V Flow

Three applications, one material

Modern track infrastructure requires different construction methods. V Flow covers both central applications in urban track construction.

 

Application: Continuous rail undergrouting

In continuous rail undergrouting, the rail is elastically supported on the concrete track slab along its entire length. A full-surface support is created between rail and subgrade instead of individual point supports. The grouting compound compensates for construction tolerances and provides a defined spring effect. The aim is not rigid fixation, but controlled elastic support.

 

This produces the following effects

• Uniform distribution of wheel loads
• Permanent stabilisation of track geometry
• Reduction of vibrations and structure-borne noise
• Protection against stray current corrosion
• Less wear on rail and vehicle

The continuous support prevents localised stress peaks in the concrete and significantly extends maintenance intervals. Typical applications are tramway, urban rail and slab track.

 

Application: Baseplate undergrouting

In baseplate undergrouting, individual rail support points are elastically undergrouted on the concrete track slab. Load transfer takes place at discrete points via defined bearing positions. The grouting compound creates a force-fit connection between concrete and steel and establishes a permanent bearing surface. At the same time, manufacturing tolerances are compensated and the precise height position is set.

 

Function of the elastic underlaying

• Uniform load distribution into the subgrade
• Protection of the concrete track slab from localised overloading
• Prevention of corrosion through water ingress
• Reduction of vibrations and noise
• Permanent positional accuracy of the rail

The construction protects the substructure and enables low construction heights, particularly in tunnels and for slab track.

 

Application: Embedded rail grouting

In embedded rail grouting, the rail is fully elastically embedded in concrete or in a steel channel. The V Flow grouting compound forms a circumferential elastic support and prevents rigid clamping. The rail remains in a defined supported position rather than being clamped. This reduces forces and increases the service life of the infrastructure. Tested for axle loads up to Category C in accordance with EN 13481-5.

 

Technical operating principle

The self-levelling V Flow grouting compound fills voids completely and produces a reproducible bearing stiffness. Excellent flowability for void-free filling. The high electrical resistance protects against stray current damage.

 

Benefits for planning and operation

A defined elastic rail support prevents:

• Settlement
• Cracking in the concrete
• Loose fastenings
• Increased maintenance costs
• Noise complaints

The result is predictable life cycle costs and stable track geometry.