www.ed i l o n . c om

EDILON B.V.P.O. box 10002003 RZ Haar lem, The Nether landsT: +31 (0)23 - 531 95 19F: +31 (0)23 - 531 07 51mai l@edi lon .comwww.ed i lon .com

EDILON DIRECT FASTENING SYSTEMS(EDF)

EDILON RAIL SYSTEMS

EDILON DIRECT FASTENING SYSTEM (EDF)The Edilon EDF fastenings system is discretely supported rail fastening system for ballastless track. The intended use is for all kind of rail traffic such as tram, metro, freight & commuter trains and high speed trains. And all kind of rail types such as the standard vignole and groove rail.

The system consists of:• steel base plate in 2 holes or 4 holes configurations with various railclip systems such as SKL or e type or other• Edilon designed rail pad or other• Edilon designed base plate pad or other• Edilon Dex-G epoxy or Edilon Corkelast for grouting the base plate• Various types of Edilon EDF rail anchors such EDF HD or EDF MD and various types of nuts• Edilon Dex-R 2K 2-component adhesive or EDF cast-in insert.

All components are tuned for different requirements such as straight track, curves, speed and axle loads and are tested according to the internationally accepted rail standard EN13146 and DIN 45673. Edilon supplies the Edilon EDF system as a complete system according to the quality assurance system ISO 9001-2000.

EDILON SLAB TRACK SYSTEMSFor over 130 years, tracks for mainline rail traffic and urban mass rapid transit systems were based almost exclusively on track panels and cross sleepers supported on stone ballast. During the 1960’s, increasing train loads, higher speeds and the demand for more cost effective track installation methods, led to the development of ballastless track or slab track systems.

Since the introduction of ballastless track systems, Edilon has developed and become a specialist of ballastless rail systems. Currently, Edilon supplies three ballastless track systems each with its own individual characteristics. These systems are:

• Edilon Corkelast® Embedded Rail System (ERS) Installed since1970

• Edilon Corkelast® Embedded Block System (EBS) Installed since 1974

• Edilon Direct Fastening System (EDF)® Installed since1964

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GENERAL ADVANTAGES OF THE EDILON EDF• Low maintenance requirements• Long life span• No high elastic rail clamps• Reduced construction height• Top down or bottom up installation possible• Different support stiffness possible• Vibration attenuation• Vertical & Horizontal post adjustment• Direct access to the rail• Excellent electrical insulation of the track• Easy to clean track• Proven Technology

EDF APPLICATION AREASThe Edilon EDF system is applied over a range of rail constructions, such as open track, switches, depots, main-tenance pits, station areas, tunnels and elevated structures. It gives the user the advantages of minimal maintenance requirements, low construction height and excellent elec-trical insulation.

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TUNNELS• Reduced construction height• Smaller tunnel cross section• Minimal maintenance requirements• Stray current insulation• Simple drainage• Easy to clean track• Vibration insulation

BRIDGES• Applicable on steel, concrete and hybrid bridges• Low construction height• Reduced height of the supporting structure and

track structure• Weight reduction• Watertight surface with simple drainage• Reduced bridge vibration• Secondary noise counter measures are simple to

implement on the track and bridge structure SPECIAL TRACK STRUCTURES

• Check Rails• Compensation Joints• Transition zones• Washing plants• Insulated joints• Maintenance Pits• Switches

ELEVATED STRUCTURES• Reduced construction height• Smaller tunnel cross section• Minimal maintenance requirements• Stray current insulation• Simple drainage• Easy to clean track• Vibration insulation

STATIONS• Low construction height• Reduced height of the supporting structure and

track structure• Weight reduction• Water tight surface with simple drainage• Easy to clean track

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EDF-FOR HEAVY RAIL (HR) AND HIGH SPEED RAIL (HSR) The Edilon EDF-HR/HSL meets the various requirements for heavy rail and high speed rail. All system variations of the Edilon EDF are designed according to UIC code 700, or according to UIC load model 71 as specified in the UIC Code 702.

EDF-HR/HSL SYSTEM VARIATIONSDifferent support stiffness is possible with the Edilon EDF system, so optimising the EDF system for the required track characteristics and supporting distances. Hence it is possible to influence the ride comfort and vibration attenuation.

SYSTEM VARIATION SUPPORTING STIFFNESS DEFLECTION (STATIC) EDF-HR/HSL-SS Standard Stiffness 60 kN/mm < 1,0 mmEDF-HR/HSL-MS Medium Stiffness 30 kN/mm 1,0 - 2,0 mm

SYSTEM CHARACTERISTICS• Permanent and accurate track geometry• Maximum operational speed 300km/h• Maximum super elevation: 150mm• Maximum super elevation deficiency 120mm• Vertical and horizontal adjustability according to requirements• Applicable to all standard rail profiles• Rail inclination 0 or 1:20 or 1:40 or as required• Meets the requirements for stray current insulation and electrical insulation (EN 13146-4/ EN 50122-2) • Compatible with the European Train Control systems: e.g. ETCS, ASFA, ATB, LZB, ZUB 121, ZUB 262/

Integra, Indusi/PZB Given values are just indications. All design criteria are dependant on speeds, curve radius, braking and acceleration forces and other operational criteria. For advice please contact Edilon.

EDF-LR FOR TRAM LINES, LIGHT RAIL AND METRO

EDF-LR SYSTEM VARIATIONSIn the Edilon EDF system it is possible to change the sup-porting stiffness and optimise the track to the required track characteristic and supporting distances. Hence optimising the ride comfort and vibration attenuation.

SYSTEM VARIATION SUPPORTING STIFFNESS DEFLECTION (STATIC) EDF-LR-SS Standard Stiffness 60 kN/mm < 1,0 mmEDF-LR-MS Medium Stiffness 15 kN/mm 1,0 - 2,5 mm

SYSTEM CHARACTERISTICS• Permanent and accurate track geometry• Vertical and horizontal adjustability according to requirements• Applicable to all standard rail profiles• Rail inclination 0 or 1:20 or 1:40 or as required• Meets the requirements for stray current insulation and electrical insulation (EN 13146-4/ EN 50122-2)• Compatible with the European Train Control systems: e.g. ETCS, ASFA, ATB, LZB. ZUB 121, ZUB 262/

Integra, Indusi/PZB

The Edilon EDF-LR meets the requirements for tram, light rail and metro. With Edilon EDF it is possible to change the supporting stiffness.

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EDF SYSTEM DESIGN

AXLE LOADS AND SPEEDSEdilon EDF can be applied in a broad range of appli-cations eg Tram, Metro, Light Rail, Heavy Rail and High Speed Rail, with different axle loads and operational speeds.

BASIC CONFIGURATIONS

EDF system EDF Rail anchor Supportstiffness*

Traffic loadaccording toUIC 700**

Speedupto:

LRLight Rail

HRHeavyRailHSLHigh

Speed

LRLight Rail

HRHeavyRail

HSLHigh

Speed

SS

MS

60 kN/mm

15 kN/mm

30 kN/mm

A 160 kN

D4 225 kN

C3 200 kN

A 160 kN

D4 225 kN

D3 200 kN

100k m/h(120k m/h)

200k m/h(220k m/h)

300k m/h(330k m/h)

100k m/h(120k m/h)

200k m/h(220k m/h)

300k m/h(330k m/h)

* Stiffness is also dependant on frequency and condition of supporting surface ** Base plate supporting intervals is 600-650mm*** Curve radius is used as an indication. Smaller curve radii are possible or larger curve radii are required. Values depend

of speed, super elevation, accelerating and braking forces and temperature

EDF MD EDF MD 4 EDF HD EDF HD 2 hole baseplate 4-hole baseplate 2-hole baseplate 4-hole baseplate

Curve radius Curve radius <300m > 100m <300m

X

X

X

X

X

X

X

X

XCant deficiency

>30mm<120mm

XCant deficiency

>30mm<120mm

XCant deficiency

>30mm<120mm

XCant deficiency

>30mm<120mm

XCant deficiency

>30mm<120mm

XCant deficiency

>30mm<120mm

XCant deficiency

>30mm<120mm

XCant deficiency

>30mm<120mm

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EDF INSTALLATIONTOP DOWN INSTALLATIONFor the Top Down installation, the Edilon EDF Baseplate is grouted. To realize & is easily fitted the required quality, the Edilon Dex-G (Fast Curing Epoxy pouring grout) is used to produce a strong base-plate support. When grouting with Edilon Dex-G a space of 5 up to 35 mm is required between the supporting construction and the elastic base plate pad.

SUPPORTING CONSTRUCTIONEdilon EDF is easily fitted onto the supporting con-struction. Depending on the installation method used for the Edilon EDF system the following will have to be considered.

ADJUSTING DRILLING

GLUEING GROUTING

EDF INSTALLATION

BOTTOM UP INSTALLATIONFor Bottom Up Installation, the supporting construction is manufactured according to the required tolerances for height and super elevation and in such manner that during installation of the EDF system the Rail alignment can be realised. There are different proven techniques to achieve accurate concrete support tolerances. These tolerances can be realised by:

• accurate casting moulds• grinding the top of the concrete plinth

ADJUSTING DRILLING

GLUEING GROUTING

ADJUSTING DRILLING

GLUEING GROUTING

BUILDING SURFACEAFTER CASTING

BUILDING SURFACEAFTER CASTING

BUILDING SURFACEAFTER GRINDING

BUILDING SURFACEAFTER GRINDING

When installing the EDF system on the concrete support struc-ture, a drilling depth for the EDF rail anchor has to be allowed for. There either has to be a clear zone, free from steel reinfor-cement bars, or it has to be constructed to be acceptable that reinforcement bars are cut during drilling.

EDF FF (FIT & FORGET) & EDF POLIVALENTEDF FFEdilon can supply the Edilon EDF system in a Fit & Forget ver-sion. The Edilon EDF FF is installed according to a Top Down installation method in which the Edilon EDF FF is pre-assembled and mounted on to the rail. Then the track is aligned in height, position and gauge. After correct alignment of the track, the concrete is cast under and around the EDF system.

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EDF POLIVALENTThe Edilon EDF system can be supplied as a polivalent version. With the Edilon EDF polivalent system it is possible to alter the track gauge. For example from 1668mm to 1435mm. The Edilon EDF polivalent system is supplied such that all provisions for altering the track gauge are already incorporated in the initial installation of the track system.

To achieve this, the Edilon EDF baseplate is mounted on a soleplate. In this soleplate sockets are mounted at the required positions for installing the Edilon EDF rail anchors for the different track width.

ADVANTAGES OF THE EDF FFConcrete track supporting plinth/slab is easy to install Relatively high casting tolerances

ADVANTAGES EDILON EDF POLIVALENTEasy reassembly of the track gaugeA standard Edilon EDF fastening system is usedThe Edilon fastening system is mounted on a soleplate which guarantees the maintaining the Top of Rail and inclinations after altering the track gauge.

EDF INSTALLATIONInstallations dimensions & application limit

EDILON DEX-R 2K®

The Edilon Dex-R 2K is a high performance anchor adhesive for con-structive bonding of anchors in concrete. The Edilon Dex-R 2K is for-mulated to perform under the most critical conditions which can occur in practice and is tested according the European Technical Approval Guideline (ETAG1/001-5).

ADVANTAGES OF THE EDF FFEDILON DEX-R 2K INSTALLATION REQUIREMENTDrill Method Diamond Core or Hammer bit drillConditions Dry/Damp/FloodedApplication Hand or Pneumatic dispensor

INSTALLATION EDILON EDF RAIL ANCHOR EDF Rail anchor HD T HD E HD T HD E MD T MD E MD T MD E

Installation Method Top Down Bottom Up Top Down Bottom UP

Anchor Bold length 260 260 225 225 260 260 225 225

A Drill Depth (mm) 110/135mm 110/135mm 105 105 110/135mm 110/135mm 105 105

B Drill Diameter (mm) Ø 32 mm Ø 32 mm Ø 32 mm Ø 32 mm Ø 26 mm Ø 26 mm Ø26 Ø 26 mm

C Grout layer (mm) 10-35 mm 10-35 mm None appl. None appl. 10-35 10-35 mm None appl.

D Vert.Adjustable (mm) 17 30 17 30 17 30 17 30

E Collar Bush (mm) Ø 35 mm Ø 35 Ø 35 Ø 35 Ø 35 Ø 35 Ø 35 Ø 35

Other dimensions can be used in client specifications!

D

E

CA

B

1/2

5

10

20

35

T(ºC)

1 6 12 18 24(HOUR)

t-notouch t-install t-operate

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PRODUCTIONThe production of all parts in the Edilon EDF systems EDF are carried out under a strict quality regime. All parts leaving Edilon undergo thorough quality control inspection before shipped to the client.

EDILON EDF SYSTEMEdilon supplies the Edilon EDF in different configurations, depending upon requirements such as speed, curve radii, axle loads and required installation method etc.

MAINTENANCE AND REPLACEMENT OF THE EDILON EDFEdilon EDF can be adjusted both horizontally and verti-cally allowing small alignment corrections to be made. Edilon also has an EDF version available in which extra correction options are incorporated. These systems have a horizontal adjustability of 15mm (left or right) and a vertical adjustability up to 30mm (height).

All parts of the Edilon EDF are easy to replace, including the rail anchor by diamond core drilling and re-installing.

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EDILON EDF SYSTEM DEVELOPMENT AND PRODUCTIONAs with all EDILON products the Edilon EDF system must undergo extensive external system testing to satisfy the strict appro-val criteria of their various user organizations. These clients include railway companies (e.g. NS, SBB-CFF-FFS, RENFE), metro operators (e.g. Madrid and Rotterdam), and companies that operate tram and light rail lines (e.g. Bilbao, the Hague, Utrecht and Dublin). For many years the Edilon Research and Development Department has collaborated closely with research insti-tutes, certification agencies and the technical universities in Delft, Munich Budapest, Barcelona and Cambridge

Edilon B.V achieves these objectives by drawing on experience gained in more then 30 years of supplying systems for rail track operations. It employs comprehensive simulation and test facilities such as: climate-testing laboratories, finite element method (FEM) calculations and servo hydraulic testing machines for long-term load testing. In addition to system design from the structural engi-neering and noise abatement aspects, Edilon has concentrated its efforts towards the following areas:

• Lateral stability• Deflection characteristics• Vibration performance• Rail-lift resistance• Temperature stability• Fatigue strength of system and components• Anti-corrosion resistance• Anchor pull out test• Isolation measurements

EDILON, places great emphasis on the continuous development and quality control of all the compo-nents contained in the Edilon EDF system. Our goal is to satisfy the special needs of our customers and to develop individual solutions when required.

EDILON RESILIENT BASEPLATE PADSEdilon Resilient Baseplate Pads are specifically developed for the Edilon EDF rail fastening system. The baseplate pads can by supplied in different sizes and with different stiffness and vibration damping properties (type 3000 and type 4000). The final choice will depend on the client’s required track characteristics.

The development of Edilon Resilient Baseplate Pads started in the late 1960s when Edilon focused on elastically supported slab track systems. Edilon has thus gained long experience and a good reputation in this field

The Edilon Resilient Baseplate Pad forms part of the product range of special elastomers for rail and track applications, such as:

Edilon Resilient Strips for Embedded RailEdilon Slab Track Mats for Floating SlabEdilon Corkelast®

Edilon Dex®

MAIN PROPERTIES OF EDILON RESILIENT BASEPLATE PADSDurable and weather resistantLittle variation in properties over wide temperature range (-20 till +50oC)High energy absorptionLittle creep sensitivity under permanent loadTuneable vertical stiffnessLow static-to-dynamic stiffening ratioLow stiffening for higher frequenciesNegligible water absorptionVery good electrical insulationFire retardantResistant to impact loads and extreme loads

CHARACTERISTICS OF EDILON RESILIENT BASEPLATE PADSType Compression Load range Specific electrical surface Water absorption modulus (typical) (nominal) resistance (IEC 60093) (EN ISO 62) Dry Wet 3000 approx. 2.4 MPa to 0.8 MPa >3000 MΩ >150 MΩ <1.0%4000 approx. 7.5 MPa to 2.0 MPa >3000 MΩ >150 MΩ <1.0%

EDILON RAIL ANCHOR EDF MD/HD E/TThe rail anchors, EDF HD and EDF MD have been speci-ally developed for the application in Edilon EDF rail faste-ning systems and other direct fastening rail systems. Edilon supplies different versions of the Edilon EDF rail anchor for Tram, Metro, Light Rail, Heavy Rail and High Speed Lines. Dependent on the traffic loads Edilon EDF HD or MD rail anchors are used.

The Edilon EDF rail anchors are suitable for Top Down installation and Bottom Up installation. The chosen buil-ding method defines the length of the rail anchor.

Edilon supplies the EDF HD rail anchors and the EDF MD rail anchors in two types of locking nut. Edilon EDF T version uses a self locking nut, Edilon EDF E version is sup-plied with a plastic cap with a integrated nut. Combined with the collar bush, additional plastic rings

can be installed. This allows the Edilon EDF E rail anchor be adjusted vertical when slab settlement occurs. The plas-tic rings are removed and the space under the baseplate can be grouted using Edilon Dex-G.

EDF HD T EDF HD E

ADVANTAGES OF THE EDILON RAIL ANCHOR EDF ERail anchor and spring are protected against dirt, salt and moisture, so increasing the life span of the EDF rail anchor

The EDF plastic cap is not subjected to corrosion and can be easily loosened when required, even after many years of service

The EDF plastic cap gives an excellent reference for installation height of the EDF spring, so reducing instal-lation failure of the spring.

When settlement occurs high loadings on the rail anchor can occur which will result in failure of the rail anchor or concrete. The EDF plastic cap will act as a warning because it will fail well before the rail anchor or the concrete will fail

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0.1-80 -60 -40 -20 0 20 40 60 80 100 120

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Temperature (ºC)

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odulu

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a)

EDILON RESILIENT 3000 BASEPLATE PAD