interface and not just a proprietary

subsystem or components
Note 1 to entry: See EN 16432-2:2017, Figure 1.
3.9
substructure

earthworks (embankment, cutting or at-grade) or bridges (or similar civil structures) or tunnel floor that

lie below the ballastless track system
4 Symbols and abbreviations
Symbol/Abbreviation Definition
T Surveying tolerance
Geodetic tolerance
Construction tolerance
ITP Inspection and Testing Plan
WAP Works Acceptance Plan
G (j) Power Spectral Density
dF Spacial frequency interval
---------------------- Page: 7 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)
Symbol/Abbreviation Definition
D0, D1, D2 Wavelength ranges
Deformation modulus
CRCP Continuously Reinforced Concrete Pavement
JPCP Jointed Plain Concrete Pavement
5 General
5.1 Overview
The following paragraphs provide a short guidance through the standard.

5.2 provides a procedure how to identify whether a ballastless track system design is novel and proposes

measures for implementation. For the acceptance of any track system, a Works Acceptance Plan should

summarize all steps and criteria for acceptance as described in 5.3 and 5.4.

Clause 6 defines the key acceptance criteria for ballastless track after completion. All criteria defined in

the following Clauses 7 and 8 aim to ensure that the overall criteria as defined in Clause 6 are met during

construction.

Clause 7 defines criteria for subsystems which are used in various ballastless track systems.

Clause 8 defines criteria for specific types of ballastless track systems.

5.2 Validation of fitness for construction of a novel ballastless track system design

The Common Safety Method for risk assessment, or an equivalent methodology, shall be used to

determine the significance of novel aspects of a proposed ballastless track system, (for example, see

informative Annex A).

To determine the significance of novel aspects of a proposed ballastless track system, a risk assessment

methodology (e.g. the Common Safety Method or an equivalent method) shall be used.

NOTE 1 National rules can be applied.

NOTE 2 An introduction to risk assessment is provided in the informative Annex A.

Where differences (or new aspects) are identified, then additional requirements shall be agreed between

supplier and customer, based on the findings of the evaluation.

If a proposed design is significantly different from any existing design, it should be considered a new

design.

Unless otherwise specified, a new ballastless track system design (for the design itself see part 2) can be

accepted based on the acceptance of the subsystems and an agreed step-by-step procedure of the

following tests (but not limited to):

— Laboratory tests designed to study especially the behaviour and the load transfer performance of the

interfaces in-between different subsystems under design load combinations (mechanical, thermal…);

— Installation test by building a short (50 m) track section to demonstrate the ballastless track system

installation. The documentation should also cover the analysis and evaluation of tolerances;

— In case of a positive evaluation of the laboratory test and the installation test, a test section may be

built. It is recommended to install the test section along a line, representative of the planned

application of the ballastless track system. The test section should be tested and monitored based on

---------------------- Page: 8 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)

an agreed testing and monitoring regime. Where appropriate, testing and monitoring should cover a

period that represents the characteristic climatic conditions.
5.3 Establishing the criteria for acceptance of works

Criteria for the acceptance of works shall be developed from the detailed system design and specifications

in accordance with EN 16432-2. The complete set of criteria thus developed shall encompass all identified

performance risks for the specified design life and define how they shall be inspected, checked or tested.

This set of criteria shall include all the requirements that influence how the ballastless track system

interacts with other elements of the railway system.

The acceptance process for the ballastless track system shall be completed before the start of in-service

traffic. The different subsystems (see EN 16432-2) shall be validated prior to installation of the

subsequent subsystem.

The long term (designed) performance required for a safe and economically sustainable ballastless track

is, in part, dependent on the quality of installation. There is a need during construction for rigorous

inspection, monitoring and, where appropriate, testing.

In view of the more permanent nature and higher performance to be expected from a ballastless track

certain quality controls and evidence, different from those applying to ballasted track, need to be

provided.

A failure to meet the defined criteria may be corrected by remedial measures to the track or by a revision

of the design considering the achieved as-built parameters.
5.4 Integration in the assurance process/Works Acceptance Plan (WAP)

To integrate the acceptance criteria into a project assurance process, a form of documentation to plan all

the necessary tests and inspection work during and after construction should be prepared.

A WAP shall be created to set out all agreed measurements, tests and reports required to provide

evidence that the works have met the specified criteria. Where a System Assurance Plan has been

generated in the design phase (see EN 16432-2:2017, 6.2) this may be developed to form or incorporate

the WAP.

The final WAP should implement a risk-based approach to decide what level of verification is necessary.

The degree of novelty and level of risk (uncertainty and consequence, see 5.2) should be used to decide

the tests, inspections and their frequency, to gather the evidence needed to support the acceptance.

Reference to national codes of practice or other standards could also be required to define typical

frequencies of tests and inspections.

The WAP should detail all the requisite Inspection and Testing Plans (ITP) that define both the applicable

tests and the stage in construction to provide a progressive assurance process. This should recognize the

linear and layered nature of track construction work and ensure that required tests are instigated and

checked from the commencement of works and applied in an ongoing process to avoid the incorporation

of hidden defects. The verification should be defined based on quantifiable measures and include

pass/fail criteria that have a reasonable basis and defined method of measurement, including

methodology and number of tests.

The criteria in the WAP shall ensure that the various subsystems (as defined in EN 16432-2) have been

accepted on a progressive basis prior to installation of subsequent subsystems.
---------------------- Page: 9 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)
6 Acceptance of works
6.1 Track geometry and position
6.1.1 Introduction

The relative track geometry and the absolute track position shall be checked and documented after

completion of the work.
6.1.2 Relative track geometry
6.1.2.1 General

Unless otherwise specified, the relative track geometry shall be in accordance with EN 13231-1.

The tolerances in EN 13231-1:2013, Table 1 and Table 2, are for loaded track measurements. For

unloaded track measurements, the customer can specify the tolerances for the relative track geometry

parameters, which can be stricter than the tolerances for loaded track measurements.

6.1.2.2 Additional requirements for V > 160 km/h

To avoid deviations of track geometry in the long wavelength range, the unloaded track geometry shall

be checked before final fixation of track alignment and longitudinal level (e.g. before concreting). Unless

otherwise specified, the following criteria and limits shall be applied:

— Maximum allowable deviation of versine ≤ 2 mm using a 30 m chord for track alignment and

longitudinal level (overlap of chords 5 m). This check shall be done for all rail seats;

and

— Maximum allowable deviation of versine ≤ 10mm using a 300 m chord for track alignment and

longitudinal level (overlap of chords 150 m). This check shall be done for all rail seats.

To avoid negative effects of wavelike deviations of loaded track geometry up to 50 m on the running

behaviour of rail vehicles the waviness of track alignment and longitudinal level shall be checked

separately.

The loaded track geometry data shall be recorded using track recording car measurement and signal

processing procedures according to EN 13848-2. The track recording car shall be able to measure the

track geometry according to the required wavelength range of at least 1 m to 70 m.

NOTE 1 This wavelength range includes D0 (wavelength 1 m ≤ λ ≤ 5 m), D1 (wavelength 3 m ≤ λ ≤ 25 m) and

D2 (wavelength 25 m ≤ λ ≤ 70 m) according to EN 13848-1.

Track deviations shall be determined based on wavelength (inverse of spatial frequency) and evaluated

e.g. using Power Spectral Density PSD (see EN 13848-6:2014+A1:2020, 5.6).

The Power Spectral Density G (j) is determined by the squared effective value of the track deviation

divided by the spatial frequency interval dF.

The Power Spectral Density of track deviations for both the track alignment and the longitudinal level

should not exceed the limit shown in Figure 1 in a spatial frequency range of 0,015 [1/m] to 1 [1/m].

If peaks of a determined PSD exceed the limit in Figure 1, the specific root cause should be investigated

and the required actions agreed between supplier and customer.

NOTE 2 For calculating PSD of the track geometry parameters “track alignment” and “longitudinal level” an

equidistant spatial frequency spacing of 0,000 5 [1 / m] and a rectangular window function can be used.

---------------------- Page: 10 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)
Key
X Spatial frequency [1/m]
Y G [(m^2)/(1/m)]

Figure 1 — Limit for power spectral density for track alignment and longitudinal level

6.1.3 Absolute track position
The absolute track position shall be in accordance with EN 13231-1.

Unless otherwise specified, the unloaded track shall comply with Class AP 1 of EN 13231-1:2013, see

Table 1.
Table 1 — Tolerances for the deviation from design track position
Class Vertical position Lateral Longitudinal position of the
position switches and crossings
mm mm mm
AP 1 ±10 ±10 ±10
6.2 Track stiffness
6.2.1 Vertical track stiffness

The vertical stiffness performance of the subsystems and components providing the designed vertical

track stiffness of the ballastless track system shall be specified during track design and verified prior to

the track construction. Therefore, no on-site testing is required to demonstrate the vertical track stiffness.

---------------------- Page: 11 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)

NOTE The requirements for the subsystems or components providing the elasticity (e.g. EN 13481-5 for

fastening systems) are decided by the ballastless track designer and verified by subsystems and components

approval testing (e.g. EN 13146-9 for fastening systems).

Alternatively, local measurements of absolute or relative rail deflections can be performed. Based on the

measured rail deflections, the track stiffness can be calculated. In this case, a suitable measurement

procedure including reference load shall be described.
6.2.2 Vertical track stiffness uniformity

Vertical track stiffness should be uniform along the track except along designed transitions to control

additional dynamic vehicle-track interaction forces.

If it is agreed to use the loaded track geometry (by using track recording cars) as reference for acceptance,

no additional on-site testing is needed as long as the track geometry is within the limits of 6.1.2.

Alternatively track stiffness recording vehicles can be used for acceptance.

If alternative methods for determination of dynamic factors for ballastless track design according to

EN 16432-1 are applied, then the demonstration of uniformity of track stiffness by on-site measurements

can be performed according to the method accepted for the design.
6.3 Track stability
6.3.1 Key acceptance criteria for new design
Track stability shall be demonstrated according to EN 16432-2:2017, 6.5.

NOTE Track stability of ballastless track system design following EN 16432-2:2017, 6.5 is of special

importance and can be demonstrated with the help of a laboratory test, on site testing or calculation.

6.3.2 Key criteria for acceptance of work

Documentation shall be provided demonstrating that interfaces between different subsystems have been

built according to the ballastless track system design.

If the ballastless track system uses connectors (elements designed to accommodate horizontal forces

between subsystems) the correct number and sequence of connectors shall be checked. All connectors

shall comply with the design and it shall be documented that the installation has been done according to

the designed installation procedures.
6.4 Durability

The durability criteria for the acceptance of works have been defined in the design, according to the

materials used and the design concept applied (see EN 16432-2:2017, 6.2 System assurance plan). For

application to the constructed works, the durability shall be defined in terms of:

— what is acceptable;
— what is unacceptable.

NOTE This is related to the materials and components, subsystems or layers, environmental requirements, e.g.

exposure classes for concrete.

This should include guidance on what is considered with respect to performance and safety.

Where the installed works do not meet the criteria, the constructor shall be permitted to propose, with

evidence, that a specific problem is not structurally significant or, their method of rectifying the defect

that relates to the specific location and significance of the defect.
---------------------- Page: 12 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)
6.5 Drainage

All drainage paths that could affect the performance of the track shall be checked with regards to

functionality.

It shall be ensured that the drainage is free from debris and that the surface roughness and slopes are in

accordance with the design. If the drainage is easily accessible this can be done by visual inspection. For

parts of the drainage that are not easily accessible, e.g. pipes, cameras can be used for inspection.

Inspections should also make sure that no alterations nor additions have been made to the design that

can hinder drainage, e.g. noise barriers or location specific cabling.
7 Acceptance of substructure and subsystems
7.1 General

Because some parameters cannot be checked after completion of works, and because they have influence

on the quality and the durability of the ballastless track, the items listed below should be checked during

track construction.
7.2 Acceptance of substructures
7.2.1 Introduction

Before commencement of construction of a ballastless track system, the substructure over which it is to

be built should be checked to ensure that the critical parameters identified in the design have been

complied with and are fully understood.
7.2.2 Ballastless track on earthworks

As a minimum requirement, the following verifications should be undertaken before commencement of

the construction:

— Verification of the type and date of original acceptance testing of the formation of the earthworks

(e.g. deformation modulus E ). If there is a risk of change of structural performance of the

earthworks since completion, then new tests should be arranged to verify the design condition

remains valid;

NOTE 1 Refer to EN 16907-5 for information on acceptance testing methodologies for earthworks.

— Verification that estimated remaining settlement or heave is within the design allowances (total and

differential settlements or heave);

— Where heave of the subsoil is a risk identified in the design, the required controls and checks shall be

applied.

NOTE 2 Residual risks following completion of the earthworks can relate to whether any precipitation or traffic

has acted on the formation surface causing disturbance or changes in moisture content.

A verification of the drainage function should be undertaken prior to commencing the construction (see

6.5).
7.2.3 Ballastless track on bridges

The following parameters of a bridge shall be verified against design prior to commencing the

construction:
---------------------- Page: 13 ----------------------
SIST EN 16432-3:2022
EN 16432-3:2021 (E)

— geometric requirements on the constructed deck of a bridge structure to confirm that adjustments

or precautions defined in the design to account for e.g. precamber or temperature, can be applied or

...

SLOVENSKI STANDARD
oSIST prEN 16432-3:2020
01-september-2020
Železniške naprave - Progovni sistemi z utrjenimi tirnicami - 3. del: Prevzem
Railway applications - Ballastless track systems - Part 3: Acceptance
Bahnanwendungen - Feste Fahrbahn-Systeme - Teil 3: Annahme
Applications ferroviaires - Systèmes de voie sans ballast - Partie 3 : Réception
Ta slovenski standard je istoveten z: prEN 16432-3
ICS:
45.080 Tračnice in železniški deli Rails and railway
components
93.100 Gradnja železnic Construction of railways
oSIST prEN 16432-3:2020 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

---------------------- Page: 1 ----------------------
oSIST prEN 16432-3:2020
---------------------- Page: 2 ----------------------
oSIST prEN 16432-3:2020
DRAFT
EUROPEAN STANDARD
prEN 16432-3
NORME EUROPÉENNE
EUROPÄISCHE NORM
June 2020
ICS 93.100
English Version
Railway applications - Ballastless track systems - Part 3:
Acceptance

Applications ferroviaires - Systèmes de voies sans Bahnanwendungen - Feste Fahrbahn-Systeme - Teil 3:

ballast - Partie 3 : Approbation Annahme

This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee

CEN/TC 256.

If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations

which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other

language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC

Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,

Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,

Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and

United Kingdom.

Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are

aware and to provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without

notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels

© 2020 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 16432-3:2020 E

worldwide for CEN national Members.
---------------------- Page: 3 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)
Contents Page

European foreword ....................................................................................................................................................... 4

1 Scope .................................................................................................................................................................... 5

2 Normative references .................................................................................................................................... 5

3 Terms and definitions ................................................................................................................................... 5

4 General ................................................................................................................................................................ 6

4.1 Overview ............................................................................................................................................................ 6

4.2 Validation of fitness for construction of a novel ballastless track system design ................... 7

4.3 Establishing the criteria for acceptance of work ................................................................................. 7

4.4 Integration in assurance process/Works Acceptance Plan ............................................................. 8

5 Acceptance of works, measurements, checks and related documentation ............................... 8

5.1 Track geometry and position ...................................................................................................................... 8

5.1.1 Introduction ...................................................................................................................................................... 8

5.1.2 Relative track geometry ............................................................................................................................... 8

5.1.3 Absolute track position .............................................................................................................................. 10

5.2 Track stiffness ............................................................................................................................................... 11

5.2.1 Vertical track stiffness ................................................................................................................................ 11

5.2.2 Vertical track stiffness uniformity ......................................................................................................... 11

5.3 Track stability ............................................................................................................................................... 11

5.3.1 Key acceptance criteria Track stability – New design .................................................................... 11

5.3.2 Key acceptance criteria Track stability – Acceptance of work .................................................... 11

5.4 Durability criteria for acceptance of work ......................................................................................... 11

5.5 Drainage .......................................................................................................................................................... 12

6 Acceptance of substructure and subsystems ..................................................................................... 12

6.1 General ............................................................................................................................................................. 12

6.2 Substructure acceptance ........................................................................................................................... 12

6.2.1 Introduction ................................................................................................................................................... 12

6.2.2 Ballastless Track on Earthworks ............................................................................................................ 12

6.2.3 Ballastless Track on Bridges .................................................................................................................... 13

6.2.4 Ballastless track in tunnels....................................................................................................................... 13

6.2.5 Transitions in Substructure ..................................................................................................................... 14

6.3 Acceptance of pavements .......................................................................................................................... 14

6.3.1 Acceptance of base layers ......................................................................................................................... 14

6.3.2 Concrete and asphalt pavements ........................................................................................................... 16

6.4 Acceptance of intermediate layer .......................................................................................................... 18

6.4.1 Acceptance of foil, sheeting ...................................................................................................................... 18

6.4.2 Acceptance of intermediate layer, boot, fixation (concrete filling layer) ................................ 18

6.4.3 Acceptance of levelling layer ................................................................................................................... 19

6.5 Acceptance of prefabricated element (sleeper, block, slab, frame) .......................................... 19

6.6 Rail fastenings ............................................................................................................................................... 19

6.6.1 General ............................................................................................................................................................. 19

6.6.2 Adjusting capabilities of fastening system .......................................................................................... 19

6.6.3 Rail seat spacing – needs to be checked during construction ...................................................... 19

6.6.4 Out of square of the rail seat pair ........................................................................................................... 19

6.7 Rails ................................................................................................................................................................... 19

---------------------- Page: 4 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)

6.7.1 Introduction.................................................................................................................................................... 19

6.7.2 Stressing work ............................................................................................................................................... 19

6.7.3 Welds ................................................................................................................................................................. 20

6.7.4 Insulated joints .............................................................................................................................................. 20

6.8 Specific measurements for switches and crossings and rail expansion devices ................... 20

7 System specific requirements for installation methods ................................................................. 20

7.1 Acceptance of ballastless track system with continuously supported or embedded

rails .................................................................................................................................................................... 20

7.2 Acceptance of Ballastless track system with discrete rail seats on prefabricated

element, supported by a pavement ........................................................................................................ 21

7.2.1 Pavements providing direct support ..................................................................................................... 21

7.2.2 Indirect support (e.g. using grouting) ................................................................................................... 22

7.3 Acceptance of ballastless track system with discrete rail seats on prefabricated

element, independent from the surrounding concrete filling layer or pavement ................ 22

7.3.1 Before concreting ......................................................................................................................................... 22

7.3.2 After Concreting ............................................................................................................................................ 23

7.4 Acceptance of Ballastless track system with discrete rail seats on prefabricated

element, monolithically integrated in a pavement .......................................................................... 23

7.4.1 Before concreting ......................................................................................................................................... 23

7.4.2 After Concreting ............................................................................................................................................ 23

7.5 Acceptance of Ballastless track system with discrete rail seats on a concrete

pavement ......................................................................................................................................................... 23

Annex A (informative) Risk assessment of novelty in a proposed ballastless track system

design ................................................................................................................................................................ 25

Annex B (informative) Material acceptance tests for intermediate layers .......................................... 26

Annex ZA (informative) Relationship between this European Standard and the

interoperability requirements of Directive2016/797/EC aimed to be covered ................... 27

Bibliography ................................................................................................................................................................. 29

---------------------- Page: 5 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)
European foreword

This document (prEN 16432-3:2020) has been prepared by Technical Committee CEN/TC 256 “Railway

applications”, the secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.

This document has been prepared under a mandate given to CEN by the European Commission and the

European Free Trade Association, and supports essential requirements of EU Directive(s).

For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this

document.
---------------------- Page: 6 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)
1 Scope

This document specifies the methods for the implementation of ballastless track system designs and the

criteria for the acceptance of works concerning construction of ballastless track systems. It does not

include any criteria for inspecting, maintaining, repairing and replacing ballastless track systems during

operation.
2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. For dated references, only the edition cited applies. For

undated references, the latest edition of the referenced document (including any amendments) applies.

EN 206, Concrete — Specification, performance, production and conformity

EN 12390-5, Testing hardened concrete — Part 5: Flexural strength of test specimens

EN 13231-1:2013, Railway applications — Track — Acceptance of works — Part 1: Works on ballasted

track — Plain line, switches and crossings

EN 13848-2, Railway applications — Track — Track geometry quality — Part 2: Measuring systems —

Track recording vehicles

EN 13877-2, Concrete pavements — Part 2: Functional requirements for concrete pavements

EN 14587 (all parts), Railway applications — Infrastructure — Flash butt welding of new rails

EN 14730 (all parts), Railway applications — Track — Aluminothermic welding of rails

EN 16432-2:2017, Railway applications — Ballastless track systems — Part 2: System design, subsystems

and components
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

— ISO Online browsing platform: available at http://www.iso.org/obp
— IEC Electropedia: available at http://www.electropedia.org/
3.1
tolerance
permissible deviation from reference or specified value
3.2
relative track geometry

group of parameters defining the position of the rails, usually the following: gauge, alignment,

longitudinal level, twist and cross level
Note 1 to entry: As described in EN 13848 series.
---------------------- Page: 7 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)
3.3
absolute track position
position of the track when measured from external absolute references
Example: Network of geodetic reference points.
3.4
alignment
horizontal position of e.g. the track in relative or absolute co-ordinate system
3.5
longitudinal level
vertical position of e.g. the track in relative or absolute co-ordinate system
3.6
design

comprises the calculations, drawings, evidence and specifications relating to the materials and

configuration of ballastless track for a specific project or location within the project

3.7
system design

process of applying a systematic approach to ensure that all elements specified will work together to

fulfil the performance requirements
3.8
ballastless track system

entire structure of a ballastless track from rail to substructure interface and not just a proprietary sub-

system or components
Note 1 to entry: See Figure 2 of EN 16432-2:2017.
3.9
substructure

earthworks (embankment, cutting or at-grade) or bridges (or similar civil structures) or tunnel floor

that lie below the ballastless track system
4 General
4.1 Overview
The following paragraph provides a short guidance through the standard.

Subclause 4.2 provides a general guidance how to identify whether a ballastless track system is novel

and proposes measures necessary to implement it. For the acceptance of any track system a work

acceptance plan should summarize all steps and criteria for acceptance as described in 4.3.

Clause 5 defines the key acceptance criteria for the completed track. All criteria defined in the following

Clauses 6 and 7 aim to ensure that the overall criteria as defined in Clause 5 are met during

construction.

Clause 6 defines parameters for subsystems which are used in various ballastless track system designs.

Clause 7 defines particular requirements for specific types of ballastless track systems.

---------------------- Page: 8 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)

4.2 Validation of fitness for construction of a novel ballastless track system design

A method shall be used (example see Annex A) that will determine whether a proposed ballastless track

system design is similar enough to an in-service system.

Acceptance can be agreed without further action if the proposed design was already implemented such

that it is proven to fulfil the customers’ requirements.

Where differences (or new aspects) are identified, then additional requirements for implementation

shall be established, based on the findings of the evaluation.

If a proposed design is significantly different from any existing design it will be considered a new

design.

Unless otherwise specified a new ballastless track system design (for the design itself see part 2) can be

accepted based on the acceptance of the subsystems and an agreed step-by step testing procedure of

following tests (but not limited to):

— Laboratory tests designed to study especially the behaviour and the load transfer performance of

the interfaces in-between different subsystems under design load combinations (mechanical,

thermal…);

— A short (50 m) track section built outside the rail infrastructure to demonstrate the ballastless

track installation. The documentation should also cover the analysis and evaluation of tolerances;

— In case of a positive evaluation of laboratory testing and of demonstrator, a test section shall be

built. It is recommended to install the test section along a line, which receives high annual tonnage

representing the planned application of the ballastless track system. The test section shall be tested

and monitored based on an agreed testing and monitoring regime. Where appropriate, Testing,

monitoring and documentation shall cover a period that represents the characteristic climatic

conditions.
4.3 Establishing the criteria for acceptance of work

The acceptance criteria shall be developed from the detailed system design and specifications in

accordance with EN 16432-2. The complete set of criteria thus developed shall encompass all identified

performance risks for the specified design life and define how they shall be inspected, checked or tested

and thereby verified prior to acceptance. This shall include all the requirements that influence how the

ballastless track system interfaces with other elements of the railway system.

The completed ballastless track system shall be accepted before start of in-service traffic. The different

subsystems as stated in EN 16432-2 shall be validated prior to installation of the subsequent

subsystem.

The long term (designed) performance required for a safe and economically sustainable ballastless

track is, in part, dependent on the quality of installation. There is a need during construction for

rigorous inspection, monitoring and, where appropriate, testing.

In view of the more permanent nature and higher performance to be expected from a ballastless track

certain different quality controls and evidence need to be provided.

A failure to meet the defined criteria may be corrected by reparative measures to the track or by a

revision of the design considering the achieved as-built parameters. The second approach does not

relieve the executing contractor from its general obligation to meet the defined criteria.

---------------------- Page: 9 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)
4.4 Integration in assurance process/Works Acceptance Plan

To integrate the acceptance requirements into a project assurance process, a form of documentation to

plan all the necessary tests and inspection work during and after construction should be prepared.

A Works Acceptance Plan (WAP) shall be created to set out all agreed measurements tests and reports

required to provide evidence that the works have met the specified requirements. Where a System

Assurance Plan has been generated in the design phase (EN 16432-2:2017, 6.2) this may be developed

to form or incorporate the WAP.

The final WAP should implement a risk-based approach to decide what level of verification is necessary.

The degree of novelty and level of risk (uncertainty and consequence, see 4.2) should be used to decide

the actual checks, tests and trials applied and their frequency, to gather the evidence needed to support

the acceptance. Reference to national codes of practice or other standards may also be required to

define typical frequencies of testing or inspection.

The WAP should detail all the requisite inspection and testing plans (ITP) that define both the

applicable tests and the stage in construction to provide a progressive assurance process. This should

recognize the linear and layered nature of track construction work and ensure that required tests are

instigated and checked from the commencement of works and applied in an ongoing process to avoid

the incorporation of hidden defects. The verification should be defined based on quantifiable measures

and include pass/fail criteria that have a reasonable basis and defined method of measurement,

including methodology and number of tests.

The requirements of a suitable ITP/WAP shall ensure that the various subsystems (as defined in

EN 16432-2) have been accepted on a progressive basis prior to installation of subsequent subsystems.

All the acquired evidence shall be validated against requirements before the acceptance can be

considered complete.
5 Acceptance of works, measurements, checks and related documentation
5.1 Track geometry and position
5.1.1 Introduction

The relative track geometry and the absolute track position shall be checked and documented after

completion of the work.
5.1.2 Relative track geometry
5.1.2.1 General

Unless otherwise specified, the relative track geometry shall be according to EN 13231-1:2013.

The tolerances in Table 1 and Table 2 of EN 13231 1:2013 are for loaded track measurements. For

unloaded track measurements, the customer can specify the tolerances for the relative track geometry

parameters, which can be stricter.
5.1.2.2 Additional requirements for V > 160 km/h

To avoid deviations of track geometry in the long wavelength range, the unloaded track geometry shall

be checked before final fixation of track alignment and longitudinal level (e.g. before concreting). Unless

otherwise specified following criteria and limits shall be applied:

— Max. allowable deviation of versine ≤ 2 mm using a 30 m chord for track alignment and longitudinal

level (overlap of chords 5 m). This check shall be done for all rail seats;
and
---------------------- Page: 10 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)

— Max. allowable deviation of versine ≤ 10mm using a 300 m chord for track alignment and

longitudinal level (overlap of chords 150 m). This check shall be done for all rail seats.

To avoid negative effects of wavelike deviations of loaded track geometry up to 50 m on the running

behaviour of rail vehicles the waviness of track alignment and longitudinal level shall be checked

separately.

The loaded track geometry data shall be recorded using track recording car and measurement and

signal processing procedures according to EN 13848-2. The track recording car shall be able to measure

the track geometry according to the required wavelength range of at least 1 m to 70 m.

NOTE 1 This wavelength range is including the wavelength ranges D0 (wavelength 1 m ≤ λ ≤ 5 m),

D1 (wavelength 3 m ≤ λ ≤ 25 m) and D2 (wavelength 25 m ≤ λ ≤ 70 m) according to EN 13848-1.

Track deviations shall be determined according to wavelength (invers of distance frequency) and

evaluated e.g. using power spectral density PSD (see EN 13848-6:2014; 5.6).

The power spectral density G (j) is determined by the squared effective value of the track deviation

divided by the distance frequency interval dF.

The power spectral density of track deviations for both, the track alignment and the longitudinal level

should not exceed the limit shown in Figure 1 in a distance frequency range of 0,015 [1/m] to 1 [1/m].

In case peaks of a determined PSD exceed the limit in Figure 1 the specific root cause should be

investigated and the required actions agreed with the client.

NOTE 2 For calculating PSD of the track geometry parameters “track horizontal alignment” and “longitudinal

level” an equidistant distance frequency spacing of 0,000 5 [1 / m] and a rectangular window function can be

used.
---------------------- Page: 11 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)
Key
X Distance frequency [1/m]
Y G [(m^2)/(1/m)]

Figure 1 — Limit for power spectral density for track horizontal alignment and longitudinal

level
5.1.3 Absolute track position
The absolute track position shall be according to EN 13231-1:2013.

Unless otherwise specified, the unloaded track shall comply with Class AP 1 of EN 13231-1:2013, see

Table 1.
Table 1 — Tolerances for the deviation from design track position
Class Vertical position Lateral position Longitudinal position of the
switches and crossings
mm mm mm
AP 1 ±10 ±10 ±10
---------------------- Page: 12 ----------------------
oSIST prEN 16432-3:2020
prEN 16432-3:2020 (E)
5.2 Track stiffness
5.2.1 Vertical track stiffness

The vertical stiffness performance of the subsystem/component providing the designed vertical track

stiffness of the ballastless track system shall be specified during track design and verified prior to the

track installation. Therefore, no on-site testing is required to demonstrate the vertical track stiffness.

NOTE The requirements for the subsystems or components providing the elasticity (e.g. EN 13481-5 for

fastening systems) are decided by the ballastless track designer and verified by subsystem/component approval

testing, e.g. EN 13146-9 for fastening systems.

Alternatively, local measurements of absolute rail deflections can be performed. Based on the measured

rail deflections, the track stiffness can be calculated. A detailed measurement procedure including

reference load shall be described.
5.2.2 Vertical track stiffness uniformity

Vertical track stiffness should be uniform along the rail except along designed transitions to control

additional dynamic vehicle-track interaction forces.

If it is agreed to use the loaded track geometry (by using track recording cars) as reference for

ballastless track acceptance, no additional on-site testing is needed as long as the track geometry is

within the limits of 5.1.2.
Alternatively track stiffness recording vehicles can be used.

If alternative methods for determination of dynamic factors for ballastless track design according to

EN 16432-1 are applied, then the demonstration of uniformity of track stiffness by on-site

measurements can be performed according to the method accepted for the design.
5.3 Track stability
5.3.1 Key acceptance criteria Track stability – New design
Track stability shall be demonstrated according to EN 16432-2:2017, 6.5.

NOTE Track stability of ballastless track system design following EN 16432-2:2017, 5.2.2.1 is of special

importance and can be demonstrated with the help of a laboratory test or on site testing.

5.3.2 Key acceptance criteria Track stability – Acceptance of work
...

Questions, Comments and Discussion

Ask us and Technical Secretary will try to provide an answer. You can facilitate discussion about the standard in here.