News for our costumers...
Calenberg launches new product line and production location
Calenberg is extending its product line for structure-borne sound and vibration protection in track bed structures with micro-cellular EPDM rail pads and base plate pads. A new production facility has been built at its Losheim location and went into operation in October.
A dedicated team of employees handles production and marketing of products. Initial projects at home and abroad have already been successfully completed.
JR Nagano trialled the use of portable noise protection measures on ballast tamping machines as part of a research project. In the trial, a shield of Cisilent was mounted closely around the drive without limiting the movement of the machine. JR Nagano has now published the results of the trial in the form of a report to other JR offices.
Air-borne sound was reduced by 38 dB, which meant a considerable reduction of the noise load on residents along the refurbished section of line.
The project shows that the measures provided effective noise protection for the people in the surrounding area, without adversely affecting the efficient use of the machine.
Live music during the Maschseefest is just one of the event's attractions. However, local residents are increasingly finding the bands' performances to be a nuisance.
For the first time during the festival an event stage was equipped with Cisilent in order to take into account both the residents' concerns and the wishes of the music enthusiasts. The modular sound proofing system was developed together with our partner Gerüstbau Samiez and will soon be available to rent.
Although we are still awaiting the results from the final measurements, first impressions are extremely positive.
Calenberg has prevailed against heavy competition and, together with its Chinese partners, provides support for elastic rail bearings in the railway and underground sector for over 50 major projects. Both ballasted and slab tracks are provided with proven sub-ballast or track mats.
In particular, the high quality of the vibration and structure-borne noise insulation, outstanding options for drainage in the tunnel area due to the special mat design and the long service life have contributed to the decision to use these Calenberg products.
Calenberg is meanwhile the undisputed market leader in this field on the world's largest market.
In the Katzenbergtunnel a high quality product of Calenberg
Ingenieure was installed as a mass spring system.
The works at the Katzenberg Tunnel are now complete. One of the many innovations realised on this project was the technologically advanced mass-spring system incorporating our proven USM 1000 W as the elastic element. More details in our References section.
Industry professionals are well informed about the advantages of truncated cone-shaped studs, which are responsible for the consistent dynamic effectiveness of our systems over a large range of loads. Now we can point to a further advantage for railway infrastructure operators when used in the construction and fitting out of tunnels and bridges: the drainage of track superstructures.
Water creates pressures in the permanent way, whether in tunnels or on bridges. A functioning drainage system is crucially important for the continuous long-term performance of the track superstructure. Full-contact elastic components of vibration protection systems make controlled drainage of track beds extremely complicated particularly when used in slab track.
The tunnel bottom or the bridge deck, which otherwise would offer a drainage path for rain water, is no longer fully available. Water fills and remains in even the smallest of voids because it cannot flow away. The problem is made worse if the elastic component itself absorbs water.
As a train passes, the dynamic effects interact with the inertia of the water. Because water is incompressible, this creates enormous hydrostatic pressures, which load the material and the track. Even with conventional ballast track construction, it is not good when water ponds on the surface of the elastic component and the track construction has to become a drainage system.
These Calenberg profiled mats with their truncated cone studs have no voids that water can penetrate and fill. The voids between the studs allow drainage in the longitudinal and transverse directions so that water, which cannot be prevented from penetrating the track construction, can be reliably conducted in a controlled way to the drainage outlets.
Slurries formed by ballast wear and sediments from the rocks surrounding a tunnel inevitably wash down to the plane of the elastic component. However, the deflection of the back of the sub-ballast mat when a train passes creates a pumping effect.
These flow processes taking place under the sub-ballast mat prevent deposits from building up between the studs. These under-mat flow processes cannot occur with full-contact elastic components.
Truncated cone profiled mats not only provide advantageous dynamic characteristics arising from their materials and shape, they also ease the task of providing controlled and effective drainage of modern railway track construction.
Calenberg exhibited at InnoTrans 2012 – the International Trade Fair for Transport Technology in Berlin - for the first time with its new trade fair stand to highlight the increasing importance of structure-borne noise and vibration protection in railway engineering.
The effort was rewarded with a thoroughly positive response to our redesigned trade fair branding. Even trade fair design professionals did not spare their compliments for the inspired stand design.
Many visitors from home and abroad praised not only the competence of the stand staff but also the excellent job we had made of the trade fair stand. For the first time, in addition to two new cooperation agreements with international partners, we also concluded supply agreements with customers at the stand. Once more this demonstrates that a fresh approach to presenting proven quality pays dividends.
De Uithof is a district of Utrecht and contains a large part of the university, the university hospital and several further educational facilities. The unique character of De Uithof owes much to the impressive architecture of its numerous buildings.
A 50,000 m² multi-storey car park with 2000 parking spaces, the largest in Utrecht, is currently under construction there. The high loads and large rotations are taken at the fixed bearing end by Calenberg Compact Bearings CR 2000.
The movements occurring at the free end are transferred by Calenberg Perforated Sliding Bearings. The precast members can have more slender dimensions thanks to the low maximum friction value of 2.3 %. The selection and design of the elastomeric bearings was undertaken in conjunction with Hurks Delphi Engineering.
The English edition of our book "Satisfying the highest Requirements
of Elastomeric Bearings for the Buildings & Civil Engineering
Industry" by Calenberg Ingenieure has been published.
We are proud that the second book by Calenberg Ingenieure is now also available for the international market.
A number of inventions as well as pioneering products and services are referred to in the book, which also contains guidance and technical rules that every engineer will find useful in practice. The book is available and can be requested directly from us.
Our new office in Berlin, Wielandstrasse 4, is now open.
The Synchrotron is a particle accelerator in which charged elementary particles can be accelerated to very high velocities with the result that they possess very high kinetic energy.
The particles are - depending on the energy level reached - directed along a continuous path by adjustable magnetic fields during which they approach the speed of light.
To protect this highly sensitive system against undesirable vibrations, as was done for the DESY (Deutsches Elektronen Sychrotron) and CERN (Conseil Européen pour la Recherche Nucléaire) particle accelerators, the designers called upon Calenberg elastomer technology.
The crucial components are supported on Cibatur mats while vertical decoupling is achieved with Civerso, a closed-cell, microcellular EPDM.
Two connected six- and eleven-storey buildings are being constructed in an industrial zone on the edge of Moscow directly adjacent to Sheremetjevo Airport. The project is expected to have cost more than EUR 150 million by mid-2013, when the new buildings, which have a total usable floor area of 57 000 square metres, are planned to be ready for occupation.
The beams in the roof construction are supported on Calenberg Perforated Bearings 205-ST, which can be loaded up to a compressive stress of 25 N/mm².
The free ends of the beams are allowed to move by Perforated Sliding Bearings, which centre the load and distribute angular distortions as well as accommodate the horizontal deformations of the beams at the supports with an extremely low coefficient of friction of less than 2 %.
The Bureau of High Speed Rail MOTC (BOHSR) have initiated and awarded contracts for the construction of a new MRT line running from Taipei to the Taiwan Taoyuan International Airport and on to Jhongli. The project is known as the Taiwan Taoyuan International Airport Access MRT System and is meant to significantly improve the travel connection between city centre and airport.
The prime contractors for BOHSR for the E&M System of the project are Marubeni Corporation, Kawasaki Heavy Industries Ltd and Hitachi Ltd, whom form the Consortium MKH JB. They in turn have awarded various subsystem works to specialist contractors.
The line is starting in Taipei, passing through Sanchong, Xinzhuang, T'ai Shan, Gui Shan, Lin Kou and Lu Chu, crossing under the aviation buildings in section I to section III of Taiwan Taoyuan International Airport, and then passing through Ta Yan and Chin Pu, crossing HSR Taoyuan station in the Northeast-Southwest direction and finally reaching the station in Jhongli. The full length of the line is about 51.2 km with numerous stations and 2 depots.
Calenberg Ingenieure were awarded the contract for the supply of elastomer bearings to mitigate noise and vibrations in sensitive track sections of the railway line.
The specially shaped elastomer bearings chosen for that purpose have been proven in similar projects around the world, amongst others Kaohsiung Metro, and were selected by the vibration experts because of their outstanding vibration reduction performance as well as their high material quality and longevity. The bearings type USM 1000 W and USM 2025 had to pass rigorous tests first before obtaining the required approval by the end client BOHSR.
About 6000 custom made strip bearings plus 2535 m² of roll material were shipped to Taipei from 2010 until middle of 2012. The resilient bearings will be integrated into the permanent way (mass-spring-system) of the track to protect residents efficiently from disturbing structure-borne noise and vibrations when the line is finally put into operation and hence to contribute to some better quality of life.
Ten years have past since the Sinzheim section of the Karlsruhe - Basel line went into operation.
The trough construction used for this section carries trains at speeds of up to 250 km/h, while at night goods movements form the main proportion of its traffic. To date, the track has carried over 600 million tonnes of freight.
From the beginning, this section was under special observation and regularly checked by DB's maintenance engineers. Now a departmental report from DB confirms that the section of track incorporating the USM 4010 track mats has so far required only negligible maintenance.
The experience with adjoining section of conventionally constructed ballasted track served as the basis for the comparison. This clearly demonstrates that investing in quality from Calenberg pays off.
We are looking forward to a successful working relationship with Vilton. The medium-sized company with its headquarters in Almere is expanding its range of products with building and vibration bearings from Calenberg Ingenieure.
Vilton is well-known for providing expert, relevant advice and assistance to its customers and its technically supported marketing of high-quality products. You can find contact details by clicking the Partners tab.
In December 2011, one of our colleagues at Calenberg, Dr. Rong Le, took up an invitation from Tongji University in Shanghai to lecture there as a visiting professor. She delivered five parts of the "Modern Railway Construction" series of lectures to students at the Railway & Urban Mass Transit Postgraduate Research Institute during the 2011/12 semester.
In addition, she supervised three of Prof. Luo's students working on their postgraduate dissertations. She has now successfully completed her duties in Shanghai.
Before Dr. Le joined Calenberg, she had spent more than 13 years with Deutsche Bahn AG in the national railway operator's Systems Technology Department in Munich working mainly on the following:
With a background like this, Dr. Le is well qualified make a success of the cooperative relationship between Calenberg and Tongji University. There will be further opportunities for Calenberg and the Railway & Urban Mass Transit Postgraduate Research Institute to work together; for example we have agreed to cooperate on joint projects for vibration reduction and noise protection on railways, as well as on the development of new products.
Two 26 m high buildings, the Vodafone Campus, are built in the centre of Düsseldorf between Königsallee, Hofgartenallee and Schadowplatz. The appendant multi-storey car park has four underground floors with access via a vehicular tunnel.
Likewise the neighbouring theater the buildings are erected in a swung shape. Special Ciparall®-Sliding Bearings ST are used both for the expansion joint along the linear support of an earth covered underground car park ceiling and for the expansion joint along the multi-story building.
The layout of the expansion joint is elliptic. The method how to fix both the slide plate and the bearing body to the in-situ concrete components was developed by Calenberg Ingenieure in cooperation with the planners. Slide plate and bearing body move relatively to each other. No need for maintenance and a high degree of operational reliability guarantee a long service life.
Tropical adventure park Gondwanaland Leipzig - Calenberg
bearings carry the loads of the roof structure according to plan
Europe's biggest tropical hall was opened at Leipzig zoo on 1st July 2011. The planning was very demanding with regard to the structural realization. A steel structure consisting of triangular elements put together spans the hall.
The 2165 ton steel structure has a free span of 160 m. The dome is 34 m high. The surface area of the insulating three-ply UV-permeable roof construction is 17.900 m².
The perimeter columns of the equal-sided roof construction form a hinged column structure. The movements resulting from both the structural condition and the temperature differences as well as the dead weight and maximum loads taking into consideration large twisting of components, are safely absorbed by Calenberg Perforated Bearings ST.
Due to the great functionality and quality of the mounted Calenberg bearings all static impacts are absorbed as planned and transferred into the adjoining hinged columns.
The accompanying consulting service by the Calenberg engineers as well as their high-quality products made it possible to realize a project such as the Gondwanaland Leipzig.
The editorial team at Germany's Statutory Social Insurance Provider (DGUV) responsible for the DGUV's magazine "Arbeit & Gesundheit" (Work & Health) design and produce practical publications in print, off-line and on-line formats aimed specifically at people affected by these issues. "Arbeit & Gesundheit" provides advice about occupational health and safety - for everyone, whatever their field of work.
The edition of "Arbeit & Gesundheit" dated 11/12 2011 carries an article about Cisilent®, one of our products.
DB confirms: The BSO/MK trough system with
Calenberg USM® 4000 effectively protects against vibrations
Here is a quotation from a DB Projektbau GmbH publication: "The BSO/MK is an active vibration-protection system for installation in the permanent way. A concrete trough forms the base to the system. A ballast mat is laid in the trough.
Ballast, sleepers and track are installed as normal on top of the ballast mat. The special aspect: this combination eliminates the frequencies responsible for the vibration load."...."The railway operator installed this novel vibration-protection system at the northern end of Baden-Baden Station in 1996 and 1997.
The result: the system successfully compensated for the poor ground conditions. From the experience gained and measurements taken there, BSO/MK was approved and used in 2000 for the first time above ground as a vibration-protection system on a section of track clear of any stations at Sinzheim.
Monitoring under live traffic in September 2002 showed that the system performed better than the design predictions by a large margin. The recorded values were well below the limit defined in the planning permission approval report."
Full details can be found in the publication: The upgraded and new high-speed line Karlsruhe - Basle (in German), Publisher: DB Projektbau GmbH, Karlsruhe
Calenberg Ingenieure's bi-Trapezlager® bearing safeguards
vehicular access along the raised walkway in the Katzenberg Tunnel
The latest railway emergency rescue concept has been implemented in the 10 km long twin tubes of the newly constructed Katzenberg Tunnel. Once the tunnel has been handed over, trains will be rushing through it at speeds of up to 250 km/h with the safety of their passengers being as paramount as ever.
As well as the many access galleries and ventilation shafts, the tunnel must also be able to be driven through by road vehicles so that the emergency services can arrive at an incident as quickly as possible. The covers to the inspection openings in the raised side walkways are supported on elastic bearings designed to withstand heavy vehicle wheel loads, stationary as well as transient.
The Calenberg bi-Trapezlager® ensures that the high requirements for safety and durability are fulfilled. Almost 2.5 km of this bearing, manufactured and installed by Calenberg since the start of the seventies, have been incorporated into the tunnel works.
In 2011 the employers' liability insurance association "Berufsgenossenschaft Rohstoffe und chemische Industrie" (BG RCI) has given one of their promotion awards to the flexible noise protection system CISILENT®. The innovation which uses light and flexible noise protection satisfied the jury and caused much interest at the presentation in conjunction with the award ceremony.
Custom made application for industrial use as well as counteracting the noise nuisance on construction sites help many companies to operate in a more environmentally friendly manner and thereby providing more health protection. More information can be found under products in the section noise protection.
We are looking forward to the cooperation with our new partner company Pronouvo in Waldkirch. Pronouvo is a medium-sized company and will represent our products for building construction in Switzerland.
Pronouvo offers a complementary product range to the Calenberg bearings and has made a name for itself as qualified partner for advice and service. The contact address can be found under "Partner".
After DIN 45673 was issued our proven track mats were tested according to the new requirements. Although the requirements have been raised considerably the track mats meet all demanded tests. Again the high quality of the Calenberg products was confirmed.
The incorrect story that the cone-shaped studs of the Calenberg products would harden due to plasticiser migration was repeated circulated.
To dispel this myth Calenberg Ingenieure handed over the cone-shaped stud mats to the renowned Institute for natural rubber Technologies in Hanover for analysis.
Trade fairs and exhibitions 2018
18. - 21.
Level: 5.2, Stand: 517
Calenberg Ingenieure GmbHAm Knübel 2-4
+49 5153 9400-0
+49 5153 9400-49