1. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 1 Milano November 8, 2005 Presented by: Heinz OSSBERGER Head of Engineering and Design VAE GmbH Austria LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways

2. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 2 L ife C ycle C ost Look at Total Life Cycle of Components / Products What you see is not always what you get

3. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 3 LCC calculations: The way of VAE to provide the maximum benefit  Identification of the optimal product for each field of application (speed, loads etc.) regarding the LCC (identification of minimal LCC) Costs during Service Life Purchasing Costs Total Costs performance, quality costs

4. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 4 LCC calculations: The way of VAE to provide the maximum benefit

5. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 5 LCC: Influence and Solutions LCC INFLUENCE SOLUTIONS

6. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways 6 Cost factor: Wear and RCF-Defects Wear RCF- defects Corrugation Higher speeds Increasing axle load Higher annual tonnage Higher Loads  Poor running behaviour  Damage on rolling stock and superstructure  Less service life of components Noise Increase of life cycle cost

7. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 7 Trends in Rail Steel Development 200 260 230 290 370 320 350 400 430 460 196019702010198019902000 year 19501940 Hardness [BHN] R200 R260 R320Cr R350HT / R350LHT Micro- alloyed Heat Treated (HT) 400UHC+ Hyper- eutectoid, HT Standard Carbon DOBAIN ® Bainite, HT Higher Wear- and RCF- resistance 370LHT  -al

8. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 8 Test results – Wear: Improvement factors 10 7 5 4 3 2 1 R200R220S900R320CrR350HT base grade improvement ratio R260 8,5 R350HT / HSH 5 R320Cr 1,7 R200 R220 3 Source: ERRI and European Rail Operators 370HT/400UHC

9. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 9 Test results – RCF-Cracks (Head Checks)

10. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 10 LCC considerations Better track performance of harder rail grades 3-times better wear-resistance & 3-times better RCF-resistance for R350HT compared to R260 Less corrugation (approx. 50 % of R350HT compared to R260) Decrease in rail maintenance 3-times longer rail machining cycles (R350HT vs. R260) or Less metal removal necessary Longer rail service life 3-times longer for R350HT compared to R260 Less Life Cycle Cost (LCC)

11. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 11 LCC results – example DB AG and ÖBB  DB AG: Reduction of LCC by about 35 %  Medium speed lines (up to 230 km/h)  Curve radii approx. 3000 m  Load approx. 90.000 tons/day  Period under consideration: 40 years  ÖBB: 15 % annual cost saving for R350HT compared to R260 in tight curves.  conservative assumption: 30 % longer life span of R350HT  Less grinding needs  Rate of return 5 % net

12. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 12 Conclusion – LCC and rail grade strategy Premium high strength Rails (HSH ® -type) Load related application of and applying LCC optimized maintenance strategies  will diminish rail damage,  increases service life time of the system,  saves costs and  makes track operation more cost effective, reliable and safe.

13. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 13 VAS Outlook  New high strengths premium rail grades (Wear ↓ RCF↓)  Extensive track testing of the new rail grades.  LCC reduction by optimization of load related rail grade application and maintenance strategies by using LCC models (“LCC RAIL”)  Verification of the best track test practice rail grade strategy together with railways

14. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 14 LCC: Influence and Solutions LCC INFLUENCE SOLUTIONS

15. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 15 Crossover Gallese – Italy UIC60-7500/3000/15000-tg 0,026

16. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 16 Comparison of calculated and measured forces in turnouts

17. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 17 Comparison Calculation - Measurement Lateral Force measured calculated

18. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 18 LCC: Influence and Solutions LCC INFLUENCE SOLUTIONS

19. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 19 Close Link between RAMS and LCC LCC Life Cycle Costing RAMS Safety Availability Reliability Maintainability FMECA RCM FTA HA MA/MP RP/RA SA OperationMaintenanceInvestment LCALCC-P/AInvestment Analysis

20. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 20 High Speed Rail Link Taiwan TThe actual largest BOT Project worldwide LLenghts: 345 km, 80 % on viaducts and in tunnels SSpeed 300/160 km/h 1161 turnouts for High Speed

21. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 21  All turnouts are equiped with VAE Monitoring System „Roadmaster 2000“ High Speed Rail Link Taiwan Turnout Monitoring System VAE Roadmaster 2000

22. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 22 Safety and Reliability Report – Verification of the Performance of the RAMS Requirements according to EN 50126  The safety and reliability report is the final document with the summary of the findings of all activities during the RAMS process  Including all analysis performed during the RAMS process  Provides the evidence of achieving the RAMS requirements according to EN 50126 and the customer´s specification

23. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 23 HYDROSTAR ® Innovative Switch Operating System

24. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 24 Hydraulic switch operating system HYDROSTAR ® HYDROSTAR fulfils four functions  Driving (electro-hydraulic)  Setting (hydraulic)  Positive Locking  Detection (electro-mechanic)

25. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 25 Functions of the HYDROSTAR ® - displayed at the HYDROSTAR ® ZV Drive Tongue detector Force transmission Locking device

26. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 26 Drive I Principle: All setting levels of the switch or the moveable point frog are driven by one hydraulic device only. This hydraulic device is normally integrated in the first hollow steel sleeper. With this hydraulic device, it is possible to set a multiplicity of setting levels only by one active unit.

27. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 27 Locking I Principle: At every setting level, there is a unit for setting and locking integrated into the hollow steel sleeper. These cylinders were set hydraulically. in theses cylinders a double form fitting locking at the end position of the tongue or the moveable point frog takes place.

28. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 28 Tongue detector I Principle: This device has the same function as a normal tongue detector of an conventional drive. The correct end position of the tongue or the moveable point frog will be monitored.

29. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 29 Force transmission I Principle: Force transmission between the setting levels is done by hydraulic pipes. These pipes are mounted between the rails at the tongue section or along the rails at the moveable point frog. The pipes are covered to protect them against damage.

30. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 30 Comparision of HYDROSTAR ® ZV with a conventional turnout with single drives

31. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 31 LCC: Influence and Solutions LCC INFLUENCE SOLUTIONS

32. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 32 Railputler: Just-in-Time Delivery of Rails

33. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 33 Preassembled turnout with HYDROSTAR ® switch section prepared for shipping

34. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 34 Preassembled turnout HYDROSTAR ® loading of the switch section

35. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 35 Plug and Play: Installation of a preassembled turnout

36. LCC and RAMS Based Track Work Technology for the Economical Benefit of High Speed Railways Girsch 36 LCC: The objective of voestalpine: What you see is what you get! Thank you for your attention