Railway Infrastructure

Competent Solutions for Electric Railways and Tramways

THE PFISTERER GROUP

the power connection

Railway Infrastructure
Solutions for Today’s and
Future Challenges
Reliable and maintenance-free infrastructure provides the basis for trouble-free
operation of electric railways for local and long-distance travel. Rail traffic is
steadily increasing around the world. This places new demands on railway lines –
both on existing routes as they expand and on newly built lines. PFISTERER is a
full-service provider offering innovative and sustainable solutions for electric
railways and tramways. We maintain a consistent focus on the reliability of the
overhead contact system and high track availability.

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50 Years of Railway Expertise For Railways and Tramways
PFISTERER has been delivering solutions for railway Short distances between stops, high peak capacities and
electrification for more than 50 years – everything from high train density are the greatest challenges in local
a single source. Our products are installed around the transport. Another point to consider with tram systems
world on underground, tram and high-speed rail lines. is the increasing preference for aesthetic design.
Today they set the standard for railway companies. All Networks are complex and the geographical extent is
our products represent the highest quality while meeting limited.
and exceeding international standards as well as the
requirements of renowned railway operators. Benefit Conditions are different in long-distance transport:
from our experience in engineering, construction and high-speed passenger services and large forces from
installation. starting freight trains mean that overhead contact lines
need to be extremely robust. Modern high-speed lines
with numerous tunnels and bridges require compact
solutions that can be easily integrated into structures.
The network as a whole extends over a wide area, while
railway stations and stops are far apart.

At the same time, in local and long-distance transport,

the operational safety of lines, the protection of
passengers e.g. at stops and stations, and the prevention
of vandalism are becoming increasingly important
factors. PFISTERER offers solutions for all the
challenges associated with modern rail and tram lines.

Overhead contact systems by PFISTERER: reliable power supply systems for

railways and tramways worldwide.

Our Expertise
„„Overhead line construction
„„Tensioning

„„Insulation technology

„„Power supply

„„Safety equipment

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Expertise

Overhead Line Construction

Better capacity utilisation of railway lines, denser intervals between trains and
higher speeds mean that stresses and strains on overhead lines are constantly
increasing. PFISTERER offers overhead contact solutions and an extensive range
of cantilevers, suspension clamps and connectors for all applications. Our
innovative spring-tensioning system TENSOREX C+ is a forward-looking alternative
that offers many advantages over conventional wheel tensioners. Devices for
measuring the height of overhead contact lines round out the offering.

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Our portfolio includes cantilevers for all applications,
for AC and DC systems, and made from steel, stainless
steel and aluminium.

Cantilevers
Overhead lines need to be optimally matched to the
respective requirements. At the same time, installation
should be simple and warehousing should preferably be
kept to a minimum. The PFISTERER product portfolio
comprises the complete range of cantilevers, tunnel
suspensions and steady arms for AC and DC systems, for
railways, underground train systems and tramways.

Components are manufactured from high-grade

materials in controlled production processes. For the
insulation of cantilever tubes, a choice of PFISTERER
composite or porcelain insulators is available. Our
cantilevers are used around the world on both standard
and high-speed lines.

New: the adjustable cantilever from PFISTERER. Extendable telescopic

rods facilitate fast adjustment for catenary construction.

Adjustable cantilever
„„Pull-out telescopic rods
„„ Supplied ready-to-install
„„Fast fitting
„„Reduced warehousing

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Suspension Clamps and Connectors

Suspension Clamps
PFISTERER manufactures suspension clamps and
connectors using hot and cold forging processes. We
custom-produce to enable significantly better installation
with minimal length tolerances. All suspension clamps
conform to EN 50119 and have a long life-span.

Benefits
„„Fast and simple installation
„„Custom-manufactured

„„Catenary cable 25-300 mm²,

PFISTERER manufactures suspension clamps on an individual, custo-
contact wire 80-161 mm² mer-specific basis for better installation with minimal tolerances.

Connectors
PFISTERER offers a complete range of compression and
bolted connectors for all cable types.High-grade
aluminium and copper alloys ensure a secure connection
and reliable current flow.

Benefits
„„Perfect electrical contact
„„Faultless current flow
Our connectors are made from high-grade aluminium and copper
„„For all cables from 10-300 mm² alloys and guarantee a reliable connection on all types of cable.

CuNiSi-connectors
Made from a high-strength copper alloy, these
connectors have excellent mechanical and electrical
properties. CuNiSi connectors deliver outstanding
performance especially for use on very demanding
high-speed lines.

Benefits
„„Lightweight and durable
„„Very good mechanical and electrical properties
„„Perfect
Outstanding performance for use on high-speed lines:
solution for high-speed lines
CuNiSi connectors from PFISTERER.

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Catenary Laser Measuring Device
Modern high-speed trains travel at up to 350 km/h state-of-the-art tools and equipment that meet and
(217 mph). To ensure a constant power supply at such exceed all requirements of international railway
speeds, catenary systems need to be installed with operators.
precision and tight tolerances. PFISTERER provides

High-precision measurement systems are needed to set

Benefits
up and maintain catenary systems. The PFISTERER
„„Contactless laser measurement
catenary geometry laser measuring device combines
„„ Precise measurement of height and lateral position
ease of operation with maximum precision in a compact
design. „„Robust mechanical construction
„„ Simple to adjust, adjustment by manufacturer is
not required
„„ Weatherproof and corrosion-resistant
„„Easy to transport
„„Measures track superelevation and pole distance
(depending on model)

Catenary geometry laser measuring device

in numbers
„„ Working height: approx. 1.2 m above rail top edge
„„ Suitable for all types of catenary systems
„„Contact wire stagger: +/- 75 cm
„„Track gauge: 1435 mm, 1524 mm, 1000 mm
(other track gauges on request)
„„Measurement accuracy: lateral position +/- 5 mm
– contact wire height +/- 0.5 mm
Precise and compact:
the PFISTERER catenary geometry laser measuring device. „„ Weight: 11 kg

Railway Infrastructure 7
Expertise

Tensioning
Modern railway tracks place extremely high demands on their tensioning systems.
High-speed lines with numerous tunnels need tensioning devices that can be easily
integrated into the tunnel geometry. There is a growing trend for urban transport
systems to be aesthetically designed, requiring tensioning devices that blend
inconspicuously into their environment. TENSOREX C+ by PFISTERER is an
innovative solution for both types of application.

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TENSOREX C+ is significantly more compact than
conventional tensioning devices, and can be fitted in
about an hour.

TENSOREX C+
TENSOREX C+ is a spring-based tensioning system for
overhead lines on electric railways and tramways. It
ensures that cables and wires remain at a constant
height under tension. The necessary tensioning force is
generated by the patented interaction between a spiral
spring and a cam with variable radius – concrete and
steel weights are not needed.

TENSOREX C+ is a maintenance-free, economic system.

Fast and easy installation – in about an hour – means
lower personnel expenses and requires no additional
expertise. This significantly reduces installation costs
in comparison with conventional solutions.

MSpring

FContact wire

rPulley

lWork

FContact wire =
f (Mr ) = const.
Benefits
„„Lighter and more compact than wheel tensioning
systems
„„High response accuracy
„„ Superior safety
„„ Simple installation – low installation expenses
„„Practically maintenance-free
„„Low susceptibility to vandalism

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Expertise

Insulation Technology
Insulators are a key component in all energy networks –
including on electrical overhead lines and in distribution
stations. Mainly porcelain or composite insulators are
used in railway engineering. There is no functional
difference between the two types of material – but
porcelain or silicone may be advantageous depending on
the application. PFISTERER together with our daughter
company LAPP Insulators can look back on decades-long
experience in the manufacture of insulators. The
PFISTERER Group operates its own laboratories for
high-voltage testing and material investigations.

Composite Insulators
Composite insulators consist of a fibreglass core
surrounded by a silicone rubber sleeve and fitted with
steel or aluminium connections. The complete product
range serves all applications from conventional 750 V
DC lines to 25 kV AC high-speed lines. The main
advantages are that they are not susceptible to
vandalism and are self-cleaning in rain. As a result,
they are suitable for use in heavily polluted areas.

Our patented modular system means that composite

insulators can be adapted to all railway applications.
High-grade third-generation HTV silicone rubber and
the patented shed with underribs design provide extra
reliability and safety.

Benefits
„„Low weight
„„No risk of vandalism
„„Easy storage and handling Our composite insulators can be individually adapted to all railway
applications thanks to our patented modular system.

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Porcelain Insulators
Porcelain insulators are made from high-grade C130
porcelain, with galvanised cast iron fittings or steel
fittings, to ensure a long life-span and reliable
protection under different environmental conditions.
The complete railway portfolio of porcelain insulators
ranges from 1 to 36 kV.

Benefits
„„Ecological material
„„High electrical and mechanical strengths
„„Diverse applications

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Expertise

Power Supply
Connecting and joining metallic conductors has been a PFISTERER core
competence for almost 100 years. We are constantly working on solutions
to make installation easier and safer, and energy networks more efficient.
At PFISTERER we have an extensive portfolio for all applications and for
connecting all common conductors – whether between stations or in
substations.

SICON 2DIREKT Substation Clamps

SICON bolted connectors can be used The 2DIREKT transformer terminal and Connectors
regardless of the conductor material simply connects directly to the dis-
and conductor type. The connectors tribution transformer. Wires can be We manufacture and sell an
are fitted directly onto the conductor connected in parallel or offset by 90°. extensive range of aluminium and
ends using standard tools. The intelli- The patented connection system copper alloy clamps and connectors
gent SICON bolt prevents damage to prevents damage to the wires and for use on electrical wires and/or
the conductor and ensures the ensures constant contact pressure. tubular busbars.
correct contact force.

Benefits Benefits Benefits

„„Reliable electrical contact with „„Large voltage range:
„„Conductors can be connected
all conductors horizontally and/or vertically 500 V to 400 kV
„„Optimal contact force for any „„For busbar diameters
„„Individual wires do not get
conductor cut off up to 250 mm
„„No damage to individual wires „„Current-carrying capacity
„„Low space requirements
„„Installation using standard tools up to 6,300 A
„„For indoor and outdoor use
„„Large clamping range from „„Installation using standard
10 to 630 mm² tools, no crimping

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Earthing Branch Terminal RSC-T
To protect people and surroundings, metallic
components along electrified railway lines need to be
earthed. PFISTERER has developed a simple solution in
the shape of the RSC-T, which saves a lot of time in
comparison with established practice. The earthing
branch terminal can be integrated directly into an
existing system – no preparatory work is required.

Benefits
„„Compatible with anti-theft cables
„„No break in main conductor
„„No sharp knife required to strip insulation
„„Cuts installation time by up to 50%
„„No open flame required for installation Simple and well-thought-out earthing solution. The RSC-T can be easily
integrated into an existing system, and cuts installation time by up to 50%.

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Expertise

Safety Equipment
Safety equipment is one of the most sensitive aspects of
railway electrification. Reliable products, ease of use and
operational safety are therefore essential. PFISTERER
offers a complete range of voltage detectors, earthing and
short-circuiting devices, as well as earthing and operating
poles, which can be exactly matched to any requirements
thanks to our modular system design. Our safety
equipment represents the highest international standards
of quality, safety and reliability.

Voltage Detectors
PFISTERER offers voltage detectors for all common
railway voltage systems worldwide. Our voltage
detectors are universal – depending on the model they
can be used on contact wires and power lines or on
switchgear – and they are impressively easy to use. For
maximum safety and certainty, PFISTERER uses a
double signal system. An audible and a visual signal
give a clear warning if voltage is present. Each time they
are switched on, our voltage detectors perform a self-
test before giving a ready signal – an important safety
feature.

Benefits
„„Clear and unambiguous signalling
„„ Self-test every time it is switched on
„„Intelligent modular system for all applications
„„Use the same device indoors and outdoors
„„Design meets international standards

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Earthing and Short-circuiting Devices
Because earth cables can lash about in a short-circuit
situation and endanger personnel in the immediate
vicinity, they should not be unnecessarily long and the
optimal cable should be selected for the specific
application. PFISTERER therefore manufactures all
earthing and short-circuiting devices exactly and
individually to meet respective customer requirements.

PFISTERER offers an extensive range of conductor and

earthing clamps for use in all cases.

Portfolio
„„Earthing clamps for all applications
„„Conductor screw clamps for all applications
„„Cylindrical, ball and T-bolts as earthing bases
„„Earthing poles
„„Earthing and short-circuiting devices
„„Rail earthing clamps
„„Contact wire earthing terminals

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PFISTERER Holding AG

Rosenstrasse 44
73650 Winterbach
Germany
Phone: +49 7181 7005 0

Railway Infrastructure   M2016-040 EN 02  03 / 2017  © PFISTERER Holding AG  www.pfisterer.com  We do not assume any liability for printing misprints/Subject to technical modifications
Fax: +49 7181 7005 565
info@pfisterer.com
www.pfisterer.com

The PFISTERER Group, which also includes LAPP Insulators, is amongst

the world’s leading specialist equipment and system suppliers in the energy
infrastructure industry. Around 2,700 employees develop, produce and
distribute components and complete solutions for the particularly sensitive
interfaces in modern energy networks. With a complete range of products and
services, the PFISTERER Group provides customised solutions for the complete
transmission chain from low and medium to high and ultra-high voltage.
Everything from a single source. Worldwide For our customers, that means:
the best possible solutions for all their requirements – now and in the future.

www.pfisterer.com