Technology, Construction

and Functionality.
The Slab Track
NBU System.

ThyssenKrupp GfT Gleistechnik

02

Slab Track NBU System

Further development of a
proven track concept.

1
2
3
4
5

International endeavours to innovate the time-tested

concept of stable positioned slab tracks as an alternative to traditional ballasted tracks are numerous.
A particularly economic example of these efforts is
represented by the Slab Track NBU System that was
approved by the Federal Railway Authority of Germany
(EBA) for field tests in 2004. Within this concept all
sleeper elements were wiped out in favour of a wholly
monolithic construction type. The construction is made
by using the technology of slipform pavers and applying
the fastening system Krupp ECF/Elastic Clip Fastener.

Continuous production of concrete support slab

Production segment Longitudinal groove profile
Tunnels without superelevation
Viaducts/bridges with superelevation
General section view Slab Track NBU System
with fastening system Krupp ECF

The conceptual starting point for this type of construction was the search for a long lasting solution of material compound by the use of highly efficient slip-form
pavers throughout the whole fabrication. Due to the
optimal design set-up of the construction Type NBU a
manual fabrication of the slab track can be performed
under tight spatial conditions on the construction site
as well.

A broad range of system applications for tunnels,

bridges and trough structures can be covered by the
multiple designs of the Slab Track NBU System.
The necessary precision, accuracy and stability are the
result of well tested principles of track and road paving.
Transitional areas towards the ballast track are built by
special system design features.

rail runway 0.00

rail UIC 60
rail fastening

1.435

longitucainl
groove
melting joint

concrete support
layer

ballast
hydraulically bonded layer
frost protection layer

soll

asphalt-top
layer

03

Innovation and efficiency

on testing ground.
1 Measurement of track gauge and
horizontal set-up
2 Inspection of track geometry
3 Position map and particularities
of the test track

In the frame of a Field Test Agreement concluded with DB Netz AG

the construction of the Slab Track NBU System was executed within
the range of the section 2600 Cologne Aachen Federal border in
early summer 2008. The length of this special section NBU System
is approximately 100 metres. In addition a transition area composed
of 5 m Rheda 2000 and 45 m roadbed with ballast gluing was built
at both ends. Thus the total construction section comprises a length
of approx. 200 m.
The overall fitting of the Hydraulically Bonded Layer (HBL), reinforcement/earthing, the Concrete Support Layer (CSL) and the rigging
of the mounting rail as well as the grouting of the longitudinal chan-

nels were effected in an optimal way. The key steps of the construction scheme are described and documented by the following
record.
After a strong winter period the field test was completed already in
summer 2009. DB Netz AG in its technical statement concluded
that the new track system FF NBU provides a huge saving potential
through the elimination of sleepers and further optimization of its
construction and cross-section. Thereby the recommendation was
made to classify the NBU System as a new slab type for final
standard approval by Deutsche Bahn in its track network. Our next
goal is to obtain the standard approval from DB.

04

Record of major construction steps.

In view of the construction process

one distinguishes mainly between:
the set-up until the upper edge of the
HBL and subsequently the fitting of
the CSL including the complete track
laying. The following record focuses
on the chronological comments and
display of the run of major construction steps in phase two.

1 Fitting of the HBL occurred in two layers of 0.15 m

thickness each and setting out of the track axis and the
positioning of the formwork for the CSL.
2 At a distance of 0.2 m the laying of the transverse
reinforcement as well as longitudinal reinforcement with
4 earthing irons were made; in order to guarantee a safe
and stable interconnection in the transition area 4 x 4
exhaust dowels were cemented.
3 Completion of formwork including fitting and compaction
of the C 30/37 LP concrete by a hose pump.
4 Chamfers production of dummy joints with a depth of
at least 0.12 m.
5 Finishing treatment of the concrete according to
DIN 1045 by moistening and airproofed barriers.
6 Placement of set-up rails via rail winches and discrete
support point Krupp ECF at a distance of 0.65 m, exact
vertical and longitudinal adjustment and fixation by
special tools.
7 Inspection of the railway track.
8 Final inspection of the railway track before the filling of
the longitudinal channels by high end grout.
9 During the grouting work the permanent control over the
consistency by verification of the spreading gauge and
test specimen was carried out.

05

06

Record of major construction steps.

10

11 12

10 Altitude correction at individual support points by

inserting equalisation plates.
11 Gluing of the ground ballast by two-components
polyurethane mixture and placement of support rails
in the transition area.
12 Bracing of anchors with the necessary torque and
documentation by a twin headed screw machine.

07

Efficiency and design advantages of the

Slab Track NBU System.

One of the significant advantages of the NBU System

in tunnels is that the full drive over by road vehicles in
cases of emergency is permanently ensured. Due to
this special feature, NBU System will be used in the
tunnel project in Cochem. Further applications of this
product are still in progress.

1 Completed track section

2 Manufacture of concrete
support slab with longitudinal grooves
3 Survey of the track and
soil compaction

Advantages and particular areas of application

High potential of industrial execution and running by proved

and well tested construction
and paving technology known
for its high productivity.

Advantages in logistics and

local safety by obstacle-free
move on the CSL during its
construction as well as in case
of emergencies and damage
repairs due to a plain and
sleeper-less surface.

Special advantages in view of

track construction in special
climatic areas as desert zones
where a high potential of silt up
exists due to Iow surface and
blocking resistance in case of
adequate and elevated track
design.

Abolition of joint transition

areas between prefabricated
parts and the in situ concrete
construction that ensures
optimal LCC-values, Iow maintenance routine and long life
of the system.

High efficiency of the construction cycle by the use of conventional and easy-to-mobilize road
paving and track laying technology through all fabrication steps
without depending extensively
on special tools and machinery.

Independence of prefabricated
elements and extended transportation logistics by complete
local construction in situ and
easy feeding of ready mix concrete by mobile plants following
the progress and advancement
of the construction site.

TKGT_BRO_NBU_GB_RZ_Layout 1 11.09.12 09:03 Seite 1

SALES
Regional office

Location of sales

North
Vahrenwalder Str. 205
30165 Hannover Germany
Phone: +49 511 6703-25
Fax: +49 511 6703-37

Waidmannstr. 26
22769 Hamburg Germany
Phone: +49 40 85340-700
Fax: +49 40 85340-701

West
Hollestr. 7a
45127 Essen Germany
Phone: +49 201 844-563745
Fax: +49 201 844-563750
East
Rotherstr. 7
10245 Berlin Germany
Phone: +49 30 628901-15
Fax: +49 30 628901-20/-21

An der Kreuzkirche 6
01067 Dresden Germany
Phone: +49 351 4902040
Fax: +49 351 4902480

Humboldtstr. 3
04105 Leipzig Germany
Phone: +49 341 6017054
Fax: +49 341 6017055

Vertriebsbereich
Waggonausrstung
Rotherstr. 7
10245 Berlin Germany
Phone: +49 30 628901-15
Fax: +49 30 628901-22

South
Frstenrieder Str. 267
81377 Mnchen Germany
Phone: +49 89 7871-300
Fax: +49 89 7871-343
South-West
Weilimdorfer Str. 74/2
70839 Gerlingen Germany
Phone: +49 7156 430730
Fax: +49 7156 430740

Dortmunder Str. 2
68219 Mannheim Germany
Phone: +49 621 8906-120/-121
Fax: +49 621 8906-122

EXPORT SALES

Export
Hollestr. 7a
45127 Essen Germany
Phone: +49 201 844-563764
Fax: +49 201 844-563757

MRT Track &

Services Co., Inc.
270 Broad Street
07003 Bloomfield NJ-USA
Phone: +1 973 748-8899
Fax: +1 973 748-9243

ThyssenKrupp
GfT Polska Sp. z o.o.
Al. Slowackiego 66
30-004 Krakw Poland
Phone: +48 12 6204130
Fax: +48 12 2677548

ThyssenKrupp Weichenbau
Obere Stahlindustrie 4
44793 Bochum Germany
Phone: +49 234 9114-343
Fax: +49 234 9114-557

Betrieb Industrieweichen
Am Wasserturm 3b
06869 Coswig/Anhalt Germany
Phone: +49 34903 4741-0
Fax: +49 34903 4741-20

MANUFACTURING PLANT
Holzschwellenwerk
Am Bahnhof 2
29393 Gro Oesingen Germany
Phone: +49 5838 9905-0
Fax: +49 5838 9905-79

Betrieb Spannmittel
Am Wasserturm 3b
06869 Coswig/Anhalt Germany
Phone: +49 34903 4741-0
Fax: +49 34903 4741-24

ThyssenKrupp Langschienen
Ladestr. 8
39175 Knigsborn Germany
Phone: +49 39292 6958-17
Fax: +49 39292 6958-20

Solid Slab Track GmbH

A Joint Venture of
Naumburger Bauunion and
ThyssenKrupp GfT Gleistechnik

ThyssenKrupp GfT Gleistechnik GmbH

Hollestr. 7a 45127 Essen Germany
Phone +49 201 844-563710 Fax +49 201 844-563714
www.tkgftgleistechnik.de gleistechnik@thyssenkrupp.com

Technical advice:
Phone +49 201 844-563712 Fax +49 201 844-563775
manfred.schatter@thyssenkrupp.com

Subject to alterations 09/2012 e

Naumburger Bauunion GmbH & Co Bauunternehmung KG

Gewerbegebiet Sd 06618 Grschen Germany
Phone +49 34445 70-101 Fax +49 34445 70-200
www.naumburger-bauunion.de info@naumburger-bauunion.de