EDILON LC Level Crosssing system

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edilon)(sedra bv

Nijverheidsweg 23

NL-2031 CN Haarlem

P.O.Box 1000

NL-2003 RZ Haarlem

T +31 / (0)23 531 95 19

F +31 / (0)23 531 07 51

[email protected]

www.edilonsedra.com

EDILON Level Crossing

Systems (LC)

For over 130 years tracks for mainline rail traffi c 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, resulted in the

development of ballastless track or slab track systems.

Since the introduction of slab track systems edilon)(sedra

evolved as a specialist in this fi eld. Based on 40 years of

experience edilon)(sedra developed specially for road–rail

intersections a range of EDILON Level Crossing Systems,

called EDILON LC.

EDILON LC have given assurance and comfort for more

than 30 years, for both rail and road traffi c. The weight and

stiffness of the EDILON LC enables a good distribution

of forces, which guarantees both a durable as well as a

settlement free system. In addition the EDILON Corkelast®

Embedded Rail System (ERS) also provides signifi cant

noise and vibration reduction opportunities, more and

more important these days in densely populated areas.

The EDILON LC range consists of the following types:

• EDILON LC-H, known as the Dutch “Harmelen”

level crossing, installed since 1976

• EDILON LC-1, known as the German “Stelfundo”

level crossing, installed since 1997

• EDILON LC-L installed since 2002

Naturally edilon)(sedra is ISO 9001 certifi ed.

EDILON LC introduction the history

2 3

GENERAL ADVANTAGES• Proven minimal costs-of-ownership

• Durable long life structure

• Proven technology resulting in a range of technical

approvals

• One structural monolithic unit

• Continuous elastic rail support

• Smooth transition between rail and road

• EDILON LC track elasticity matches elasticity of

adjacent track

• Excellent electrical insulation of the track

COST EFFECTIVENESS• Simple and fast installation

• EDILON LC service life more than 30 years

• Reduction of rail wear and rail corrugation

• Maintenance free

• Low lifecycle costs (LCC)

In EDILON LC the use of mechanical fastening systems, such as clips, anchors and

baseplates, for both the crossing as well as the rail are made completely redundant

because of EDILON Corkelast® ERS.

By using EDILON Corkelast® ERS, the rails are connected to the EDILON LC concrete

slab in a fl exible yet extremely durable way.

Continuous elastic rail support means that horizontal and vertical forces are

more evenly distributed. Furthermore, the chance of rail breaks compared to

traditional level crossing systems based on ballast track, is signifi cantly reduced

and rail corrugation is effectively eliminated.

EDILON Corkelast® ERS also offers maximum electrical insulation.

EDILON LC types

All EDILON LC systems meet the various requirements

for heavy rail and high-speed rail. EDILON LC systems

all meet the requirements of UIC load model 71 as speci-

fi ed in UIC code 702. The extremely durable longwearing

surface meets the highest road load class standard of

load class 60. Certain EDILON LC systems are applicable

in heavy loaded level crossings with train axle loads

up to 37 tons and heavy traffi c axle loads up to 90 tons

The top surface of EDILON LC slabs can be prepared in

such a way that high skid resistance values (SRV) can be

obtained. SRV of more than 45 up to 70, are possible with

special concrete mixtures of the top surface.

EDILON LC is applied in all possible kinds of intersections

where road meets rail. There are almost no restrictions.

EDILON LC offers a unique solution, which combines in

an ideal way the track ballast bed, rail fastening and the

paved road into one structural monolithic unit.

By combining EDILON LC concrete slabs, level crossings

from 6 to 50 meters length can be installed in a period

of 8 hours, including the removal of the old crossing as

well!

Quality and installation speed are both very important.

Depending on the condition of the subsoil and the

function of the level crossing in e.g. continuous welded

track a choice can be made between EDILON LC-H and

EDILON LC-L or EDILON LC-1.

Application areas where a road meets rails

EDILON LC-HEDILON LC-H is especially designed for continuous

welded track where the high weight of the slabs is of

major importance to prevent track movement. Because

of the thickness of the EDILON LC-H concrete slabs, the

structural stiffness is high, which allows application in

areas with a subsoil with low foundation coeffi cient, ks =

20 MN/m³, which is equivalent to a subsoil modulus, Ev2

= 35 MN/m².

The installation of EDILON LC-H is done with a “top-down”

approach: the slabs are levelled at the proper Top of Rail

position by using hydraulic jacks and an injection grout

is used to fi x the correct slab position. In this way the

forces of the slab are evenly distributed over the supporting

subsoil. The rail channels are protected and strengthened

by strong steel edge profi les.

EDILON LC-1 and EDILON LC-LEDILON LC-1 and EDILON LC-L are both EDILON LC

systems that offer an optimized slab design which still

meets all rail and road requirements with a slab thickness

of 400 mm.

The installation of EDILON LC-L and EDILON LC-1 is

carried out with a “bottom-up” approach were the slabs

are placed on a smooth and levelled split bed with the

appropriate subsoil foundation stiffness. Application of

these slabs is possible in subsoil areas with a foundation

coeffi cient, ks = 70 MN/m³, which is equivalent to a subsoil

modulus, Ev2 = 120 MN/m².

Protection and strengthening of the rail channels is also

possible. Depending on the channel design all vignole

and grooved rails are accommodated.

All EDILON LC systems include the EDILON Corkelast®

Embedded Rail System (ERS) and offer the following ERS

characteristics:

• Continuous rail support

• Track stiffness tunable following for instance

UIC LM71

• Excellent electrical insulation

• Top-down rail alignment and levelling

Embedded Rail Characteristics

4 5

The fi elds of application of

EDILON LC

• main roads with high density of traffi c

• industrial areas with intensive heavy traffi c

• rural routes

• in city track

• crossing with angles up to 0-180°

• S-shaped roads and horizontal turn movements

edilon)(sedra obtained its Dutch product approval for EDILON LC-H concrete level crossing slabs type “Harmelen” in

September 2007 but the principle of the heavy EDILON LC-H system was developed already in 1974 in close co-operation

with Netherlands Railways NS.

Since 1976, more than 1250 level crossings of this type have been installed.

The EDILON LC-H level crossing is available in two standard slab lengths.

Depending on track curvature and rail type the EDILON LC-H slabs can be tapered or wider channels or curved channels can

be applied.

LC-H6 LC-H9

Standard slab type R ≥ 1000m R ≥ 1500m

Tapered slab with straight channels 225m ≤ R ≤ 1000m 500m ≤ R ≤ 1500m

Tapered slab with curved channels R < 225m R < 500m

EDILON LC-H – type “Harmelen”

6 7

Features• Used in heavily loaded road-rail combinations

• Standard asphalt road approach

• Suitable for roads crossing at angles up to and

even exceeding 45 degrees

• Suitable for curved track sections with super elevation

• Intensive heavy road traffi c will not move nor damage

EDILON LC-H

• Standard level crossing drainage solutions

Slab characteristics• Minimal slab settlement and optimal distribution of

forces


• Ability to connect slabs to form longer crossings

• Road surface is extremely durable (special dressings

and treatments)

• Edges and channels protected with strong steel

profi les

• Rails fastened securely using EDILON Corkelast®

ERS

• Reduced rail corrugation

• Optimized reinforcement design with C45/55 concrete

• Seamless connection to the road surface

• Rapid installation method maximizes the track

availability

• Motorbike, bicycle and wheelchair friendly

Concrete Slab length Slab width Slab height Weight Radius Vmax

slab type [mm] [mm] [mm] [kg] [m] [km/h]

LC-H6 6.000 2.300 580 20.000 1000 200

LC-H9 9.000 2.300 580 30.000 1500 200

• Maximum train speed V 200 km/h

• Rail traffi c load classes - 150, 250 and 270 kN

• Road traffi c load class - Load class 60

• Maximum superelevation/track cant D 75 mm

• Maximum cant defi ciency I 40 mm

• Maximum cant excess E 40 mm

• Rail inclination - 0 or 1:40 or 1:20 or as required

• High skid resistance value SRV 70 (typical)

• Stray current insulation and electrical insulation in compliance with EN 13146-5 / EN 50122-2 requirements

ProRail Netherlands

Infrabel Belgium

SNCF France

MAV Hungary

Ontario Northland Canada

RENFE / ADIF Spain

REFER EP Portugal

EDILON LC-H track curvature slab range

EDILON LC-H system characteristics

Approvals

Prefab Embedded - Harmelen LC

edilon)(sedra obtained its approval for EDILON LC-1 concrete level crossing slabs type

“Stelfundo” from the German Federal Bureau of Railways already in September 2003.

EDILON LC-1 is a logical addition to EDILON LC-H. Developed in the mid 1980’s, these

crossings have also enjoyed worldwide acceptance. Although of lower weight, the reinforcement,

surface treatments and various colours make the slabs also suitable for a wide range of applications.

EDILON LC-1 slabs are installed on a layer of well compacted levelled grit. Crossings of, for instance,

50m length can be installed in track possessions of only eight hours. Again, steel profi les can be

used on the edges of the channels to increase slab durability. It is possible to couple individual slabs

to prevent problems caused by subsoil settlements.

EDILON LC-1 is available in the following slab lengths:

EDILON LC-1 – type “Stelfundo”



2600 2.600 2.400 400 5.990 85 160

3000 3.000 2.400 400 6.450 100 160

4000 4.000 2.400 400 8.600 200 160

4500 4.500 2.400 400 9.675 255 160

5000 5.000 2.400 400 10.750 315 160

5500 5.500 2.400 400 11.825 380 160

6000 6.000 2.400 400 12.900 450 160




• Rail inclination - 0 or 1:40 or 1:20



8 9

EBA Germany

DB Netz AG Germany

ÖBB Austria

SBB Switserland

Approvals

EDILON LC-1 system characteristics

Features• Suitable for all rail and road traffi c

• Used in all types of road crossings

• Suitable for road crossing angles up to 45 degrees

• Ideal for curved and inclined track

Slab Characteristics• Minimal settlement and optimal distribution of forces

• Various slab lengths available (L codes)

• Available for curves (R codes)

• Highly durable surfacing

• Maintenance free; no rutting, reduced rail corrugation

• C45/55 concrete with optimized reinforcement design

• Increased safety for cyclists, motorbike and wheel

chairs riders

• Minimal installation times

• Slabs can be connected to longer crossings

• Re-adjustability after installation possible



LC-L1,5 1.500 2.400 400 3.300 75 80

LC-L3 3.000 2.400 400 6.500 150 80

LC-L4 4.000 2.400 400 8.600 200 160

LC-L5 5.000 2.400 400 10.725 300 160

LC-L6 6.000 2.400 400 12.850 450 160

EDILON LC-L

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edilon)(sedra obtained approvals for EDILON LC-L

concrete level crossing in several countries i.e. Poland

and France. The principle of EDILON LC-L is based on

the proven concept of EDILON LC-H and EDILON LC-1.

The EDILON LC-L slab design gives freedom to apply

virtually all rail profi les and install track with different gauge

widths.

EDILON LC-L slabs are installed on a well compacted

subgrade with a fi ne split bed top layer. Steel profi les can

be used on the edges of the channels to increase the

slab durability.

EDILON LC-L is available in the following range of slab

lengths:

Features• Used in highly loaded road-rail combinations

• Standard asphalt road approach

• Suitable for roads crossing at angles up to 45

degrees

• Standard level crossing drainage solutions

Slab characteristics• Minimal slab settlement and optimal distribution of

forces


• Ability to connect slabs to longer crossings

• Durable road surface, special dressings and

treatments possible

• Edges and channels protected with steel profi les

• Rails fastened securely using EDILON Corkelast® ERS

• Optimized reinforcement design with C45/55 concrete

• Seamless connection to the road surfacing

• Rapid installation method maximizes the track

availability




• Rail inclination - 0 or 1:40 or 1:20 or as required



EDILON LC-L system characteristics

Approvals

SNCF France

RATP France

PKP Poland

Banverket Sweden

DSB Denmark

MAV Hungary

SNCF France

ENR Egypt

APTA Alexandria

MTRC Hong Kong

GVB Amsterdam

Design on rail and channelThe forces arising from rail and road traffi c on the slab are

most critical around the rail.

To understand this, extensive modelling and laboratory

tests are performed to analyze and optimize the system.

Rail profi le and mechanical properties, channel dimen-

sions, materials and building tolerances are all included

in the process of fi nding the most durable EDILON LC

system possible.

Depending on its application and the type of EDILON

LC a range of standardized channel designs have been

developed which gives freedom to apply each possible

rail profi le and will also meet the requirements set by road

and rail authorities.

System featuresThe use of slabs means that provisions for cables for

signalling, water drainage and a protection against loose

train couplings, must be made. Standard solutions are

available and can be included in the system design. In

EDILON Corkelast® ERS, multi functional plastic tubes

are applied.

These tubes offer the opportunity to:

• align the rails in the channels and to adjust the width

of the gauge

• reduce the amount of Corkelast® and so the material

costs

• pull cables for signalling through the tubes

EDILON LC system design and installation method

EDILON Corkelast® ERS

installation materials

• EDILON Corkelast®

• EDILON Primer 21

• EDILON Primer U90WB

• EDILON Resilient ERS Strip

• EDILON Dex®-G

• EDILON Fillerblocks and tubes

• EDILON Nylon spacers

• EDILON Polymer wedges

• EDILON Polymer (inclination) shims

On both ends of the crossing, a steel protection plate

is mounted to protect the concrete and/or the drainage

system from impact forces caused by loose couplings,

hanging from passing trains

Geotextile mats are preferred to be applied adjacent to

EDILON LC to provide a long lasting stable ballasted

track. The concrete slab reinforcement is optimized and

together with the applied concrete the electrical insulation

of the slabs is durably secured.

Rail fastening systemEDILON Corkelast® Embedded Rail Systems (ERS)

offers many advantages because of its continuous rail

support. Track stiffness can be tuned by choosing the

appropriate resilient ERS components. edilon)(sedra is

able to perform stiffness analysis using fi nite element

methods (FEM) and is able to test new system designs in

its own laboratory.

edilon)(sedra offers a range of EDILON LC systems optimized for supporting the forces from both rail as well as road traffi c.

A distinction is made in strength and defl ection behaviour between different EDILON LC slabs. A common characteristic

is that the slabs must be installed on stabilized ground. The ground support stiffness plays an important role in the choice

between the different types of EDILON LC systems.

Track facilitiesEDILON LC systems are compatible with all international

train control systems.

EDILON LC systems have been in service in a wide range

of light rail, high-speed and heavy rail applications over a

period of many years.

EDILON LC installation method

For all EDILON LC systems a well consolidated subgrade

is essential. The excavation profi le depends on the type

of installation. In case of a level crossing replacement

the excavation depth can be kept limited, whereas the

bottom of the excavation should be disturbed as little as

possible.

EDILON LC-H allows for a “top-down” approach were the

slabs are levelled with hydraulic jacks and an injection

grout is used to fi x the correct slab position. Because of

the high structural stiffness of EDILON LC-H, a low ground

support stiffness is permitted.

EDILON LC-1 and EDILON LC-L have a reduced slab

thickness, which requires a reduced excavation depth.

The installation of both EDILON LC-1 and EDILON LC-L

is done with a “bottom-up” approach were the slabs are

placed on a compacted smooth and levelled split bed

with the appropriate ground support stiffness.

In all cases the forces of the EDILON LC slabs are evenly

distributed over the supporting subsoil.

Special attention must be paid to the adjacent ballasted

track, which must be sound and stable.

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EDILON LC mainten ance and recycling

rail wearIt is well known that a well supported rail as well as one

of good quality will have positive infl uences on the life of

the rail. EDILON LC ensures a well supported rail through

various aspects: the support of the slab, the weight of the

slab, the tight tolerances of the slab, the alignment of the

slab and the exceptionally accurate alignment of the rail

on the slab. Connecting the slabs together also ensures

for better slab support over a longer period of time.

Furthermore, a well documented advantage of EDILON

Corkelast® ERS is a reduction of rail wear. With EDILON

Corkelast® ERS rigid points are omitted. This results in

an improved spreading of the forces and signifi cantly

reducion of high dynamic forces in the rails.

Track with EDILON LC is designed to work exactly how our clients want it to work. Should, for any reason, the track no

longer meets these expectations, either maintenance or rail replacement may be necessary. Height corrections of EDILON

LC concrete slabs can be carried out easily by high pressure injecting a special mortar underneath the slabs and lift them in

this way.

Rail replacement of EDILON Corkelast® ERS is only necessary when rail wear or rail fatigue limits are exceeding the regula-

tions, or in the exceptional case that a rail break did occur. EDILON Corkelast® ERS can be removed completely from both

channels and after cleaning the channels new EDILON Corkelast® ERS can be installed. EDILON Corkelast® ERS installation

can be done in very tight track possession periods.

recycling and environmentAll components used in EDILON LC systems are fully

recyclable. Cured embedding and pouring compounds

can be disposed as domestic waste, in accordance with

the European Waste Catalogue.

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logistics and supplyThe logistic process for EDILON LC track follows a detailed and accurate planning.

Each part, from initial discussions, channel design, production, transport, installation and commissioning, are all included in

the planning. All materials supplied are subject to constant quality control.

partnershipedilon)(sedra supplies EDILON LC as a complete track

system, from initial contacts to system delivery, and from

commissioning to removal. We work with our clients on

questions and advice. EDILON LC delivers the benefi ts

of prefab element quality and rapid installation, and

combines our specialists knowledge of track, concrete

and civil engineering.

EDILON LC Level Crosssing system

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