concrete sleeper - wikipedia, the free encyclopedia

8/12/2019 Concrete Sleeper - Wikipedia, The Free Encyclopedia

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Concrete sleepers

Concrete sleepers were used for the

entire length of the Adelaide-Darwin

railway line

From Wikipedia, the free encyclopedia

A concrete sleeperis a railroad tie made out of steel reinforced concrete.

1 History

2 Types

3 Advantages

4 Under Sleeper Pads

5 Disadvantages

6 Alternatives

7 Characteristics

7.1 Gauge and weight

7.2 Axleload

7.3 Sharp curves

7.4 Guard Rails

8 Manufacture

8.1 Ingredients and components

9 Transport

10 Installation11 Oldest

12 Turnouts

13 Problems

14 Examples

14.1 Pakistan

14.2 United States

15 List of plants

15.1 Angola15.2 Australia

15.3 Azerbaijan

15.4 Bangladesh

15.5 Botswana

15.6 Bulgaria

15.7 China

15.8 Democratic Republic of Congo

rete sleeper - Wikipedia, the free encyclopedia http://en.wikipedia.org/wiki/Concret

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15.9 Ethiopia

15.10 Germany

15.11 Ghana

15.12 Greece

15.13 India

15.14 Iraq15.15 Kenya

15.16 Korea, North

15.17 Korea, South

15.18 Libya

15.19 Malawi

15.20 Malaysia

15.21 Mozambique

15.22 Namibia15.23 New Zealand

15.24 Pakistan

15.25 Poland

15.26 Romania

15.27 Russia

15.28 Saudi Arabia

15.29 Sierra Leone

15.30 South Africa15.31 Sudan

15.32 Switzerland

15.33 Syria

15.34 Tanzania

15.35 Thailand

15.36 Togo

15.37 Turkey

15.38 United Arab Emirates15.39 United Kingdom

16 Damaged or obsolete sleepers

17 Inventors

18 See also

19 References

20 External links


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In 1877, Joseph Monier, a French gardener, suggested that concrete reinforced with steel could be used formaking ties for railway track. Monier designed a tie and obtained a patent for it, but it was not successful.

Concrete sleepers were first used on the Alford and Sutton Tramway in 1884. Their first use on a main linerailway was by the Reading Company in America in 1896, as recorded by AREA Proceedings at the time.

Designs were further developed and the railways of Austria and Italy used the first concrete ties around the turnof the 20th century. This was closely followed by other European railways.

Major progress was not achieved until World War II, when the timbers used for ties were scarce due to

competition from other uses, such as mines.[1]Following research carried out on French and other Europeanrailways, the modern pre-stressed concrete tie was developed. Heavier rail sections and long welded rails werealso being installed, requiring higher-quality ties. These conditions spurred the development of concrete ties inFrance, Germany and Britain, where the technology was perfected.

Interest in concrete railroad ties increased after World War II following advances in the design, quality and

production of pre-stressed concrete.

Concrete sleepers can be one piece of uniform or variable dimensions. They can also consist of two separateblocks connected by a steel tie rod. Exceptionally, the concrete can be poured as two separate longitudinal slabsas has been used in Namibia.

Slab track consists of a continuous concrete roadbed without division into separate sleepers, and these are mostoften used in tunnels.

Austrak (http://www.austrak.com/) has developed a concrete Timber Replacement Sleeper(http://www.austrak.com/content/sleeper-technology/timber-replacement-sleepers/) that can be interspersed withtimber sleepers. These sleepers have a similar profile to the timber but have the benefits of concrete - especiallywhen it comes to holding gauge.

Do not rot like timber sleepers.

Extra weight makes track more stable, particularly with changes in temperature.

Withstand fire hazards better than wooden sleepers.

Longer life than wooden sleepers.

Less maintenance means lower ongoing costs and fewer track closures.

The date (or at least the 2-digit year) of manufacture is usually molded into the top surface.

Concrete sleepers lack the elasticity of wooden sleepers and therefore ballast tracks with Concrete sleepers


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BNSF line north of Yakima,

Washington

usually have a much quicker degradation of the ballast when loaded.This is especially true in bends and turnouts/switches. To reduce thewear on the ballast and in some cases offer vibration isolation pads arefitted to the base of the sleeper. The pads are usually manufactured ofpolyurethane foams with a stiffness tailored to meet the elasticityrequirements of the track.

To reduce the wear of the ballast only, the best material to use is a very

stiff semi-plastic polyurethane foam which mimics the plastic behaviourof wooden sleepers (the ballast stones are pressed into the surface of thesleeper, increasing contact area) typically these pads are 710 mm thick.

In order to achieve vibration isolation as well the elastic layer needs to be softer and in many cases thicker aswell. A vibration isolation of 5-12 dB can be achieved, but the results will depend on many factors such as axleload, velocity, subsoil stiffness, ballast thickness, ballast quality and more. Therefore it is very difficult topredict the results exactly.

When trains derail and the wheels hit the sleepers, timber sleepers tend to absorb the blow and remain

intact, while concrete sleepers tend to shatter and have to be replaced.

Gives more retentivity to the track.

Initial costs are greater.

Unsuitable for change of gauge, unless this is already taken into account.

Concrete sleepers are up to 300 lbs heavier than their wooden counterparts. As a result, larger sized

ballast is required to both support and hold in place the sleepers on the roadbed.

They do not absorb as much vibration from passing trains as wooden ties do. This can cause degradationof the ties themselves ranging from small cracks to complete failure over time. This problem is most

prevalent when the ties are located next to joints in the rails. For this reason, most railroads do not use

concrete sleepers on turnouts and interlockings.

Sleepers made of recycled plastics, which are less brittle than concrete, where reported to be under development

in 2007.[2]Fibre glass is also an option.

Gauge and weight

Concrete sleepers are heavier with wider gauges, and also with heavier track.

1,435 mm (4 ft 812in) - 335 kg heavy duty Pilbara Railways, Australia [3]


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1,435 mm - 282 kg ordinary New South Wales, Australia [4]

1,668 mm (5 ft 52132

in) - 300 kg in Spain

Axleload

Fortescue - 40t[5]

Sharp curves

Special sleepers may be necessary on extremely sharp curves, such as the new triangle at Newmarket,

New Zealand on the 1,067 mm (3 ft 6 in) gauge of radius 95 m (312 ft). Here the sleepers are extra heavy,

about 250 kg, and may include gauge wideningwith transitional gauge widening.[6]

Guard Rails

Special measures are needed to support guard rails.

Concrete sleepers are made upside down in moulds, several sleepers long. Pandrol clip bases or other fittingsare inserted into the moulds. Pretensiled steel wire are installed in these moulds, and then the concrete ispoured. It takes several days for the concrete to cure, after which the sleepers are removed from the moulds andcut into individual sleepers. The bottom of the mould is marked with the logo of the manufacturer and adatestamp.

Occasionally sleepers are made with conduits for track circuit wiring, or extra fixtures for guard rails.

Sleepers can be made using a Long Line method or a Short Line method; each method has its advantages anddisadvantages (http://www.austrak.com/content/production-technology/long-line-vs-short-line/).

Ingredients and components

Portland cement made into suitable concrete.

Steel wire usually galvanised, and pre-tensioned.

Railclips such as Pandrol.

When transported in small piles, pieces of timber are interposed between the layers of concrete sleepers.

The sleepers are laid either using manual methods or using various sleeper laying machines.


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The 1 ft 1112in (597 mm) gauge Lynton and Barnstaple Railway (1898 to 1935) in North Devon, experimented

with concrete sleepers at a number of locations along the line. Currently unknown why experiment was not

continued.

Some concrete sleepers can now be seen on display at Woody Bay Station.[7]

Chaired bullhead concrete sleepers have been around since at least the 1950s.[8]

Concrete sleepers for turnouts are much longer than normal sleepers, have gaps for switch motors, have sleepersindividually designed, and are generally made by a small number of specialist manufacturers. If a turnout is

needed in a hurry, it may be made with timber sleepers which can simply be drilled to suit.

German rails have experienced cracking of their sleepers on high speed lines.[9]

Pakistan

Line: Karachi - Lahore main line.

Gauge: 1676 mm gauge.

Cost per km: Rs3385m

Rail: UIC-54 rails

Number per km: 1,640

Fastenings: Vossloh

United States

On November 8, 2011, the US Federal Railroad Administration (FRA) put into effect new regulations onconcrete ties, with notices published by the FRA in the April 1 and September 9, 2011 U.S. Federal Register.The FRA notices said that the need for the new rules was shown by the derailment of an Amtrak train nearHome Valley, Washington on April 3, 2005, which according to the U.S. National Transportation Safety Boardwas caused in part by excessive concrete tie abrasion. To be counted as a good tie under FRA regulation213.109(d)(4), concrete ties shall not be deteriorated or abraded under the rail to a depth of one-half inch ormore. Limits on other types of concrete tie deterioration are also given.


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Austrak concrete sleeper factory in

Wagga Wagga

Angola

(Three plants needed)

North - Bengo Province

Centre - Liangongo - Benguela

South - Caraculo[10]

South - Namialo - concrete sleeper plant.[11]

Australia

(clockwise)

Townsville Austrak - 1,067 mm (3 ft 6 in) - defunct[12]

Mackay Austrak - 1,067 mm - defunct[12]

Rockhampton Austrak - 1,067 mm[12]

610 mm are also made for cane tramways.

Mittagong - 1,435 mm (4 ft 812in)

Taree - 1,435 mm

Denman - 1,435 mm

Mittagong - 1,435 mm[13]

Grafton - 1,435 mm

[13]

Wagga Wagga - 1,435 mm (Bomen) Austrak - 1,435 mm

Geelong (Avalon) Austrak - 1,435 mm & 1610 mm (2 ft)

Port Hedland Austrak - 1,435 mm

Wedgefield Austrak - `610 mm, 1,067 mm, 1,435 mm[14]

Wickham - 1,435 mm

Katherine Austrak - 1,435 mm - defunct[12]

Tennant Creek Austrak - 1,435 mm - defunct[12]

Austrak (http://www.austrak.com/) - Australia's largest manufacturer of concrete railway sleepers[15]

Azerbaijan

Sleeper Factory Baku [16]

Bangladesh

Chhatak[17]


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Botswana

Gaborone - Kwena Concrete Works[18]

Bulgaria

Svishtov [19]

ZPSV-Varna [20]

China

China United Railway Logistics[21]

Democratic Republic of Congo

Due 2012 [22]

Ethiopia

Dire Dawa - 1,000 mm (3 ft 338in)[23][24]

Germany

1,435 mm (4 ft 812in)[25]

DW Schwellen Gsen sleeper production plant - see http://www.thosti.com.de/guesen-sleeper-production-plant.html and http://dw-schwellen.de/unternehmen/werke/guesen/index.html

DW Schwellen Neuss sleeper production plant - see http://dw-schwellen.de/unternehmen/werke/neuss

/index.html

DW Schwellen Augsburg sleeper production plant - see http://dw-schwellen.de/unternehmen/werke

/augsburg/index.html

Ghana

Huni Valley - 1,435 mm (4 ft 812in)/1,067 mm (3 ft 6 in) dual gauge (?)[26]

Number: 2 m

Cost: Euro 85m

Cost each: Euro 42.5 per sleeper.

Cost of plant: Euro 7

Jobs: 130

Output: 400,000 per annum


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Output: 1096 per day (about 0.5 km of track).

Makers: Kampac and Rail.One

Gauge: possibly dual gauge 1,435 mm (4 ft 812in)/1,067 mm (3 ft 6 in)

1,000 mm (3 ft 338in) gauge.

In 2014, a new siding from Lom across the border from Togo to a cement works in Ghana opened using

concrete sleepers.[27]

Greece

Sleeper Factory Trikala - Strotires [28]

India

[29]First use in 1977[30]

Hindustan Prefab Limited[31]

PCM Group - 3 plants - first in 1991[32]

Patil Group - 8 plants - first in 1971[33]

Nandgaon, Maharashtra

Madhepura[34]

Kathua[35]

Vishal Nirmiti

[36]

Iraq

Abu Ghraib[29]

Kenya

2005 - proposed[37][38]

Korea, North

Rahung[39]

Korea, South

Pusan[40]


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Libya

Khoms[41]by Walterbau,[42]Germany.

Ra's Lanuf - for Russian contract

Malawi

plant supplied earlier by same maker as plant for Mozambique (Nacala).[43]

Malaysia

Malaysia - 1,000 mm (3 ft 338in) - proposed[12]

Mozambique

Namialo for northern line of Caminhos de ferro do Moambique (CFM) of Nacala to the Malawian

border.[43][44]

Dondo[45]

Sena - 600 per day

Namibia

Tsumeb[46][47]

New Zealand

Te Rapa, Hamilton, North Island [48]

Pakistan

Kohat, Khyber Pakhtunkhwa [49]

Khanewal, Punjab

Sukkur, Sindh

Kotri, Sindh

Poland

Goczalkow sleeper production plant [50]

Romania

Metabet (http://gulfbusiness.tradeholding.com/default.cgi/action/viewcompanies/companyid/166508/)


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Dunapref -Blejoi [51][52]

Dunapref -Giurgiu [52][53]

Russia

Viazma[54]

Saudi Arabia

Ha'il - Transport in Saudi Arabia 32.5T axleload - 1,435 mm (4 ft 812in)[55]

Rail. one[56]

PCM Strescon Overseas Ventures Ltd, Manufacturers of Heavy Haul Concrete Sleepers with capacity of

100,000 sleepers a month[57]

Hofuf sleeper production plant [58]

Sierra Leone

Racegroup[59]

South Africa

Infraset[60][61]

Sudan

Sudan - north Khartoum, producing 1,200 concrete sleepers a day.[62][63]by Shanghai Hui Bo Investment

Co (SHIC) [64]

Cost of factory - $5m[62]

Switzerland

Tribeton[65]

Syria

Sleeper Factory Homs [66]

Tanzania

Tanzania called tenders in 2008 for sleeper plant.


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Thailand

Wihan Daeng in Saraburi Province[67]

Togo

In 2014, a new siding from Lom across the border into Ghana to a cement works opened using concrete

sleepers.[27]

Turkey

Sleeper Factory Denizli [68]

United Arab Emirates

Mirfa - Etihad Rail

United Kingdom

Trackwork Moll Ltd.[69]

Damaged concrete sleepers cannot be repaired. Old concrete sleepers can be used for things like retaining walls,

else they might be crushed to recycle gravel and the steel reinforcing.[70]

1877 Joseph Monier, France

1912 Bonnet (diagram)[71]

1929 Stent[72]

Timms

Sleeper

Ladder track - longitudinal sleepers

Tubular Modular Track

Bi Block sleepers[73]

Cement in Africa


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Ballast

^Hay 1982, p. 4701.

^Railway Sleepers Made from Recycled Plastic

(http://www.azom.com/news.asp?newsID=8437)

2.

^http://www.railpage.com.au

/f-p1907729.htm#1907729

3.


/f-p1907789.htm#1907789

4.

^[1] (http://www.fmgl.com.au

/irm/ShowStaticCategory.aspx?CategoryID=213&

HideTopLine=True)

5.

^Railway Gazette International March, 2012, page

23

6.

^http://www.lynton-rail.co.uk7.

^ndrailusers Mag09

(http://ndrailusers.wikispaces.com/Mag09)

8.

^:: View topic - German track in big trouble

(http://railuk.forumup.co.uk/about1924-railuk.html)

9.

^Railways Africa - NAMIBE RAILWAY

INSPECTED (http://railwaysafrica.com

/index.php?option=com_content&task=view&

id=3055&Itemid=35)

10.

^RailwaysAfrica 5/2013 p2011.

^ abcdefAustrak: Factories - Overview

(http://www.austrak.com/factories.asp)

12.

^ abRocla13.

^Laing O'Rourke - Intelligent Thinking Intelligent

Construction (http://www.laingorourke.com.au

/Specialist/Austrak.aspx)

14.

Âustrak: In Profile (http://www.austrak.com/)15.

^Baku sleeper production plant - Thosti-International

(http://www.thosti.com.de/baku-sleeper-production-

plant.html)

16.

^Chhatak concrete sleeper plant idle for months :

Dhaka Mirror (http://www.dhakamirror.com

/?p=2376)

17.

^RailwaysAfrica (http://railwaysafrica.com

/index.php?option=com_content&task=category&

sectionid=4&id=15&Itemid=35)

18.

^Svishtov sleeper production plant - Thosti-

International (http://www.thosti.com.de/svishtov-

sleeper-production-plant.html)

19.

^ZPSV-Varna sleeper manufacturing palnt

(http://zpsv.bg/)

20.

^Concrete Sleeper - Trains and Railroads Product -

from China Railway United Logistics Co., Ltd. |

asiaproduct.net (http://www.asiaproduct.net

/Showroom/product/104418/Concrete_Sleeper.aspx)

21.

Ôur projects | SNCC: La Socit Nationale des

Chemins de Fer du Congo (http://sncc.cd/en/sncc

/projects/)

22.

ÊthioBlog - Archives for: January 2008, 22

(http://nazret.com/blog/index.php?m=20080122)

23.

^Consta (http://allafrica.com/stories

/200802252066.html)

24.

^Walter Beton Concrete Sleepers Germany

(http://www.walter-beton.com/references.html)

25.

^[2] (http://www.railone.com/en/top-navigation

/news/press/news-single-view/browse/3/article

/railone-beteiligt-sich-an-der-erneuerung-der-western

and-central-line-in-der-republik-ghana/90.html)

26.

^ abCement siding opened. (http://graphic.com.gh

/news/general-news/18126-rail-line-linking-diamond-

cement-lome-port-completed.html)

27.

^Trikala sleeper production plant - Thosti-

International (http://www.thosti.com.de/trikala-


28.

^ abManufacturer of Prestressed Concrete Railway

Sleepers from India, Prestressed Concrete Monoblock

Railways Sleeper (http://www.indianhumepipe.com

/rsleeper.html)

29.

ÎRFCA (http://www.irfca.org/faq/faq-history5.html)30.


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^Hindustan Prefab Limited (A Government of India

Enterprise) (http://www.hindprefab.org/)

31.

^PCM GROUP of Industries

(http://www.pcmgroup.co.in/)

32.

^Patil Group Of Industries (http://www.123eng.com

/forum/viewtopic.php?t=35719)

33.

^[3] (http://www.ircon.org/railways.asp)34.^RAILWAYS PLANS TO SET UP CONCRETE

SLEEPER PLANT AT KATHUA - Hindustan Times

(New Delhi, India) | HighBeam Research

(http://www.highbeam.com

/doc/1P3-1000014461.html)

35.

^Vishal Nirmiti Pvt. Ltd. - Concrete sleeper Plant

(http://wikimapia.org/10924305/Vishal-Nirmiti-

Pvt-Ltd-Concrete-sleeper-Plant)

36.

^Sudan Tribune (http://www.sudantribune.com/spip.php?article12871)

37.

^September 2004 Panapress 24 June 2004

(http://www.panapress.com

/newslatf.asp?code=eng057705&dte=24)

38.

^Past news (http://www.kcna.co.jp/item/2001

/200109/news09/17.htm)

39.

^Pusan Industrial Co (http://www.taemyung.com

/e-introd.htm)

40.

^Walter-Beton (http://www.walter-beton.com

/references.html)

41.

^Parts and Components - Image Gallery - Railway

Technology (http://www.railway-technology.com

/contractors/rail/gallery.html)

42.

^ abSLEEPERS FOR NACALA | Railways

AfricaRailways Africa

(http://www.railwaysafrica.com/blog/2013

/08/sleepers-for-nacala/)

43.

^SLEEPERS FOR NACALA | Railways

AfricaRailways Africa

(http://www.railwaysafrica.com/blog/2013

/08/sleepers-for-nacala

/?utm_source=Railways+Africa&

utm_campaign=3fd2d2d34d-

RSS_EMAIL_CAMPAIGN&utm_medium=email&utm_term=0_a785c99d84-3fd2d2d34d-

386816265#sthash.CsgM89pr.dpuf)

44.

^allAfrica.com: Mozambique: Reconstruction of

Sena Line Behind Schedule (Page 1 of 1)

(http://allafrica.com/stories/200803210738.html)

45.

^Railway to new opportunity

(http://www.africasia.com/archive/ab/00_02

/abcf0201.htm)

46.

^Namibia Archives | Railways AfricaRailwaysAfrica (http://www.railwaysafrica.com/blog/category

/africa-update/sadc/namibia-sadc/)

47.

^Track & Signal Winter 2012, pg 5448.


/f-p1908358.htm#1908358

49.

^Goczalkow sleeper production plant - Thosti-

International (http://www.thosti.com.de/goczalkow-


50.

^Blejoi sleeper production plant - Thosti-

International (http://www.thosti.com.de/blejoi-


51.

^ abReferences - Thosti-International

(http://www.thosti.com.de/references.html)

52.

^Giurgiu sleeper production plant - Thosti-

International (http://www.thosti.com.de/giurgiu-


53.

^Viazma Concrete Sleeper Plant

(http://www.kompass.com/uk/RU010874)

54.

^RailwaysAfrica 2007/6 p3655.

^[4] (http://www.railway-technology.com/contractors

/engineering/pfleiderer2

/Press27.html?WT.mc_id=DN_PR&

mxmroi=15093578/2651435/false)

56.

^PCM Strescon Overseas Ventures Limited :: Home

(http://www.pcmstrescon.com)

57.


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^Hofuf sleeper production plant - Thosti-

International (http://www.thosti.com.de/hofuf-


58.

^Grindrod Rail Construction | Group Companies |

Grindrod Limited (http://www.racecgroup.com

/our-services/rail-construction/)

59.

ÎNFRASET (http://www.railway-technology.com/contractors/rail/infraset/)

60.

ÎNFRASET SLEEPERS FOR ORE LINE |

Railways AfricaRailways Africa

(http://www.railwaysafrica.com/2009/11/infraset-

sleepers-for-ore-line/)

61.

^ abSudan Vision Daily - Details

(http://news.sudanvisiondaily.com

/details.html?rsnpid=206913)

62.

^Winne.com - Report on Sudan, Beyond CommonPerceptions (http://www.winne.com/sudan/to06.html)

63.

^Sudan / Africa / Forums / Railpage

(http://www.railpage.com.au/f-t11328857-s25.htm)

64.

^[5] (http://www.tribeton.ch/uploads/media

/We_re_right_on_track.pdf)

65.

^Homs sleeper production plant - Thosti-

International (http://www.thosti.com.de/homs-


66.

ÎTALIAN-THAI Development Public Company

Limited (http://www.itd.co.th/en/complex.php)

67.

^Denizli sleeper production plant - Thosti-

International (http://www.thosti.com.de/denizli-


68.

^Trackwork MOLL :: Pre-stressed concrete railway

sleepers (http://www.trackwork-moll.co.uk)

69.

^concrete sleeper crusher - YouTube

(http://www.youtube.com/watch?v=NrkgMQ5ppyg)

70.

^"ENGINEERING." (http://nla.gov.au/nla.news-

article10498135). The Argus (Melbourne, Vic. : 1848

- 1956)(Melbourne, Vic.: National Library of

Australia). 12 December 1912. p. 10. Retrieved 20

December 2011.

71.

^"Concrete Railway Sleepers." (http://nla.gov.au

/nla.news-article22919615). The Queenslander(Brisbane, Qld. : 1866 - 1939)(Brisbane, Qld.:

National Library of Australia). 17 October 1929.

p. 62. Retrieved 20 December 2011.

72.

^Wallonia (http://www.sectors.wallonia-export.be

/en/firm.asp?pole_id=4&sector_id=83&

firm_id=2053)

73.

Concrete sleeper research URL http://ro.uow.edu.au/

Media related to Concrete sleeper at Wikimedia Commons

Concrete Sleeper Manufacturers Association (http://www.britishprecast.org/associations/concrete-

sleeper.php)

ARTC (http://www.minister.infrastructure.gov.au/aa/releases/2011/November/AA218_2011.aspx)

Freeze-thaw Performance Testing of Whole Concrete Railroad Ties, Phase 1 Report (http://purl.fdlp.gov

/GPO/gpo46594) Federal Railroad Administration

Gallery (https://www.google.com.au/search?q=concrete+sleeper+kenya&client=firefox-a&hs=YvM&

rls=org.mozilla:en-US:official&channel=sb&tbm=isch&tbo=u&source=univ&sa=X&ei=ubM_U-

6TA8T6kAXQ1YCABA&ved=0CGQQsAQ&biw=1360&bih=733#facrc=_&imgdii=_&

imgrc=eqd5TR7LOCkkCM%253A%3BN2hbINp3AZ62oM%3Bhttp%253A%252F%252Fwww.krc.co.k

e%252Fjoomla%252Fimages%252Fstories%252Fthe%252520standard%252520gauge%252520railway


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%252520map.jpg%3Bhttp%253A%252F%252Fwww.skyscrapercity.com%252Fshowthread.php%253Ft

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