INNOTRANS Berlin, Germany September 24th , 2008 Björn Paulsson, UIC/Banverket

1. Information from the EC-project INNOTRACK INNOTRANS Berlin, Germany September 24th , 2008 Björn Paulsson, UIC/Banverket 1

2. INNOTRACK - innovative Track Systems • Introduction to INNOTRACK • Project Organisation & Management and Methodology • A small selection of result from INNOTRACK • Summary

3. INNOTRACK - innovative Track Systems • A 6th Framework Integrated Project with Financial Support from EU • Project Budget: €18.6 m • Project Grant: from EU €10.0 m • First EU project with comprehensive cooperation between IMs & Industry • Opportunity for a step change in infrastructure products & processes essential to make substantial improvements in costs & performances: Current and Future • INNOTRACK is focusing on mixed traffic

4. INNOTRACK - innovative Track Systems • The INNOTRACK Cooperation • Total Partners: 36 • RU/IM: 9 • Supply Industry: 11 • Contractors: 3 • Academics: 8 • Associations: 5 • From 11 countries

5. Vehicle & track Characteristics General model of failure/degradation SP1 - Duty NR LCC methodology RAMS technology LCC models SP6 - LCC DB Best logistics practices New logistics processes Cost effective methodologies SP5 - Logserv ALSTOM INNOTRACK - project organisation SP0InnoTrack Coordination UIC SP2 Track Support Structure SNCF Track subgrade monitoring & assessment Evaluation and test of superstructure innovations SP3 Switches and Crossings DB Predictive Models for S&C Switch designs Standards & LCC analysis SP4 Rails & Welding VAS/ CORUS Methodology for Duty conditions Supported track Form Rail steel Material Grinding methodology SP7Dissemination and Training UIC

6. PRODUCTS • new rail steel materials • optimised track components (sleepers, resilient elements etc.) • innovative switch designs • improved driving and locking devices (DLDs) • new subgrade treatments • new cost effective track forms PROCESSES • logistics processes (construction, inspection, maintenance) • sensor technologies & signal processing • soil improvement methods • innovative grinding methods • improved welding techniques • preventive and plannedmaintenance • inspection techniques METHODOLOGIES • classification methods for track and vehicle characteristics • defining duty conditions from vehicle track interaction • assessment of technical and economical problems • Europe-wide accepted LCC and RAMS evaluations INNOTRACK - Project Methodology Innovation: the translation of research and development into added value, reduced LCC and improved RAMS INNOVATION

7. INNOTRACK - innovative Track Systems A small selection of result from INNOTRACK

8. SP1 - DutyExamples of deliverables

9. SP2 – Track Support StructureExamples of deliverables

10. SP2 – Track Support StructureExamples of demonstrationInclined deep cement mixing in SwedenStability Problem Axle load upgrading from 22,5t to 25 t

11. SP2 – Track Support StructureInclined deep cement mixing in SwedenTime schedule and costsTotal schedule: Three monthsDeep mixing: Two weeksTraffic interruption: Three weeks

12. SP2 – Track Support StructureExamples of improvements: Inclined deep Lime/Cement walls with deep mixing in Sweden

13. SP2 – Track Support StructureExamples of improvements: Installation of Lime/Cement walls 7-14 July 2008

14. SP2 – Track Support StructureExamples of improvements: Control measurements of pore pressure and ground water level

15. SP2 – Superstructure Optimisation • Objectives: • “Optimisation, Validation & Implementation of innovative solutions for superstructure improvements” • Demonstrate the benefits of a consistently supported track form for rail and track life

16. SP2 – Superstructure Optimisation Innovative Track Forms - BBEST

17. SP2 – Superstructure Optimisation Innovative Track Forms - Corus Steel-Concrete-Steel Slab for Low Maintenance S&C

18. Damages due to severe duty conditions • Axle loads • Speed • Boogies • Power units with slip control • Discontinuous track Wear Surface spalling Severe wear Rail breaks in the spring area RCF, eg head checks Severe head checks Spalling SP3 – Switches and CrossingsThe Cost drivers in S&C´s are: - Damage and wear

19. SP3 – Switches and CrossingsThe Cost drivers in S&C´s are:- Malfunction and Non-availability of Driving & Locking devices Which construction have the best LCC ? - Low investment - High availability - Low Maintenance

20. SP3 – Switches and CrossingsDB test site in Haste (near Hanover): - For INNOTRACK frog demonstrators(mixed traffic vmax = 160 km/h) Frogs with measurement equipment Perspective of track

21. SP3 – Switches and CrossingsExample of result - Switch negotiations

22. SP3 – Switches and CrossingsExample of result - High-frequency loading • Maximum measured lateral contact force in the switch panel • Maximum measured vertical contact force in the switch panel • The high frequency contribution to the vertical contact force in the crossing is significant • A train–track model valid in a wide frequency range is needed

23. SP3 – Switches and CrossingsDemonstrations • Optimized blades • Optimized frogs • Manufacturing of innovative DLD • Innovative monitoring system

24. SP4 is committed to a total of 27 deliverables 19 are knowledge development that support the innovative products, processes, & methodologies 8 are guidelines that need to be considered for LCC and have special treatment SP4 – Rails and Welding Example of result – deliverables and guidelines

25. SP4 – Rails and Welding Example of result – coming guidelines

26. SP4 will deliver “A methodology for establishing minimum action rules for the key selected defects” 10 defect types have been selected – the proposed methodology will demonstrate its usefulness through examples The output is a software based on fracture mechanics, probability of detection, frequency of inspection, and traffic characteristics The primary objective is to provide scientific backing to the current “Minimum Action” rules and to move from “reactive” to “planned” maintenance of defects SP4 – Rails and Welding Example of result – D4.2.6 – Minimum Action Rules

27. SP4 will deliver “A comparative evaluation of grinding strategies & target profiles with suggestions for new optimised approaches to grinding and providing inputs for LCC calculations” SP4 – Rails and Welding Example of result – D4.5.1 to D4.5.3 – Grinding Strategies & Target Profiles

28. SP4 – Rails and Welding Example of result – Insulated joints – impact loads Influence of rail dip and speed Contact load as function of position UIC April 2008

29. SP4 – Rails and Welding Example of result – Insulated joints – degradation

30. SP 5: LogisticsKey question is: Which has the lowest LCC under what circumstances?

31. SP 5: Logistics Identified: Seven Success-Critical Areas

32. Contracting Strategies Rules and Regulations Plant Market Strategies Long Term Funding and Strategic Planning Work programming Project Management and Logistics SP 5: Logistics Crossing success-critical areas with track components related WP WP5.3 Logistics & Support WP5.4 Logistics & S&C WP5.5 Logistics & Rails&Welding

33. SP 5: LogisticsA – Market Strategies • IMs are responsible for make/buy decisions • Strategic step in structuring markets • No point in IMs and contractors competing for position; we propose a relationship where tasks are done by those who add most value • Needs a true understanding of long-term costs and openness of dialogue

34. SP 5: LogisticsE - Contracting Strategies • The most efficient contracts for IMs and their contractors will tend to: • Be longer term • Be output oriented • Be incentivised to drive efficiency • Share risk and reward allocation equitably • Share the benefits of innovation equitably • Be based on open and honest communications • Be based on fair tender procedures that include sensible timescales and documentation of adequate quality • Depending to some extent on individual markets

35. Based on WP5.1 conclusions on best practices, recommendations will be issued to be tested, for validation purposes and possible adjustments Validation procedure to be developed will list the validation criteria with participating IM’s (DB, NR) In accordance with the work environment and safety rules in force in Germany and UK SP 5: LogisticsSP5 / WP 5.2 – Design of Validation Procedures UIC April 2008

36. SP 5: LogisticsBasis of WP5.3, 5.4, 5.5 • Development of WP5.3 to WP5.5 is based on : • Output of WP5.1 • Output of SP2, SP3, SP4

37. SP6 – LCC and RAMS Example of result – Workflow and data structure Workflow – schematic diagram Top down vs. bottom up ? Technical issues Real routes Global data European Cost driving segments Segmentation SP 2 SP 3 SP 4 Detailed data Data base & Analyses “Technical” data SP 6 • The data base depends on • Technical issues and • Available data Root causes LCC

38. SP6 – LCC and RAMS Example of result – Situation today • State of the art reports concerning LCC is ready • A workshop/training has been held with a tailored software • Reports concerning RAMS technology and potentials for railways is today ready

39. INNOTRACK - innovative Track SystemsSummary • The projected has now been running for twenty-four months and more than 70 deliverables have been produced • The matrix organisation is positive but more complex than expected • Good partnership established between participating organisations • Challenging cooperation between participants • Data availability is one of the key challenges and has been more difficult than expected

40. Summary INNOTRACK - innovative Track Systems • European railway knowledge is impressive when you have passed the language and country barriers • The Official Deliverables are now on the website www.innotrack.eu/results

41. Thank you for your Attention! INNOTRACK - innovative Track Systems