Delivering Turnout

Solutions

DESIGN SUPPLY INSTALL MAINTAIN

 Introduction

GLOBAL TURNOUT SOLUTIONS

 Introduction

BROWNFIELD CONSTRUCTION SOLUTIONS

 Introduction

MAJOR PROJECTS
 Introduction

CRANE RAIL CONSTRUCTION

 Introduction

We specialise in:
▪ Turnout design and integration
▪ Developing turnout technology
▪ Turnout supply management
▪ Critical junctions design and installation
▪ Turnout pre-assembly and installation
▪ Turnout installation staging solutions
▪ Turnout refurbishment and track reconditioning
▪ Crane rail specialist (supply and construct)
▪ Slab track construction
▪ Turnout and track inspections, maintenance and asset
management
Design – Supply – Install – Maintain
 Introduction

Turnout range:

▪ Light rail
▪ Metro
▪ Passenger and freight
▪ Heavy haul
▪ High Axle Load Heavy Haul (HAL-HH)
▪ All gauges and rail profiles

Design – Supply – Install – Maintain

 Projects

WE HAVE BEEN BUSY

AT MARTINUS RAIL

347 TURNOUTS SUPPLIED

SUPPLIED 51 BUFFER STOPS
CONTRACTED FOR THE SUPPLY OF 400+ TURNOUTS
60KM OF TRACK INSTALLED
33KM OF CRANE RAIL INSTALLED
INSTALLED 102 TURNOUTS
 Projects
Kiwi Rail

▪ 22.5t axle load

▪ AS60 rail
▪ 200+ tangential turnouts
 Projects

Doha Education City – Qatar

▪ 96 Turnouts and Diamonds
▪ 17t axle load
▪ S49, 60R2 rail
▪ Groove and full depth turnouts
▪ Direct fix Vossloh
▪ Edilon Sedra Encapsulation
Projects
 Projects
Sydney Ports – Botany third line and yard upgrade

▪ 30t axle load

▪ 60E1 rail
▪ 26 Tangential turnouts
 Projects
OneSteel – Whyalla – Iron Ore Project

▪ 32t axle load

▪ 60E1 rail
▪ 9 Tangential and conventional turnouts
▪ 54t axle load flangeway running diamond
 Projects
ARTC – 30TAL Gunnedah

▪ 30t axle load

▪ AS60 rail
▪ 15 Tangential and conventional turnouts
 Projects

ARTC – HRR & LTTSF Hexham

▪ 32.5t axle load

▪ AS60 rail
▪ 41 Tangential turnouts
▪ swing nose crossings
 Projects

ARTC – Kooragang Island

32.5t axle load
AS60 rail
8 Tangential turnouts
Monoblock crossings
 Projects
ARTC – Upper Hunter Valley

32.5t axle load

AS60 rail
12 Tangential turnouts
Monoblock crossings
 Projects
MBRL - Brisbane

• 30km of track
• 19 turnouts
 Projects
ARTC – East/West Productivity works turnout upgrade
 Projects
PKCT

• Upgrade the 6km of rail system within the 1km long coal stockyard to facilitate
the introduction of new stacker and reclaimer equipment in the yard.
 Projects
Southpine bridge renewals

• 2 x 700m tracks along two bridges and an embankment, and was

undertaken within a 168 hour rail closedown
 Projects
Webb dock

• 1,304m of Gantrex Slab Track – Ship to Shore (STS)

• 5,680m of Gantrex Ballasted – Automatic Stacking Crane (ASC) track
 Projects
GCLR Stage 2

• Light rail turnouts (49E1 & 51R1)

• Diamonds and scissor crossovers
• 13km ballast track
• 2km embedded track
 Projects
Buffer stops

• NWRL (NRTIJV) – x23 stops

• MBRL – x13 stops
• SEQ Yards – x8 stops
• Wickham – x5 stops
• Perth stadium – x2 stops
• Katoomba – x2 stops
• MTM – x1 stop
• GCLR – x2 stops
 Factories
Manufacturing facility – Century, Australia
 Factories
Manufacturing facility – DT, Czech Republic
 Factories
Global Turnout Solutions
Manufacturing facility- GWQC, China
 Factories
Global Turnout Solutions
Manufacturing facility- CRSBG, China
 Products
What is a turnout?
 Products
Breakdown of a turnout

1. Switch panel
2. Closure panel
3. Crossing panel
 Products
Breakdown of a turnout
 Products
Breakdown of a turnout

• Bearers
• Switch set
• Infill closure rails
• Crossing
• Check rail unit
• End infill closure rails
• Points machine
• Rodding
• Platework
• Jewellery
 Products
Different types of turnout

▪ Similar flexure
▪ Contra flexure
▪ Crossover
▪ Diamond
▪ Scissor crossover
▪ Single slip
▪ Double slip
▪ Catchpoints
 Products
Conventional vs Tangential
 Products
Conventional vs Tangential
 Products
Conventional vs Tangential

• Tangential = improved technology

– Reduced forces
– Increased speed
– Longer service life
– Improved ride quality
– Concrete bearers
– Asymmetric thick web switch
– Resilient fastened stock rail
– Raised adjustable check rails
 Products
Conventional vs Tangential
 Products
Conventional vs Tangential
 Products
Conventional vs Tangential
 Products
Conventional vs Tangential
 Products
Rail Bound Manganese (RBM)

▪ Fully cast manganese insert

▪ Explosively hardened
▪ AS60 Wing rail
▪ CNC machined nose profile to suit
client wheel profile
▪ Life expectancy: 300MGT
 Products
Monoblock

▪ Fully cast manganese

▪ Explosively hardened
▪ No bolts
▪ FBW 60kg Legs
▪ CNC machined WR & nose profile to suit
client wheel profile
▪ Life expectancy: 400MGT
 Products
Swing nose crossing

▪ Rail type
▪ Frame type
▪ Manganese cradle
- Eliminates impact
- Reduced noise
- Suitable for longer rate
turnout (high speed)
- Life Expectancy: Greater
than 1000 MGT
 Products
High axle load (48T) heavy haul turnout
 Products
Designs according to axle loads and speed
 Products
Temporary Takeoff Turnout

The Temporary turnout creates a

temporary siding allowing track
machines to move on and off track at
will.

▪ Allows safe and easy removal of

track machines with up to 23T axle
loads from mainline
▪ Once the track machine is located
on the temporary siding it is as
simple as removing two switch
ramps and a crossing ramp,
weighing only 350kg each, in order
to restore mainline running
 Products
Temporary Takeoff Turnout

PWI Ken Erickson

Innovation Award Winners
 Products
Points operation rodding
Deflection Plates
Rear Drive Rod

Linking rods

Backdrive Crank
Heel of Switch

Drive Locking Bars

Detection Bars

Points Motor

Points of switch
 Products
Hydraulic points machine – Alstom CTS2
 Products
Electric points machine - Siemens M3A/20A
 Products
Electric points machine - Siemens D84M
 Products
Track forms – Concrete bearers
 Products
Track forms – Composite bearers
 Products
Expansion Switches

▪ Used for thermal and

subsidence management
▪ Moving Stockrail - gauge is
kept within tolerance
▪ Small Expansion – Up to
100mm
▪ Medium Expansion – Up to
330mm
▪ Long Expansion – Up to
600mm
 Products

Buffer Stop systems – Friction Hydraulic

 R&D

• New product development is key to ensure that Martinus

Rail stays at the forefront of turnout technology and
meets increasing network and operational demands from
the client
• Martinus Rail carries out design validation (can be by an
independent third party) to:
– Ensure product conformance
– Ensure product suitability
– Ensure product life cycle
• Validation will include:
– Engineering reports
– Design review
– Risk analysis review
 R&D

• All new crossing designs are verified for performance

using finite element analysis (FEA) techniques
• Tested up to 48T for both static and fatigue analysis
• Fatigue life tested for 2.4 x 107 cycles.
 R&D

• New crossing designs undergo wheel / rail interface

design studies to ensure that new and hollow wheel
profiles transfer through the crossing in the most
efficient manner without causing impacts, wheel strikes
or wear
 R&D
• All products undergo rigorous QA testing and follow up
analysis
Install
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Kiwi Rail – NZR50 Turnouts
• Martinus Rail designed brand new tangential turnout design solutions in
collaboration with KiwiRail based around the in track conventional turnouts
currently installed in track. The following table displays current details of turnouts
in use in Kiwi Rail:
Crossing Rate (Strike) Crossing Angle (°) Speed (km/h)

1 in 7.5 7.59463 25

1 in 9 6.34019 30

1 in 12 4.76364 40

1 in 18 3.17983 60

• Martinus Rail has reverted to turnout design fundamentals to provide a newly

designed suite of the turnout sizes to incorporate full tangential design and
features that will provide a turnout with an increased life cycle giving Total Cost
of Ownership (TCO) benefits for Kiwi Rail. Martinus Rail has designed the four new
layouts to the following details:
Radius (m) Crossing Rate (Strike) Crossing Angle (°) Lead Length (m) Divergent Road
Speed (km/h)

R96 1 in 7.5 Straight 7.59463 14.675 28

R140 1 in 9 Straight 6.34019 17.386 33
R250 1 in 12 Straight 4.76364 22.393 42
R560 1 in 18 Straight 3.17983 34.487 66
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Kiwi Rail – NZR50 Turnouts
Item Description Reference Document
In accordance with
Turnout Type Tangential – mixed traffic
AS1085 and EN 13232
Turnout
96m, 140m, 250m, 560m
Radius
Crossing Rate 1 in 7.5, 1 in 9, 1 in 12, 1 in 18
Gauge 1068mm Kiwi Rail T151
GB 2585-2007 &
Rail Size NZR50
Kiwi Rail dwg. 88323/1
Kiwi Rail T151, T160 &
Bearers Concrete / Composite
AS1085.14
Turnout Design Criteria Dimension (mm)
As per Table 7
Road Speed
Nominal track gauge 1068
Axle Load 22.5T Kiwi Rail T151
Wheel Kiwi Rail dwg. 7604-11,- Design wheelset back to back dimension 993 - 998
NZ A,C & E series
Profile 13 & -15 Check rail effectiveness 1026 - 1032
Rail Cant in
Zero Crossing Flangeway width 41
Turnout
Points Suitable for M3A, CTS-2 & Racor Check rail gap 38
Operation Lever
Maximum superelevation (cant) deficiency
Yearly 60
18 MGT P.A. through diverging track
Tonnage
Switch rail toe / stock rail open throw
≥ 115
dimension
Switch rail throat opening ≥ 50

Check rail flared end opening to gauge ≥ 80

Check rail height above the running rail 0

Flangeway depth clearance 45

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Kiwi Rail – NZR50 Turnouts

Switch assembly – The switch assembly is fabricated from 50AT asymmetric switchblades and NZR50 head
hardened stockrail.
Asymmetric tangential switchblades – The switchblade is manufactured from 50AT rail. The last 500mm of the
switchblade is forged to the NZR50 profile for connection to the infill closure rails.
• Rail type 50AT, U71 V quality according to TB/T 3109-2005. Rail head is post CNC machined factory
pearlitized to produce a head hardened grade material

Stockrail – Manufactured from NZR50 head hardened (to HB 340) rail. Stock rails are drilled for locking device,
anti-creep device and switch stops.
• Rail type NZR50 quality U75V (HT) according to GB2585-2007

• Head of stockrail undercut to 1:3

Monoblock Crossing Assembly – Manufactured from cast austenitic manganese steel manufactured to TB/T
447-2004
• Explosively hardened within range 320 – 350 HB, all running surfaces up to 100mm from ends of
casting, 20mm from top of rail

• FBW Crossing legs NZR50 quality U75V (HT) according to GB2585-2007

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Kiwi Rail – NZR50 Turnouts

Adjustable Check Rail - The check rail unit (two per turnout) comprises the check rail and the check rail
bracket. The check rail is bolted to the bracket using M24 x 80 fasteners. The ends of the check rail are flared to
allow gathering of the wheel flange.
• Check rail type 33C1 (UIC33) to EN 13674-3

• Closure rail clipped to the check rail plate using resilient clips

• Fully adjustable using shim set

Closure Rail - The infill closure rails (rails between the end of the switches and start of the crossing) are supplied
either straight or pre-curved from NZR50 quality U75V (HT) according to GB2585-2007.

Concrete Bearers – Prestressed concrete bearers to AS1085.14 with M24 Screwspike ferrules and Pandrol
shoulders
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Kiwi Rail – NZR50 Turnouts
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Quality Management Plans
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Risk management
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Quality Inspections

• Manufacturing inspection – In process inspection by the manufacturer

• Third party inspection - In process and post production inspection by a
third party expert
• FAT – Factory Acceptance Test carried out by Martinus Rail senior
engineers
• 100% inspection at factory – All products 100% inspected by Martinus
Rail prior to shipping
• 100% inspection on delivery– All products 100% inspected by Martinus
Rail on delivery
• Trial lay – First off article trial lay for KiwiRail proving
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Quality Inspections
ITEM VERIFYING INSPECTED
PROCESS / OPERATION / DESCRIPTION TARGET ACTUAL TOLERANCE COMMENTS
No. DOCUMENTS BY

Gauge to Gauge Distance at A/B/C/D/E 122.4

122
(Switch closed) ±1 mm (pass)
156.2
156
1<x<1.5mm
193.5 (note)
1.13 SG.NZR50-7.5-101 193 KJ
233 x>1.5mm
232
(adjust with
275.5 shim)
275

1.14 Switch assembly end opening SG.NZR50-7.5-101 427 426 ±1 mm KJ

1.15 Switch tip to end of stock rail SG.NZR50-7.5-101 1090 1090 ±3 mm KJ

ø22 22 ±0.5 mm
Stockrail Drilling from End of Stockrail
1.16 SG.NZR50-7.5-101 1500 1500 ±2 mm KJ
(diameter/distance/height from foot)
63 64 ±1 mm
1.17 Switch Drilling Hole Diameter – Foot SG.NZR50-7.5-101 Ø32 32 ±0.5 mm KJ

1.18 Switch Drilling Hole Diameter – Web SG.NZR50-7.5-101 Ø22 22 ±0.5 mm KJ

1.19 Stock rail head machining clearance to switch tip SG.NZR50-7.5-101 40 39 ±10 mm KJ
+2 mm
1.20 Foot of the rail to the inside edge of the hole - 17 17.5 KJ
-0 mm
+2 mm
1.21 From the foot relief to the bottom of the holes - 14 14 KJ
-1mm
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Quality Inspections
ITEM VERIFYING INSPECTED
PROCESS / OPERATION / DESCRIPTION TARGET ACTUAL TOLERANCE COMMENTS
No. DOCUMENTS BY
Ø32 Holes: Ø32 Holes:
Switch Drilling from Toe of Switch 50, 49.7,

117, 116.7,

184, 184.5,

690, 690,

Ø22 Holes: Ø22 Holes: ±1 mm

1.22 SG.NZR50-7.5-101 KJ
294 294.5

+232 +232

+253 +253

+100 +100

Check M20 Checked

Bolt Fit
Switch stops correctly positioned
1.23 VISUAL 0 0 +2, -0 mm KJ
(gap between switch stop and rail web)

450 450
Length of plates under switch:
650 649
50-FLAT
50-SW/50-SWH
790 790
1.24 50-7.5-13-RH-RS/50-7.5-13-LH-LS - KJ
±2 mm (OK)
50-7.5-14-RH-RS/50-7.5-14-LH-LS
840 841
50-7.5-15-RH-RS/50-7.5-15-LH-LS
>2 mm
50-7.5-16-RH-RS/50-7.5-16-LH-LS
850 849 (Check Hole to
Hole
906 (Loose) L-70mm, ±1)
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Quality Inspections
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Product Marking

1 in 7.5 - Right Hand Turnout

1 in 12 - Right Hand Turnout

1 in 18 - Right Hand Turnout

1 in 7.5 - Left Hand Turnout

1 in 9 - Right Hand Turnout

1 in 18 - Left Hand Turnout

1 in 12 - Left Hand Turnout
1 in 9 - Left Hand Turnout
ITEM DESCRIPTION

1 Left hand side - switch rail + stock rail * I * I * I * I

2 Right hand side - switch rail + stock rail * I * I * I * I
3 Crossing * I * I * I * I
4 Check rails – C * I * I * I * I
5 Check rails – K * I * I * I * I
6 Closure – C * I * I * I * I
7 Closure – K * I * I * I * I
8 Closure – F * I * I * I * I
9 Closure – D * I * I * I * I

10 Closure – A N/A N/A N/A N/A * I * I

11 Closure – H N/A N/A N/A N/A * I * I

12 Loose Items (Box) * I * I * I * I

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Delivery
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Logistics
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Trial Lay
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Trial Lay
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Trial Lay
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Trial Lay
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Installation
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Installation
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Points operation rodding
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Points operation rodding
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Teamwork
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Teamwork
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Summary

• Challenges
• Brand new turnout design
• New manufacturer
• Shipping rail from NZ
• Logistics of moving parts around the world
• Earthquake!

• Successes
• Turnouts on the ground
• Rodding installed
• Working relationships
• Manufacturing quality