Railway applications - Ballastless track systems - Part 2: System design, subsystems and components

This part of prEN 16432 covers system and subsystem design and component configuration for ballastless track system.
The system and subsystem design requirements are assigned from the general requirements of prEN 16432 1:2014. Where applicable existing subsystem or component requirements from other standards are to be referenced.

Bahnanwendungen - Feste Fahrbahn-Systeme - Teil 2: Teilsysteme und Komponenten

Dieser Teil der prEN 16432 behandelt die Bemessung von System und Teilsystem und die Anordnung der Komponenten für Feste Fahrbahn-Systeme (FF-Systeme).
Die Entwurfsanforderungen an das System und das Teilsystem sind prEN 16432 1:2015 entnommen. Auf Anforderungen an bestehende Teilsysteme oder Komponenten aus anderen Normen ist zu verweisen, sofern zutreffend.

Applications ferroviaires - Systèmes de voies sans ballast - Partie 2 : Sous-systèmes et composants

La présente partie de l’EN 16432 traite de la conception du système et des sous-systèmes et de la configuration des composants destinés au système de voie sans ballast.
Les exigences relatives à la conception du système et des sous-systèmes sont dérivées des prescriptions générales du prEN 16432 1:2014. Le cas échéant, les exigences existantes relatives aux sous systèmes ou aux composants figurant dans d’autres normes doivent être appliquées.

Železniške naprave - Progovni sistemi z utrjenimi tirnicami - 2. del: Projektiranje sistema, podsistemi in sestavni deli

Ta del standarda prEN 16432 zajema projektiranje sistemov in podsistemov ter konfiguracijo sestavnih delov za progovni sistem z utrjenimi tirnicami.
Zahteve glede projektiranja sistemov in podsistemov so navedene v skladu s splošnimi zahtevami standarda prEN 16432 1: 2014. Po potrebi se je treba sklicevati na obstoječe zahteve za podsisteme ali sestavne dele iz drugih standardov.

General Information

Status
Published
Public Enquiry End Date
02-Jul-2015
Publication Date
30-Aug-2017
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
17-Aug-2017
Due Date
22-Oct-2017
Completion Date
31-Aug-2017

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SLOVENSKI STANDARD
SIST EN 16432-2:2017
01-oktober-2017

Železniške naprave - Progovni sistemi z utrjenimi tirnicami - 2. del: Projektiranje

sistema, podsistemi in sestavni deli

Railway applications - Ballastless track systems - Part 2: System design, subsystems

and components
Bahnanwendungen - Feste Fahrbahn-Systeme - Teil 2: Teilsysteme und Komponenten

Applications ferroviaires - Systèmes de voies sans ballast - Partie 2 : Sous-systèmes et

composants
Ta slovenski standard je istoveten z: EN 16432-2:2017
ICS:
45.080 7UDþQLFHLQåHOH]QLãNLGHOL Rails and railway
components
93.100 Gradnja železnic Construction of railways
SIST EN 16432-2:2017 en,fr,de

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

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SIST EN 16432-2:2017
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SIST EN 16432-2:2017
EN 16432-2
EUROPEAN STANDARD
NORME EUROPÉENNE
August 2017
EUROPÄISCHE NORM
ICS 93.100
English Version
Railway applications - Ballastless track systems - Part 2:
System design, subsystems and components

Applications ferroviaires - Systèmes de voies sans Bahnanwendungen - Feste Fahrbahn-Systeme - Teil 2:

ballast - Partie 2 : Conception du système, sous- Systementwurf, Untersysteme und Komponenten

systèmes et composants
This European Standard was approved by CEN on 28 May 2017.

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, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,

Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, 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: Avenue Marnix 17, B-1000 Brussels

© 2017 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 16432-2:2017 E

worldwide for CEN national Members.
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SIST EN 16432-2:2017
EN 16432-2:2017 (E)
Contents Page

European foreword ....................................................................................................................................................... 6

Introduction .................................................................................................................................................................... 7

1 Scope .................................................................................................................................................................... 8

2 Normative references .................................................................................................................................... 8

3 Terms and definitions ................................................................................................................................... 9

4 Symbols and abbreviations ...................................................................................................................... 10

5 General ............................................................................................................................................................. 15

5.1 Ballastless track system, subsystems and components ................................................................. 15

5.2 Subsystems configuration ......................................................................................................................... 16

5.2.1 Ballastless track system with continuous support and embedded rails ................................. 16

5.2.2 Ballastless track system with discrete rail seats .............................................................................. 17

6 System design ................................................................................................................................................ 18

6.1 Establishing the system criteria ............................................................................................................. 18

6.2 System assurance plan ............................................................................................................................... 19

6.3 System integration ....................................................................................................................................... 19

6.4 Vertical track stiffness ................................................................................................................................ 19

6.5 Track stability ............................................................................................................................................... 19

6.6 Load distribution and load transfer by subsystems and components ...................................... 20

6.6.1 Principles ........................................................................................................................................................ 20

6.6.2 Calculation steps........................................................................................................................................... 21

6.6.3 Determination of forces (rail seat loads) between subsystems fastening system and

supporting structure (prefabricated element or pavement) ....................................................... 22

6.6.4 Prefabricated element loading and load distribution .................................................................... 22

6.6.5 Pavement design .......................................................................................................................................... 23

6.7 Loading of substructure ............................................................................................................................. 25

6.8 Transitions ..................................................................................................................................................... 26

7 Rails ................................................................................................................................................................... 26

8 Rail fastening systems ................................................................................................................................ 26

8.1 General ............................................................................................................................................................. 26

8.2 Rail fastening spacing ................................................................................................................................. 26

8.3 Adjustment ..................................................................................................................................................... 26

9 Prefabricated elements .............................................................................................................................. 26

9.1 General ............................................................................................................................................................. 26

9.2 General design considerations ................................................................................................................ 27

9.2.1 Data to be supplied for the general system design .......................................................................... 27

9.2.2 Individual precast element design ........................................................................................................ 27

9.3 Manufacturing process ............................................................................................................................... 27

9.3.1 General requirements ................................................................................................................................ 27

9.3.2 Curing ............................................................................................................................................................... 28

9.3.3 Surface finish ................................................................................................................................................. 28

9.3.4 Marking ............................................................................................................................................................ 28

9.4 Quality control .............................................................................................................................................. 28

9.4.1 General ............................................................................................................................................................. 28

9.4.2 Quality control during design approval tests .................................................................................... 28

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SIST EN 16432-2:2017
EN 16432-2:2017 (E)

9.4.3 Quality control during manufacturing .................................................................................................. 29

9.5 Concrete sleepers, bearers and blocks ................................................................................................. 29

9.6 Prefabricated slabs and frames ............................................................................................................... 29

9.6.1 Classification .................................................................................................................................................. 29

9.6.2 Design ............................................................................................................................................................... 30

9.6.3 Materials .......................................................................................................................................................... 31

9.6.4 Geometrical tolerances ............................................................................................................................... 32

9.6.5 Storage, handling, transport and on-site installation ..................................................................... 32

9.7 Filling layer ..................................................................................................................................................... 33

10 Pavements (layered structure)................................................................................................................ 33

10.1 General ............................................................................................................................................................. 33

10.2 Concrete pavements .................................................................................................................................... 34

10.2.1 Application ...................................................................................................................................................... 34

10.2.2 Materials .......................................................................................................................................................... 34

10.2.3 Functional requirements ........................................................................................................................... 34

10.3 Asphalt pavements ....................................................................................................................................... 37

10.3.1 Application ...................................................................................................................................................... 37

10.3.2 Design ............................................................................................................................................................... 37

10.3.3 Geometrical requirements ........................................................................................................................ 37

10.3.4 Asphalt materials and mix design .......................................................................................................... 38

10.3.5 Materials for surface layer ........................................................................................................................ 38

10.3.6 Requirements for layers ............................................................................................................................ 38

10.4 Unbound, hydraulically bound and bituminous bound base-layers .......................................... 38

10.4.1 Application ...................................................................................................................................................... 38

10.4.2 Hydraulically bound base layer ............................................................................................................... 39

10.4.3 Cement treated base layer (CTB) ............................................................................................................ 39

10.4.4 Concrete base layer ...................................................................................................................................... 39

10.4.5 Bituminous base layer ................................................................................................................................ 40

10.4.6 Unbound base layer ..................................................................................................................................... 40

11 Intermediate layers ..................................................................................................................................... 41

11.1 Functions of intermediate layers ............................................................................................................ 41

11.2 Effects of intermediate layers on ballastless track system ........................................................... 41

Annex A (informative) Vertical vehicle load .................................................................................................... 43

A.1 Distribution of vertical railway traffic load and calculation of rail seat loads ....................... 43

A.1.1 General ............................................................................................................................................................. 43

A.1.2 Rail seat load P [N] ..................................................................................................................................... 43

A.1.3 Rail seat loads P [N] due to wheel loads Q [N] .................................................................................. 45

j i

A.2 Rail bending moment and bending stress at the rail foot .............................................................. 46

A.2.1 Rail bending moment M [Nmm] ............................................................................................................ 46

A.2.2 Bending stress at the rail foot σ [N/mm ] ........................................................................................ 46

Annex B (informative) Thickness design calculations for slabs, pavements, frames, beams ........ 47

B.1 General ............................................................................................................................................................. 47

B.1.1 Introduction.................................................................................................................................................... 47

B.1.2 Effective pavement thickness h [mm] ................................................................................................. 48

B.1.3 Bedding modulus k [N/mm ] ................................................................................................................... 49

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SIST EN 16432-2:2017
EN 16432-2:2017 (E)
B.1.4 Bearing capacity of beam or slab/pavement supported by cementitious or

bituminous base layer ................................................................................................................................ 52

B.1.5 Slab on Winkler foundation (Westergaard): Longitudinal and lateral bending

moments as well as tensile stresses activated by rail seat loads ................................................ 54

B.1.6 Beam on Winkler foundation (Zimmermann): Longitudinal bending moment and

tensile stress due to rail seat loads ........................................................................................................ 60

B.1.7 Critical longitudinal bending tensile stress ........................................................................................ 64

B.1.8 Critical lateral bending tensile stress ................................................................................................... 64

B.2 Stresses in concrete slab/pavement due to thermal impact ........................................................ 64

B.2.1 General ............................................................................................................................................................. 64

B.2.2 Constant stresses σ due to temperature changes ΔT acting in concrete slabs or

pavements ....................................................................................................................................................... 65

B.2.3 Linear stresses σ due to temperature changes Δt acting in concrete slabs or

pavements ....................................................................................................................................................... 67

B.3 Determination of maximum allowable flexural fatigue stress due to railway traffic

load σ ............................................................................................................................................................. 68

B.3.1 Maximum allowable tensile flexural stress in winter (longitudinal stresses) ...................... 68

B.3.2 Maximum allowable tensile flexural stress in summer (lateral and longitudinal

stresses) ........................................................................................................................................................... 68

Annex C (informative) Vertical loading ............................................................................................................. 69

Annex D (informative) Examples of calculations ........................................................................................... 70

D.1 First example (variant II: unbonded multiple layers) and second example (variant

III: bonded layers) ........................................................................................................................................ 70

D.2 Distribution of vertical railway traffic loading and calculation of rail seat loads ................ 70

D.2.1 Rail seat load P [N] .................................................................................................................................... 70

D.2.2 Rail seat loads P [N] due to wheel loads Q [N] ................................................................................. 72

j i

D.2.3 Rail bending moment and bending stress at the rail foot ............................................................. 79

D.3 First example (variant II: unbonded multiple layers) .................................................................... 80

D.3.1 General ............................................................................................................................................................. 80

D.3.2 Bending moment due to rail seat loads ................................................................................................ 82

D.3.3 Stresses due to thermal impact ............................................................................................................... 91

D.3.4 Determination of maximum allowable flexural fatigue stress due to vehicle load σ ....... 92

D.4 Second example (variant III: bonded multiple layers) ................................................................... 93

D.4.1 General ............................................................................................................................................................. 93

D.4.2 Bending moment due to rail seat loads ................................................................................................ 95

D.4.3 Stresses due to thermal impact ............................................................................................................. 107

D.4.4 Determination of maximum allowable flexural fatigue stress due to vehicle load σ ..... 108

Annex E (informative) Quality control – Routine tests and frequency of testing ............................ 109

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SIST EN 16432-2:2017
EN 16432-2:2017 (E)

E.1 General .......................................................................................................................................................... 109

E.2 Data of the slabs to be checked ............................................................................................................. 109

E.3 Examples for frequency of testing ....................................................................................................... 111

Annex F (informative) Example of ballastless track system design calculation and analysis

based on analytical tools ......................................................................................................................... 112

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

Requirements of EU Directive 2008/57/EC ..................................................................................... 113

Bibliography .............................................................................................................................................................. 115

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SIST EN 16432-2:2017
EN 16432-2:2017 (E)
European foreword

This document (EN 16432-2:2017) 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 February 2018, and conflicting national standards

shall be withdrawn at the latest by February 2018.

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.

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 2008/57/EC.

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

document.

This European Standard is one of the series EN 16432 “Railway applications — Ballastless track systems”

as listed below:
— Part 1: General requirements;
— Part 2: System design, subsystems and components;
— Part 3: Acceptance (in preparation).

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the

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

Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia,

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

Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,

Turkey and the United Kingdom.
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SIST EN 16432-2:2017
EN 16432-2:2017 (E)
Introduction

This part of the series EN 16432 covers the design of the ballastless track system, subsystems and

components and is used in conjunction with the following parts:
— Part 1: General requirements;
— Part 3: Acceptance.

A ballastless track system may consist of, but is not limited to, subsystems and components shown in

5.1, Figure 1. Those items are designed in accordance with the requirements defined in this standard, or

if applicable, other existing European standards.

NOTE Typical examples are rails defined in EN 13674–1, EN 13674–2 and EN 13674–3 or rail fastenings for

ballastless track system defined in EN 13481–5.
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SIST EN 16432-2:2017
EN 16432-2:2017 (E)
1 Scope

This part of EN 16432 specifies system and subsystem design and component configuration for

ballastless track system.

The system and subsystem design requirements are assigned from the general requirements of

EN 16432-1. Where applicable, existing subsystem or component requirements from other standards

are to be referenced.
2 Normative references

The following documents, in whole or in part, are normatively referenced in this document and are

indispensable for its application. For dated references, only the edition cited applies. For undated

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

prEN 197-1:2014, Cement — Part 1: Composition, specifications and conformity criteria for common

cements

EN 206:2013+A1:2016, Concrete — Specification, performance, production and conformity

EN 1097-6:2013, Tests for mechanical and physical properties of aggregates — Part 6: Determination of

particle density and water absorption
EN 1992 series, Eurocodes

EN 1992-1-1:2004, Eurocode 2: Design of concrete structures — Part 1-1: General rules and rules for

buildings

EN 1992-2:2005, Eurocode 2 — Design of concrete structures — Concrete bridges — Design and detailing

rules

prEN 13043:2015, Aggregates for bituminous mixtures and surface treatments for roads, airfields and

other trafficked areas

EN 13108-1:2016, Bituminous mixtures — Material specifications — Part 1: Asphalt Concrete

EN 13108-5:2016, Bituminous mixtures — Material specifications — Part 5: Stone Mastic Asphalt

EN 13230-1:2016, Railway applications — Track — Concrete sleepers and bearers — Part 1: General

requirements

EN 13230-2:2016, Railway applications — Track — Concrete sleepers and bearers — Part 2: Prestressed

monoblock sleepers

EN 13230-3:2016, Railway applications — Track — Concrete sleepers and bearers — Part 3: Twin-block

reinforced sleepers

EN 13230-4:2016, Railway applications — Track — Concrete sleepers and bearers — Part 4: Prestressed

bearers for switches and crossings

EN 13230-5:2016, Railway applications — Track — Concrete sleepers and bearers — Part 5: Special

elements

prEN 13230-6:2015, Railway applications — Track — Concrete sleepers and bearers — Part 6: Design

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SIST EN 16432-2:2017
EN 16432-2:2017 (E)

EN 13242:2002+A1:2007, Aggregates for unbound and hydraulically bound materials for use in civil

engineering work and road construction

EN 13286-47:2012, Unbound and hydraulically bound mixtures — Part 47: Test method for the

determination of California bearing ratio, immediate bearing index and linear swelling

EN 13481 (all parts), Railway applications — Track — Performance requirements for fastening systems

EN 13674-1:2011+A1:2017, Railway applications — Track — Rail — Part 1: Vignole railway rails 46

kg/m and above

EN 13674-2:2006+A1:2010, Railway applications — Track — Rail — Part 2: Switch and crossing rails

used in conjunction with Vignole railway rails 46 kg/m and above

EN 13674-3:2006+A1:2010, Railway applications — Track — Rail — Part 3: Check rails

EN 13877-1:2013, Concrete pavements — Part 1: Materials

EN 13877-2:2013, Concrete pavements — Part 2: Functional requirements for concrete pavements

EN 13877-3:2004, Concrete pavements — Part 3: Specifications for dowels to be used in concrete

pavements

EN 14227-1:2013, Hydraulically bound mixtures — Specifications — Part 1: Cement bound granular

mixtures

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

3 Terms and definitions

For the purposes of this document, the following terms and definitions apply as well as terms and

definitions according to EN 16432-1.
3.1
filling layer

monolithic structure connecting prefabricated elements or subsystems of a ballastless track system and

establishing load transfer to the pavement or any supporting structure
3.2
pavement
continuous, layered structure that forms a hard and durable surface and it is d
...

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