IRITS

18th February 2016

NBT Presentation

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 2

Agenda

1. Introduction / HSL Tracks context

2. NBT system presentation

3. Mock-up lab test

4. Construction process

5. Monitoring

6. Test section in Russia

7. Maintenance

8. A thorough qualification process

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 3

1. Introduction / HSL Tracks context

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 4

HSL Context

Concrete tracksBallasted tracks

Construction pace (>1000 meters per day)

Easy alignment modifications

Low CAPEX

Structure life-span below 25 years

High maintenance:

Track geometry corrections (tamping)

Damages caused by flying ballast

Low availability

Low maintenance

Long life duration

High availability

Low construction rate (lower than 200 meters

per day)

High CAPEX

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 5

HSL Context – Customer needs

IMPROVEMENTS ON CONSTRUCTION PHASE

• Higher construction rate

• Smaller footprint

• More flexible schedule

IMPROVEMENTS ON OPEX

• Long life

• Less maintenance

• Less need for renewals

• High availability

• Mixed traffic

• Compatiblity with extreme climatic conditions

Increasing worldwide demand for ballastless tracks (esp. in China)

French consortium to develop a competitive slab-track solution: NBT

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 6

2. NBT system presentation

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 7

Requirements for NBT

Design

• Life-span of the structure: 100 years

• Mixed traffic:

High-speed (up to 360km/h)

Freight (25T/axle)

• Compatibility with any track alignment and S&Cs

• Reduced ground footprint

High construction rate

• Automatised track laying: from 500 m/day/front

Reduced maintenance

• Maintenance of track components is similar to ballasted track

• No corrective maintenance of the structure

• Easy repairs in case of localised structural damages in the structure

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 8

NBT Design – Main components

Structure design based on road experience

2 slipping concrete slabs

Slab track:

• C35/45 reinforced concrete (2.5 m x 0.24 m)• Direct insertion of fastening system with

spacing of 0.6 m

Foundation layer:

• C25/30 concrete (2.8 m x 0.3 m)• Non erodible

Localized transversal joints• 4.8 m • Staggered between slabs• Avoid cracks near fastening system

Consolidated earthwork structure • 120 MPa“Shear key” to ensure

stability in curves

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 9

3. Mock-up lab test

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 10

Real scale mock-up test in lab

1-scale mock-up, 10m long

Both slabs fully instrumented (strain gauges, thermocouples, displacement sensors)

Elastomer mast to simulate the sub-base (~100MPa)

8 cylinder jacks (100 kN each, 5 Hz) to apply static and cyclic loads

Objective: to validate the calculation model and the track’s behavior

2.7 m

2.7 m 4.2 m 2.7 m

Jacks Group V5-

V8

(Upper sight)

2.1

m

0.3

mP=200 KN

Foundation

slab

Slab track

Rail

(Cross

section)

Jacks Group V1-

V4

Elastomer mast: Sylomer (5cm)

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 11

Mock-up loading

10 million cycles of loading were applied during 3 months

Mechanical loading only Mechanical loading combined with thermal cycling

100kN

150kN

175kN

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 12

4. Construction process

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 13

Test section in France – Video

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 14

Construction process

Consolidation of the ground sub-base

to reach a 120MPa bearing capacity

Underground drainage

Foundation slab (unreinforced

concrete) casting with the slipform

machine

Rebars installation

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 15

Construction process

Slab track construction with APPITRACK process:

• Slab casting with slipform machine

• Automatic rail fasteners insertion

Rail installation, then automated final adjustment

High performance construction process from 500m/day

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 16

Construction process

Single turnout installation

• Vossloh-Cogifer TG0.085

• Manual installation: “top-down”

• Locked in direct track position

Compatibility to any track

configuration

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 17

Transition zone with ballast

Characteristics:

• 25m long

• Ballast is contained between walls

• Ballast lies on concrete

• Rigidity rails 30m long

• Under-sleeper pads

• Progressive evolution of the rail

pads stiffness

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 18

5. Monitoring

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 19

Monitoring and results

Operated since Dec. 2013

• Passenger traffic (14T/axle)

• Maximum 110km/h

One-year monitoring

• 150 sensors and optic fiber

• Internal: Accelerations, stresses, thermal

gradients, displacements

• External: Wheel/rail contact force (kN),

weather conditions

Train detection

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 20

Monitoring and results

Deformation

• Good correlation between measures

and calculation

Structure’s behaviour as predicted

• Slabs are independent (no connection)

• No damage observed

Slipping interface is confirmed

Thermal gradients

• Measures: -0,3 à 0,7°C/cm

• Hypothesis: -0,6 à 0,8°C/cm

• Coherent with slabs deformations:

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 21

6. Test section in Russia

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 22

Scherbinka test section (Moscow)

125m test section into VNIIZHT

test ring

Opening on 15th November

2014

2 years testing with heavy load

(600MlnT)

4 solutions tested :

• NBT (Alstom);

• Bögl (prefab);

• LVT (single blocks);

• Tines (Edilon embedded block

system)

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 23

Scherbinka test section (Moscow)

VNIIZHT Certification reports after 100MT, 200MT and 300MT

circulated

No structural damage observed

Test section construction process and service proven

(300MlnT circulated)

23

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 24

7. Maintenance

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 25

Maintenance

Usual track maintenance

• Cracks and joints repairs are possible without impact on traffic

• Maintenance of components (rail and fasteners) is similar to ballast

Structural maintenance• In case of heavy structural

damages, slab replacement is possible: Easy removal of slabs (joints, no

continuous reinforcement) Replacement by precast slabs

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 26

Maintenance

Direct insertion

One level of resilience under

the rail

Friction grip anchorage

Vertical adjustment

• up to 30 mm

• with shims

Lateral adjustment

• Typically +/- 10 to 20 mm

• No additional component needed

High range adjustable direct fastening system

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 27

NBT Competitiveness

CAPEX results

Construction costs:

NBT : + 30% compared to ballasted track

NBT : - 10% compared to Rheda 2000 solution

Possible advantages:

Increased gains on CW thanks to a reduced footprint and track weight

Reduced bridges and tunnels thanks to greater admissible cant

OPEX results:

Maintenance scope restricted to rail and fasteners

Overall cost for NBT < overall cost for ballasted track after around 15 years

of operation

Increase revenue thanks to higher availability of the track

LCC analysis based on a typical HSL project in France

© ALSTOM 2015. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NBT Presentation – IRITS – 25/02/2016 – P 28

8. A thorough qualification process

Achievements:

VNIIZHT Certification (Russia) reports after 100MT

and 200MT circulated on Shcherbinka test section

HSL TSI requirements compliance by CERTIFER

Preliminary certification from SNCF UIC3 @ V160

In progress:

EMC interface, dynamic study

Design improvement of the rail fastening system with

Railtech

German bodies recognition (TÜV, EBA, DB)

Permanent certification from SNCF UIC3 @ V160

www.alstom.com