WO2004033795A1 - Cladding of rails - Google Patents

Cladding of rails Download PDF

Info

Publication number
WO2004033795A1
WO2004033795A1 PCT/GB2003/004345 GB0304345W WO2004033795A1 WO 2004033795 A1 WO2004033795 A1 WO 2004033795A1 GB 0304345 W GB0304345 W GB 0304345W WO 2004033795 A1 WO2004033795 A1 WO 2004033795A1
Authority
WO
WIPO (PCT)
Prior art keywords
rail
sheath
adhesive
boot
sections
Prior art date
Application number
PCT/GB2003/004345
Other languages
French (fr)
Inventor
Robert Paul Vennell
Original Assignee
Hyperlast Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hyperlast Limited filed Critical Hyperlast Limited
Priority to AU2003271910A priority Critical patent/AU2003271910A1/en
Publication of WO2004033795A1 publication Critical patent/WO2004033795A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B19/00—Protection of permanent way against development of dust or against the effect of wind, sun, frost, or corrosion; Means to reduce development of noise
    • E01B19/003—Means for reducing the development or propagation of noise
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B21/00—Track superstructure adapted for tramways in paved streets
    • E01B21/02—Special supporting means; Draining of rails

Definitions

  • This invention relates to cladding of rails, with a view to reducing noise and vibration and improving electrical isolations. It is well known to mount rails for tramways or mainline railways in a sheath of rubber or polyurethane or other similar materials. Such sheaths include cladding applied to the exterior of the rail and mouldings which are cast on the rail and are usually effective to some degree for noise attenuation and electrical isolation. For many mainline railways, electrical isolation for use as a return conductor for electrical propulsion systems is not required.
  • One method of providing an insulating sheath about a rail is to invert the rail on a mould base, arrange shaped mould side plates spaced from the rail on each side of the rail, on the base; fill the cavity with a selected polymeric material, such as a cork-filled polyurethane elastomer, and after setting or curing removing the mould sides to leave a rail clad in an elastomeric sheath.
  • a selected polymeric material such as a cork-filled polyurethane elastomer
  • This assembly is capable of good electrical and sound insulation properties and vibration damping, but requires factory assembly due to the moulding step and the sheath or boot is exposed to possible damage during transit.
  • a method of assembling a rail and a sheath or boot comprises forming a sheath or boot by moulding from an elastomeric material separately from the rail, bringing the rail and sheath together at an assembly site, applying an adhesive to either the rail or the inner surface of the sheath or both, inserting the rail into the sheath before curing of the adhesive, and allowing the adhesive to cure to create a chemical bond between the sheath and the rail.
  • the invention also provides a rail and sheath assembly as made by the method set out above.
  • the sheath or boot is preferably made from a natural or synthetic rubber material, preferably an elastomeric polyurethane microcellular foam.
  • the adhesive is preferably a polyurethane adhesive, an epoxy resin, or incorporates or is based on a contact adhesive or a hot melt system.
  • the adhesive may be applied by brush, roller, or spray or as appropriate for the adhesive composition used, particularly having regard to its viscosity and/or curing properties.
  • the rail surface and the inner surface of the sheath or boot are preferably prepared before application of the adhesive, for example by cleaning, descaling, brushing, degreasing, or the like as appropriate.
  • the method is useable with all types of rail, particularly grooved track, and flat-bottomed standard track, or reversible double-headed track.
  • the combined assembly of the sheath or boot and the rail upon which the sheath is fitted and to which it is bonded can be used in embedded rail constructions wherein the rail is embedded in concrete, with asphalt or paving slab finish.
  • the assembly can also be used in the construction of so-called "slabtrack” , and is suitable for use in conjunction with pre-cast shaped concrete sections.
  • the sheath or boot can be produced in long sections to reduce the frequency of joints, and can be cut to facilitate use on curved rails.
  • the ends of adjacent sections may be bonded together to form a watertight seal between sections, and a reinforced tape may be used to protect the joint during all stages of assembly and installation.
  • the sites of rail welds are also in filled after welding, by applying sections of the sheath and bonding these to the adjacent sections of sheath as well as the rail.
  • the adhesive bond not only bonds the sheath or boot securely to the rail, but also provides additional electrical and corrosion resistance by preventing ingress of water at the rail/polymer interface, between the rail and the sheath.
  • Fig 1 Is a cross-sectional view of a rail and sheath or boot assembly in accordance with the invention wherein the rail is a flat bottomed grooved rail, as customarily used in urban tram tracks; and Fig 2 is a cross-sectional view of a rail and sheath or boot assembly in accordance with the invention wherein the rail is a flat bottomed symmetrically- headed rail as customarily used in main line and suburban railways.
  • a steel rail 10 has a flat base or foot 1 1 , a central web 1 2, and a grooved head comprising a running surface 1 3, a groove 1 5 for accommodating wheel flanges, and a guard flange 1 5.
  • the rail 1 0 is clad with a sheath or boot 1 6 or microcellular polyurethane which is bonded over all the mutually contacting surfaces of the sheath and rail with a polyurethane cement or adhesive.
  • the sheath or boot 1 6 covers all parts of the rail except the upper surface of the head, including the running surface 1 3, groove 1 5 and the top and inner surface of the guard flange 1 5.
  • Fig 2 similarly shows a mainline rail 20, having a flat bottomed foot 21 , a central web 22, and a running head 23.
  • the rail is clad in a sheath or boot 24 of microcellular polyurethane which is bonded over all mutually contacting surfaces of the rail and sheath with a polyurethane cement or adhesive.
  • the sheath covers all of the rail except the upper running surface of the rail head 23 and one side face of the head which is placed on the inner side of the track and is contacted by the flanges of rail vehicle wheels.
  • An optional feature of this track configuration is an insulated flangeway 26, shown in broken lines, which is formed as an extension of the sheath 24 on the inner side of the rail.
  • the assembly is produced by forming e.g by moulding or continuous extrusion length of the sheath 1 6 or 24 from micro cellular polyurethane, although any suitable natural or synthetic rubber or substitute may be used, of the desired cross-section and dimensions.
  • This step can be carried out in bulk manufacturing process at a factory site remote from the site of installation.
  • the rails and sheath sections are transported to the site of installation separately, and are then made into the rail and sheath assemblies of the invention at a service site close to the actual track which is being laid.
  • the rail is first cleaned, and if necessary de-scaled using one or more techniques such as blast cleaning, water blasting, wire brushing or the like to remove rust and illscale or other containments.
  • the inside of the polyurethane sheath is also degreased or otherwise cleaned as necessary.
  • the surfaces of the sheath and of the rail are then coated with a suitable adhesive or cement system, this is preferably a polyurethane adhesive or cement, but can be an epoxy resin system, or based on a contact adhesive or hot melt system.
  • the adhesive may be applied as appropriate by brushing, roller or by a spray.
  • the sheath is then placed onto the rail, which as the sheath is flexible does not present a problem despite the re-entrant profile of the rail cross- section, and the adhesive allowed to cure.
  • the sheathed rail can then be installed for example, by freestanding (not embedded) supported on sleepers and secured with standard clips; or embedded in concrete topped with paving stones leaving only the running surface exposed, as in a street tramway.
  • the sheathed rail is also suitable for used in construction of slab track and in conjunction with precast shaped concrete sections. The sheath can be cut to facilitate use on curved rails.
  • the polyurethane foam composition and density may be selected to suit required performance requirements for particular sites.
  • Polyurethane rubber foam is particularly suitable as it is tough, durable, resistant to hydrolisis and is non-biodegradable.
  • the adhesive not only bonds the sheath to the rail, but also provides additional electrical and corrosive resistance by preventing ingress of water at the rail/polymer interface.
  • the rail can be supported by the head or on suitable base plates to facilitate concrete pouring, and can also be used in conjunction with concrete slip forming techniques.
  • the assembly can be used in conjunction with segmented pre-cast concrete systems, and in general, as the sheath is not bonded to the concrete segments or other infill, worn rail can be rapidly replaced.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Railway Tracks (AREA)

Abstract

A rail (10) is clad with a sheath or boot (16) which is bonded to the rail over the flanking and base surfaces of the rail, leaving running surfaces (13) exposed, by means of an epoxy or polyurethane adhesive to the sheath (16) and rail (10). The sheath (16) may comprise a body of suitable polyurethane microcellular foam.

Description

Cladding Of Rails
This invention relates to cladding of rails, with a view to reducing noise and vibration and improving electrical isolations. It is well known to mount rails for tramways or mainline railways in a sheath of rubber or polyurethane or other similar materials. Such sheaths include cladding applied to the exterior of the rail and mouldings which are cast on the rail and are usually effective to some degree for noise attenuation and electrical isolation. For many mainline railways, electrical isolation for use as a return conductor for electrical propulsion systems is not required. However there is such a requirement for mainline and tramway systems where electrical propulsion is used, and also at a lower current level, for use of the rails as conductors in signalling systems, for example track circuits which indicate the locations of trains to a centralised signalling control centre. It is thus known for example from WO 01 /83889 (IRON HORSE) to encase a rail in a virtually all-encompassing 'boot' or sheath which leaves only the running surface of the rail exposed. Securing systems such as clips which fasten the rail base flanges to sleepers act on the rail through the sheath.
It is also known, from EP-A-0,364,756, to secure a composite body to a rail, for example below the foot of the rail, or in contact with the centre web of a waisted rail profile, the composite body comprising a visco-elactic -damping medium, and a constraining member of for example ^teel, the damping medium is bonded by an adhesive to the surface of the rail which it covers and also to the constraining member. The edges of the constraining member grip the metal of the rail, and the body is thus not effective for electrical insulation.
One method of providing an insulating sheath about a rail is to invert the rail on a mould base, arrange shaped mould side plates spaced from the rail on each side of the rail, on the base; fill the cavity with a selected polymeric material, such as a cork-filled polyurethane elastomer, and after setting or curing removing the mould sides to leave a rail clad in an elastomeric sheath. This is usually installed by placing on a support over a sub base, and the rail bed then filled with concrete to the required height about the jacketed rail.
This assembly, with suitable choice of materials, is capable of good electrical and sound insulation properties and vibration damping, but requires factory assembly due to the moulding step and the sheath or boot is exposed to possible damage during transit.
It is an object of the invention to provide a method of forming a rail construction comprising a metal rail and a sheath or boot of synthetic material, whereby the components can be assembled on site.
According to the invention, a method of assembling a rail and a sheath or boot, comprises forming a sheath or boot by moulding from an elastomeric material separately from the rail, bringing the rail and sheath together at an assembly site, applying an adhesive to either the rail or the inner surface of the sheath or both, inserting the rail into the sheath before curing of the adhesive, and allowing the adhesive to cure to create a chemical bond between the sheath and the rail. The invention also provides a rail and sheath assembly as made by the method set out above.
The sheath or boot is preferably made from a natural or synthetic rubber material, preferably an elastomeric polyurethane microcellular foam.
The adhesive is preferably a polyurethane adhesive, an epoxy resin, or incorporates or is based on a contact adhesive or a hot melt system.
The adhesive may be applied by brush, roller, or spray or as appropriate for the adhesive composition used, particularly having regard to its viscosity and/or curing properties.
The rail surface and the inner surface of the sheath or boot are preferably prepared before application of the adhesive, for example by cleaning, descaling, brushing, degreasing, or the like as appropriate. The method is useable with all types of rail, particularly grooved track, and flat-bottomed standard track, or reversible double-headed track.
The combined assembly of the sheath or boot and the rail upon which the sheath is fitted and to which it is bonded can be used in embedded rail constructions wherein the rail is embedded in concrete, with asphalt or paving slab finish. The assembly can also be used in the construction of so-called "slabtrack" , and is suitable for use in conjunction with pre-cast shaped concrete sections.
The sheath or boot can be produced in long sections to reduce the frequency of joints, and can be cut to facilitate use on curved rails. The ends of adjacent sections may be bonded together to form a watertight seal between sections, and a reinforced tape may be used to protect the joint during all stages of assembly and installation. The sites of rail welds are also in filled after welding, by applying sections of the sheath and bonding these to the adjacent sections of sheath as well as the rail.
The adhesive bond not only bonds the sheath or boot securely to the rail, but also provides additional electrical and corrosion resistance by preventing ingress of water at the rail/polymer interface, between the rail and the sheath.
Two embodiments showing the method of the inventions as applied to two different but widely used sections of rail will now be described with reference to the accompanying drawings, wherein:-
Fig 1 Is a cross-sectional view of a rail and sheath or boot assembly in accordance with the invention wherein the rail is a flat bottomed grooved rail, as customarily used in urban tram tracks; and Fig 2 is a cross-sectional view of a rail and sheath or boot assembly in accordance with the invention wherein the rail is a flat bottomed symmetrically- headed rail as customarily used in main line and suburban railways.
In Fig 1 , a steel rail 10 has a flat base or foot 1 1 , a central web 1 2, and a grooved head comprising a running surface 1 3, a groove 1 5 for accommodating wheel flanges, and a guard flange 1 5. The rail 1 0 is clad with a sheath or boot 1 6 or microcellular polyurethane which is bonded over all the mutually contacting surfaces of the sheath and rail with a polyurethane cement or adhesive. The sheath or boot 1 6 covers all parts of the rail except the upper surface of the head, including the running surface 1 3, groove 1 5 and the top and inner surface of the guard flange 1 5.
Fig 2 similarly shows a mainline rail 20, having a flat bottomed foot 21 , a central web 22, and a running head 23. The rail is clad in a sheath or boot 24 of microcellular polyurethane which is bonded over all mutually contacting surfaces of the rail and sheath with a polyurethane cement or adhesive. The sheath covers all of the rail except the upper running surface of the rail head 23 and one side face of the head which is placed on the inner side of the track and is contacted by the flanges of rail vehicle wheels.
An optional feature of this track configuration is an insulated flangeway 26, shown in broken lines, which is formed as an extension of the sheath 24 on the inner side of the rail.
In each of the embodiments, the assembly is produced by forming e.g by moulding or continuous extrusion length of the sheath 1 6 or 24 from micro cellular polyurethane, although any suitable natural or synthetic rubber or substitute may be used, of the desired cross-section and dimensions. This step can be carried out in bulk manufacturing process at a factory site remote from the site of installation. The rails and sheath sections are transported to the site of installation separately, and are then made into the rail and sheath assemblies of the invention at a service site close to the actual track which is being laid. The rail is first cleaned, and if necessary de-scaled using one or more techniques such as blast cleaning, water blasting, wire brushing or the like to remove rust and illscale or other containments. The inside of the polyurethane sheath is also degreased or otherwise cleaned as necessary. The surfaces of the sheath and of the rail are then coated with a suitable adhesive or cement system, this is preferably a polyurethane adhesive or cement, but can be an epoxy resin system, or based on a contact adhesive or hot melt system. The adhesive may be applied as appropriate by brushing, roller or by a spray.
The sheath is then placed onto the rail, which as the sheath is flexible does not present a problem despite the re-entrant profile of the rail cross- section, and the adhesive allowed to cure.
The sheathed rail can then be installed for example, by freestanding (not embedded) supported on sleepers and secured with standard clips; or embedded in concrete topped with paving stones leaving only the running surface exposed, as in a street tramway. The sheathed rail is also suitable for used in construction of slab track and in conjunction with precast shaped concrete sections. The sheath can be cut to facilitate use on curved rails.
When the rail and sheath assemblies are assembled into track, the ends of adjacent sheath sections are bonded together to form a water tight seal, and rail weld areas are infilled after welding with short sections of the sheath which are then welded to adjoining sections. A reinforced tape can be used to protect the joint during all stages of installation.
The polyurethane foam composition and density may be selected to suit required performance requirements for particular sites. Polyurethane rubber foam is particularly suitable as it is tough, durable, resistant to hydrolisis and is non-biodegradable. The adhesive not only bonds the sheath to the rail, but also provides additional electrical and corrosive resistance by preventing ingress of water at the rail/polymer interface. The rail can be supported by the head or on suitable base plates to facilitate concrete pouring, and can also be used in conjunction with concrete slip forming techniques.
The assembly can be used in conjunction with segmented pre-cast concrete systems, and in general, as the sheath is not bonded to the concrete segments or other infill, worn rail can be rapidly replaced.
It is of course to be understood that the invention is not intended to be restricted to the details of the above embodiments which are described by way of example only.

Claims

1 . A method of assembling a rail and a sheath or boot, comprising forming a sheath or boot by moulding from an elastomeric material separately from the rail, bringing the rail and sheath together at an assembly site, applying an adhesive to one or both of the rail or inner surface of the. sheath or boot, inserting the rail into the sheath before curing of the adhesive, and allowing the adhesive to cure to create a chemical bond between the sheath and the rail.
2. A method according to claim 1 wherein the sheath or boot is made from a natural or synthetic rubber material.
3. A method according to claim 2 wherein the material comprises an elastomeric polyurethane microcellular foam.
4. A method according to any one of claims 1 to 3, wherein the adhesive comprises one of a polyurethane adhesive, an epoxy resin or is based on a contact adhesive or hot melt system.
5. A method according to any preceding claim wherein the adhesive is applied by brush, roller or spray.
6. A method according to any preceding claims, comprising preparing the rail surface and the inner surface of the sheath or boot by cleaning, descaling, brushing or degreasing.
7. A method according to claim 1 wherein the sheath or boot is produced in long sections and the ends of adjacent sections bonded together to form a watertight seal between sections.
8. A method according to claim 7, wherein a reinforced tape is used to protect the joint.
9. A rail assembly, comprising a rail and a sheath or boot moulded from an elastomeric material, separately from the rail, and assembled by applying an adhesive to one or both of the rail or inner surface of the sheath or boot, the rail being inserted into the boot before curing of the adhesive, and by allowing the adhesive to cure to create a chemical bond between the sheath and the rail. 0. A rail assembly according to claim 9 incorporated into an embedded rail construction wherein the rail is embedded in concrete.
PCT/GB2003/004345 2002-10-08 2003-10-08 Cladding of rails WO2004033795A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003271910A AU2003271910A1 (en) 2002-10-08 2003-10-08 Cladding of rails

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0223276.7 2002-10-08
GB0223276A GB0223276D0 (en) 2002-10-08 2002-10-08 Cladding of rails

Publications (1)

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WO2004033795A1 true WO2004033795A1 (en) 2004-04-22

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AU (1) AU2003271910A1 (en)
GB (1) GB0223276D0 (en)
WO (1) WO2004033795A1 (en)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1518963A1 (en) * 2003-09-23 2005-03-30 Johann Bogel Damper
FR2869627A1 (en) * 2004-04-28 2005-11-04 Robert Chartier Applic Rca Sa Rail joint manufacturing and fitting procedure, especially for tramline, uses elastomer granules mixed with supple bonding agent and containing hollow cells
EP1830002A1 (en) * 2006-03-02 2007-09-05 BTE Stelcon Deutschland GmbH Track structure adapted for tramways
WO2007145635A1 (en) * 2006-06-16 2007-12-21 Ryan Michael Sears Rubber laminate and composites including the laminate
US7556209B2 (en) 2006-06-16 2009-07-07 Ryan Michael Sears Rubber laminate and composites including the laminate
DE202011109278U1 (en) * 2011-12-19 2013-03-21 Kraiburg Elastik Gmbh Rail covering element and rail clamping device for a rail covering system
EP2960370A1 (en) * 2014-06-26 2015-12-30 Polycorp Ltd. Rail assembly
CN105274915A (en) * 2015-11-26 2016-01-27 洛阳双瑞橡塑科技有限公司 Method for eliminating track system stray current
CN105735057A (en) * 2016-03-07 2016-07-06 青岛思锐科技有限公司 Steel rail cladding vibration reduction structure of embedded type railway and preparation method thereof

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0364756A2 (en) 1988-09-22 1990-04-25 British Steel plc Improvements in railways
DE19706936A1 (en) * 1997-02-20 1998-08-27 Hermann Ortwein Rail track
EP0939164A1 (en) * 1998-02-26 1999-09-01 Alstom Construction method for a railway track
DE19911467A1 (en) * 1999-03-15 2000-09-21 Knape Vermoegensverwaltungs Gm Track construction with insulated / elastic mounting of rails on a support layer formed around insulating material / elastic material
US6125608A (en) * 1997-04-07 2000-10-03 United States Building Technology, Inc. Composite insulated framing members and envelope extension system for buildings
WO2001083889A1 (en) 2000-05-03 2001-11-08 Iron Horse Engineering Co. Rail boot

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0364756A2 (en) 1988-09-22 1990-04-25 British Steel plc Improvements in railways
DE19706936A1 (en) * 1997-02-20 1998-08-27 Hermann Ortwein Rail track
US6125608A (en) * 1997-04-07 2000-10-03 United States Building Technology, Inc. Composite insulated framing members and envelope extension system for buildings
EP0939164A1 (en) * 1998-02-26 1999-09-01 Alstom Construction method for a railway track
DE19911467A1 (en) * 1999-03-15 2000-09-21 Knape Vermoegensverwaltungs Gm Track construction with insulated / elastic mounting of rails on a support layer formed around insulating material / elastic material
WO2001083889A1 (en) 2000-05-03 2001-11-08 Iron Horse Engineering Co. Rail boot

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1518963A1 (en) * 2003-09-23 2005-03-30 Johann Bogel Damper
FR2869627A1 (en) * 2004-04-28 2005-11-04 Robert Chartier Applic Rca Sa Rail joint manufacturing and fitting procedure, especially for tramline, uses elastomer granules mixed with supple bonding agent and containing hollow cells
EP1830002A1 (en) * 2006-03-02 2007-09-05 BTE Stelcon Deutschland GmbH Track structure adapted for tramways
WO2007145635A1 (en) * 2006-06-16 2007-12-21 Ryan Michael Sears Rubber laminate and composites including the laminate
US7556209B2 (en) 2006-06-16 2009-07-07 Ryan Michael Sears Rubber laminate and composites including the laminate
DE202011109278U1 (en) * 2011-12-19 2013-03-21 Kraiburg Elastik Gmbh Rail covering element and rail clamping device for a rail covering system
EP2960370A1 (en) * 2014-06-26 2015-12-30 Polycorp Ltd. Rail assembly
US9617688B2 (en) 2014-06-26 2017-04-11 Polycorp Ltd. Rail assembly
US10370798B2 (en) 2014-06-26 2019-08-06 Polycorp Ltd. Rail assembly
CN105274915A (en) * 2015-11-26 2016-01-27 洛阳双瑞橡塑科技有限公司 Method for eliminating track system stray current
CN105274915B (en) * 2015-11-26 2017-07-18 洛阳双瑞橡塑科技有限公司 A kind of method for eliminating rail system stray electrical current
CN105735057A (en) * 2016-03-07 2016-07-06 青岛思锐科技有限公司 Steel rail cladding vibration reduction structure of embedded type railway and preparation method thereof

Also Published As

Publication number Publication date
AU2003271910A1 (en) 2004-05-04
GB0223276D0 (en) 2002-11-13

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