Turnouts are technically complex track components that cannot be adapted arbitrarily to adjacent structures. The design of the turnout sleeper must therefore be largely adapted to the turnout design. RAILONE has mastered these adaptation processes and also possesses the necessary expertise to manufacture the wide variety of different sleepers cost-effectively and to a consistent standard of quality. RAILONE reached a milestone in this regard in 2019 with the commissioning of its latest switch sleeper plant in Schwandorf. There, switch sleepers are manufactured using a highly automated and digitalised process, achieving productivity and quality that are unrivalled worldwide.
The pre-assembly of turnouts and large turnout assemblies, meaning the assembly of turnouts in the turnout production plant rather than at the installation site, offers not only economic advantages but, above all, significant quality benefits.
The transport of such pre-assembled turnout assemblies has historically not become widely established due to the limited availability and distribution of specialised transport wagons. To address this challenge, RAILONE worked closely with Deutsche Bahn to develop the Hinged Turnout Bearer, an innovation that received the CNA Innovation Award in 2011.
The Hinged Turnout Bearer makes it possible to fold those turnout sections that exceed the permitted transport width for standard transport (W > 3 m) into a compact position. In this folded state, they can be transported using standard flat wagons and subsequently returned to their operational position at the installation site.
Identical manufacturing and installation process as for non-divided long turnout sleepers
Cost-effectiveness: Reduced transport and installation costs, as well as shorter installation times
Quality: Hinged Turnout Bearers are subject to the same quality standards as non-divided long turnout sleepers
Flexibility:
High availability thanks to straightforward transport on standard freight wagons; divided and foldable Hinged Turnout Bearers with a rigid coupling joint
Folding back, unloading and installation using either a rail-mounted crane or a road-rail excavator
Standard application | Turnout sleeper |
Maximum speed | 250 km/h |
Axle load | 25 metric tons |
Length | 800–4,700 mm |
Width | 300 mm |
Sleeper height | 220 mm |
Weight | 155 kg/m |