Strength of a brand 2 From 30 years we support the rail industry PLASTWIL has been a leading manufacturer of the rail surface elements especially the elements of rail – sleeper assembly for 30 years. In a rail surface in Poland and Central and Eastern Europe, PLASTWIL company installed over 120 mln pieces of different details to rail surface, such as: rail pads, electro-insulating hold down parts, dowels, anchors, insulation etc. The primary objective, that for many years we keep on successfully fulfill, is to built a brand which is a symbol of high quality, with guaranteed durability and safety. We have our own R&D facility, through which we create complete solutions from design to implementation, providing the solutions that meet the needs of our clients, the industry and the market. There are plenty of granted protective rights and utility models of plastic elements for rail fastening systems, as well as many different technical products from the rail industry, that confirm the innovation of our company. Our knowledge and experience gives us the leading and recommended position as a partner of the top executive companies, co-operators in the rail and construction industry. The high quality standards of our products are confirmed by the conducted performance tests, admissions and certificates granted by accredited laboratories, technical and research institutions in accordance with the standards of the European Union. that the new project is treated as a dedicated service. We work with a passion. You are welcome to cooperate! Many years of tradition combined with the innovation and individual approach to the customer makes Izabella Wałkowska CEO 3 Quality 4 The smooth functioning of the Quality Control System is a key to success To assure the highest quality of any undertaken actions, PLASTWIL operates according to the implemented principles of an Integrated Management System in relation to the following standards: •Quality assured to PN-EN ISO 9001:2009, •Environmental Management System assured to PN-EN ISO 14001:2004. The certificate of TÜV Rheinland certification body is a proof of the fulfillment of this requirements, as well as an implemented Production Control System as a 2+ compliance assessment system with technical approvals issued by the Railway Institute. All of the products have a required certificates of approval to operation in accordance with the requirements of the European law. In order to raise the standard of service PLASTWIL uses its own, modern laboratory and runs full control over all important areas of production. In this way company ensures, so important in the area of its operations, safety and long life of products built in the track surface. Adaptation of the processes and products to the highest European and world standards allows the company to pursue highly professional and ambitious technological projects, while respecting and ensuring the highest quality parameters. 5 R&D 6 The company is based on the knowledge The company’s commitment in the field of continuous innovations is based on the use of knowledge, years of experience, developing human resources and investments. Directive Technical Specifications for Interoperability which allow for their introduction to the European market and other overseas markets. DESIGNING MODERN LABORATORY The high quality of the products and used technologies are based on a foundation of extensive research program conducted by the R&D department in the company. Top-class specialists and high quality measuring devices allow the improvement of technical solutions and the optimization of the functional characteristics of the products and the implementation of new innovations. The effect of dynamically executed research program are further patent applications implemented over the years. COMPLIANCE WITH DIRECTIVES, INCLUDING TSI PLASTWIL development engineers use in their work CAD software (Solid Edge)/CAM software (NX), which combined with their experience and knowledge gives our products the highest quality standards. CUSTOMER SERVICE AND SUPPORT Details and injection molds are designed in terms of: •Technical Drawing/3D Models. Services and service in terms of: •Production of injection molds, •Generating the path of a tool for CNC machines (CAM), •Modification of the forms (machining). Company’s products are designed, produced and tested in accordance with the applicable standards and 7 Team 8 An infinite optimism in the continuous pursuit of excellence PLASTWIL is made up of people whose value is not only expertise, but also a personal commitment to the continuous development of the company. Creative and open to innovation are eager to seek sensational solutions. They work with a passion, which translates into the highest quality projects. Our specialists are not only engaged in business, but also wish to change reality, and operate in accordance with ethical values. Our five principles are: freedom, responsibility, quality, efficiency and reciprocity. Atmosphere of trust and respect make all the tasks of all project stages, regardless of their degree of complexity, easy to carry in a both professional and timely manner. Quality refers to all elements of our work, but above all it concerns what finally is delivered to the customers. 9 We build the future 10 The complex rail fastening systems PLASTWIL company in 1983 started the production of the minor elements of the rail surface, such as: dowels and rail pads to the conventional rail fastening system of a K-type. Successively and consistently with other companies and research units PLASTWIL had implemented in Poland the rail fastening system of a SB-type, in particular had developed the most popular in the Central and Eastern Europe the rail pads and insulation parts. The rail fastening system of SB-type is the most popular and is used in Poland and Central and Eastern Europe since the 80s of the twentieth century. That system can be applied to all categories of railway lines in accordance with EN 13481-2: 2012 and tram lines. PLASTWIL with many years of experience in the design, testing and implementation of this system has gained a high competence in the knowledge of the rail fastening systems. As a result of continuous development, company gradually implement more innovative products to the rail surface, extending its offer also for the metal parts. The company’s goal is to be a professional manufacturer of a complete rail fastening system in the framework of a long-term strategy. In the next stage of business development, company implemented the production of spring clips. Currently, company designs and optimizes all elements of the system making sure they are the best. As a result of all these activities combined with the technical and scientific inputs, PLASTWIL developed two optimized SB-type systems: •resilient rail fastening system of SB W1-type, •resilient rail fastening system of SB W3-type, and •the rail fastening system W14. All systems are characterized by a rapid and simple installation, vibration damping coming from the rolling stock as well as the electrical insulation limit to minimum traction stray currents. These products provide the best resistance to the load, the highest damping coefficients, the highest quality and economical efficiency of the use. 11 The rail fastening system of SB-type The rail fastening system of SB-type is used only on the pre-stressed monoblock sleepers. The rail laid on the surface of the rail pad between anchors (constantly sunk in the sleeper) is mounted with the SB-type spring clip, connected from one side to the anchor, on the other hand like a spring pressing the top of rail foot. Under the rail foot additionally the rail pad is placed, while the rail foot is insulated from the rail clip and anchors with electro-insulating hold-down parts. 1 2 3 4 CHARACTERISTICS AND ADVANTAGES OF THE RAIL FASTENING SYSTEM OF SB-TYPE: reducing the transmission of vibrations from the rail to the sleepers and ballast electrical insulation reducing to minimum traction stray currents high durability in service and adaptation to the high speed railway THE COMPONENTS OF A SB-TYPE RAIL FASTENING SYSTEM: 1 rail pad of PKW-type (str. 25) 2 electro-insulating hold-down part of WKW- type (str. 19) 3 casting iron anchor SB 3/3 (str. 45) 4 rail clip SB4 Vossloh-type reducing the level of noise in the passenger cars a small number of the components; rapid and easy installation the possibility of using the mechanical mounting devices 12 The rail fastening system of SB W1-type The rail fastening system of SB W1-type is an optimized version of the SB-type rail fastening system with PWE-type rail pad which is designed and manufactured by PLASTWIL. Its main advantage is a high ability to attenuate impact load of 54%. This ability allows it to be classified into the category of high vibration damping in accordance with the requirements of EN-13481-2: 2012. The SB W1-type rail fastening system successfully passed performance tests. The PKW-type rail pad has been used in Poland since 2006. 1 2 3 4 CHARACTERISTICS AND ADVANTAGES OF THE RAIL FASTENING SYSTEM OF SB W1-TYPE: shape and PWE-type rail pad material significantly improves the resilience and the static and dynamic stiffness THE COMPONENTS OF A SB W1-TYPE RAIL FASTENING SYSTEM: electric insulation between the rail foot and the sleeper 1 reducing the dynamic interactions of rolling stock transmitted through the rails on the sleepers rail pad of PWE-type ! PLASTWIL INNOVATION! (str. 23) 2 electro-insulating hold-down part of WKW-type (str. 19) 3 casting iron anchor SB 3/3 (str. 45) 4 rail clip SB4 Vossloh-type PWE-type rail pad can be used in the rail fastening systems to all kinds of pre-stressed monoblock sleepers and turnouts and concrete turnout sleepers 13 The rail fastening system of SB W3-type The rail fastening system of SB W3-type is a next modification of SB-type rail fastening system, where all of the rail mounting elements are designed and produced by PLASTWIL. The technological innovation has been applied to the construction and technological characteristics of SB8-type rail clip and electro-insulating hold-down part of WIW-type. This system is characterized by the optimized parameters responsible for the way rail is fastened. The SB8-type rail clip can be used alternative to SB4-Vossloh type rail clips. The unique bending technology and high quality material guarantee that the product ensures the required pressure of the rail to the sleeper, as well as the possibility of resilient deformation of the rail in a horizontal plane by the action of lateral forces. 1 2 CHARACTERISTICS AND ADVANTAGES OF THE RAIL FASTENING SYSTEM OF SB W3-TYPE: the unique construction of SB8-type rail clip effect on smaller change of the clamping force as a result of exposure to repeated loading guaranty of stability of SB8-type rail clip during the longterm service (without the risk of disconnection by itself) improved quality of SB8-type rail clip, favorable stress distribution in the arms of the rail clip WIW-type electro-insulating hold-down part of WIWtype reduces the utility costs without loss of performance parameters, thanks to the reduced weight and its asymmetrical shape the used combination of PWE-type rail pad and SB8-type of rail clip allows to obtain a very high ability to attenuate impact loads of 61,2% 14 3 4 THE COMPONENTS OF A SB W3-TYPE RAIL FASTENING SYSTEM: 1 rail clip SB8-type ! PLASTWIL INNOVATION! (str. 49) 2 electro-insulating hold-down part of WIW-type ! PLASTWIL INNOVATION! (str. 21) 3 rail pad of PWE-type ! PLASTWIL INNOVATION! (str. 23) 4 casting iron anchor SB 3/4 ! PLASTWIL INNOVATION! (str. 45) The rail fastening system of SB-type to the tram lines The rail fastening system of SB-type to the tram lines works with the pre-stressed monoblock sleepers using tram rails of the following types: R1, R2 and 180S. The rail laid on the surface of the rail pad between anchors (constantly sunk in the sleeper) is mounted with the SB8-type rail clip (or interchangeably with SB4 Vossloh typ), connected from one side to the anchor, on the other side like a spring pressing the top of rail foot. Under the rail foot additionally the rail pad is placed, while the rail foot is isolated from the spring clip and anchors with electro-insulation hold-down part. CHARACTERISTICS AND ADVANTAGES OF SB-TYPE RAIL FASTENING SYSTEM TO THE TRAM LINES: reducing the transmission of vibrations from the rail to the sleepers and ballast electrical insulation reducing to minimum traction stray currents high durability in service reducing the level of noise a small number of the components; rapid and easy installation the possibility of using the mechanical mounting devices THE COMPONENTS OF A SB-TYPE RAIL FASTENING SYSTEM TO THE TRAM LINES: • rail pad of PKW 170/220-type • electro-insulation hold-down part of WKW-type • r ail clip SB8-type (or interchangeably with SB4 Vossloh type) • casting iron anchor SB 3/3, SB 3/4 15 The rail fastening system of W14-type The rail fastening system of W14-type is well-known and proven all over the world. In this system the rail is mounted with the W-shaped tension clamps, screws and angular guide plate Wfp 14K. The rail is based on the rail pad. The central loop of the spring clip allows the fastening system to have an additional elasticity what excludes the possibility of arms overload and their plastic deformation. It also prevents the rotation of the rail. 1 2 3 4 5 CHARACTERISTICS AND ADVANTAGES OF THE RAIL FASTENING SYSTEM OF W14-TYPE: simple installation, all of the components can be pre-assembled to the sleeper before taking it to the construction site THE COMPONENTS OF A W14-TYPE RAIL FASTENING SYSTEM: the construction and characteristic of tension clamp Skl limiting the rotation of the rail when running through narrow track curves 1 rail pad Zw900 2 angled guide plate Wfp 14K high rail resistance value to longitudinal displacement, which prevents the dangerous deformations of the rail in the contactless tracks 3 tension clamp Skl 14 4 dowel Sdu25 5 sleeper screw Ss35 + ULS7 all components are exchangeable 16 The conventional rail fastening system of K-type The rail fastening system of K-type is a conventional system that can be commonly found on the polish railway lines. It is applied on the both wooden sleepers and pre-stressed monoblock sleepers. The base plate is assembled to the sleeper. Underneath the base plate needs to be additionally mounted under-base plate pad. Under the rail foot the rail pad is placed. The clip Łpa 2 connects the rail to the sleeper. 1 2 3 4 5 6 THE COMPONENTS OF A K-TYPE RAIL FASTENING SYSTEM: CHARACTERISTICS AND ADVANTAGES OF THE RAIL FASTENING SYSTEM OF K-TYPE: the possibility of applying with both wooden sleepers and pre-stressed monoblock sleepers electrical insulation between the rail and sleeper is provided 1 base plate 2 under-base plate pad (only for pre-stressed monoblock sleepers) 3 rail pad 4 screw dowel 5 screw 6 Łpa 2 clip 17 Electro-insulating hold-down parts 18 Electro-insulating hold-down part of WKW-type The electro-insulating hold-down part is used in SB-type rail fastening system and perform the following functions: •providing the electrical insulation of at least 5 kΩ, necessary for the reliable operation of railway traffic control devices, •providing the proper transfer of clamping force of the rail clip to rail foot ( up to 10 kN), Electro-insulating hold-down part type •ensuring the tolerated gauge, •protecting the anchor against the contact with the rail foot. Electro-insulating hold-down part of WKW-type can be used interchangeably with electro-insulating holddown part of WIW-type. Dimension [mm] a b c WKW 49 41 66 10 WKW 60 41 66 10 WKW 60G 40 66 12 a – height of the electro-insulating hold-down part b – width of the electro-insulating hold-down part c – l ength of the electro-insulating hold-down part 19 Electro-insulating hold-down parts 20 Electro-insulating hold-down part of WIW-type The electro-insulating hold-down part of WIW-type is a result of several years of work of company’s R&D department. The product features are: •visible asymmetry of the shape that ensures the correct assembly process, •narrower recess under the spring clip, that guarantee the favorable stress distribution at the Electro-insulating hold-down part type interface of spring clip and electro-insulating holddown part. Electro-insulating hold-down part of WIW-type can be used interchangeably with electro-insulating holddown part of WKW-type. Dimension [mm] a b c WIW 49 40,5 66 10 WIW 60 40,5 66 12 WIW 60G 41 66 12 a – height of the electro-insulating hold-down part b – width of the electro-insulating hold-down part c – l ength of the electro-insulating hold-down part 21 Shaped rail pads 22 Rail pad of PWE-type The rail pads of PWE-type in the rail fastening systems (f.e. SB-type) serve to provide an adequate electrical insulation between the rail foot and the sleeper or turnout sleeper. Moreover, rail pads reduce the dynamic effects of the rolling stock transmitted by the rails and possibly through the ribbed base plates to the sleepers or turnout sleepers. The PWE-type rail pad produced by PLASTWIL can be easily found on the different railway line sections in both Poland and Europe. Furthermore, these rail pads meet the highest requirements of the applicable standards. Dimension [mm] Rail pad type Rail type Sleeper type 72 60E1 PS-94 8 72 60E1 PS-93 150 8 72 60E1 PS-83 145 125 8 72 49E1 PS-94 169 145 125 8 72 49E1 PS-93 169 145 125 8 72 49E1 PS-83 a b c d e f PWE6094 160 194 170 150 8 PWE6093 150 194 170 150 PWE6083 130 194 170 PWE4994 160 169 PWE4993 150 PWE4983 130 a – length of the rail pad b – width of the rail pad c – mid-width of the rail pad d – width of the rail pad e – height of the rail pad f – mid-length of the rail pad 23 Shaped rail pads 24 Rail pad of PKW-type The rail pads of PKW-type in the rail fastening systems (f.e. SB-type) serve to provide an adequate electrical insulation between the rail foot and the sleeper or turnout sleeper. Moreover, rail pads reduce the dynamic effects of the rolling stock transferred by the rails or base plates to the sleepers or turnout bearers. The PKW–type rail pads can be also used as under-base plate pads in turnouts and concrete turnout bearers. Dimension [mm] Rail pad type Rail type Sleeper type a b c d e f PKW 60A 160 200 170 150 8 72 60E1 PS-94 PKW 60K 154 200 170 150 8 72 60E1 PS-93 K-83, INKB-7 PKW 60Ps 136 200 170 150 8 72 60E1 PS-83 PKW 49A 168 175 145 125 8 72 49E1 PS-94 PKW 49K 154 175 145 125 8 72 49E1 PS-93 K-83, INKB-7 PKW 49Ps 136 175 145 125 8 72 49E1 PS-83 a – length of the rail pad b – width of the rail pad c – mid-width of the rail pad d – width of the rail pad e – height of the under rail pad f – mid-length of the rail pad 25 Flat rail pads 26 Rail pad of B, D and R-type for conventional K-type rail fastening system The flat rail pads are used to the wooden and concrete sleepers ( f.e. K-type) and to the turnouts (f.e. K-type) to ensure the electrical insulation between the rail foot and sleeper or turnout bearer as well as to reduce the dynamic effects of the rolling stock transmitted by the rails and possibly through the ribbed base plates to the sleepers or turnout bearers. Flat rail pad type Dimension [mm] Rail type Sleeper type 132 60E1 concrete 166 180 60E1 wooden B 118 132 49E1 concrete D 166 180 49E1 wooden R 166 180 60E1 concrete/wooden a b B 118 D a – internal width of a rail pad b – external width of a rail pad 27 Flat rail pads 28 Rail pad for conventional K-type rail fastening system The rail pad for conventional 60E1 rail fastening for concrete sleepers is intended for use as the rail pad in indirect rail fastening systems for concrete sleepers. Rail pad type for conventional 60E1 rail fastening a – hole spacing Dimension [mm] a b 315 ø26 Rail type 60E1 b – hole diameter 29 Turnouts 30 Turnouts The rail pads are divided into sets depending on the rail type and turning radius. The following sets of rail pads are assigned to the 49E1-type of rail: •49E1-190 •49E1-300 •49E1-500 The following sets of rail pads are assigned to the 60E1-type of rail: •60E1-190 •60E1-300 •60E1-500 •60E1-1200 •60E1-2500 PLASTWIL company produces sets of the rail pads of PKW and PWE-type to the turnouts in accordance with approved specifications and drawings of manufacturers of railway turnouts. 31 Rail pads for turnouts 32 Rail pad for turnouts The rail pad – both flat and shaped – of PKW and PWE type can be also used as the rail and sleeper pads in turnouts on wooden and concrete turnout sleepers. An example of technical drawing of rail pad for turnouts. ATTENTION: width, length, hole spacing – alternatively, in accordance with the drawings and specifications of the manufacturers of the railway turnouts. Dimension [mm] Rail pad type for turnouts a – hole spacing b – hole spacing a b c d 310 90 170 385 c – width of a rail pad d – length of a rail pad 33 Insulating elements of the rail joint 34 Longitudinal rail insulating spacer The insulating elements are used in insulating rail joints of the 49E1 and 60E1 rails to ensure the reliable operation of railway traffic control devices. Dimension [mm] a – length of a spacer Spacer type Rail type 6-hole a b 49E1 920 24 4-hole 49E1 590 34 6-hole 60E1 950 43 4-hole 60E1 620 43 b – width of a spacer 35 Insulating elements of the rail joint 36 Transverse insulating rail spacer The insulating elements are used in insulating rail joints of the 49E1 and 60 E1 rails to ensure the reliable operation of railway traffic control devices. The transverse insulating spacers are used between the end faces of rails in the joint. Spacer type Dimension [mm] a b c d for the rail 49E1 67 39,8 149 125 for the rail 60E1 72 37,5 172 150 a – width of the head b – height of the head c – height of the rail d – width of the foot 37 Insulating elements of the rail joint 38 Insulating sleeve The insulating elements are used in insulating rail joints of the 49E1 and 60E1 rails to ensure the reliable operation of railway traffic control devices. The insulating sleeves are used in the openings for connecting bolts. 1 x4 5° b a Sleeve type insulating a – length of the insulating sleeve c Dimension [mm] a b c ø27 ø30,5 ø25 b – exterior diameter of the insulating sleeve c – interior diameter of the insulating sleeve 39 Screw dowels 40 B and C-type screw dowels with a cylindrical opening for pre-stressed monoblock sleepers The B-type screw dowels are intended for the use of the 60 A screws for fastening the base plates to the concrete sleepers. The C screw dowels are intended for the use of the 42R screws for fastening the pads and base plates to the turnout sleepers and MIROSŁAW-type external crossing slabs. The screw dowels are used in: •Pre-stressed monoblock sleepers as a component of the K-type rail fastening •Pre-stressed monoblock turnout sleepers as a component of the fastening of turnout parts •Beams supporting the level crossing structure as a component of the slab fastening. Dowel type Dimension [mm] a b c Screw dowel of C-type 15 167 Screw dowel of B-type 12 140 ø17 ø16,5 a – height of the dowel’s collar b – length of the dowel c – dowel diameter, thread outline 41 Screw dowels 42 Four-split dowels for sleeper regeneration The four-split dowels are used for the regeneration of wooden and concrete sleepers. Dimension [mm] Dowel type 4-split dowel for sleeper regeneration a – length of the dowel a b c 117,5 ø23,5 ø50 b – interior dowel diameter c – exterior dowel diameter 43 Metal parts 44 Casting iron anchor for rail fastening system of SB-type Casting iron anchor of SB-type is intended for use in a rail surface as a part of the rail fastening system, only with concrete sleepers. The anchors serve to fasten a 60E1 and 49E1 rail to a concrete sleeper. SB 3/4-type of an anchor SB 3/3-type of an anchor Anchor type a – length of the anchor They allow to keep the an adequate track gauge and adequate resistance to lateral displacement of the rails. The anchors are made from the special spheroidal casting iron 500-7 to provide the high tensile strength of the material while ensuring the high impact strength. Dimension [mm] a b c SB 3/3 190 50 33 SB 3/4 175 50 33 b – width of the anchor’s head c – hole spacing 45 Metal parts 46 Rail clip SKL-type The spring clips are used in the rail fastening system to the rails of a type: 49E1 or 60E1 and tram lines of types: R1, R2 and 180S. The spring clip ensures the suitable pressure to prevent the rails displacement relative to the sleepers Dimension [mm] Rail clip type SKL 14 a – height of the rail clip b – length of the rail clip a b c d 46 152 17,5 28,5 c – width of the lower part of a rail clip d – width of the upper part of a rail clip 47 Metal parts 48 Rail clip SB8-type The innovative rail clip of SB8-type was created as a result of the work of the specialists from the R&D department of PLASTWIL company. The rail clips are used in the rail fastening system to the rails of a type: 49E1 or 60E1 and tram lines of types: R1, R2 and 180S. The rail clip ensures the suitable pressure to prevent the rails displacement relative to the sleepers. Advantages of rail clip SB8-type: •Significant reducing of bending stresses and plastic deformation that arise in the spring clip shaping process, •Improved quality of the installation of the spring clip in the anchor, •Much less loss of the performance parameters during the operation, compared to the conventional rail clip. Dimension [mm] Rail clip type SB8 a – height of the rail clip b – length of the rail clip a b c d 82 102 34 58 c – width of the lower part of a rail clip d – width of the upper part of a rail clip 49 Metal parts 50 Face pressing The face pressings made from 3 mm-thick steel plates with a suitably profiled shape are used as wearing-iron of the face profile of reinforced concrete slabs, which are components of the modern MIROSŁAW-type crossing surface that is used for the construction of the intersection of a railway track with a road at rail level. PLASTWIL company has the ability to perform other profiles to individual customer order. Dimension [mm] Pressing type Face a – width of the pressing a b c 167 598 80 b – length of the pressing c – height of the pressing 51 Plastwil Spółka z ograniczoną odpowiedzialnością Sp. j. ul. Wierzbowa 2 | 64-850 Ujście | tel. +48 67 28 40 740 | fax. +48 67 28 40 378 [email protected] | [email protected] | www.plastwil.pl Information in this catalog does not constitute an offer within the meaning of Art. 66 et seq. Civil Code but are for informational purposes only. All rights reserved.
© Copyright 2025 ExpyDoc