SEKISUI Chemical Co., Ltd.
70 years leading manufacturer of synthetic products Worldwide more than 200 subsidiaries Approx. 23.000 employees
Annual Turnover SEKISUI Chemical Co. Ltd.
[billions €]
2014 2015 2016
9.100 9.080 8.850
Pultrusion process
Fibre reinforced Foamed Urethane
Since 1980 | 1.400 km track
1 2
Glass fiber supply Impregnation, Spray Molding Cooling Pulling Cutting Finishing & Inspection
Continuous glass-fibre and Polyurethane FFU sleepers are manufactured by Pultrusion. Glass fibers are soaked in polyurethane and the linkage is then hardened at a raised temperature
glass fiber before adding polyol
molding pulling
Long glass fiber
Foamed Urethane
ISO 9001 Management System Certificate ISO 14001 Environmental Management certificate
Possible dimensions: • Up to 10 m length, • Up to 600 mm width, • height according request.
Milling and Drilling
Fabrication of FFU sleeper
Since 1980 | 1.400 km track
Bonding of basic sleeper
FFU will be milled to adjust height very precisely (mm). Holes will be drilled according to the drawings from the customer.
basic sleepers after pultrusion
Switches | Bridges | Specials
Bridges Steel and Ballast
Switches
Slim tie
Since 1980 | 1.400 km track
1980 Railway Technical Research Institute (RTRI) adopted FFU after laboratorial approval in Japan and started the following field tests:
Miomotegawa Bridge of Uetsu Line Kanmon Tunnel of Sanyo Line
1985 very good results of field tests
FFU sleeper became a approved standard product of JNR 1991 RTRI reported the results of 10 years field tests, which showed almost no deterioration.
Application of FFU by private and municipal railways. 1996 RTRI reported the results of 15 years field tests, which indicated that the strength
deterioration of 15 year old wooden sleepers will be equal to the strength deterioration of 50 year old FFU sleepers.
2007 Japanese Industrial Standard JIS 1203 2011 RTRI tested FFU sleeper installed in 1980 positive – announced further use for the next 20
years positive to JR
Historical development - 35 years in service
Since 1980 | 1.400 km track
Historical development Europe since 2004
2004 Austria: First FFU Railway project in Europe, Metro bridge in Vienna
2008 Germany: 16 cm FFU sleeper positive tested by TU Munich First switch on FFU in Germany – Chempark Leverkusen
Austria: LCC Analysis TU Graz - FFU is more economical than wood at bridges
2009 Germany: Approval of FFU by EBA for German Railway Infrastructure
2011 Germany: Deutsche Bahn – first Bridge with FFU sleepers and low height sleepers
2012 Germany: Deutsche Bahn – two switches 70,000 t/day & sleepers & bridges Netherland: Pro Rail installed 3 bridges
2013 Austria: Wiener Linien installed 78 switches with FFU Germany: 12 cm slim tie positive tested by TU Munich - 22,5 t axel load | 200 km/h
2014 Switzerland:BAV approval for FFU sleepers starting by 12 cm height RHB - bridges plus slim ties 12 cm | BLS - switches
UK: Network Rail longitudinal (40/40/750cm) and regular bridge sleepers World: ISO Standard 12856-1 for synthetic sleepers enters into force
2015 Belgium: Infrabel: first bridge project France: Tisseo Toulouse: two switches in slab track Switzerland: SBB first switch project UK: Network Rail longitudinal sleepers in a curve
2016 France: Keolis – 2 switches in slab track RATP uses FFU 100 for switches at slab track Norway: Jernbaneverket – first bridge project UK: LU first bridge project Germany: TU Munich tested FFU 100 positive and lateral resistance test positive
2017 Germany: April 2017 - final approval from EBA UK: November 2017 final certification for all bridge types Sweden: SL: Stockholm center bridge with 5 tracks Ireland: Irish Rail: bridge in Limerick
Since 1980 | 1.400 km track
Worldwide approximately 90.000 FFU Synthetic Sleepers are installed annually Accumulated installation amount until 2015 has become more than
2,2 million sleepers 1.400 km of track
FFU sleepers installed since 1980
Since 1980 | 1.400 km track
0
500
1,000
1,500
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0
20
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60
80
100
120
88
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91
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95
96
97
98
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00
01
02
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[1000pcs.]
Thou
sand
sleepe
rs230
/140
/220
0mm
Technical properties
property unitbeech FFUsynthe1cwood
standardnew new 10years 15years 30years
density [kg/m3] 750 740 740 740 740 JISZ2101
flexuralstrength [kN/cm2] 8 14,2 12,5 13,1 11,7 JISZ2101
elasHcmodulus [kN/cm2] 710 810 800 816 816 JISZ2101
Compressivestrength [kN/cm2] 4,0 5,8 6,6 6,3 6,0 JISZ2101
Shearstrength [kN/cm2] 1,2 1,0 0,95 0,96 0,93 JISZ2101
hardness [kN/cm2] 1,7 2,8 2,5 2,7 2,4 JISZ2101
Impactflexuralstrength+20°C [J/cm2] 20 41 - - - JISZ2101
-20°C [J/cm2] 8 41 - - - JISZ2101
WaterabsorpHon [mg/cm2] 137 3,3 - - - JISZ2101
InsulaHonresistancedry [Ω] 6,6x107 1,6x1013 2,1x1012 3,6x1012 8,2x1011 JISK6852
wet [Ω] 5,9x104 1,4x108 5,9x1010 1,9x109 - JISK6852
Pull-outforcedognail [kN] 25 28 28 23 22 RTRI
Pull-outforcescrew [kN] 43 65 - - - RTRI
Since 1980 | 1.400 km track
EBA (German Railway Authority), research of: • The impact of vertical and horizontal loads during the effect of repeated
loading. Bedding in ballast track DIN-EN 13481-3 • Tightening torque tests: determine tensile strength of sleeper screws
depending on torque moment. • Sleeper screw extraction tests DIN EN 13481-2. (concrete sleeper) • Impact tests to simulate derailment • Electrical resistance in accordance with DIN EN 13146-5 • Static/dynamic tests according DIN EN 13230-2.(concrete sleeper)
TU Munich September 2008 Since 1980 | 1.400 km track
Up to a load of 240 kN, corresponding to a tensile bending strength of 74 N/mm² on the bottom of the sleeper, no crack was detected within the bending area where flexural tension was applied.
Static Tests at Sleeper Centre
Static Pressure Test Up to a load of 150 kN no plastic deformation was detected Thus, a load of 300 kN (supporting force) below the rib plate shows a plastic deformation of a maximum of 0.8 mm. Generally the support force for an axle load of 250 kN is 150 kN under the most severe conditions.
Static Bending at T = RT and T = -10°C FFU sleepers were stored in a climate-controlled environment at T=-20°C for two days. The average testing temperature is T = -10°C . The sleeper shows no signs of embrittlement at low temperatures. A comparison of deformation results does not show any significant differences. Test of temperature dependency of sleeper deformation behavior showed no significant bending differences at T=RT and T=10°C. At T= -10°C there is no noticeable brittleness due to temperature variation. Deformation is predominately purely elastic.
TU Munich September 2008 Since 1980 | 1.400 km track
Coefficient of thermal extension For FFU 74 sleepers is 0,79 x 10-5/°K = 0,0000079 m/°K Delta T = 50 °C leads to 1 mm extension for a 2,600 mm long sleeper
Lateral resistance of FFU synthetic sleepers comparing with wood 45 sleepers from each type have been installed in ballasted track. 15 sleeper of each type have been tested. The unconsolidated test happened after the installation Consolidated test happened after 1 year and around 23 million load tonnes were running over it
Lateral resistance test October 2016 Since 1980 | 1.400 km track
Approvals in Europe 2017 Europe: 2017 - EC Certificate Germany: 2017 - final Approval for FFU starting by 10 cm height
and for a speed up to 230 km/h Switzerland: 2018 – final approval starting by 12 cm height sleeper Netherland: 2015 – certification for railway use United Kingd: 2017 – certification for all bridge applications
Approvals in Europe 2017 Since 1980 | 1.400 km track
Details of final EBA approval for Germany
Easy repair For example: Fastening position may be readjusted by filling nail holes
Optimize your solutions with FFU
Since 1980 | 1.400 km track
FFU Joint sleeper for Switches On site is it realizing high tolerances with all FFU materials Advantages: No short circuit Shorter working time ( approx.1.5 hours/pcs/5persons for connection) Possible to attach base plates almost everywhere Bending strength at the connecting part of the FFU joint sleeper is lower than that of regular sleeper - as you can see on the diagram. But it has sufficiently high bending strength, wider elastic area and the same young’s modulus as regular sleeper, therefore, it can be used in track safely
Joint sleeper - Switches Since 1980 | 1.400 km track
Projects in Japan since 1980 Bridges – open steel constructions – concrete
Since 1980 | 1.400 km track
Projects in the United Kingdom since 2014 Longitudinal baulks, cross sleepers and run on and off
Since 1980 | 1.400 km track
Projects in the United Kingdom since 2014
Longitudinal baulks – frame | London Underground
Since 1980 | 1.400 km track
Recycling 100% & Sustainability K-FFU, R-FFU
Recycling
Since 1980 | 1.400 km track
SEKISUICHEMICALCO.,LTD.hasbeenselectedforthefourthyearinarow(starHng2012)bythe"WorldIndex"ofthe"DowJonesSustainabilityIndices(DJSI)"
Experienced Advantages
Customized sleepers mm exactly optimizing of design & profile
Form retentive always good bearing on construction
Easy & fast installation minimizes: installation costs / track closing time
Easy care/repair minimizes: installation time/sleeper amount
Chemical/oil resistance application in special areas
Ecological 100% recyclable
Maintenance very little; minimizes maintenance costs/time
High availability of track maximizing possible trains on the track
Workability/weight like wood, 740 kg/m3
Long life time reduces total cost of track and saves money for further project investments
LCC Analysis bridges, TU Graz, Prof. Veit and Dr. Maschnig, 2008 in order of ÖBB, life time of bridge longer than 15 years FFU more economical than wooden sleepers
switches, SBB, Dölf Egloff, 8.11.2013, 7 – 10% more economical than wood (50 years) up to 15% more economical than concrete sleepers if the substructure has to be improved
Since 1980 | 1.400 km track
SEKISUI CHEMICAL GMBH Königsallee106 40215 Düsseldorf Germany
TEL: +49-(0)211-36977-0 FAX: +49-(0)211-36977-31 E-Mail: [email protected] www.sekisui-rail.com
Since 1980 | 1.400 km track