FFU Synthetic Sleeper Patrick Childs UK Sales Manager – Sekisui Chemical

FFU synthetic sleeper

SEKISUI Chemical Co., Ltd.

70 years leading manufacturer of synthetic products Worldwide more than 200 subsidiaries Approx. 23.000 employees

Annual Turnover SEKISUI Chemical Co. Ltd.

[billions €]

2014 2015 2016

9.100 9.080 8.850

Business Units

High Performance Plastics

Housing

Urban Infrastructure and Environmental

Pultrusion process

Fibre reinforced Foamed Urethane

Since 1980 | 1.400 km track

1 2

Glass fiber supply Impregnation, Spray Molding Cooling Pulling Cutting Finishing & Inspection

Continuous glass-fibre and Polyurethane FFU sleepers are manufactured by Pultrusion. Glass fibers are soaked in polyurethane and the linkage is then hardened at a raised temperature

glass fiber before adding polyol

molding pulling

Long glass fiber

Foamed Urethane

ISO 9001 Management System Certificate ISO 14001 Environmental Management certificate

Possible dimensions: •  Up to 10 m length, •  Up to 600 mm width, •  height according request.

Milling and Drilling

Fabrication of FFU sleeper

Since 1980 | 1.400 km track

Bonding of basic sleeper

FFU will be milled to adjust height very precisely (mm). Holes will be drilled according to the drawings from the customer.

basic sleepers after pultrusion

Switches | Bridges | Specials

Bridges Steel and Ballast

Switches

Slim tie

Since 1980 | 1.400 km track

Any kind of track

Direct Fixation

Slab track

Ballast track

Since 1980 | 1.400 km track

1980  Railway Technical Research Institute (RTRI) adopted FFU after laboratorial approval in Japan and started the following field tests:

Miomotegawa Bridge of Uetsu Line Kanmon Tunnel of Sanyo Line

1985  very good results of field tests

FFU sleeper became a approved standard product of JNR 1991  RTRI reported the results of 10 years field tests, which showed almost no deterioration.

Application of FFU by private and municipal railways. 1996  RTRI reported the results of 15 years field tests, which indicated that the strength

deterioration of 15 year old wooden sleepers will be equal to the strength deterioration of 50 year old FFU sleepers.

2007  Japanese Industrial Standard JIS 1203 2011 RTRI tested FFU sleeper installed in 1980 positive – announced further use for the next 20

years positive to JR

Historical development - 35 years in service

Since 1980 | 1.400 km track

Historical development Europe since 2004

2004  Austria: First FFU Railway project in Europe, Metro bridge in Vienna

2008  Germany: 16 cm FFU sleeper positive tested by TU Munich First switch on FFU in Germany – Chempark Leverkusen

Austria: LCC Analysis TU Graz - FFU is more economical than wood at bridges

2009  Germany: Approval of FFU by EBA for German Railway Infrastructure

2011  Germany: Deutsche Bahn – first Bridge with FFU sleepers and low height sleepers

2012  Germany: Deutsche Bahn – two switches 70,000 t/day & sleepers & bridges Netherland: Pro Rail installed 3 bridges

2013  Austria: Wiener Linien installed 78 switches with FFU Germany: 12 cm slim tie positive tested by TU Munich - 22,5 t axel load | 200 km/h

2014  Switzerland:BAV approval for FFU sleepers starting by 12 cm height RHB - bridges plus slim ties 12 cm | BLS - switches

UK: Network Rail longitudinal (40/40/750cm) and regular bridge sleepers World: ISO Standard 12856-1 for synthetic sleepers enters into force

2015  Belgium: Infrabel: first bridge project France: Tisseo Toulouse: two switches in slab track Switzerland: SBB first switch project UK: Network Rail longitudinal sleepers in a curve

2016  France: Keolis – 2 switches in slab track RATP uses FFU 100 for switches at slab track Norway: Jernbaneverket – first bridge project UK: LU first bridge project Germany: TU Munich tested FFU 100 positive and lateral resistance test positive

2017  Germany: April 2017 - final approval from EBA UK: November 2017 final certification for all bridge types Sweden: SL: Stockholm center bridge with 5 tracks Ireland: Irish Rail: bridge in Limerick

Since 1980 | 1.400 km track

Worldwide approximately 90.000 FFU Synthetic Sleepers are installed annually Accumulated installation amount until 2015 has become more than

2,2 million sleepers 1.400 km of track

FFU sleepers installed since 1980

Since 1980 | 1.400 km track

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[1000pcs.]

Thou

sand

sleepe

rs230

/140

/220

0mm

Technical properties

property unitbeech FFUsynthe1cwood

standardnew new 10years 15years 30years

density [kg/m3] 750 740 740 740 740 JISZ2101

flexuralstrength [kN/cm2] 8 14,2 12,5 13,1 11,7 JISZ2101

elasHcmodulus [kN/cm2] 710 810 800 816 816 JISZ2101

Compressivestrength [kN/cm2] 4,0 5,8 6,6 6,3 6,0 JISZ2101

Shearstrength [kN/cm2] 1,2 1,0 0,95 0,96 0,93 JISZ2101

hardness [kN/cm2] 1,7 2,8 2,5 2,7 2,4 JISZ2101

Impactflexuralstrength+20°C [J/cm2] 20 41 - - - JISZ2101

-20°C [J/cm2] 8 41 - - - JISZ2101

WaterabsorpHon [mg/cm2] 137 3,3 - - - JISZ2101

InsulaHonresistancedry [Ω] 6,6x107 1,6x1013 2,1x1012 3,6x1012 8,2x1011 JISK6852

wet [Ω] 5,9x104 1,4x108 5,9x1010 1,9x109 - JISK6852

Pull-outforcedognail [kN] 25 28 28 23 22 RTRI

Pull-outforcescrew [kN] 43 65 - - - RTRI

Since 1980 | 1.400 km track

EBA (German Railway Authority), research of: •  The impact of vertical and horizontal loads during the effect of repeated

loading. Bedding in ballast track DIN-EN 13481-3 •  Tightening torque tests: determine tensile strength of sleeper screws

depending on torque moment. •  Sleeper screw extraction tests DIN EN 13481-2. (concrete sleeper) •  Impact tests to simulate derailment •  Electrical resistance in accordance with DIN EN 13146-5 •  Static/dynamic tests according DIN EN 13230-2.(concrete sleeper)

TU Munich September 2008 Since 1980 | 1.400 km track

Up to a load of 240 kN, corresponding to a tensile bending strength of 74 N/mm² on the bottom of the sleeper, no crack was detected within the bending area where flexural tension was applied.

Static Tests at Sleeper Centre

Static Pressure Test Up to a load of 150 kN no plastic deformation was detected Thus, a load of 300 kN (supporting force) below the rib plate shows a plastic deformation of a maximum of 0.8 mm. Generally the support force for an axle load of 250 kN is 150 kN under the most severe conditions.

Static Bending at T = RT and T = -10°C FFU sleepers were stored in a climate-controlled environment at T=-20°C for two days. The average testing temperature is T = -10°C . The sleeper shows no signs of embrittlement at low temperatures. A comparison of deformation results does not show any significant differences. Test of temperature dependency of sleeper deformation behavior showed no significant bending differences at T=RT and T=10°C. At T= -10°C there is no noticeable brittleness due to temperature variation. Deformation is predominately purely elastic.

TU Munich September 2008 Since 1980 | 1.400 km track

Coefficient of thermal extension For FFU 74 sleepers is 0,79 x 10-5/°K = 0,0000079 m/°K Delta T = 50 °C leads to 1 mm extension for a 2,600 mm long sleeper

Lateral resistance of FFU synthetic sleepers comparing with wood 45 sleepers from each type have been installed in ballasted track. 15 sleeper of each type have been tested. The unconsolidated test happened after the installation Consolidated test happened after 1 year and around 23 million load tonnes were running over it

Lateral resistance test October 2016 Since 1980 | 1.400 km track

Approvals in Europe 2017 Europe: 2017 - EC Certificate Germany: 2017 - final Approval for FFU starting by 10 cm height

and for a speed up to 230 km/h Switzerland: 2018 – final approval starting by 12 cm height sleeper Netherland: 2015 – certification for railway use United Kingd: 2017 – certification for all bridge applications

Approvals in Europe 2017 Since 1980 | 1.400 km track

Details of final EBA approval for Germany

Easy repair For example: Fastening position may be readjusted by filling nail holes

Optimize your solutions with FFU

Since 1980 | 1.400 km track

FFU Joint sleeper for Switches On site is it realizing high tolerances with all FFU materials Advantages: No short circuit Shorter working time ( approx.1.5 hours/pcs/5persons for connection) Possible to attach base plates almost everywhere Bending strength at the connecting part of the FFU joint sleeper is lower than that of regular sleeper - as you can see on the diagram. But it has sufficiently high bending strength, wider elastic area and the same young’s modulus as regular sleeper, therefore, it can be used in track safely

Joint sleeper - Switches Since 1980 | 1.400 km track

Manufacturing of FFU

Since 1980 | 1.400 km track

Customized production

Since 1980 | 1.400 km track

Handling at the project Drilling, sawing, chiselling

Since 1980 | 1.400 km track

Projects in Japan since 1980 Bridges – open steel constructions – concrete

Since 1980 | 1.400 km track

Projects in Japan since 1980 Switches – ballasted track - slab track

Since 1980 | 1.400 km track

Bridge, Switches, 38 t Axel load Projects in Australia since 2011 Since 1980 | 1.400 km track

Projects in Austria since 2004 Bridges & switches

Since 1980 | 1.400 km track

Projects in Germany since 2008 Ballast, bridge, switches, slim tie

Since 1980 | 1.400 km track

Projects in Russia since 2008 Switches

Since 1980 | 1.400 km track

Projects in Netherland since 2012 Bridges

Since 1980 | 1.400 km track

Projects in Switzerland since 2014 Bridges & switches

Since 1980 | 1.300 km track

Projects in the United Kingdom since 2014 Longitudinal baulks, cross sleepers and run on and off

Since 1980 | 1.400 km track

Projects in the United Kingdom since 2014

Longitudinal baulks – frame | London Underground

Since 1980 | 1.400 km track

Projects in Belgium since 2015 Since 1980 | 1.400 km track

Bridge

Projects in France since 2015 Since 1980 | 1.400 km track

Switches

Projects in Norway since 2016 Since 1980 | 1.400 km track

Bridge

Projects in Ireland since 2017 Since 1980 | 1.400 km track

Bridge

Projects in Sweden since 2017 Since 1980 | 1.400 km track

Bridges

Track crossings

Since 1980 | 1.400 km track

2008 2017

Recycling 100% & Sustainability K-FFU, R-FFU

Recycling

Since 1980 | 1.400 km track

SEKISUICHEMICALCO.,LTD.hasbeenselectedforthefourthyearinarow(starHng2012)bythe"WorldIndex"ofthe"DowJonesSustainabilityIndices(DJSI)"

Experienced Advantages

Customized sleepers mm exactly optimizing of design & profile

Form retentive always good bearing on construction

Easy & fast installation minimizes: installation costs / track closing time

Easy care/repair minimizes: installation time/sleeper amount

Chemical/oil resistance application in special areas

Ecological 100% recyclable

Maintenance very little; minimizes maintenance costs/time

High availability of track maximizing possible trains on the track

Workability/weight like wood, 740 kg/m3

Long life time reduces total cost of track and saves money for further project investments

LCC Analysis bridges, TU Graz, Prof. Veit and Dr. Maschnig, 2008 in order of ÖBB, life time of bridge longer than 15 years FFU more economical than wooden sleepers

switches, SBB, Dölf Egloff, 8.11.2013, 7 – 10% more economical than wood (50 years) up to 15% more economical than concrete sleepers if the substructure has to be improved

Since 1980 | 1.400 km track

SEKISUI CHEMICAL GMBH Königsallee106 40215 Düsseldorf Germany

TEL: +49-(0)211-36977-0 FAX: +49-(0)211-36977-31 E-Mail: contact@sekisui-rail.com www.sekisui-rail.com

Since 1980 | 1.400 km track

Q&A

FFU Synthetic Sleeper Patrick Childs UK Sales Manager – Sekisui Chemical