TINES® ERS – Embedded Rail System

The TINES® ERS Embedded Rail System is a type of direct rail fastening system designed for the construction of ballastless track systems. In the TINES® ERS system, the rails are continuously embedded along their entire length in rail channels using TINES® Polyrail 60/65 polyurethane elastomer. It forms a permanently resilient, homogeneous rail encapsulation that performs two essential fastening functions: securing the rail and supporting the rail foot within the rail channel. Due to the excellent adhesion of TINES® Polyrail to concrete and steel surfaces, no additional fastening using bolted connections is required. The continuous rail fastening provided by the TINES® Polyrail material system ensures the durable and resilient transfer of loads resulting from metro train traffic and thermal expansion and contraction of the rail, including loads acting in both vertical and horizontal planes. As a result, the TINES® ERS system effectively attenuates vibrations and noise generated by metro train traffic. The material properties of the resilient rail encapsulation made of TINES® Polyrail 60/65 elastomer also contribute to protecting the surrounding environment along the route against stray currents. The TINES® ERS system can optionally incorporate a continuous, resilient under-rail pad, TINES® Railstrip, which can serve as an additional component for adjusting the support stiffness.

The TINES® ERS Embedded Rail System can be used in ballastless track structures for metro infrastructure. The system is suitable for fastening all types of Vignole rails, including 60E1 and 49E1 rail profiles, as well as special rail profiles. The TINES® ERS system can be used on both straight track sections and horizontal curves with a radius of R ≥ 150 m.

System Components

The TINES® ERS Embedded Rail System consists of the following components:

• TINES® Polyrail Material Set

TINES® Polyrail 60/65 – a two-component, solvent-free polyurethane elastomer designed for the resilient fastening of rails. In the TINES® ERS system, TINES® Polyrail 60/65 forms a resilient rail encapsulation that secures (bonds) the rail to the side walls and bottom of the rail channel, providing continuous resilient rail fastening and support.

TINES® Polyrail Primer – a two-component epoxy primer with dielectric properties. In the TINES® ERS system, it is used to prime dry concrete substrates (rail channel walls) and steel substrates (rail surfaces or steel channels) in order to improve the adhesion of TINES® Polyrail 60/65 to these substrates.

TINES® Polyrail 53+ – a two-component epoxy resin with dielectric properties. In the TINES® ERS system, TINES® Polyrail 53+ is used to prime dry and wet concrete substrates (rail channel walls) and steel substrates (rail surfaces and steel rail channel walls) in order to improve the adhesion of TINES® Polyrail 60/65 to these substrates. It is also used for bonding the continuous TINES® Railstrip under-rail pad to the bottom of the rail channel, as well as for bonding concrete blocks or TINES® Railfiller inserts into the rail joint chambers.

• TINES® Railstrip – a continuous resilient under-rail pad. In the TINES® ERS system, it is used optionally to reduce the rail support stiffness and, consequently, reduce noise and vibrations transmitted to the surrounding environment of the track. It is installed at the bottom of the rail channel using TINES® Polyrail 53+ adhesive.
• TINES® Railshim – resilient adjustment pads (under-rail pads) available in various thicknesses. In the TINES® ERS system, they are used to adjust the vertical position of the rail and its transverse inclination. They should be placed at the bottom of the rail channels at equal intervals of 1.5 to 2.0 m. When correctly positioned, the pads do not affect the stiffness of the system.

• TINES® Railwedge – adjustment wedges. In the TINES® ERS system, they are used to adjust the horizontal position of the rail. Their side surfaces feature specially designed grooves, enabling stable wedging of adjacent components and preventing rail displacement during track installation.

• TINES® Railspacer – holders used to securely position PVC pipes in the rail channel. The pipes serve as filling elements for the rail joint chambers in one of the TINES® ERS system variants. The holders are stabilized using TINES® Railwedge wedges. They should be positioned along the rails at equal intervals of 1.5 to 2.0 m.

Rail Joint Chamber Filling Elements depending on the system variant, the rail joint chambers can be filled using:

• PVC pipes – made of synthetic polymer, with a diameter depending on the rail profile; commercially available from suppliers serving the construction industry.
• Concrete blocks – chamber inserts made of concrete with a minimum strength class of C20/25, available in various shapes depending on the rail profile; commercially available from suppliers serving the rail transport industry.
• TINES® Railfiller – chamber inserts for filling rail joint chambers, made of rubber granulate and available in various shapes. Manufactured by TINES Rail S.A.

System Advantages

• Noise and vibration reduction – the resilient rail fastening system eliminates rigid, bolted rail fastening, reducing dynamic stresses caused by frequent train traffic, which is particularly important under intensive metro operating conditions.
• Electrical insulation of the rail – the system provides protection against stray currents, increasing safety in tunnels and metro stations where electrical systems are located in close proximity to the track.
• Low track construction height – the system is ideal for metro tunnels and areas with limited technical space, enabling track modernization without the need to increase the tunnel cross-section.
• High operational durability – the system is resistant to intensive traffic and frequent braking typical of metro operations, helping to reduce maintenance costs and downtime.
• Elimination of secondary rail deflections – stable rail fastening ensures safe and smooth train operation, which is particularly important at high speeds and with frequent train services.
• Versatile applications – the system can be used both for new metro lines and for the modernization of existing sections, including tunnels, viaducts and stations, turnouts and crossings, train washing facilities, inspection halls and repair workshops.
• Adjustable noise and vibration damping properties – the system allows its vibration and noise damping characteristics to be adapted to specific local project conditions.
• Simple and fast track installation – the system features a technologically straightforward installation process, enabling fast track construction.
• Low track maintenance requirements – the system requires minimal maintenance and servicing, contributing to lower lifecycle costs.

Documents

• Certificate No. PL 59 2024 0017 – Type Approval Certificate for operation, issued by the President of the Office of Rail Transport (UTK)
• Type Conformity Certificate No. IK/CZT/004/2024/V01, issued by the Railway Research Institute
• Declaration of Type Conformity
• System Information Sheet

For the preparation of a technical and commercial offer, please contact: handlowy@tinesrail.com