Elasticity in Slab Trackwith Baseplate Pads

1 Optimisation ofSlab Track

High-speed rail fastening system
during assembly

Baseplate pad in urban
railway network

Less maintenance.
Less noise.
Getzner baseplate pads provide theelasticity that a slab track superstructure requires. The advantages
include lower life cycle costs fornetwork operators and less noisein the surroundings of railway lines.

Slab track with bridgetransition zone in theDB network

lab track is used all over the world
for railways, tramway lines andsubway systems. The lack of elasticity,which in the case of ballasted track isprovided by the ballast itself, meansthat the superstructure components
are subjected to high levels of loading.
In addition, the noise levels caused byS

passing trains are considerably higher
than with a ballasted track. Vibrations
and structure-borne noise are transmitted into neighbouring buildings,
adversely affecting living and working
conditions.

Getzner Sylodyn® baseplate pads add elasticity to the slab track.

3

Baseplate pad ZWP 104/150 NT 22.5

Lower dynamic forces
Fastening systems elasticallysupported with Sylodyn® baseplatepads significantly increase theelasticity of the slab track superstructure. The rails are decoupledfrom the subsoil and the highdynamic forces exerted on therail, fastening system and slab
are greatly reduced.
Everyone benefits from thehigher levels of elasticity
For network operators, there isless damage to the superstructurecomponents. Installing baseplatepads significantly reduces the life
cycle costs of a line and extends its
service life. Surveys demonstrate that
railway lines generate less structure-borne noise, resulting in better
protection for residents and vibration-sensitive buildings and systems.
Passenger comfort increases as well,as the amount of vibration in the railvehicle is also minimised.

Slab track with elastically supported
fastening systems for high-speed
network
4Sylodyn® HS (High Strength) baseplate padfor maximum loading

Baseplate pad for special applications

Advantages— Defined elasticity in theslab track— Lower dynamic forces— Improved load distribution— Less maintenance required— Reduced life cycle costs— Less emission ofstructure-borne noise— Protects vibration-sensitivebuildings— Less vibration in rail vehicles

Baseplate padfrom Getzner

5

2 System Solutions
for all Applications

Elastically supported fastening system
in high-speed turnout, South Korea

Perfectly tailored.
Extremely durable.
Getzner produces customised
solutions. What type of baseplate
pad to use is determined by thecharacteristics and requirementsof the line in question.
hether for urban railway
networks or high-speed lines,
Getzner baseplate pads provide higher
levels of elasticity for every type ofapplication. What type of baseplate
pad to use depends on a number offactors: on the one hand, the material specification is dictated by thedynamic requirements, while on theother the stiffness and geometry of the
baseplate pad are determined by theproperties of the fastening system.

WSpecial solutions
Maintenance-intensive parts of therailway network, such as turnouts,
bridges and transition zones, requirea great deal of attention, as they playa major role in determining theprofitability of a line. As the loadingof superstructure components inthese areas is well above average, theamount of maintenance they requireis much higher than in “normal”
track sections.

baseplate pad is determined usingsophisticated forecasting models.
The result: asymmetrical loading
and stiffness fluctuations are reduced
and less maintenance is required.
Quick installation
Baseplate pads can be installed
quickly and easily directly under thebaseplate. The instructions provided
by the manufacturer of the respective
fastening system must be considered(e.g. preload forces).

Getzner provides special solutions forthese critical areas. The most suitable

Design of baseplate paddetermined by:— Dynamic requirements— Stiffness specification— Permitted deflection— Baseplate geometry— Design of fastening system

Customised solutions to satisfy the most stringent requirements

6Baseplate pads on a bridge transition zone
in the DB network

Elastically supported urban railway
turnout

Sylodyn® — the high-tech material

Properties

Advantages

Sylodyn® is a polyurethane material
and has been used with great successfor baseplate pads all over the world
for more than 20 years. The advanced
Sylodyn® HS (High Strength) version isdesigned specifically for applications
where extreme loads are encountered— for example heavy haul.

— High mechanical load capacity— Excellent dynamic to static
stiffness ratio— Defined level of elasticity— Homogeneous material(volume-compressible)— Outstanding long-term
behaviour— Stiffnesses and geometries
for every application— Improved track bed stability— Protects track superstructure(optimal load distribution)— Effective vibration protection— Constant performance underhigh loads and environmental
impacts— Reduced life cycle costs (lessmaintenance required)— Permits flexible fastening
system design

Installation of baseplate pads in the NYC Transit subway system – in use for 20 years

73 Advanced
Manufacturing
Technologies
Punching

Individual solutions.
Unlimited opportunities.
Tailoring
The wide range of manufacturingmethods used for the productionof baseplate pads offers immense
versatility.
etzner develops tailor-madesolutions for every customer.
The choices available in the production of baseplate pads are equallywide-ranging — be they special
formulations, geometries or material
combinations. Semi-finished goods
are cast continuously or in moulds.
They are then tailored and labelled.

G— Punching— Water jet cutting— Skiving— Milling— BondingLabelling— Inkjet— Screen print— Laser— In the mould
Water jet cutting123

1 + 2 Cast moulding 3 Milling8

4 Tested andApproved

Extensive system tests

Impressing quality.
Before they leave the factory, Getzner
baseplate pads are tested, in-houseand externally, in accordance with therelevant standards and deliveryconditions. Beyond that Getzner
possesses national approvals forcertain types.
aseplate pads are subject to acontinuous strict quality testing,even during the production process.
This involves thoroughly testing themfor their suitability in rail fastening
systems not just on the in-house test
rig, also in many cases by independentB

external bodies as well, such as theTechnical University of Munich (Chairand Institute of Road, Railway andAirfield Construction).
Standards & supply agreements
Getzner baseplate pads are normallytested according to the relevant national or European standards (e.g. EN 13146& EN 13481) or supply agreements(e.g. DBS 918 235). Alternative testing
parameters can, if requested by thecustomer, be included in the productspecification.

Approvals
Many Getzner baseplate pads —such as the ZWP 104 NT — havebeen approved by the German Federal
Railway Authority and Deutsche Bahn,
as well as from various other nationalbodies.

Getzner as a solutions
provider— System testing on thein-house large-scale test rig— Forecast calculations basedon finite element method— Customised solutions— Compatible with a wide
range of fastening systems— Versatile application options— On-site support

Baseplate pads are subject to intensive testing on the in-house test rig

95 References

Slab track construction in China

Proven solutions
around the world.
Getzner baseplate pads have beenin use all over the world for decades
and are well established.

ShanghaiWuhan

High-Speed LineWuhan-Guangzhou, China
The 1,000 km Wuhan-Guangzhou
section is part of China’s high-speed
network. The slab track, which isdesigned to handle speeds of up to350 km/h, came into service in 2009.
The Sylodyn® ZWP 104 NT 22.5
baseplate pads, which have now beenin use for more than 6 years, wererecently subject to a series of random
tests. The results speak for themselves:the baseplate pads have not suffered
any damage and the stiffness figures
remain within the tolerance range
associated with brand new products.
The dynamic to static ratio of 1.13 isoutstanding.
Getzner has to date supplied morethan 30 million baseplate pads for theChinese high-speed network.

10

revealed that the pads are retaining
their full functionality. Their thickness
remains within the tolerances laid
down in 1996 and the dynamic to static
stiffness ratio of 1.5 is very good.
The test results give us confidence thatthe baseplate pads will retain theireffectiveness for decades to come.

Guangzhou
Hong Kong

Jubilee Line Extension, LondonUnderground, Great Britain
Getzner baseplate pads were installed
during the extension of the London
Underground Jubilee Line in 1996. The
aim was to protect the buildings in thesurroundings from noise and vibration.
Having lain in track for 20 years,
London Underground decided to remove some baseplate pads in different
sections to check their material properties. A series of extensive tests

Wuhan-Guangzhou (CN)— High-speed line with speeds
up to 350 km/h
— Installed 2009
— In use for 6 years: values
the same as brand new
baseplate pads
— More than 30 million
baseplate pads in use inChina (approx. 4,500 km
double-track)
Jubilee Line (GB)— Urban railway— Installed 1996
— 565 million metric tons
by 2016— More than 200 million
passengers a year
— After 20 years' service:
dynamic to static ratio 1.5

ZWP 104 baseplate pad in China
after 6 years

Removing of baseplate pads atLondon Underground network

References (extract)— DB, Hanover – Berlin (DE)— DB, VDE 8 (DE)— DB, bridge transitions (DE)— NS, HSL South (NL)
— CR, Beijing – Shanghai (CN)— CR, Wuhan – Guangzhou –Shenzhen (CN)— CR, Shanghai – Kunming (CN)— CR, Lanzhou – Urumchi (CN)— CR, Zhengzhou – Xi’an (CN)— KRNA, Honam HSR (KR)— KRNA, Donhae Nabu Line (KR)— KRNA, Suseo – Pyeongtaek (KR)— VALE, Carajas Line (BR)— Wiener Linien, Vienna (AT)— Tramway line, Geneva (CH)
— Rapid transit, Berlin (DE)— Tramway line, Munich (DE)— Tramway line, Augsburg (DE)
— Underground, Nuremberg (DE)
— Underground, Frankfurt (DE)— Metro Budapest (HU)
— Metro Prague (CZ)— Metro Milan (IT)— Tramway line, Strasbourg (FR)— Tramway line, Rouen (FR)— Tramway line, Nantes (FR)— London Underground (GB)— New York City Subway (US)— TTC Toronto (CA)— Metro São Paulo (BR)— Metro Santo Domingo (DO)— Metro Chennai (IN)
— Metro Delhi (IN)
— Metro Hyderabad (IN)
— Metro Bangalore (IN)
— Metro Kochi (IN)
— SMRT Singapore (SG)— Hong Kong Airport Express Link (CN)— Metro Seoul (KR)— Gimpo Urban Rail (KR)For more references, visit:https://www.getzner.com/en/
references11

Getzner Werkstoffe GmbHAm Borsigturm 1113507 Berlin
Germany
T +49-30-405034-00
F +49-30-405034-35
info.berlin@getzner.com
Getzner Werkstoffe GmbH
Grünwalder Weg 3282041 Oberhaching
Germany
T +49-89-693500-0
F +49-89-693500-11
info.munich@getzner.com
Getzner Spring Solutions GmbH
Gottlob-Grotz-Str. 1
74321 Bietigheim-Bissingen
Germany
T +49-7142-91753-0
F +49-7142-91753-50
info.stuttgart@getzner.com
Getzner France S.A.S.
Bâtiment Quadrille
19 Rue Jacqueline Auriol
69008 Lyon
FranceT +33-4 72 62 00 16
info.lyon@getzner.com
Getzner France S.A.S.
19 Rue Hans List
78290 Croissy-sur-Seine
FranceT +33 1 88 60 77 60

Getzner Vibration Solutions Pty Ltd
Unit 1 Number 2-22
Kirkham Road West,Keysborough Victoria 3173
Australia
Getzner India Pvt. Ltd.
1st Floor, Kaivalya
24 Tejas Society, Kothrud
Pune 411038, India
T +91-20-25385195
F +91-20-25385199
info.pune@getzner.com
Nihon Getzner K.K.
6-8 Nihonbashi Odenma-cho
Chuo-ku, Tokyo
103-0011, Japan
T +81-3-6842-7072
F +81-3-6842-7062
info.tokyo@getzner.com
Getzner Materials (Beijing) Co., Ltd.
No. 905, Tower D, the Vantone Center
No. Jia 6, Chaowai Street, Chaoyang District
10020, Beijing, the P.R.C.
T +86-10-5907-1618
F +86-10-5907-1628
info.beijing@getzner.com
Getzner USA, Inc.
8720 Red Oak Boulevard, Suite 460
Charlotte, NC 28217, USA
T +1-704-966-2132
info.charlotte@getzner.com

www.getzner.com

B ZWP en © Copyright by Getzner Werkstoffe GmbH | 10-2016

Getzner Werkstoffe GmbH
Herrenau 56706 Bürs
Austria
T +43-5552-201-0
F +43-5552-201-1899
info.buers@getzner.com