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Vignole turnout systems - voestalpine

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Progress guaranteed:Meeting tomorrow’srequirements today


The increasing need for mobility is a dynamicallygrowing trend worldwide, making huge demandson public infrastructure. Pressure to increase thecarrying capacities of rail based passenger andfreight transport <strong>systems</strong> whilst remaining safe,comfortable, environmentally friendly andeconomical, has increased at least as much. Inorder to meet these requirements, innovative andintelligent product, system and service solutionsare needed. <strong>voestalpine</strong> VAE develops andproduces <strong>Vignole</strong> <strong>turnout</strong>s, crossovers, diamondcrossings, slips, rail expansion joints andcomplete layouts (halts, switch groups, yards anddepots) according to international standards andindividual customer requirements. Our <strong>systems</strong>can be provided in any virtually any rail profile,geometry or track gauge. The use of innovativetechnology and integrated, modern diagnostic<strong>systems</strong> provides trendsetting concepts in themaintenance arena. The result is a clearoptimisation of asset service life, efficiency,availability, reliability and maintenancefriendliness.


Innovative <strong>systems</strong> and servicesIntelligent system solutions from a single sourceIn-house designed, developed and manufactured locking, drive and monitoring<strong>systems</strong>, individually or combined into a single integrated system, can be integratedinto <strong>voestalpine</strong> VAE <strong>turnout</strong>s. <strong>voestalpine</strong> VAE’s proximity to our world-renown railmanufacturing sister company and the casting knowhow of <strong>voestalpine</strong> VAE’s ownproducers of high grade cast manganese steel <strong>turnout</strong> crossings provides ourcustomers with system solutions “from a single source”.LCC – Life Cycle CostLife cycle costs are of enormous significance in the infrastructure area. In the RAMS(reliability, availability, maintainability, safety) management concept, productspecifichazards are identified and investigated in a targeted manner and reliability,maintainability and safety analyses undertaken.Made to measure <strong>turnout</strong> geometry and kinematic optimizationA system of kinematic gauge optimization in the transition area of switches, which<strong>voestalpine</strong> VAE has named KGO, is a proven design which sustainably achievesimproved ride comfort, improved wear behavior and extended service life. KGO’s<strong>turnout</strong> geometries, including circular arcs, higher-order curves and combinedcurves, or our TOZ designs (carrying capacity-optimised tongue geometry) result inindividually tailored <strong>systems</strong>.Elasticity and sleeper padsOptimal elasticity of the <strong>turnout</strong> running track is one key for the reduction of theforces on both track and wheels, simultaneously resulting in reduced structure- andair-borne noise. The proper use of special elastic rail bearing <strong>systems</strong> makes itpossible to reduce wear and rolling contact fatigue. In addition, sleepers with elasticpads, which aid in the achievement of desired deflection values and reduce the wearon sleepers and ballast, are also available.Plug & Play – just in time (JIT)Innovative, modularly structured <strong>turnout</strong> <strong>systems</strong> represent a new era – systemintelligence. The entire modular <strong>turnout</strong> system is pre-assembled, fully functional, atone of the <strong>voestalpine</strong> VAE plants so that it can be installed in track in the leastpossible time. This means short track down-time, high “initial positional quality”, averifiably positive influence on function, wear and maintenance and, thus, on trackavailability and asset life cycle cost.


Innovative products for the mostdemanding requirementsSwitchesSwitches are available in different designs which can always be adjusted toindividual requirements. High strength rail steel, state of the art manufacturingtechnologies and operating optimised design options like KGO and TOZ are used. Toensure the best stability at the highest speeds, the rail cant of the entire <strong>turnout</strong> areamatches that of the adjacent running track (e.g. 1:40 or 1:20).Elastic plate <strong>systems</strong>Rail fastening in <strong>turnout</strong>s is usually determined by the rail fastening system used inthe adjacent track <strong>voestalpine</strong> VAE <strong>turnout</strong>s utilise any common fastening. The plate<strong>systems</strong> vary according to the sleepers used (concrete or wood) or to the trackfoundation (ballasted or ballastless). This all results in optimised load distributionthroughout the <strong>turnout</strong> and in the required vibration and noise attenuation. Further,there is not only a demonstrative increase in tamping cycles, but also reducedrail-wheel contact stresses. The stiffness of the system can be varied during design inorder to eliminate the negative effects of abrupt rigidity changes.HYTRONICSThe range of products includes hydraulic drives, locking and monitoring <strong>systems</strong>,electronic safety <strong>systems</strong> as well as hazard alert <strong>systems</strong> for rolling stock. All <strong>systems</strong>are low-maintenance, installation-friendly, and are especially noted for their low lifecycle cost. Our new monitoring <strong>systems</strong> for fixed infrastructure assets like <strong>turnout</strong>s,level crossings, etc. allow for early detection of impending failures well before oneoccurs.Rail expansion jointsDepending on the required operating parameters, rail expansion joints are designedwith movable switches, movable stock rails or as butt joints. Fixed switches andmovable stock rails are used for expansion lengths from 300mm, while expansionlengths up to 1200mm (+/- 600mm) will use a standard fixed stock rails design.Special expansion lengths are also available, with <strong>voestalpine</strong> VAE solutions forexpansion lengths of 2200mm (+/- 1100mm) having a history of excellentperformance.Concrete <strong>turnout</strong> bearersMain line <strong>turnout</strong>s are usually placed on mono-block concrete bearers. These bearersguarantee optimal positional stability of the <strong>turnout</strong> in ballasted track. In terms ofefficiency, the advantages of concrete bearers cannot be denied. They have a longservice life without losing quality and are unaffected by environmental factors suchas frost, heat or water. They can also be recycled readily.


Built-up crossingsBolted built-up crossings come in a multiplicity ofdesigns and are especially suitable for thesmaller, ‘one-off’ type application. While a widevariety of materials may be used in the <strong>turnout</strong>,the rail most commonly used is head hardened(perlite or bainite structure) with a highresistance to rolling contact fatigue and wear.The switch points may also be manufacturedusing heat-treated steel and composite materialswith even higher hardness.Highestefficiency.Strongestperformance.For the sakeof theenvironment.Crossings of cast manganese steelIn the high-performance area, welded monoblockcrossings made from high-manganese caststeel with a 12%–14% manganese content havebeen proven to provide the optimal life cycle cost.These cast manganese steel crossings guaranteeexcellent resistance to wear and are particularlylow-maintenance. Refurbishment following longperiods of use in the track can be easilyperformed as the manganese is able to be weldedwithout pre-heating and can thus be re-profiled.<strong>voestalpine</strong> VAE has developed a method forpre-hardening (explosive hardening) of therunning surfaces of cast manganese steelcrossings which further prolongs the service lifeof the crossing.Moveable point crossingOperating in the same fashion as switch devices,a movable point in a <strong>turnout</strong> crossing ensures asmooth transition through the crossing area. Acheck-rail is no longer required and there are no“interference points” during transition.Depending on the customer’s requirements,different designs and materials are used,including for example, flexible movable points ofrail (standard and special profiles), wing rails ofcast manganese or high strength rail steel.


<strong>voestalpine</strong> VAE GmbHRotenturmstraße 5-91010 Wien, AustriaT. +43/50304/12-0F. +43/50304/52-222www.<strong>voestalpine</strong>.com/vae

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