Third Rail Systems

Efficient. Economical. Safe.

 Moving people.
Delivering the goods.
travelling safely with
third rail.

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A DEPENDABLE POWER SUPPLY
FOR MODERN MASS TRANSIT
Today efficient, safe and reliable public transport systems SPL Powerlines Austria, SPL Powerlines Benelux, SPL Pow-
have become essential for every modern economy. Urban erlines Czech Republic, SPL Powerlines Germany, SPL Pow-
areas in particular are faced with the challenge of continually erlines Hungary, SPL Powerlines Norway, SPL Powerlines Po-
expanding and improving their mass transit systems in order land, SPL Powerlines Slovakia, SPL Powerlines Sverige and
to cope with people’s growing need for mobility. SPL Powerlines UK – all members of the Powerlines Group –
are professionals for the design, installation and maintenance
The Powerlines Group is one of Europe’s leading companies of conductor rails.
for the construction and improvement of power engineering
infrastructure facilities. The “Third Rail” products offered by the In markets in which Powerlines Group does not operate a
mass transit division of this internationally operational group local subsidiary, the sale of “Third Rail” solutions is adminis-
of companies are an innovative, but above all safe means tered by Powerlines Products GmbH.
of providing public transport networks with a reliable power
supply, thus ensuring that mass transit systems run smoothly.

02|03
ADVANTAGES OF
CONDUCTOR RAIL SYSTEMS

A reliable source of current Toward the future

Conductor rails – also known as “Third Rails” – are a key ele- Powerlines Group’s conductor rail systems provide more
ment in ensuring maximum mobility at peak times on under- comfort and higher efficiency.They were designed for new –
grounds, metro systems and metropolitan railways. Their generation trains as well as long-serving ones.
­function is to transmit electrical energy safely and reliably to
railway vehicles.

High current intensity guaranteed

Conductor rails are always located in the immediate vicinity of
the railway tracks. Like a dense network of arteries running Current take-off from below.
alongside each track, they supply trains with electricity via a
conductor rail. This ensures the necessary high current
intensity despite the fact that lower direct current voltages are
generally used for mass transit systems. Depending on local
circumstances, the current may be fed to the train in one of
three different conductor rail systems: a special collector shoe
contacting the conductor rail from below, from above, or from Current take-off from above.
the side.

Optimal current transmission

Optimal current transmission is achieved by using high quality
combinations of materials, such as a conductor rail of aluminium
with a stainless steel contact surface, or a continuous welded
soft iron rail. These factors can be adapted accord­ing­ly to suit
the required train power, electrical conductivity and customer
requirements. Current take-off from the side.

Safety on all fronts

An insulating protective cover made of plastic provides the
necessary degree of safety for passengers and staff with
every kind of current collector. In tunnels we use only halogen-
free materials for our protective covers, whereas in the open
we use weather-resistant materials like PVC.

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ECONOMIC TRANSPORTATION
USING HIGH-TECH COMPONENTS

“Third Rail” systems provide durable Some of the many advantages of the “Third Rail” include
and cost-effective solutions. When one considers the electri- opera­tional safety, reliability, efficiency and eco-friendliness.
fication of a railway line as a complete system, it becomes
obvious that – specially with respect to durability and reliability Powerlines.
– the “Third Rail” system offers a particularly economical and For a safe and reliable train operation
efficient solution for high current intensities. Powerlines’ “Third Rail” systems are highly effective, for they
even provide excellent sliding contactin extreme weather
Save time and costs with professional conditions. Besides, they pose no danger whatsoever to peo­
design and tight project management ple or other facilities, and are therefore safe. The Powerlines
Before the start of any construction project, there is a phase Group always makes sure its facilities are designed to be
of detailed preparation, design and engineering. Experienced highly efficient.
engineers from the Powerlines Group develop universal, flexible
concepts – always mindful of their economy in operation. Economic operation
Even at this stage, it is important to consider factors like wear and cost-efficient maintenance
and maintenance. Our rails are extremely durable due to their mechanical and
The standardized “Third Rail” system facilitates the design dielectrical strength, their corrosion resistance, and the power
process at the engineering stage – and this has a positive rail’s high resistance to wear.Our sophisticated solutions keep
impact on the overall costs of the project right from the outset. the maintenance costs low, which includes highly cost-
Over and above this, in all its projects the Powerlines team efficient operation and servicing. To put it in a nutshell: value
attaches great importance to rapid completion, tight personnel added guaranteed. Wherever possible, we re-use compo-
planning and efficient use of resources. nents via a type-segregation recycling process to reduce the
burden on the environment. Yet we always focus on the cli-
Modular system – flexible solutions ents, as we tailor solutions to individual demands.
The Powerlines Group’s “Third Rail” is conceived as a flexible
modular system that can be adapted to any situation –
whether for historic metropolitan railway buildings, modern
urban architecture, bridges or underpasses. Individual,
­
optimally matched components and modules are assembled
depending on operating conditions and requirements.

04|05
 ][Rail VALUE FOR PROFESSIONAL SYSTEMS

The Powerlines Group’s new product line A][Rail provides unique features the Powerlines Group has patented its con-
state-of-the-art “Third Rail” systems and proven Austrian qual- ductor rails. Customers can choose between two basic sys-
ity. Since the A][Rail incorporates a number of innovative and tems, tailored to their demands.

This product variant puts economy first and is implemented into A][Rail Infinity
existing systems. A][Rail Economy ensures that servicing and This new product from the Powerlines Group is the epitome of
maintenance works are carried out in a most efficient way – innovation. Infinite rail is a splendid achievement of engineer­
and withmaximum flexibility: individual components can easily ing, combining precision and eco-friendliness. A][Rail Infinity
be replaced by high-tech components. has excellent running characteristics and thus improves the
technical performance of third-rail systems. Moreover, all
Advantages: components can be fully recycled. A][Rail Infinity: best quality
– safe, solid form due to use of steel and aluminium parts, for the highest demands.
not purely mechanical
– extremely rigid steel with a high degree of geometric Advantages:
integrity along the entire rail – savings due to use of fewer brackets and bolts
– easily manufactured by way of a heat-reduced FSW – reduced construction times
process – lower costs
– reduced Co2 footprint in production – innovative, cutting-edge product based on
– extra end-of-life financial benefit of cost-saving state-of-the-art technology
type-segregated recycling – excellent smooth-running characteristics of the
– optional choice of materials and forms, suitable for continuous rail
individual demands and technical requirements – low maintenance due to optimised system
– great advantage for aluminium and power rails due to components
greater distances between the feed points – improved technical performance
– high-tech components provide maximum flexibility and – eco-friendly, recyclable technology; all parts are fully
effectiveness for the whole system recyclable

Various rail types Type 47 Type 45 Type 37

Due to the variety of requirements presented by our customers
we have developed three rail cross-sections, each of which
differs in its capacity to conduct electricity. All three types of rail
incorporate the economical, hi-tech benefits typical of our
products.

www.powerlines-group.com
third Rail
Center of Competence

Our aim is to keep you moving! Optimization all along the line
The Powerlines Group provides over 35 years of experience in All our products are based on state-of-the-art technology. Prior
the design, erection, installation and on-schedule commis- to installation by the Powerlines’ specialists, all components
sioning of “Third Rail” systems. Our project management is are tested and certified to make sure they meet the stringent
professional, accurate and fast. Each of our individual services COC (Certificate of Conformity) guidelines.
is optimally coordinated, our guarantee for a high-grade and
durable conductor rail system. When implementing the new third-rail system, our engineers
are anxious to ensure maximum performance, yet at the
Complete solutions same time they reduce partswherever possible.This not only
The Powerlines Group offers proven, complete solutions facilitates maintenance but also reduces costs in the long run
tailored to our clients’ individual needs and specific demands. and thus contributes to a fair business relationship with our
Our experts analyze the existing power rail network and develop partners.
a new, customized concept on the basis of their findings.
What makes our solutions special is that we guarantee full Real-time monitoring
compatibility with the old system. When it comes to large cable projects, the Powerlines Group
provides outstanding expertise. The concept phase alone is
In various studies all the measurements, materials and country characterized by a close cooperation with other agen­cies,
specifics are evaluated, until eventually they merge into one technical crews and contractors, so as to make sure that
comprehensive solution. In particular, the existing aluminum things run smoothly. Planning includes the full cable length –
rails are measured for the wear and thickness of their steel face. and of course precise dimensioning of all components.

To measure damage due to wear, a section of a track is Any special requests from the client will already be taken into
monitored andthe results are fed into a detailed measuring account in the planning phase. A sophisticated system makes
report. The values are yielded by way of permanent monitoring it possible to monitor all traction cables in real time.
and illustrated by color indicators. Cutting-edge technology –
including ultrasound scanners – is applied to measure the
thickness of the steel face.

06|07
COMMITMENT, EXPERTISE
AND THE BEST EQUIPMENT AND TOOLS

Around the clock, in every weather

We work whenever your operations on the line permit: in track
occupation times, under difficult construction and weather
conditions, and even during operation on adjacent tracks.

Qualified & motivated

The Powerlines linesmen are highly qualified and technically
superbly trained. Our professionals are familiar with all
documented conductor rail systems, and employ only proven
and practical methods. An ongoing staff training scheme
ensures they are always at the forefront of their profession.
When a new project starts, the members of the team can call
on years of experience with a large number of “Third Rail”
projects for a wide variety of customers as well as the latest
expertise.

Equipped for every eventuality

The Powerlines Group has a large pool of modern equipment
and vehicles at its disposal. Depending on circumstances on
site, we can employ the latest technologies and only ideally
suited tools and equipment, including special-purpose
installation vehicles and heavy equipment.

www.powerlines-group.com
Plastics Technology.
Top Quality, Highly Individualized and Effective

Research and Development The benefits of Powerlines’

It takes knowhow and state-of-the-art technology to create plastic components
high-quality plastic products. When it comes to manufacturing
special designs geared to our clients’ demands, the Power­ Our push-fit system does without screws or rivets.
lines Group only cooperates with well-established partners.
In plastics technology, the choice of raw materials and the The plastic covers can be produced in any form or color
composition of finished parts is crucial. and applied in any way (on top, sidewise or underneath)

It is also possible to make adjustments to individual

Depending on the requirements and operational field (i.e. in
measurements and country specifications.
the exterior or in the tunnel), the basic material varies (PVC or
GRP), although the profile remains the same.
For the Powerlines Group, the technological development
and research into new materials and resources takes top
The plastic components are manufactured to the strict COC
priority.
(Certificate of Conformity) specifications, and in conformance
with the provisions of both an accreditedtesting institute and
the client.

08|09
Cover Boards.
Maximum Safetyand Protection

Protection covers The cover boards are made of PVC or GRP, depending on the
Insulating cover boards are used as a contact guard for range of application and on the component that needs to be
conductor rail systems. Their form varies according to the covered.
place of application, i.e. on open tracks or in tunnels.
PVC-covers:
Conductor rail covers are designed to meet the highest safety – No degradation of material properties due to UV light
standards. To prevent them from coming off unintentionally, and weather
they are fixed directly to the power rail. –N
 o water absorption (max. weight increase after a
6-hour water bath: 0.2%)
Spacers keep the distance between the conductor rail and
the cover system.In addition, all parts are connected to the GRP-covers:
push-fit system. – Fire resistantdue to halogen-free flame retardant
– Usablebetween-30 and +70 °C
Custom designs may include expansion joints, cable junctions,
insulators, connecting pieces, or ramps. To minimize the risk – High electric strength
of an accident, emergency exits are fitted with additional
protective guards.

100% plug-fit
system. No bolts,
screws or rivets!

Large cover board Small cover board

– No special accessories for extension joint and ramp – Accessories for extension joint and ramp
– Single construction height of cover along entire length – Optimised shape to fit rail
– 100 % plug-fit system – 100 % plug-fit system

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Insulators.
Flexible yet tough

The Powerlines Group’s conductor rail insulators are inspired the client or required by the field of application, they come
by 30 years of research, development and experience. All with a halogen-free flame retardant. Insulators are available for
components bear the benefits of numerous evolutionary 1.5 kV, 3 kV or higher.
steps.
The Powerlines Group has patented these products due to
Conductor rail insulators the large degree of know-how that goes into each individual
In order for a third-rail system to perform flawlessly, conductor isolator, and to their versatility and cost effectiveness.
rail insulators have a number of essential functions, carries
the maximum working load, safeguarding the whole system
against failure.

High-tech insulators enable the power rail to extend un­

impeded. Load changes on the rails cause vibrations and
there by generate forces that need to be absorbed and
neutralized by the insulators.

Powerlines products are horizontally and vertically adjustable

and can be fine-tuned after the final assembly. They are subject
to the strict COC (Certificate of Conformity) specifications. In
the event of fire, they must prove fire resistant; if desired by

100 % non-conductive isolator for voltages Isolator for voltages up to 3kV

up to 25kV

The isolator is of an identical construction for both options. This can be combined with a GRP or steel lower part
according to customer requirements.

10|11
Our Engineers’ Wide Range of Services

Construction
and Engineering
Preparation of system and device
drawings
Map of the area (plan of site)
Schematic diagram
of connections and switches
System design Manual for installation

Tender analysis Approval of components

and conductor rail system
Feasibility study
System selection
Structural statics and calculations
Certifications of new designed
products

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 Bringing into operation After-sales Services
Erection and completion
personnel schedule Training

motor pool Final inspection

transportmanagement Documentation

construction/installation Preparation of maintenance

and assembly manual
quality control
Individual follow-up care

the whole is more

than the sum of its parts.
Aristotle, Greek philosopher, 384 – 322 v. Chr.

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SELECTED REFERENCES

The acknowledged “Third Rail” specialists

There are countless successful “Third Rail” projects throughout Europe documenting the expertise of the Powerlines Group in the
field of conductor rails and demonstrating the satisfaction of the Group’s customers. The members of the Powerlines team are al-
ways happy to face new challenges.

customer km year construction type of rail

Länsimetro 29 2014 – 2015 Länsimetro Helsinki Aluminium-Steel conductor rail
Sporveien 30 2013 – 2019 (+2) Framework contract Metro Oslo, Norway Aluminium-Steel conductor rail
Wiener Linien – 2012 – 2014 change cable
T-Bane Oslo 1,7 2011 Lambertseterbanen 2 Installations, Norway
Joint Venture AGP 15,5 2013 – 2014 Rondo Daszynskiego to Dworzec Wilenski Aluminium-Steel conductor rail
Wiener Linien 13 2011 – 2025 U3 change “Third Rail”, changing sleepers Aluminium-Steel conductor rail
Wiener Linien ~ 20 2010 – 2015 U1/U2/U3 maintenance of “Third Rail” Aluminium-Steel conductor rail 
T-Bane Oslo 3,4 2011 – 2012 Lambertseterbanen 2 Aluminium-Steel conductor rail 
Wiener Linien 55 2006 – 2013 U1/U2 extensions Aluminium-Steel conductor rail
T-Bane Oslo 6,4 2010 – 2011 Lambertseterbanen 1 Aluminium-Steel conductor rail
T-Bane Oslo 17 2009 – 2010 Holmenkollen Aluminium-Steel conductor rail
Metro Brüssel 15 2009 – 2015 Frame contract devices for “Third Rail”
VAG 3 2005 Metro Nürnberg, U3 SW BA 1.1 Aluminium-Steel conductor rail
DB Project Bau GmbH 16 2004 – 2007 Pankov – Karow Aluminium-Steel conductor rail
DB AG Berlin 6,5 2004 – 2005 Papestrasse S4 Aluminium-Steel conductor rail
Metro Brüssel 7 2003 – 2007 Frame contract 40kg full-steel conductor rail
Arge S-Bahn 14 2003 – 2006 rebuilding Berlin Zoo – Westkreuz Aluminium-Steel conductor rail
DB AG Berlin 3 2003 Papestrasse S4 Aluminium-Steel conductor rail
Siemens Erlangen 2 2003 Rotan, Süd Korea Aluminium-Steel conductor rail
DB AG Hamburg 4 2003 rebuilding Hasselbrook – Barmbek 50kg full-steel conductor rail
Wiener Linien 20 2002 – 2006 U1 extension Aluminium-Steel conductor rail
MVG 1,5 2002 – 2004 U1 West München 1. und 2. BA Aluminium-Steel conductor rail
DB AG Hamburg 5 2002 – 2003 rebuilding Hauptbahnhof – Sternschanze 50kg full-steel conductor rail
DB AG Hamburg 3 2002 rebuilding track and switches Poppenbüttel 50kg full-steel conductor rail
Siemens Erlangen 18 2001 – 2005 T-Baneringen Oslo, Norway 40kg full-steel conductor rail
DB AG Berlin 4 2001 – 2002 Schöneweide – Adlershof Aluminium-Steel conductor rail
DB AG Berlin 3 2001 rebuilding S1 Schöneberg, Feuerbachstrasse Aluminium-Steel conductor rail
Siemens Erlangen 6,5 2001 Wegberg/Wildenrath 150 lbs/yard full-steel conductor rail
Wiener Linien 9,5 1999 – 2000 U3 extension Aluminium-Steel conductor rail
Siemens Erlangen 42 1997 – 1998 Metro Athen, delivery of “Third Rail” devices Aluminium-Steel conductor rail
partly installation and supervision
Siemens Erlangen 4 1996 – 1997 Wegberg/Wildenrath 60kg full-steel conductor rail
Aluminium-Steel conductor rail
DB AG Hamburg 164 1993 – 2003 engineering and rebuilding Berliner Tor – Aumühle 50kg full-steel conductor rail
misc. control cable
Wiener Linien 16,8 1990 – 1995 U3 Aluminium-Steel conductor rail
Wiener Linien 61,8 1976 – 1982 U1, U2, U4 60kg full-steel conductor rail

The “Third Rail” system has been tested and approved by several independent institutes and underground train operators.
Institutes: TGM (Federal Institute of Technology) Vienna, Austria. Tabor Instytut Pojazdów Sznowych, Uniwersytet Jagielloński Krsaków, Poland.
Rail operators: Wiener Linien, Metro Warszawskie, Sporveien Oslo, HKL-HAST (Helsinki City Transport), SL Stockholm, STIB Brussels

www.powerlines-group.com
Powerlines Group

The Group specializes in railroad line electrification

(including trolley systems and subway lines), and
in power line construction for energy suppliers.

holding company
international sites

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OFFICES & CONTACTS

Powerlines Group GmbH (Holding) 7 SPL Powerlines Hungary Kft.

Johann-Galler-Straße 39, Petöfi utca 20, HU-9552 Vásárosmiske
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Tel.: +43-2245-212 12-0, Fax: +43-2245-212 12-400 Tel.: +36-306-405091
[email protected] [email protected]
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Imprint:
Owned and published by Powerlines Group GmbH, Johann-Galler-Straße 39, A-2120 Wolkersdorf im Weinviertel
Tel.: +43-2245-212 12-0, Fax: +43-2245-212 12-400, [email protected], www.powerlines-group.com
Text – Conception und modification Zauberfunken agentur | pr | marketing, www.zauberfunken.at
Design Zauberfunken agentur | pr | marketing, www.zauberfunken.at
Photos Hannes Eichinger, Thomas Jukl, iStockphoto.com
Production Bürger-Druck Medienhaus & Verlag, Ing. V. Bürger GmbH, www.buergerdruck.com
© Powerlines Group GmbH 2014
All rights reserved. Duplication (copies, reprints) only by previous written consent. This folder is designed solely for the initial information of customers without any obligation. It does
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Powerlines Group GmbH accepts no liability for the currentness or correctness of the contents of this folder.
Third Rail Center
of Competence
www.powerlines-group.com