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.

Reliable design

The key element of CONTRACK CTS is a massive, prefabricated reinforced concrete slab that includes all ducts and connections to enable efficient, long-lasting and trouble-free operation of the turnout. Thanks to refined reinforcement, rail ducting reinforcement and using appropriate concrete, Contrack design allows for:

embedding and connecting tramway switch drives;

placing and connecting electric switch heating;

installing dewatering boxes integrated into rainwater drainage ducts;

inspecting the condition of the prefabricated element and above-mentioned elements throughout the entire lifecycle, without compromising the structure of the reinforced concrete slab.

Most importantly, the design of the reinforced concrete slabs and the rail ducting placed in them allows for removing the worn-out steel turnout structure and replacing it with a new one, without damaging the structure of these slabs.

Obtaining such a complex slab design, which at the same time allows for maintaining slab durability, was possible thanks to cooperation with experts in the field of construction of reinforced concrete slabs used in the most operationally demanding locations, such as airport runways.

Durability and initial quality

The CONTRACK CTS technology includes the simplest one-track single tram turnouts, more complex double-track single or double turnouts, as well as the most advanced junctions used at intersections and roundabouts. In order to maintain durability and faultless operation of the prefabricated element, especially for systems which include multiple switches and frogs, a proper division of the slabs forming the base of the prefabricated structure is necessary.

Slab division

Therefore, in each case the starting point for creating a complete prefabricated element is the steel part of the track layout, which is analyzed to identify the most sensitive points (welded joints, moving parts, etc.). In the next step, a “map” of rail, connection, dewatering and inspection ducting is created, so the most optimal division of reinforced concrete slabs is developed at the very end.

Construction process

CONTRACK PBR prefabrication technology also includes safe transportation and precise unloading at the construction site, using appropriately selected machinery and logistics equipment. Reinforced concrete slabs integrated with the tram turnout are placed on a properly prepared and compacted substrate according to the design documentation. In order to reduce vibrations, vibration insulation material can be laid under the prefabricated element. For final binding of the structure with the substrate, the complete prefabricated slabs are lifted on special actuators to inject a self-flowing, fast-curing cementitious grout under them. At the end of the construction process, the prefabricated tram turnouts are integrated with the adjacent road surface dedicated to buses, cars, cyclists or pedestrians.