high.tech.in.

plastics

WIRTHWEIN
and the Railway
Competencies and Products
 Contents

n TABLE OF CONTENTS PAGE 2

n IT ALL STARTED PAGE 3

n HISTORY PAGE 4

n BUSINESS DIVISIONS PAGE 5

n PLASTICS KNOW-HOW PAGE 6

n MOLD TECHNOLOGY PAGE 7

n QUALITY AND CONTROL PAGE 8

n DEVELOPMENT AND CONSTRUCTION PAGE 9

n PLASTIC COMPONENTS FOR RAIL FASTENING SYSTEMS PAGE 10

n INSULATION PAGE 11

n DOWELS FOR SLEEPER INSTALLATION PAGE 12

n DOWELS FOR SLEEPER REPAIR AND MAINTENANCE PAGE 13

n RAIL PADS PAGE 14

n INTERMEDIATE PLATES PAGE 15

n PLASTIC CABLE DUCTS PAGE 16-22

n SOUND INSULATION PAGE 23

n OUR SITE BRANDENBURG-KIRCHMÖSER PAGE 24/25

n RAILROAD SWITCH COMPONENTS PAGE 26

n CITY RAILWAYS AND STREETCARS PAGE 27

n SYSTEM COMPONENTS FOR WOODEN SLEEPERS AND SLAB TRACKS PAGE 28

n DOWELS FOR THE CONSTRUCTION INDUSTRY PAGE 29

n OTHER COMPONENTS PAGE 30

n WOOD FOR TRACK SUPERSTRUCTURES PAGE 31

n WINKLER DESIGN PAGE 32-35

n IMPRINT PAGE 35

2
 It all started

It all started with an octagonal dowel.

The small dowel used for wooden sleeper repair in railway superstructures symbolizes
the beginnings of the Wirthwein group. In 1949, company founder Walter Wirthwein
started producing lathed wooden parts in the basement of his home. The octagonal
dowel soon became the first company trademark and Wirthwein quality symbol; more
than 3,000 additional products for railway superstructures have followed since then.
And the dowel has remained one of them.

In the mid-1960’s, the key to the future was plastics. This opened the door to the
production of plastic parts and Wirthwein jumped on the bandwagon to plastic injection
molding. Today we are looking back over 40 years of experience in plastic injection
molding with an annual production volume of hundreds of millions of parts. We have
become a regular supplier to nearly all railway companies in Europe.

Also in the 60s, we realized that the production of injection molds required our own
toolshop if we wanted to implement high quality standards and technical innovations.
Mold engineering soon became its own business division and the ideal tool to perfect an
all-inclusive production. Since 1969, we have been manufacturing each and every one
of our molds in-house.

In 1990, the medium-sized family enterprise started to develop into a successful

international group of companies. The first subsidiary was founded immediately after
the reunion of the two Germanies in Kirchmöser in Brandenburg, an important railway
site in Germany. Presently, 18 companies from Germany, Poland, Spain, China and the
USA do business under the roof of the Wirthwein Group. Approximately 2,300
employees are responsible for the production of plastic components in the business
fields of automotive, railway, energy, home appliances and medical engineering.

And yet – we have remained faithful to wood: Bembé Parkett and Winkler Design
exemplify the interior design division and contribute to the diversification within the
Wirthwein group.

Then, today and into the future – Wirthwein is the synonym for
Reliability, Quality and Innovation.

3
 History

Poland
Nauen
Brandenburg
Łódź
Osterode Papiernicza
USA New Bern China
Kunshan Germany Łódź
Eichenzell Crimmitschau Dabrowskiego

Mühltal
Ober-Ramstadt Röttingen
Bad Mergentheim
Creglingen
Sasbach
Friedberg

Zaragoza

Spain

1949 Foundation of the company Walter Wirthwein in Creglingen

1951 Transformation into Walter Wirthwein KG
1967 Beginning of plastics processing
1978 Graduate engineer Udo Wirthwein assumes control of the company
1989 Company name change to Wirthwein GmbH & Co. KG
1991 Foundation of Wirthwein Brandenburg GmbH & Co. KG in Brandenburg
1995 Takeover of Winkler Design GmbH & Co. KG in Röttingen/Bavaria
1995 Foundation of Wirthwein Nauen GmbH & Co. KG in Nauen near Berlin
1998 Foundation of Wirthwein Polska Sp. z o.o. in Polish Lódz
1998 Transformation of Wirthwein Verwaltungs-GmbH into Wirthwein AG
1999 Takeover of Formtechnik Osterode GmbH & Co. KG in Osterode
in the Harz Mountains
2003 Foundation of Carolina Technical Plastics Corp. in New Bern in the USA
2005 Takeover of Riegler GmbH & Co. KG in Hessian Mühltal
2005 Takeover of Keller Fußbodentechnik GmbH & Co. KG in Würzburg
2006 Takeover of Bembé Parkett GmbH & Co. KG in Bad Mergentheim
2007 Foundation of Wirthwein Fastening Systems (Kunshan) Co. Ltd. and
Wirthwein Technical Plastics (Kunshan) Co. Ltd. in Chinese Kunshan
2009 Foundation of Wirthwein Friedberg GmbH & Co. KG in Friedberg/Bavaria
2009 Foundation of Plásticos Zaragón S.L. in Spanish Zaragoza
2009 60th anniversary of the Wirthwein group
2010 Appointment of Marcus and Frank Wirthwein as well as Rainer Zepke to the
Wirthwein AG Board of Directors; Udo Wirthwein remains Chairman of the Board
2012 Foundation of Wirthwein Eichenzell GmbH & Co. KG near Fulda and
Wirthwein Crimmitschau GmbH & Co. KG near Zwickau and
Wirthwein Sasbach GmbH & Co. KG near Baden-Baden

4
 Business divisions

Interior
Automotive Railway Energy Home Medical
Construction
Components Components Components Components Components Parquet
& & & & &
assemblies for assemblies for assemblies for assemblies for assemblies for lunch counters
company cafeteria
interior railway fastening pumps washers medical engineering
exterior systems compact fans dryers diagnostics counter & reception
functional elements cable channeling housings dishwashers labs systems
engine components transformers vaccuum cleaners cosmetics
pharmaceutics accessories

The railway was the first Wirthwein customer and solid basis for the diversification of the
Wirthwein group in the business segments of Automotive, Energy, Home Appliances, Medical
Engineering and Interior Construction over the past six decades.

Our customers benefit from our ability to exchange our expertise, manufacturing technologies
and experience among the different business areas, a decisive advantage which guarantees
all-time state-of-the-art and innovative processes.

The requirements of the different fastening systems are determined by the speeds they have to
endure. To date, Wirthwein has supplied products for a total of 10,000 km high-speed railway
lines within Europe – for train speeds up to 350 km/h.

Wirtwein also supplies plastic components for railway superstructures on wooden, concrete
and steel sleepers.

Among our customers in the railway business are, for example, international market leader for
fastening systems Vossloh Fastening Systems, the Deutsche Bahn AG, state railroads within
and across European borders, industrial and private railways, public metropolitan and suburban
commuter railway companies, industrial companies, track construction companies, concrete
producers and mining companies.

Our portfolio includes the development and design of plastic parts, tool engineering, series
production and assembly of the ready-for-sale product.

For Wirthwein AG, specialization and diversification are not contradictory but one of their
successful strategies.

5
 Plastics Know-how

For more than 40 years, Wirthwein has been synonymous for

innovative plastics processing:
nThermoplastic injection molding of complex plastic parts with shot weights from 10 g to
10 kg
nProcessing of all standard thermoplastic materials:
PA (GF/GK/TV), POM, PP (GF/LGF/TV/EPDM), PE, PMMA, COC, PS, ABS, SAN, TPU,
TPE, PU, PVDF, ETFE, EVA, PEEK, PBT, SMA, PPO, PPS, ASA, PES
nProcessing technologies:
1- and 2- component molding, insert overmolding, hybrid technology and back injection
molding, clean room production according to ISO 14644 - 1 class 7, monosandwich
technology, rotary plate part feeding, internal gas and water pressure process
nMachines with clamping forces from 150 to 16,000 kN
nCapacity: 370 injection molding machines and 15 extrusion blow molds
(in April 2012; further investments are planned)

Additional services:
n2-component PUR-foaming lines
nChemical and physical foaming
nAssembly lines and system assembly
nUltrasonic welding / vibration welding
nHot plate welding
nHot mounting and pressing of inserts
nHot stamping / pad printing / labeling / screen printing

6
 Mold Technology

All injection molds used in our production processes are made in-house. A mold maker since
1969, we – and, of course, our customers - benefit from our long experience in the automotive,
railway, energy, home appliances and medical industries by exchanging the necessary know-
how and providing innovative solutions.

nManufacturing of complex injection molds with sizes from 900 x 1,800 mm and weights
up to 20 tons
nState-of-the-art maching centers with travers paths of 2,000 x 1,800 x 1,100 mm
nCertification according to VDA 6.4
nFlexibility and know- how at every single site
nExtensive mold development and design

The toolshops at our sites and their close cooperation with our mold specialist Formtechnik
Osterode warrant the production of highly precise molds as well as uncomplicated and fast
maintenance and repair.
Innovative technologies and a vast state-of-the-art machine pool assure efficient and high-
quality production of complex plastic parts.
An extensive quality assurance using the
latest technologies in all process stages is
a matter of course.

7
 Quality and Control

You can rely on the quality of Wirthwein

Our customers can rely on the quality of our products, no matter at which of our sites they are
produced.

Since we produce safety-relevant plastic parts for railway superstructures, maximum quality
assurance has been our standard for decades. Each production step is monitored with state-of-
the-art technology.

We measure with 3-D coordinate measuring machines. In addition, we digitalize complex

geometrical shapes with an optical 3-D scanner and compare the results with our customers’
CAD models without losing precious time. Reliable information can therefore be provided
almost immediately. The results are presented in tables and graphic illustrations corresponding
to the current state of measuring and evaluation technology.

Not to forget the plastics-specific material tests such as the determination of the viscosity index,
DSC (Differential Scanning Calorimetry) analysis, melt flow index and impact resistance tests,
microtome sectioning tests, hardness and density tests as well as tensile and pressure tests.
Wirthwein guarantees a high quality
standard. The group of companies is
ISO/TS 16949:2009, DIN EN ISO
9001:2008, VDA 6.1 and VDA 6.4
certified, Q1 supplier of the Deutsche
Bahn AG and A-tier supplier of
important system suppliers.

Before your plastic parts leave our

house, we have tried and tested their
properties and found them perfect in a
multitude of ways.

8
 Development and Construction

Our performance starts with the initial idea and finishes with the after
sales service.
It is a long way from the very first draft to the consignment of the finished plastic parts. It is best
that we walk it together. We pick you up, offer the know-how and equipment for each step and
get you home quickly and safely. Professional and experienced sales engineers and project
leaders are your contacts and assure a reliable project management.
Highly qualified specialists and high-tech software tools take care of a plastics-compatible
design – right from the start.

We work closely with our customers from the concept through development and up to the series
production of the product. Trust our 40 years of experience when it comes to these
requirements:
nProcesses and procedures
nComplex injection molds
nComplex plastic components and assemblies

We see ourselves as a manufacturer of plastic components with comprehensive responsibility

and an overview of the overall process. From plastics-compatible product design, mold
development and engineering, production to final assembly.

Our design departments work with the following programs:

nCAD/CAM (Think 3) / AutoCAD-Mechanical
nPro / ENGINEER
nCATIA V5
nCimatron
nMoldflow

9
 Plastic Components for
Rail Fastening Systems

Rail Sleeper screw

Source: Vossloh Fastening Systems GmbH

Source: Vossloh Fastening Systems GmbH

Rail pad
Tension clamp

Load distribution Angle guide plate

plate

Damper plate

Dowel

Concrete sleeper

System 300 by Vossloh Fastening Superstructure W 14:

Systems for high-speed lines on slab Wirthwein supplies the angle guide
tracks. Wirthwein supplies the plastic plates, rail pads and dowels (blue).
components (blue).

Sales:
Vossloh Fastening Systems GmbH

The requirements for the different fastening systems are determined by the speeds they must
resist. To date, Wirthwein has supplied products for a total of 10,000 km high-speed railway lines
worldwide.

Wirthwein has cooperated in the supply of a great number of the rail fastening systems
worldwide. Some of the fastening systems for high-speed tracks are developed by the joint
efforts of Vossloh and Wirthwein. Wirthwein supplies the individual plastic parts which Vossloh
completes and sells as system solution.

The result: extreme load capacity, optimal sound insulation properties, highest quality and
efficiency.

The Vossloh Fastening Systems GmbH

product portfolio Wirthwein supplies plastic
components for includes a variety of fastening
systems for ballast tracks and slab tracks for all
load profiles from heavy duty to high-speed
railway lines.

10
 Insulation

Angled guide plate with isolator,

community patent Vossloh Fastening Systems GmbH
and Wirthwein GmbH & Co. KG

Railways that use the track as return conductor and whose superstructure is not electrically
insulated can guarantee the required insulation with insulating angles or pressure elements.

There are also various power supply systems with conductor rails in commuter railway and
subway systems. In order to avoid stray currents and uncontrollable ground faults,
superstructures therefore use different types of insulation components.

Insulating angles

Insulation plates Conductor Insulating bushings

for transponders rail carrier and plugs

11
 Dowels for Sleeper Installation

Dowels for the installation

of concrete sleepers

Sdü 9 / 9a
Sdü 20 / 21
Sdü 9c

As multifaceted the requirements for track superstructures, so extensive is our dowel program.

For the initial installation of concrete sleepers we produce different types of:

nscrew dowels
nspecial dowels
ncustom-made dowels and many more

Sdü 9 Sdü 21 Sdü 9c

12
 Dowels for Sleeper
Repair and Maintenance

Dowels for the repair and

maintenance of wooden and
concrete sleepers

Wdü 2
Wdü 13
Hdü 8
Sdü 9b Turning mandrel
(screw dowel repair)
Sdü 21b

Our product portfolio for the repair of wooden and concrete sleepers comprises different types
of rippled dowels, hollow dowels, half pipes for maintenance of wooden sleepers and screw
dowels.

Wdü2/Wdü13 are used to repair concrete sleepers of older types which originally were
equipped with wooden corrugated dowels.

Hdü 8 wooden dowels are used for the repair or wooden sleepers.

The Hdü 8 repairs wooden dowels and has been used most successfully by
international railway companies for many decades.
The 5 repair steps:
„ Unscrew the old sleeper screw
„ Drill open with a 23.5-mm drill to remove the decayed wood
„ Anchor the hollow Hdü 8 dowel
„ Put a new sleeper screw and force in up to the lower plate edge
„ Screw in the new sleeper screw

The Hdü 8 can be used for all screw fixations:

„ Ribbed base plate fastening with tension clamp, clip or other means

The dowel is a sophisticated product and offers the following

advantages:
„ simple installation without prior training or special tools
„ assembly does not depend on weather and outdoor temperatures
„ fast installation
„ no removal of the ribbed base plate
„ no corrosion between screw and wood
„ if the holes are oval or severely decayed, they can be repaired with additional half pipes
„ high extraction force due to nub profile
„ long-term repair

13
 Rail Pads

Rail Pads
Pads for wooden,
concrete and
steel sleepers

Pads

New installation or repair

Wirthwein offers the largest number of plastic parts for wooden, concrete and steel sleepers and
when it comes to rail pads, Wirthwein supplies the right one for the right purpose.
The Wirthwein rail pads are used worldwide and have been enduring rail traffic and its force
effects very successfully.
Material:
Polyamide plastic (PA6)
Thermoplastic polyethylene (TPE)
Thermoplastic polyurethane (TPU)
Ethylene-vinylacetate copolymer (EVA)
High-density polyethylene (HDPE)
Highly resilient
Dimensions: rail pad TPU,
Zw 900: 180/165x148x9 (flexible rail pad) cat. II, TPU category II
Zw 700: 180/165x148x7 (flexible rail pad) cat. II, TPU
Zw 787a: 180/165x148x7 (semi-flexible rail pad) EVA
Zw 687a: 180/165x148x6 (standard) EVA
Zw 687a: 180/165x148x6 (heavy duty) HDPE
(Length/maximum width of sleeper support x rail foot width (less 2mm allowance) x thickness)

Classification Zw 900 (TPU) Zw 700 (TPU) Zw 787a (EVA) Zw 687a (EVA) Zw 687a (HDPE)
according to DB: Kat. II Kat. II
Static RT approx. 60 KN/mm approx. 60 KN/mm approx. 140 KN/mm approx. 600-700 KN/mm approx. 950 KN/mm
from 18-68 KN
Deflection in mm approx.. 0,85 mm approx. 0,8 mm approx. 0,35 mm approx. 0,08 mm

Static 50°C approx. 45 KN/mm approx. 50 KN/mm approx. 60 KN/mm approx. 400-500 KN/mm
from 18-68 KN
Dynamic 10 Hz approx. 104 KN/mm approx. 106 KN/mm approx. 260 KN/mm approx. 1600-1800 KN/mm
RT / after 10 sec.
Dynamic 10 Hz approx. 295 KN/mm approx. 280 KN/mm --- ---
-10°C / after 10 sec.
Dynamic 30 Hz approx. 105 KN/mm approx. 124 KN/mm --- ---
RT / after 10 sec.

14
 Intermediate plates

Intermediate plates for

wooden and
concrete sleepers

Intermediate plates

Our intermediate plates portfolio:

For concrete sleepers and wooden sleepers:

- intermediate plates
- height regulation plates

Height regulation plate Intermediate plate

15
 Plastic Cable Ducts

Since 1995, our plastic cable ducts have

been a cost-effective technical alternative
to other solutions.

Weight of the cable ducts

With drainage possibility

Underground Elevated
(without polystyrene)

Size 1 4,5 kg 6,25 kg* 4,5 kg

Size 2 6,4 kg - 6,4 kg
Size 2 (AU-KA) - 7,3 kg * -
* lateral cover included
The use of plastic material considerably reduces the weight of the ducts and provides
installation and usage advantages as well as application possibilities that cannot be realized
with systems made of concrete.

The cable duct is available in two sizes

(all dimensions in mm)

Size I Size II

16
 The Clever Alternative

A variety of applications:
n Simple and fast installation of cables and lines into the existing ducts by means of hinges
and seal caps.
n Predetermined breaking points in the floor and the walls facilitate the feeding in and out of
cables and lines.
n The lid can only be opened with a special tool. Unauthorized opening is therefore
impossible. The lid can be opened and closed as often as needed without being destroyed.
n Simple checking of the cable looms.
n The low net load of the plastic cable duct allows a variety of additional, non-railroad
applications.
n Our cable ducts are also very effectively used in solar arrays and wind power plants.
Economical transport to the construction site:
Bulk supplies can be transported.
Duct installation by hand:
Without lifting gear, i.e. the installation does not require any additional devices. The construction
works do not have to be interrupted, the ducts can be installed during operation or with only very
short check intervals.
Easy to dismantle and to reuse:
A very important advantage in case of repair, maintenance and new construction jobs.
The ducts are made of environmentally friendly and completely recycable plastics:
The cable ducts consist of UV-stable polypropylene copolymer. The material is recyclable and
considered neither dangerous nor harmful to the environment. It is resistant to most acids, lyes
and greases.
Mechanical characteristics:
Load capacity approx. 10 KN without breaking - good impact resistance thanks to modified
properties.
Electrical behavior:
The surface resistance is approx. 1015 ? x cm providing good insulation values. The dielectric
strength Ed as defined in DIN VDE 303-ICE 243 is approx. 0.6/0.8 at 100 kV/mm. Insulation and
grounding are not necessary.
Thermal characteristics:
Deformation resistance at outside temperatures from -30°C to +85°C.
Flammabilitiy:
The resistance to fire (self-extinguishing) classifies according to DIN53438 part 2, High Fire
Resistance K1. The flame retardant contains neither diphenyl ether nor antinomy oxide. The
dioxin analysis shows that the values are clearly below the limits provided in the danger
classification.
Approved by the Deutsche Bahn AG:
Type approval by the Eisenbahn-Bundesamt 73103/8, release for series production 17/98,
framework contract no. 547/92003707 with the Deutsche Bahn AG.
In the meantime, more than 1,000,000 duct meters have been
installed on the tracks of the Deutsche Bahn AG and many
other national and international railway operators.

17
 DRAE-KA

With our cable ducts you

install your cables safely,
flexibly and reliably.

Flexibility / adaptation on site

Flexibility shows when obstacles need to be bypassed. Thanks to
our prefabricated angle elements, the ducts can be raised or
lowered, redirected or simply cut to the required length. The
DRAE-KA can be installed in radiuses of up to 230 m without
manual intervention. Around slopes we recommend the elevated
AU-KA duct type.

Simple underground installation

even on difficult construction
sites.

Adaptation of the elements on site: separate, cut, adjust.

Holes for ground Insertable bridges The two cable duct The ducts can be
nails make sure that allow orderly cable widths I and II can be plugged and in-
the duct parts can be installation. plugged together stalled side by side
safely fastened to providing a variety of or one on top of the
the subgrade. duct cross sections. other.

18
 Underground
Cable Duct Installation

Two different connectors and a

key are all you need for
installation. One long key which
relieves the back is enough to
open and close the cable ducts.

With the plug-type system, the standard and special

elements can be connected in a force-fit and form-fit way
that warrants directional stability. In longitudinal
direction, the connection provides enough play to allow
uncomplicated installation of large radiuses.

DRAE-KA, the cable duct system –

the solution for many applications

On bridges and elevated, maintenance-free even

when the environmental conditions change.
Unproblematic installation in the ground, in ballast, in
straight or curved tracks.

The plastic cable ducts are designed and ready-to-use for many applications: predetermined
breaking points on the bottom and the sides, openings for anchor rails for the fastening of
different supporting members for all types of cables and lines. The lid elements are lockable and
resistant to damage.

The DRAE-KA cable duct system is approved for use in all railroad areas.

Drainage casing of the components on request.

The cable ducts can be installed with or without

drainage casing. The casing eliminates filter grit and
construction errors.
Drainage layer of polystyrene protected by a weather-
proof filter fleece provided on request.

fleece polystyrene drainage

19
 Elevated Cable Duct

AU-KA
Elevated cable duct

The elevated plastic cable duct was developed for

use on slopes. The product is part of the successful
cable duct DRAE-KA concept. The stable steel
substructure with its adjustable height and sides
allows a maximum distance of 6 m between the
posts. The sections are entirely insulated,
grounding is not necessary.

The plugged-on AU-KA cable ducts are designed

for maximum loads of 1.5 KN per meter and come
equipped with an integrated lateral protection
against accidental contact and a lockable lid.

AU-KA
...the cable route on slopes

20
 Elevated Cable Duct

Cable trough size I Cable trough size I

without lateral cover panel with lateral cover panel

We offer the elevated cable duct in two sizes.

The size I trough is screwed onto the steel

substructure. Once mounted, the trough can be
complemented with cover plates on the sides for
improved insulation.

The size II trough comes with integrated side panels.

The cable trough is plugged onto the upright
rectangular tubes, additional connections are not
necessary. Once finished, trough and substructure
are a compact and stable unit.
We provide the appropriate
The simple and therefore fast installation is a substructures for
great advantage. installation on slopes.

Size I fixation Size II fixation

21
 Cable Duct with Drainage

Concept: the combination of cable duct and drainage system is the most efficient and
sophisticated solution if you want to avoid parallel, separately installed deep drainage and cable
routes.

Fields of application: the drainage - cable duct

combination can be used in all railroad systems
with deep drainage and a gradient of more than 1.5 %.

Weight: 14.0 kg/m

Thermal characteristics:
dimensional stability at outside
temperatures from
- 30°C to +85°C.

Shafts are required only at the

beginning and the end of the
drainage - cable duct
combination.

22
 Sound Insulation

Rail web damping system

for the sound reduction
in railway tracks

Compact damping element made

of a massive plastic element
highly filled with ferrous material.

We have something against noise!

Advantages:

n
Simple assembly
n
Reduction of the airborne noise level
(reduction of the noise from moving trains rail web damping
and screeching in curves) profile
n
No maintenance coupled by adhesive
The rail web damping system can be glued
n foil, for instance
rail base clamp
or coupled. Fixation with two railfoot clips
per element
Available for all rail profiles
n
n
Highly resistant materials
Source: Vossloh Fastening Systems
Corrosion resistance
n

Sales:
Vossloh Fastening Systems GmbH

23
 Brandenburg-Kirchmöser

The Brandenburg at the Havel district of Kirchmöser is looking back on a long railroad
tradition

The „Reichsbahn“, the German national railway

Since 1919, the administration of the German „Reichsbahn“ was headquartered in Kirchmöser,
and since 1924 operated a plant for the maintenance and repair of locomotives. The vast
premises accommodated a service shop, a railway switch shop (since 1920), a chemical
research institute and a number of other shops.

Development during GDR times

In 1952, the Kirchmöser railway switch shop started producing switches for railway companies
worldwide. Since 1965, the plant was called „Werk für Gleisbaumechanik Brandenburg-
Kirchmöser“ (plant for track engineering). All track construction machines and cranes of the
German national railway were serviced in the Kirchmöser shop.

1990 – a new beginning

The Deutsche Bahn (DB) AG was restructured into different companies and the DB research and
technology center as well as the railway environment center (BUZ) of the Deutsche Bahn AG and
other medium-sized enterprises resulted from the reorganization process.

The excellent connection to the Magdeburg - Berlin railway line makes the Kirchmöser site
particularly attractive for producers of railway components. DB facilities, the switch shop as well
as the track engineering plant are focal points for this branch of industry. Today, Kirchmöser
includes a total of 14 companies in the railroad business;
one of them is Wirthwein Brandenburg GmbH & Co. KG.

24
 Our site since 1991

In 1991, Wirthwein Brandenburg was built up on a piece of land

which was once the firing range of the ex-GDR National
Peoples’ Army. Still today the employees enthuse about the
spirit of optimism that prevailed immediately after the reunion
of the two Germanies. The clearing and levelling of the new
company premises was handled quickly and unbureau-
cratically.

The production shop located right next to the switch shop, and
the office building were pulled up in record time. In less than six
months we were producing at full capacity. Today we work with
state-of-the-art machines and most of the products go to
customers in the railway business.

After its development in Creglingen, we started the serial

production of one of our most innovative products, the cable
duct, at our Brandenburg-Kirchmöser site in 1993. In the
meantime, the product has been installed in many rail miles all
over the world.

The positive progress of the Kirchmöser site led to further

investments in 1995. A new warehouse was built and the
increased capacities allowed us to raise the number of staff to
45 people.

In 1998 we purchased the neighboring territory and started an

outdoor storage facility. Today, Wirthwein Brandenburg is a
trusted and reliable supplier for the railway market.

Our Brandenburg-Kirchmöser railway products:

Height regulation plates of different thicknesses and
n
lengths
Cable ducts with all the necessary elements
n
Rail pads and intermediate plates
n
Dowels
n

Twenty years after the foundation of the company at the

traditional railway site in Kirchmöser, around 90 employees
have a secure job at Wirthwein Brandenburg. The production
area is currently 1,920 square meters, the warehouse area
amounts to approximately 1,765 square meters.

The Brandenburg-Kirchmöser site was the first milestone in

the development of the Wirthwein group, today present in five
countries on three continents.

25
 Railroad Switch Components
We set the tracks

Source: voestalpine BWG GmbH & Co. KG

Wirthwein Brandenburg GmbH & Co.KG supplies the Butzbach,

Brandenburg and Gotha production sites of internationally operating
switch manufacturer voestalpine BWG with a variety of thermoplastic
railway switch components and accessories.
Here is a selection of components:

Different types of height

compensation plates /
pads for switch installation

Thicknesses: 2 mm / 3 mm / 4.75 mm / 10 mm
Lengths: 352 mm to 1,300 mm

Rollers for the transmission of

longitudinal motion on switches

Special rail pads made of high-quality materials

with sliding effect for switch installation

Insulation bushings and plates are necessary

Sales: accessories for switch installation
voestalpine BWG GmbH & Co. KG

26
 City Railways and Streetcars
High demands for safe operation in urban traffic

RAILFLEX rail fastening system for city railways and streetcars

Wirthwein produces the RAILFLEX system for city railways and
streetcars for a continuously resilient rail support system with the
following advantages:
n
Application in all rails and switches
n
Feasible for all grooved rail profiles Ri 60, Ri 59, Ri 55, Ri 53,
Ph 37, flat bottom rail profiles S 41 and S 49
n
Resilient and electrically insulating shell all around the rails
and rail braces
n
Advantageous continuous rail fastening with permanently
uniform resilience
n
Advantageous design with TK underground rail brace
n
Electrically insulating rail bracing through fastening points with
height-adjustable dowel foots and laterally-adjustable
ISO clamps
n
Application in all rails and switches with asphalt, concrete/
asphalt, concrete/natural stone or lawn sub-base
n
Experience since 1993 with approximately 170 km of rails and
70 switches

Application engineering:
1) 250 mm concrete C 30/37 according to TL concrete-StB 07
2) 180 mm grooved rail
3) elastic foot shell profile
4) KRUPP underground rail brace
5) flexible rail brace shell 40x65
6) 110-130 mm flowing concrete C 20/25 according to TL concrete StB 07
7) 40 or 47 mm asphalt binder according to ZTV bit-StB 84/90
8) 40 mm cover layer according to ZTV bit-StB 84/90
9) elastic, electrically insulating chamber elements
a) outside b) inside
10) bituminous casting joint carried out with the „Basel“ system
11) supporting plate with casted dowels
12) insulation clamp
13) screw
14) setting foot

Sales:
ThyssenKrupp GfT Gleistechnik GmbH

27
 System Components
For wooden sleepers and slab tracks

Along with our partner ThyssenKrupp we have developed a variety of fastening

systems:

TK 99 is an elastic rail support point with ribbed steel base plates, also as composite
structure of cast steel for running rail and guard rail:
n field of application: railways, light rails and subways
n TK 99 can be used for all rail profiles
n resilient spring deflection adjustable to 3 mm of the complete system
n elastic rail supporting point with two or four anchor bolts according to the reliable
DB design principle of the 314/336 system
n optimized substructure for technology and function improvement

TK 07-HS is a rail supporting point for wood sleepers with:

n a plastic support with casted pins for optimum load
transmission
n reduced number of components compared to standard
fastening systems
n optional preassembly with Skl 1 or Skl 14
n track gauge correction via ± 10 mm wedge adjustment
n best possible electrical insulation
n increased sleeper life thanks to plastic dowels with
reduced abrasion in the bore holes
n field of application: railways, light rails and subways
TK 07-HS

TK 07-R is an elastic rail support point for slab tracks with the following characeristics:
n field of application: light rails
n elastic rail support point for rails with a spring deflection of approx. 1 mm
n best possible electrical insulation values thanks to the plastic structure
n the optimized substructure allows technology and function improvements
n with additional components also suited as FLEXPOINT rail for streetcars

TK 04-R is an elastic rail support point for slap tracks with the
following characteristics:
n field of application: light rails and subways
n stepless side adjustment by ± 10 mm
n height adjustment by - 3 / + 10 mm
n elastic spring deflection, adjustable up to 3 mm

Wirthwein holds the patents for the TK 99, TK 07-HS, TK 07-

R, TK 04-R and RAILFLEX systems as well as for the rail
fastening systems for heavy duty up to 40 tons axle weight.
Angle guide plates, intermediate plates and rail clamps which TK 04-R
are specially adapted to the heavy duty of 40 tons axle weight have been
developed and successfully tested for rail fastening on concrete sleepers.

28
 Dowels for the Construction Industry

The construction industry is another area which makes use of our plastic components. Over the
last decades, hundreds of millions of them have been integrated and proven their worth in
buildings of all types.
Plastic dowels, for example, are sealed in concrete tunnel walls so that the cranes can lift and
transport the heavy system modules. In this area, the plastic dowels are exposed to extreme
unilateral loads.
Or they are sealed in concrete tunnel segments which are then screwed together inside of the
tunnel and must withstand high mechanical stress for many decades.
Only many years of experience in the production of technical plastic parts as well as constantly
high quality standards can assure the safety necessary for such heavy loads and stresses. That
is why our customers have put their trust in Wirthwein for so many decades.
Source: Anixter Sofrasar, F- 57205 SARREGUEMINES

Plastic dowels are sealed in A selection of different dowels

concrete for safe lifting of the and lids we manufacture for the
plates building industry

Prevent the penetration of We offer a great variety of Bolted dowel and grummet
water into the finished dowels for the building
concrete walls industry

29
 Other Components

Bolt connections with lids in different lengths

for height regulation in concrete sleepers

For more than 40 years we have been producing plastic components for railway
superstructures. During these 4 decades, a large number of products were developed and it
would be impossible to present them all. Which means that we might also make your product
although it is not shown on these pages.

Thanks to our many years of experience in the production of plastic products we are
accustomed to developing the required product in close cooperation with our customers, to
building high-performing molds and to mass-producing the products quickly and cost-
effectively. So why not your product, too?

We see ourselves as system supplier with comprehensive responsibility and a holistic

approach to the overall process. From plastics-oriented product design, mold development
and making, to production and final assembly.

Uncompromising quality and

innovative solutions.

Anchor screw casings

30
 Wood for Track Superstructures
Natural and Made to Measure

For more than one hundred years, sleepers are used

in track superstructures. Contrary to concrete and
steel sleepers, they are, however, subject to a natural
wear. That is why Wirthwein offers products for first
installations as well as for sleeper repair.

We started producing wooden products for track

superstructures as early as 1949 which means that
we - and you - can rely on more than 60 years of
experience. In addition, the Deutsche Bahn has been
our partner for many years and we also supply a large
number of international railway companies.

The wooden Wirthwein sleeper program comprises:

normal-track sleepers of beech, oak or pine wood
n
turnout sleepers of oak or pine wood
n
bridge sleepers of oak or pine wood
n

The wooden Wirthwein sleepers are produced in

conformity with national and international standards
such as EN 13245 and UIC-code 863. Production is
subject to constant quality control.

As wood is a natural material, it „works“ all the time, even

when it has totally dried. Visible crack formation is
prevented by using the prescribed securing method.

Further wooden Wirthwein products for track

superstructures:
Oak sleepers
n hardwood dowels
n stakes

Wooden stakes Beech sleepers

31
 Winkler Design

Winkler Design - founded in 1921 - today synonymous for high-class and state-of-the-
art interior design.
Our speciality: customer-tailored products for large-scale catering in companies, public
institutions and restaurants. The high standard of training, experience and qualifications of our
employees guarantee top service in all areas.
Our concepts create meeting places where corporate identity becomes visible. That is why we
have committed ourselves to nothing less than top quality. We strive to be and are more than
merely a manufacturer – we are your adviser, partner, mastermind.
As a subsidiary of the global Wirthwein-Group, we also offer the planning and investment
security that you expect for the realization of your projects.
We design and create: equipment and fittings for railway vehicles, food service systems,
cooling and heating systems, counters, reception areas, interior design & furnishing, company
cafeterias and more.
We process: stainless steel, wood, natural stone, cast stone, glass, textile and leather
We work for: railway companies, company cafeterias, shipbuilders, banks and insurance
agencies, administration facilities, nursing homes, rest stops, shopping centers, museums and
libraries
We assemble: when we leave your premises you will find your system completely assembled
and ready to use. Even the auxiliary work will be done by our own assembly specialists,
electricians and installation professionals.

The Extraordinary is our Standard.

32
 Railcars

Do you want to offer your guests, customers or employees

something out of the ordinary? Are you looking for
individual answers to special requirements?
Then we are exactly the partner you are looking for. We
don’t sell “off the rack”. We concentrate completely and
totally on implementing your wishes in perfectly tailor-
made solutions. We can draw from decades of experience.
We combine state-of-the-art technology with traditional
craftsmanship. We pay plenty of attention to even the
smallest detail.
When it comes to design, haptic properties, workmanship
and functionality, we feel committed to the highest
demands - your demands. From the first sketch to the final
nuts and bolts.

Production
Consulting and concept: expert consulting is the basic prerequisite for solutions that offer you
convincing aesthetics and functions in one package. We think proactively and look ahead: what
will the actual daily working conditions be like? What has to be borne in mind in terms of hygiene,
durability or safety? The result is a well thought-out, individual concept.
Design: We are known for our precise design, floor plans and sectional drawings created with
the latest CAD software generation. Every detail is thought out thoroughly, visualized
meticulously and discussed with you extensively. Our particular attention is directed towards
minor details so that our customers are not confronted with unpleasant surprises later on.
One for all: Tailor-made production of counters and reception facilities together with interior
fittings requires expertise in a wide range of different disciplines and extensive experience in
handling a large number of materials. Our employees are highly qualified designers,
carpenters, metalworkers, electricians and installation engineers so that we can offer you total,
complete support, from the initial concept through to the actual installation. This saves you a lot
of efforts and costs in project control and guarantees nonstop quality in all process stages.

Quality
Our philosophy: one for all and only the best. That we live our philosophy shows in our DIN EN
ISO 9001-2008 certification and DIN EN 15085-2 certification for welding on railcars.

Manufacture
Well-trained skilled workers, established and coordinated processes along with our modern
machinery ensure that your concept is one hundred percent realized in the production process,
whether it is stainless steel, wood, stone, glass, leather or textile. A sample installation of your
product ensures that it fulfils our standards in terms of quality and workmanship.

Delivery and installation

Who better to perfectly install your equipment than the professionals who designed and
produced it? Wherever you are: we come to your site, carry out the installation, give your staff all
the necessary instructions and make sure that all the equipment is commissioned in perfection.
Our commitment to top quality includes the entire installation process.

33
 Winkler Design

Railcars
Meals on Wheels

To allow coordinated completion of the trains,

all materials and processing stages are
subject to the same particularly high demands
on fitting accuracy, functionality, durability,
resistance and adherence to time schedules.

For more than 40 years, Winkler Design has

equipped a variety of railcars with kitchens and
counter systems.

In consideration of the special working

conditions as well as wishes and ideas of our
customers, we not only work with high-quality
steel and glass but also use different types of
wood, metals and natural stone.

All furniture is custom-made according to the

designers’ ideas or our own designs. When it
comes to the production of railcar equipment,
all materials and processing steps are subject
to particularly high quality demands.

The furniture must be able to withstand the

extremely high stress of everyday railway
operation, e.g. centrifugal forces, shocks and
vibrations.

Winkler Design interior design products have

been fulfilling these requirements every day for
many years.

www.winklerdesign.de

34
 Railway Vehicles

Referrals
Besides ICE express trains, Winkler Design has
equipped a variety of other train systems
operated by the Deutsche Bahn AG and other
international railway companies with kitchen and
counter systems:
Motorail train, DB InterRegio, DB
IC2000 Switzerland AVE, Spain Floor plan of the ICE 3 kitchen and
Trans Namib InterCity Night Line serving area.
Talgo 350, Spain Talgo hotel train, DB
ÖBB railjet Arriva, UK
HSB, Hungary InterCity, DB
Nostalgia train, DB Virgin, UK
TAF, Morocco NSB, Norway
EC Amsterdam ICT tilting train
DOSTO-FV, SBB ETR 500, Trenitalia
ETR 1000, Trenitalia
ICE first, second and third generation

Contact:
Winkler Design GmbH & Co. KG
Im Wasen 2
97285 Röttingen
Germany Floor plan of the Swiss Railway
Telephone: +49 (0)9338-9720-0 IC 2000 kitchen and service area.
Telefax: +49 (0)9338-9720-80
Email: office@winklerdesign.de

Imprint
Wirthwein and the Railway Print:
Management: Hinckel-Druck GmbH in 97877 Wertheim
Udo Wirthwein (Chairman of the Board) Press deadline: 2012-05-01
Marcus Wirthwein, Frank Wirthwein, Rainer Zepke (Directors) Printrun: 1,500 (German), 2,500 (English),
Norbert Gloos (Sales Manager Railway Division) 1,500 (Chinese), 500 (Polish), 1,500 (Spanish),
1,500 (Russian)
Editor: Daniela Pfeuffer
Layout: Daniela Pfeuffer, Laura Englert
Wirthwein AG
Sales Contact Railway Division: Walter-Wirthwein-Str. 2-10
Tel.: +49 (0) 7933-702-350 97993 Creglingen
norbert.gloos@wirthwein.de Marketing contact:
or: Tel.: +49 (0) 7933-702-390
Tel.: +49 (0) 7933-702-411 daniela.pfeuffer@wirthwein.de
bettina.boehm@wirthwein.de

Wirthwein AG reserves all rights unless indicated otherwise. Despite careful research we cannot assume any responsibility for
the context of the articles contained in this document. Reprints or other reproductions or extracts of this document are subject to
express approval of the editor.
To download the magazine, go to www.wirthwein-group.com

35
Walter-Wirthwein-Straße 2-10
97993 Creglingen
Germany
Tel: +49 (0)7933-702-0
Fax: +49 (0)7933-702-910
Mail: info@wirthwein.de
Site: www.wirthwein.de