Slab Track 'NBU System' - Naumburger Bauunion GmbH & Co. KG

A company of
ThyssenKrupp
Services
Slab Track ‘NBU System’
Concept, Execution and
Construction Site Report
ThyssenKrupp GfT Gleistechnik
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Slab Track ‘NBU System’ –
Further Development of a Proven Track Concept.
Continuous production of concrete support slab
International endeavours to innovate the timetested
concept of stable positioned slab tracks as
an alternative to traditional ballasted tracks are
numerous. A particularly economic example of
these efforts is represented by the Slab Track
System Naumburger Bauunion/NBU that was
approved by the Federal Railway Authority of
Germany (EBA) for field tests in 2004. Within this
concept all sleeper elements were wiped out in
favour of a wholly monolithic construction type.
The construction is made by using the technology
of slipform pavers and applying the fastening
system Krupp ECF/Elastic Clip Fastener.
The conceptual starting point for this type of
construction was the search for a long lasting
solution of material compound by the use of highly
efficient slip-form pavers throughout the whole
fabrication. Due to the optimal design set-up of
the construction Type NBU a manual fabrication
of the slab track can be performed under tight
spatial conditions on the construction site as well.
A broad range of system applications for tunnels,
bridges and trough structures can be covered by
the multiple designs of the Slab Track NBU
System. The necessary precision, accuracy and
stability are the result of well tested principles of
track and road paving. Transitional areas towards
the ballast track are built by special system design
features.
2
Tunnels without
super-elevation
Viaducts/bridges
with super-elevation
rail runway ± 0.00
rail UIC 60
rail fastening
ballast
concrete support
layer
hydraulically bonded layer
frost protection layer
soll
1.43 5
longitucianl
groove melting joint
asphalt-top layer
Production
segment
„Longitudinal
groove profile“
Slab Track
NBU System
System Layout:
General Section View
with Fastening System
Krupp ECF

Innovation and Efficiency
on Testing Ground.
In the frame of a Field Test Agreement concluded
with DB Netz AG the construction of the Slab Track
NBU System was executed within the range of
the section 2600 Cologne – Aachen – Federal
border in early summer 2008. The length of this
special section NBU System is approximately
100 meters. In addition a transition area composed
of 5 m Rheda 2000 and 45 m roadbed with
ballast gluing was built at both ends. Thus the
total construction section comprises a length of
approx. 200 m.
The regular production standard of the concrete
base course is allotted by a slipform paver with
special equipment. Due to the cramped spatial
circumstances in place – the central sheeting
extending into the working field, an enlarged
clearance gauge and a very short transition to the
Rheda elements – a manual casting by concrete
pump got necessary and technologically advantageous.
A high-quality design was assured and
fully verified throughout the entire fabrication.
The overall fitting of the Hydraulically Bonded
Layer (HBL), reinforcement /earthing, the
Concrete Support Layer (CSL) and the rigging of
the mounting rail as well as the grouting of the
longitudinal channels were affected in an optimal
way. The key steps of the construction scheme
are described and documented by the following
record.
Legend
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New construction
Stocks
Cable line
Excavation drainage
Passage
Shaft
Trench
Internal earth FF
Flat bar 50 x 4 cross connection with earth
bridge in accordance with 3 EBS 15.03.19
(details see drawing A-4.01)
Location of OL mast (check on site)
Fit cross connection with earth bridge on
each OL mast
Position Map and
Particularities of the
Test Track
3

Record of Major Construction Steps.
In view of the construction process
one distinguishes mainly between:
the set-up until the upper edge of the
HBL and subsequently the fitting of the
CSL including the complete track laying.
The following record focuses on the
chronological comments and display
of the run of major construction steps
in phase two.
4
1
Fitting of the HBL occurred in two layers of 0.15 m thickness
each and setting out of the track axis and the positioning of the
formwork for the CSL.

2
3
Completion of formwork including fitting and compaction of the C 30/37 LP
concrete by a hose pump.
4 5
Chamfers production of dummy joints with a depth of at least 120 mm,
finishing treatment of the concrete according to DIN 1045 by moistening
and airproofed barriers.
At a distance of 0.2 m the laying of the transverse
reinforcement as well as longitudinal reinforcement
with 4 earthing irons were made; in order to
guarantee a safe and stable interconnection in the
transition area 4 x 4 exhaust dowels were
cemented.
Placement of set-up rails via rail winches and
discrete support point Krupp ECF at a distance
of 0.65 m, exact vertical and longitudinal
adjustment and fixation by special tools.
6
7
8
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Final inspection of the railway track before the filling
of the longitudinal channels by high end grout.
9
During the grouting work the permanent control over
the consistency by verification of the spreading
gauge and test specimen was carried out.
5

Record of Major Construction Steps.
6
10
11 12
Gluing of the ground ballast by two-components
polyurethane mixture and placement of support rails
in the transition area, documentation of the torque by
a twin headed screw machine.
Bracing of anchors with the
necessary torque, altitude
correction at individual support
points by inserting equalisation
plates.

Efficiency and Design Advantages of the
Slab Track ‘NBU System’.
Talks with professional users, applied planning and execution of
the real construction gave evidence of multiple advantages and
application schemes of the NBU System that are resulting from the
specific design principles and engineering particularities, mainly the
sleeper-less construction layout
Advantages and particular areas of application
High potential of industrial
execution and running by
proved and well tested
construction and paving
technology known for its
high productivity.
Special advantages in view
of track construction in
special climatic areas as
desert zones – where a high
potential of silt up exists – due
to low surface and blocking
resistance in case of adequate
and elevated track
design.
Abolition of joint transition
areas between prefabricated
parts and the “in situ”
concrete construction that
ensures optimal LCC-values,
low maintenance routine and
long life of the system.
Independence of prefabricated
elements and extended
transportation logistics by
complete local construction
in situ and easy feeding of
ready mix concrete by mobile
plants following the progress
and advancement of the
construction site.
Advantages in logistics and
local safety by obstacle-free
move on the CSL during its
construction as well as in
case of emergencies and
damage repairs due to a
plain and sleeper-less
surface.
Manufacture of concrete support slab with longitudinal grooves
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High efficiency of the construction
cycle by the use of
conventional and easy-tomobilize
road paving and track
laying technology through all
fabrication steps without
depending extensively on
special tools and machinery.
7

Solid Slab Track GmbH
A Joint Venture of
Naumburger Bauunion and ThyssenKrupp GfT Gleistechnik
ThyssenKrupp
GfT Gleistechnik
TK
ThyssenKrupp GfT Gleistechnik GmbH
Altendorfer Straße 120
D-45143 Essen
Phone: +49 2 01 1 88-37 12
Fax: +49 2 01 1 88-37 75
e-mail: gleistechnik@thyssenkrupp.com
www.tkgftgleistechnik.de
Naumburger Bauunion GmbH & Co
Gewerbegebiet Süd
D-06618 Görschen
Phone: +49 3 44 45 70-101
Fax: +49 3 44 45 70-200
e-mail: info@naumburger-bauunion.de
www.naumburger-bauunion.de
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Subject to change without notice · TK GfT Gleistechnik · GB · 09/2008