System construction

Fast installation of slab track is made possible with the following main steps:

Slab/panel production

Panels are produced in a prefabrication or field plant, and the panel production is therefore independent of weather conditions. Due to a complete quality assurance system, a constant high quality is guaranteed and documented.
The steel molds used for panel production are adjustable and can cover all radius ranges required by a project. Design of each panel takes into consideration the needs for possible reductions of the panel length, openings in the panel, coverings, dowels etc. so that the mold is set up in a way that ensures design of the panel is executed with millimeter accuracy.
Each of the track base plate types is unmistakably marked with a corresponding bar code and can therefore be easily identified at any time

Plates factory
Track slab at the factory

Laying of the Track

Laying track slab

Laying of the track base plates is normally done with portal cranes. This enables the plates to be lifted forwards in the smallest possible space. In addition, no reloading or intermediate storage is necessary, because the plates can be taken directly from the transport wagon. In the case of islands or missing track connection, the taking over and the laying of the track base plates by a truck with a loader arm is common practice.

Calibration of the track

After installation of the laterally stored rails, the work of final track calibration begins by using spindles. This method guarantees precise track set accuracy in setting the track with no further corrections required. Adjustment work is further reduced by adequate track geometry of the track base plates. Therefore, calibration requires up to 50 % less time compared to other slab track systems.

Surveying works during installation in tunnel
Surveying works during installation in an open section

Concrete pouring

Concreting the track supporting slabs (hose pump)

Based on the space available, the concrete joint sealing compound is applied either directly or through a hose pump up to a maximum of 500 m. The use of a self-compacting concrete joint sealing compound enables an even, continuous, and even embedding of the track base plate. As a result of the vibration-free concreting process, the fine-tuning of the track unit is not affected. Furthermore, it is possible for these slab tracks to be installed in a short railway traffic interruption (example: East-West-Connection Berlin 2002) due to the fast hardening process of the self-compacting-concrete.