TKGFT_BRO_NFF_GB_RZ_Layout 1 04.09.

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Your bridge to
greater economy.
The New Slab Track
NFF System.

ThyssenKrupp GfT Gleistechnik

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Your bridge to greater economy.

The New Slab Track NFF System.

crossfall +100 mm
horizontal

Our new development the New Slab Track

NFF System has been undergoing thorough
testing on a test track since 2008. And the
results have been impressive. A licence was
issued for it by the Federal Department of
Rails at Aug. 12th. 2010. We are the only manufacturer of the system and as such we can
supply a patented solution throughout Europe
for tracks and track sections which are affected
by unfavourable or difficult soil types.
So, what are the new features? In contrast to conventional slab,
which depend on a full surface bedding, the NFF System is a
bridge-type construction with a superstructure for rail traffic. The
load demolition must not directly take place underneath the carriageway slab, but can be introduced by means of drill or pressuregrouted piles directly in (more deeply lying) load-carrying gound
layers. This innovation renders the soil exchange that is normally
required redundant, thus leading to tremendous cost savings.

1 NFF System in a bend

2 Exploded installation drawing

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Step by step innovation.

System and installation.

System

Installation

The NFF System normally consists of deep

foundations as individual foundations, which have a
positive connection to rigid portal systems. Longitudinal
bearer units (LTE) in the form of prefabricated concrete
components are installed on these in the correct position
by means of a positive connection. These LTEs consist
of two longitudinal sleepers with three lateral connections
level with the rigid portal systems so as to form a prefabricated rail support grid. The rail fasteners and
segment rails are already mounted in the correct position on the longitudinal sleepers.

The New Slab Track NFF System is manufactured

using the following procedures:

The NFF System is suitable for use with all types of

track such as gradients, bends, superelevations and
crossings. The rails are fastened using the Krupp ECF
system from ThyssenKrupp GfT Gleistechnik. This makes
subsequent height corrections of -4 mm to +26 mm
and side corrections of 10 mm possible. A rail gradient
of 1:40 or 1:20, etc. can be achieved using different rib
plates, while the requisite elasticity is provided by an
elastic pad beneath the rib plate.

Installation of the deep foundations during

breaks in service either overnight or at weekends
Concrete curing during normal operations, extension
of the sleepers and rails, bedding of the ballast
Installation of the rigid portal systems by means of
vacuum, precise adjustment and concreting of the
openings in the rigid portal systems for connection
to the threaded rods in the micropiles
Alignment and installation of the longitudinal bearer
units, prestressing with the rigid portal systems
Replacement of the segment rails with long rails
Reinstallation of the ballast material
Inspection of the rail position, concreting the
clamping channel

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05

1
2
3
4
5
6

Drill (for producing the deep foundations)

Drilled piles with sub-base course
Rigid portal system with elastomer mat
Swinging the LTEs into position
Measuring the LTEs
Rigid portal system with connected
reinforcement

Rigid portal system with thrust

mandrels
8 Rail installation
9 Rail installation; ballasting
10 Transition between ballast and
NFF System
11 Finished, ballasted (not padded)
NFF System section

10

11

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A good drive in every respect.

Benefits.

1 Passing the measurement

equipment zone
2 Krupp ECF rail fastener
3 A fully laden train passing
4 View of finished NFF System route

An integral component of any approval involves testing

under normal operating conditions. For this purpose we
set up a test track on the factory premises of Rheinkalk
AG in Wlfrath in late summer 2008. Here the existing
ballast track, approximately 120 m in length, was converted to the NFF System.
The non-homogeneity of the soil with its wildly fluctuating (bearing) properties made it ideal for trying out the
system. Axle loads up to 22.5 metric tonnes and train
loads up to approx. 1800 metric tonnes were brought to
bear here meaning a total of no less that 2,000,000
metric tonnes by mid-2010. Measurements taken by
the University of Duisburg-Essen showed that over the
entire period no major settlement or sagging had taken
place.
The result is the issue of an approval from the Eisenbahn Bundesamt (the Federal Railway Authority of
Germany). Excellent quality!
il
f ra
so
axi

15 mm
crossfall
+100 mm

15 mm

Rmin = 600

15 mm
crossfall
+100 mm

0m
0.8
1
L=

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The NFF System provides a whole host of advantages.

Economic advantages

Advantages during maintenance and renovation

No expensive foundation soil work is required during

the earthworks. The loads are directed through the
deep foundations. This means that even existing
destabilized slopes can be upgraded.
There is generally no waste disposal work because
the existing ballast can be reinstalled in and next to
the track grid.
Mounting the rail on innovative longitudinal sleepers
means reduced vibration. In turn, this increases
travelling comfort and reduces maintenance costs.

Reduction in downtimes due to improved renovation

and extension facilities.
The system also provides excellent repair and
maintenance conditions in the event of damage.
For converting existing routes, the neighbouring
track can continue to be used whilst the work is
being carried out.
Sagging is minimized by using drilled piles with
adjusted dimensions.
Ecological advantages

Advantages as a result of prefabrication

00

0m

The high level of prefabrication means considerably

reduced construction times.
Prefabrication also allows a high level of mechanisation to be used and facilitates quality assurance.

No sealing of the foundation soil takes place.

The existing soil structure (ground water) is not
altered by the drilled piles.
If necessary the appropriate modifications can be
made to the longitudinal bearer units to reduce
noise emissions.

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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

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

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

Subject to alterations 09/2012 e

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