Technology

Contrack is a technology concept for prefabricated turnouts, non-standard crossings and curved tracks, integrating a steel track layout structure with reinforced concrete slabs, using polyurethane material for continuous flexible rail fixing.

The advantage of prefabrication is quality resulting in high product durability. That is why we attach the greatest importance to our Quality Management System - CHECK IT OUT

technology technology technology

Polyurethane material for continuous elastic fastening of rails

Rail structure of a tram turnout

Road surface

Prefabricated concrete slab

Base layers and substrate provided for in specific design documentation

Vibration isolation mat (optional)

self-flowing, fast-curing cementitious grout

1

Polyurethane material for continuous elastic fastening of rails

2

Rail structure of a tram turnout

3

Road surface

4

Prefabricated concrete slab

5

Base layers and substrate provided for in specific design documentation

6

Vibration isolation mat (optional)

7

self-flowing, fast-curing cementitious grout

Comprehensive process

Our technology is comprehensive. Contrack includes both the production process, as well as safe logistics and efficient construction, and finally also the possibility of easy replacement of the steel part of the turnout or level crossing without compromising the reinforced concrete slabs.

1

Production

This stage involves the production of a specially designed tram turnout steel part (including the installation of switch drives, dewatering boxes and switch heating systems), a non-standard crossing or track curve and dedicated reinforced concrete slabs.
Precise fitting and adjustment of the entire system is performed at the factory and, ultimately, with less complex turnouts (such as one-track single), it will also be possible to integrate the entire system using polyurethane compound for continuous, flexible rail fixing. In the case of more complex track systems, final integration takes place at the construction site.
CONTRACK prefabricated elements are not mass-produced, they are designed and manufactured in accordance with a specific order. This requires the customer to account for the appropriate manufacturing time.

 

 

2

Logistic

The process of safe loading, transportation and unloading of a prefabricated elements of rail infrastructure is ensured through the use of appropriately selected machinery and equipment. The execution of these operations, depending on the context, involves the use of specialized wheeled overhead travelling cranes (transport and loading at the factory), PWP mobile gantry systems (precise unloading at the construction site, even under the overhead lines) and – if necessary, especially for long-distance transport – also specialized SWITCHER railway wagons for transporting oversized cargo.

 

3

Instalation

A refined construction process enables quick and correct installation of the prefabricated product. A prefabricated element is laid on the previously prepared substructure (additional vibration insulation mats may be used optionally). Then it is slightly lifted on hydraulic actuators, while a self-flowing, fast-curing cementitious grout is injected through special inspection holes. All components of the structure are connected and ultimately adjusted – the switch drive, switch dewatering or heating and control systems. Ultimately, the entire process described above should be completed within 72 hours, i.e. one weekend.

 

4

Maintenance

A key advantage of the CONTRACK technology is the capability of replacing the steel part of the track layout without damaging or removing the prefabricated reinforced concrete slabs. This is of considerable importance, assuming that the average service life of a tram turnout is three times shorter than that of concrete slabs. The solutions developed allow for the replacement of worn-out blades in switches (every 5 years), expansion joints between concrete slabs (every 10 years) and the entire track system (every 10–12 years). Also, when replacing a worn-out turnout, construction activities will be carried out over a standard weekend (72 hours).

 

zabudowa

Our know-how

usp-1

10 years

Production of factory-assembled railway turnouts

usp-2

600+

Logistics operations related to railway prefabricates

usp-3

20 yers

Manufacturing, installation and replacement of hundreds of tram turnouts

Advantages

Advantages of the CONTRACK technology            

time

Time saving is often a decisive argument when choosing technology, especially when it relates to construction works carried out in urban centers and the associated inconveniences. By moving a significant number of processes from the construction site to the manufacturer's factory, we significantly reduce the construction time of key elements of track infrastructure. Instead of the several weeks that are necessary, among other things, for the concrete layers to cure, we need a few days to install the turnout and integrate it with the road surface (bus and tram lanes, roundabouts, level crossings, transhipment terminals, cross-walks or bicycle crossings). Another important aspect is that the duration of works needed to replace the steel part of the turnout is shortened. Being able to remove the worn-out steel structure without compromising the reinforced concrete slab and then quickly lay a new turnout in the rail ducting provides a huge advantage for our technology.

shield

Prefabricated structures feature extended durability. This is due to the fact that they are made in a strictly controlled factory environment, unaffected by external factors (e.g. rainfall) with much greater accuracy regarding operations, dimensions, times, etc. The initial quality of the resulting prefabricated element is very high. Thus, when maintaining the highest standards of installation, we obtain a turnout, a track system or an entire junction perfectly integrated with the roadway and suitable for long-term, safe operation.

connection

An important advantage of prefabricated turnouts and level crossing is the unification of construction technologies used for both straight track sections and junctions. As the result, we are able to use the same construction and maintenance processes for very long sections. This positively affects the works organization and duration, reduction of interfaces between different technologies, which are problematic in terms of construction and operation, and consequently driving down the related expenses.

low-price

Significant savings are obtained in terms of the costs over the entire life cycle of a prefabricated turnout or level crossing. Using CONTRACK technology at the stage of construction works allows to avoid the operations and man-hours required for “wet” technology concrete grouting, works related to fitting and attaching the turnout structure to the poured slab and producing the surface layer (concrete, asphalt, paving stones).
Key savings occur during the operation of the entire prefabricated element. Since the durability of a concrete slab is about three times longer than that of a turnout steel structure, the ability to replace the latter without compromising the reinforced concrete structure means that as many as three turnouts can be installed in an efficient manner during the precast slab life cycle, reducing the cost and time of constructing a concrete grouting each time.

 

humanity

An important criterion that speaks in favor of the CONTRACK technology are the general hidden costs which accompany investment or renovation projects on the rail infrastructire and are borne by the local community, as well as the entity organizing public transport. Most importantly, these include the expenses related to organizing detours for individual vehicle drivers and maintaining alternate transportation. Efficient installation or replacement of prefabricated tram turnouts significantly reduces the time of using costly and time-consuming alternate traffic solutions, generating significant savings and reducing the social nuisance of construction processes.

Time

time

Time saving is often a decisive argument when choosing technology, especially when it relates to construction works carried out in urban centers and the associated inconveniences. By moving a significant number of processes from the construction site to the manufacturer's factory, we significantly reduce the construction time of key elements of track infrastructure. Instead of the several weeks that are necessary, among other things, for the concrete layers to cure, we need a few days to install the turnout and integrate it with the road surface (bus and tram lanes, roundabouts, level crossings, transhipment terminals, cross-walks or bicycle crossings). Another important aspect is that the duration of works needed to replace the steel part of the turnout is shortened. Being able to remove the worn-out steel structure without compromising the reinforced concrete slab and then quickly lay a new turnout in the rail ducting provides a huge advantage for our technology.

Durability

shield

Prefabricated structures feature extended durability. This is due to the fact that they are made in a strictly controlled factory environment, unaffected by external factors (e.g. rainfall) with much greater accuracy regarding operations, dimensions, times, etc. The initial quality of the resulting prefabricated element is very high. Thus, when maintaining the highest standards of installation, we obtain a turnout, a track system or an entire junction perfectly integrated with the roadway and suitable for long-term, safe operation.

Continuity

connection

An important advantage of prefabricated turnouts and level crossing is the unification of construction technologies used for both straight track sections and junctions. As the result, we are able to use the same construction and maintenance processes for very long sections. This positively affects the works organization and duration, reduction of interfaces between different technologies, which are problematic in terms of construction and operation, and consequently driving down the related expenses.

LCC Costs

low-price

Significant savings are obtained in terms of the costs over the entire life cycle of a prefabricated turnout or level crossing. Using CONTRACK technology at the stage of construction works allows to avoid the operations and man-hours required for “wet” technology concrete grouting, works related to fitting and attaching the turnout structure to the poured slab and producing the surface layer (concrete, asphalt, paving stones).
Key savings occur during the operation of the entire prefabricated element. Since the durability of a concrete slab is about three times longer than that of a turnout steel structure, the ability to replace the latter without compromising the reinforced concrete structure means that as many as three turnouts can be installed in an efficient manner during the precast slab life cycle, reducing the cost and time of constructing a concrete grouting each time.

 

Social costs

humanity

An important criterion that speaks in favor of the CONTRACK technology are the general hidden costs which accompany investment or renovation projects on the rail infrastructire and are borne by the local community, as well as the entity organizing public transport. Most importantly, these include the expenses related to organizing detours for individual vehicle drivers and maintaining alternate transportation. Efficient installation or replacement of prefabricated tram turnouts significantly reduces the time of using costly and time-consuming alternate traffic solutions, generating significant savings and reducing the social nuisance of construction processes.

Our offer
product

CONTRACK PBR

CONTRACK PBR (pol. płyty betonowe rozjazdowe), concrete turnout slabs - are advanced precast elements which integrate the steel structure of tram turnouts with specially designed reinforced concrete slabs using polyurethane material for continuous, flexible rail fixing.

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product

CONTRACK PBP

CONTRACK PBP (pol. płyty betonowe przejazdowe) – prefabricated dedicated tram crossings (long – several meters long, double, curved) installed under suspended overhead lines, integrating the reinforced concrete crossing surface with the track system using a specialized polyurethane material for continuous, flexible rail fixing.  

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product

CONTRACK PBL

CONTRACK PBL (pol. płyty betonowe łukowe)  – prefabricated dedicated tram curves installed under suspended overhead lines, integrating the reinforced concrete crossing surface with the track system using a specialized polyurethane material for continuous, flexible rail fixing.

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product

CONTRACK WM

CONTRACK WM (pol. wstawka międzysystemowa), inter-system insert module - is a component that allows a welded connection to be made between the steel pavement of a turnout and the pavement in a tangent track.

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product

CONTRACK PBPW

Expansion joint concrete slab (CONTRACK PBPW pol. Płyta Betonowa z Przyrządem Wyrównawczym), integrating a prefabricated concrete element with a track device, which eliminates track stresses resulting from thermal expansion of rail steel.

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Soon!

product

PBL Płyty Betonowe Łukowe

Product in preparation.

Multimedia

News

News
Forteczna for the second time

22 październik 2024

Forteczna for the second time

See article
Contrack Technology at the KZN Academy

17 październik 2024

Contrack Technology at the KZN Academy

See article
CONTRACK in less than 100 hours

28 sierpień 2024

CONTRACK in less than 100 hours

See article
Krakow with the CONTRACK tram crossing

19 sierpień 2024

Krakow with the CONTRACK tram crossing

See article
First CONTRACK tram crossing

13 sierpień 2024

First CONTRACK tram crossing

See article
We have ISO 1009:2015 certificate

02 lipiec 2024

We have ISO 1009:2015 certificate

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