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RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 237 of 241 07/06/2013

1/3 octave subballast-form layer acceleration insertion loss graphs for passenger train (upper graph), freight vehicle (middle graph) and dynamic load time history (lower graph) of TS3

track system compared to TS2 with ballast tamped and stabilized.

100

101

102

-2

0

2

4

6

8

10

12

14

16IL PTQ AceSB_FL GPvsGS

f(Hz)

IL(d

B)

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101

102

-4

-3

-2

-1

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1

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6IL FTQ AceSB_FL GPvsGS

f(Hz)

IL(d

B)

100

101

102

-15

-10

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15IL DFT AceSB_FL GPvsGS

f(Hz)

IL(d

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RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL 38 of 241 07/06/2013

1/3 octave form layer-embankment acceleration insertion loss graphs for passenger train (upper graph), freight vehicle (middle graph) and dynamic load time history (lower graph) of

TS3 track system compared to TS2 with ballast tamped and stabilized.

100

101

102

-5

0

5

10

15

20IL PTQ AceFL_E GPvsGS

f(Hz)

IL(d

B)

100

101

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8IL FTQ AceFL_E GPvsGS

f(Hz)

IL(d

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15IL DFT AceFL_E GPvsGS

f(Hz)

IL(d

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1/3 octave middle embankment acceleration insertion loss graphs for passenger train (upper graph), freight vehicle (middle graph) and dynamic load time history (lower graph) of TS3


100

101

102

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0

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18IL PTQ AceE142 GPvsGS

f(Hz)

IL(d

B)

100

101

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-2

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5IL FTQ AceE142 GPvsGS

f(Hz)

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100

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1/3 octave bottom embankment acceleration insertion loss graphs for passenger train (upper graph), freight vehicle (middle graph) and dynamic load time history (lower graph) of TS3


100

101

102

-6

-4

-2

0

2

4

6

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10

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14IL PTQ AceE062 GPvsGS

f(Hz)

IL(d

B)

100

101

102

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-4

-2

0

2

4

6IL FTQ AceE062 GPvsGS

f(Hz)

IL(d

B)

100

101

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-10

-5

0

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10IL DFT AceE062 GPvsGS

f(Hz)

IL(d

B)

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RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 1 of 89 10/06/2013

RIVAS

Railway Induced Vibration Abatement Solutions

Collaborative project

Results of laboratory tests for ballasted track mitigation measures

Under Sleeper Pads (USP) and heavy sleepers

Deliverable D3.7 (Part B)

Submission date: 10/06/2013

Project Coordinator:

Bernd Asmussen

International Union of Railways (UIC)

[email protected]

mailto:[email protected]

RIVAS

SCP0-GA-2010-265754


Title Results of laboratory tests for ballasted track mitigation

measures

Under Sleeper Pads (USP) and heavy sleepers

Domain WP3, Task 3.2, D3.7 (Part B)

Date 10/06/2013

Author/Authors Dipl. Ing. E. Knothe

Partner BAM

Document Code RIVAS_BAM_ WP3_D3_7_PartB_final.docx

Version V02

Status Final

Dissemination level:

Project co-funded by the European Commission within the Seventh Framework Programme

Dissemination Level

PU Public

PP Restricted to other programme participants (including the Commission Services)

RE Restricted to a group specified by the consortium (including the Commission) Services)

CO Confidential, only for members of the consortium (including the Commission Services) X

Document history

Revision Date Description

1 29/04/2013 First Draft

2 03/06/2013 Second Draft

3 10/06/2013 Final

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SCP0-GA-2010-265754


1. EXECUTIVE SUMMARY

The laboratory tests of under sleeper pads and sleepers were carried out within the research

project RIVAS Railway Induced Vibration Abatement Solutions, Grant Agreement Number

265754, of the European Union EU.

This report describes the measurement of under sleeper pads and sleepers for ballasted

tracks, work package 3 “Mitigation measures track” of RIVAS, task 3.2 “Mitigation measures

for ballasted tracks” [5].

The tests for under sleeper pads have been performed in accordance with DIN 45673-6 –

Mechanical vibration – Resilient elements used in railway tracks – Part 6: Laboratory test

procedures for under sleeper pads of concrete sleepers, [1]. The tests for the sleepers have

been performed in accordance with DIN EN 13230-2 – Railway applications – Track –

Concrete sleepers and bearers – Part 2: Prestressed monoblock sleepers.

Three different types of under sleeper pads (SLN1010, SLN0613 and SLN0315) and one

sleeper type (B90.2) were investigated. For the examination of the under sleeper pads for

ballasted tracks tests for the static and dynamic bedding modulus, fatigue strength, bond

strength, shear strength and the freeze-thaw resistance were carried out. For the sleepers

static tests, dynamic tests and in a fatigue test were carried out.

The results of the measurements are documented in detail among others in stress-

displacement diagrams for the different static bedding moduli, bond strength and shear

strength. The so called low-frequency bedding modulus was determined for 5 Hz, 10 Hz, 20

Hz and 30 Hz at 23 °C and in addition for 10 Hz at 0 °C and -20 °C. The so called high-

frequency bedding modulus was determined at 10 Hz, 20 Hz, 40 Hz, 80 Hz and 160 Hz at

room temperature.

Two standards for tests of USP with different profiled loading plates exist, the German

standard DIN 45673-6 [1] and the draft European standard CEN/TC 256 [4]. The static

bedding modulus was determined at the same specimen with the test procedure of the

German standard with the two different loading plates. Looking at the influence of the loading

plates the static bedding modulus differs depending on the material between 10% and 18%

for medium ballast compaction.

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2. TABLE OF CONTENTS

1. Executive Summary ....................................................................................................... 3

2. Table of contents ............................................................................................................ 4

3. Introduction .................................................................................................................... 6

4. Test Laboratory and Staff ............................................................................................... 7

5. Examination of the under sleeper pads for ballasted track .............................................. 8

5.1 Material and Specimen ............................................................................................ 8

5.1.1 Material ............................................................................................................ 8

5.1.2 Specimen ......................................................................................................... 9

5.2 Characteristic Values .............................................................................................12

5.2.1 Static bedding modulus Cstat and at-rest value Cstat0 of the static bedding

modulus 12

5.2.2 Different profiled loading plates (German-NSP and EU-GBP) - Static bedding

modulus 15

5.2.3 Low-frequency bedding modulus Cdyn1 (f) ........................................................17

5.2.4 Low-frequency stiffening ratio Kdyn1(10Hz) .......................................................19

5.2.5 High-frequency bedding modulus Cdyn2 (f) .......................................................20

5.2.6 High-frequency dynamic stiffening ratio Kdyn2 (80Hz) .......................................21

5.3 Serviceability ..........................................................................................................22

5.3.1 Mechanical fatigue strength.............................................................................22

5.3.2 Bond strength by pull-off .................................................................................23

5.3.3 Shear strength.................................................................................................25

5.3.4 Freeze-thaw resistance ...................................................................................27

6. Examination of the Sleepers B90.2 – ballasted track .....................................................29

6.1 Material and specimen ...........................................................................................29

6.2 Static test rail seat ..................................................................................................29

6.3 Static test centre ....................................................................................................32

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6.4 Dynamic test rail seat .............................................................................................33

6.5 Fatigue test ............................................................................................................35

7. Conclusion ....................................................................................................................37

8. Annex ............................................................................................................................38

8.1 References .............................................................................................................38

8.2 Abbreviations .........................................................................................................38

8.2.1 Terms and definitions ......................................................................................38

8.2.2 Symbols ..........................................................................................................39

8.3 Tables – Examination of the USP ...........................................................................41

8.3.1 Measuring System ..........................................................................................44

8.3.2 Results USP ....................................................................................................49

8.4 Figures - Examination of the USP ..........................................................................60

8.4.1 Specimen ........................................................................................................60

8.4.2 Test rig ............................................................................................................61

8.4.3 Evaluation static bedding modulus ..................................................................66

8.5 Data sheets USP firm Getzner Werkstoffe GmbH ..................................................75

8.6 Tables –Examination of the sleepers ......................................................................76

8.6.1 Measuring system and test forces ...................................................................77

8.6.2 Results – sleepers ...........................................................................................79

8.7 Figures – Examination of the sleepers ...................................................................81

8.7.1 Test rig ............................................................................................................82

8.7.2 Tested sleepers ...............................................................................................85

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3. INTRODUCTION

Railway induced vibrations are a growing problem in Europe. Therefore the European

Commission installed the research project RIVAS Railway Induced Vibration Abatement

Solutions, Grant Agreement Number 265754. The aim of RIVAS project is to reduce railway

induced ground-borne vibrations with mitigation measures on the track, the propagation path

and of the vehicles. The subjects investigated in this report aims for the measures in track

only.

Under sleeper pads (USP) and sleepers are investigated within the work package 3

“Mitigation measures track” of RIVAS, task 3.2 “Mitigation measures for ballasted tracks” [5].

The numerical study [7] in RIVAS-Deliverable 3.2 showed the mitigation potential of soft

under sleeper pads and heavy sleeper. Therefore, laboratory tests were carried out with soft

under sleeper pads and with a newly designed heavy sleeper. The tests include the

determination of characteristic values, which are necessary to predict the mitigation effect, as

well as serviceability tests which are necessary for the installation new elements in

commercial tracks.

During the laboratory tests three different materials from Getzner Werkstoffe GmbH for USP

were examined: SLN1010, SLN0613 and SLN0315.

One sleeper type B90.2 was examined.

All tests were planned in corporation with RAIL.ONE GmbH and all tested materials were

delivered as well by RAIL.ONE GmbH.

The report is subdivided into chapter 1 to 4 with the executive summary, the table of

contents, the introduction and the test laboratory and staff. The examination of the USP is

described in chapter 5 and the examination of the sleepers in chapter 6. The conclusions are

given in chapter 7. Additional information are given in chapter 8.

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4. TEST LABORATORY AND STAFF

The measurements were carried out at

BAM Federal Institute for Materials Research and Testing

Division 7.2 Buildings and Structures

Unter den Eichen 87

12205 Berlin

Germany

The tests were carried out between August 2012 and Mai 2013.

The measuring staff was:

Dipl. Ing. E. Knothe Project Management,

Report

Evaluation

Dipl. Ing. E. Kretzschmar

Dipl.-Ing. R.Makris

Dipl.-Ing. H.-J. Peschke

Test organisation

Evaluation

M. Peuschel Evaluation with ATOS

I. Feick

N. Neumann

Test setup and procedure

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5. EXAMINATION OF THE UNDER SLEEPER PADS FOR

BALLASTED TRACK

For the examination of the under sleeper pads for ballasted tracks the characteristic values

the static and dynamic bedding modulus were determined. The high-frequency bedding

moduli are the values which characterise the mitigation potential of the USP.

In addition tests for the serviceability the fatigue strength, bond strength, shear strength and

the freeze-thaw resistance were carried out.

The test procedure was carried out according to DIN 45673-6 [1] – Mechanical vibration –

Resilient elements used in railway tracks – Part 6: Laboratory test procedures for under

sleeper pads of concrete sleepers, English version of [1].

5.1 MATERIAL AND SPECIMEN

5.1.1 Material

Three different elastomer materials of USP from the company Getzner Werkstoffe GmbH

were examined. Table 5-1 gives the declaration of the USP as delivered by Getzner

Werkstoffe GmbH. Additional information are given in the data sheet exemplarily for the

material SLN 0315, Figure 8-30.

Table 5-1: USP, declaration of the manufacturer Getzner Werkstoffe GmbH

material thickness [mm]

declaration manufacturer

bedding modulus [N/mm³],

declaration manufacturer

SLN 1010 SLN 10 0.10

SLN 0613 SLN 13 0.06

SLN 0315 SLN 15 0.03

The single USP SLN 0613 is shown exemplarily in Figure 5-1. The USP consist of a felt layer

at the bottom, the elastomer and a geogrid. The felt layer protects the elastomer against

spiky ballast and the geogrid as a bonding layer to connect the USP with the concrete.

Pictures of USP SLN1010 and SLN0613 are shown in Figure 8-1 and Figure 8-2 in the

annex.

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Figure 5-1: Under-sleeper pad SLN0613

5.1.2 Specimen

The specimens were concrete blocks with bonded USP as a substitute for the sleeper and

single USP, see Figure 5-2. The dimensions of the concrete blocks differ depending on the

kind of tests. The concrete blocks with bonded USP and the single USP were provided by

RAIL.ONE GmbH. An overview of all delivered specimen is given in Table 8-1 to Table 8-3,

page 41ff. Every specimen had his own notation.

Material SLN1010 notation C-xx

Material SLN0613 notation B-xx

Material SLN0315 notation A-xx

Single USP P-01, P-02 or P-03

The supplier´s notation e.g. SLN 0613 means a Material Sylodyn (SLN) with 0.06 N/mm³

nominal modulus and a thickness of 13 mm.

SLN 0613

5 cm

d = 15 mm

geogrid

elastomer

felt

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Figure 5-2: Specimen, concrete blocks with USP, material Getzner Werkstoffe GmbH SLN, a) +

b) for different tests 300 * 300 * 100 mm³, 300 * 300 * 200 mm³, c) for the shear test

200 * 200 * 200 mm³

Static and dynamic Bedding modulus: For the static and at-rest value of the static

bedding modulus the specimens were concrete blocks with bonded USP with the dimensions

300 * 300 * 100 mm³ (only concrete block), see Figure 5-2. The area of the specimens was

90 000 mm². The height was reduced versus the requirement of the German standard

DIN 45673-6 [1] because of a better handling in the laboratory. The lower mass was

considered in the test.

The low-frequency bedding modulus was measured directly after the static bedding modulus

with the identical specimen as those for the static bedding modulus.

For the high-frequency bedding modulus single USP without bonding layer were used. One

side of the USP was plain and the other side had got the normal felt layer at the ballast

contact surface.

a)

b)

a)

c)

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Fatigue test: The specimen for the fatigue test was a concrete block with USP with the

dimensions 300 * 300 * 200 mm³ (only concrete block) as provided in the German standard

DIN 45673-6. The area of the specimen was 90 000 mm².

Bond strength by pull-off: For the bond strength a specimen with a test area with a

diameter of 50 mm has to be prepared. The tear chips were drilled out of a concrete block

with bonded USP. The drill was made through the USP and about 10 mm down into the

concrete block, see Figure 5-3.

\\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Bilder\

Haftabzug\bonding test USP ballasted track\JAN13\

Figure 5-3: Bond strength by pull-off, preparation of specimen, 5 test areas

Shear test: For the shear tests concrete cubes with USP on two opposite sides were

used. The dimensions of the cubes are 200*200*200 mm³ (only concrete cube) as provided

in the German standard DIN 45673-6.

Frost-thaw test: The specimen for the frost-thaw test is the same (identical in

construction) as for the static bedding modulus, concrete block with USP,

300 * 300 * 100 mm³.

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5.2 CHARACTERISTIC VALUES

5.2.1 Static bedding modulus Cstat and at-rest value Cstat0 of the static

bedding modulus

The static bedding modulus is used for the calculation of the static deformation of the

rail under the service load. It is calculated with the following formula:

It is a reference parameter for the USP. For the determination three load cycles were

applied. The third cycle was analysed and the secant modulus between stress and and

the displacements s2 and s1 was calculated, see Figure 5-4.

The at-rest value of the static bedding modulus shows the static compression under

the dead load of a train. It is calculated between stress and , measured after a resting

time of 10 minutes, see Figure 5-4, with the following formula:

Test parameters:

The static bedding modulus was determined with 3 specimens. The at-rest value of the static

bedding modulus was determined with exactly the same specimen directly after the static

bedding modulus for each condition in accordance with [1]. The test routine for both bedding

moduli is shown in Figure 5-4. The test conditions for the static bedding modulus are

summarized in Table 5-2 and the evaluation range in Table 5-3. The test conditions for the

at-rest value of the static bedding modulus are the same as for the static bedding modulus

but the loading range is different.

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Figure 5-4: Test routine static and at-rest value of the static bedding modulus

Table 5-2: Static bedding modulus - Test conditions

Conditions: dry test object,

test temperature must be achieved 16 h before the test

Specimen 3 concrete blocks with USP, 300 * 300 * 100 mm³

Temperature (23 ± 3)°C, (0 ± 3)°C, (-20 ± 3)°C

Load application The concrete block with the USP is placed on top of the profiled

plate (NSP). The USP is in contact with the plate. The weight of the

concrete block has to be taken into account for the applied force.

Loading and unloading rate /t = 0.01 N/mm²/s

Loading range: u = 0.01 N/mm², o = 0.25 N/mm²

Test rig servo-hydraulic tensile-compression testing machine with 100 kN

cylinder, see Table 8-4

Table 5-3: Static bedding modulus - evaluation ranges

Evaluation range for medium

ballast compaction:

1 = 0.01 N/mm², 2 = 0.10 N/mm²

Evaluation range for high

ballast compaction:

1 = 0.01 N/mm², 2 = 0.20 N/mm²

o

2

2*

u = 1

5 min 10 min 10 min 10 min time

str

ess

resting value

resting value

resting value

0

high ballast pressure

middleballast pres.

test forstatic bed. modulus test for at-rest value of the static bed. modulus

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The results of the static and at-rest value of the static bedding modulus for the three

different materials are shown in Table 8-9 to Table 8-11. As an example the static bedding

modulus for different temperatures and for high ballast compaction is presented in Figure

5-5. The static bedding modulus for all different USP increases while the temperature

decreases.

Figure 5-5: static bedding modulus for high ballast compaction

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5.2.2 Different profiled loading plates (German-NSP and EU-GBP) - Static

bedding modulus

The tests for the static and at-rest value of the static bedding modulus, for the low-frequency

bedding modulus and for the high-frequency bedding modulus are carried out with the

German ballast plate (NSP, in German Normschotterplatte), Figure 5-6. Surface area of the

German ballast plate is 300 x 300 mm². It is produced from a ballast cast from real ballast.

Figure 5-6: German ballast plate (NSP)

The other ballast plate is the European or Geometric ballast plate (GBP) with a pyramidal

structure instead of the real ballast and with the same surface area, Figure 5-7, according to

CEN [4].

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Figure 5-7: European or Geometric ballast plate (GBP)

For the different USP the static bedding modulus was determined with the German ballast

plate and in addition with the geometric ballast plate to compare the influence of both profiled

plates. The tests with the NSP and the GBP were performed on the identical specimen for

each material and with the same test procedure. The test procedure was chosen according

to DIN 45673-6, [1]. It is described in chapter 5.2.

Results:

The results are shown in Table 8-12 and in Figure 8-19 for SLN1010, in Figure 8-20 for

SLN0613 and in Figure 8-21 for SLN 0315.

The static bedding modulus for medium ballast compaction differs for the three materials as

follows:

USP type variance in modulus measured with

EU-GBP / German-NSP

SLN1010 -10 %

SLN0613 10 %

SLN0315 18 %

The results are not the same and the test method has to be noted with every bedding

modulus.

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5.2.3 Low-frequency bedding modulus Cdyn1 (f)

The low-frequency bedding modulus Cdyn1 (f) is used for the calculation of the time depending

bending deformation of the rail under a rolling wheel. It determines the superstructure

dynamics. The tests are carried out without preload. The low-frequency bedding modulus is

calculated with the following formula:

The low-frequency bedding modulus Cdyn1 (f) is determined at 23°C for f = 5 Hz, 10 Hz, 20 Hz

and 30 Hz and in addition for 10 Hz at 0°C and -20°C. The test routine is presented in Figure

5-8. The test conditions are summarized in Table 5-4 and the loading range was chosen for

main-line-railways, Table 5-5.

Figure 5-8: Test routine dynamic bedding modulus; 5, 10, 20, 30 Hz

~ 3 min ~ 10 s 10 cycles

str

ess

time

max

m

min

5 Hz 10 Hz 20 Hz 30 Hz

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Table 5-4: Low-frequency bedding modulus - Test conditions


test temperature must be achieved 16 h before the test

Specimen 3 concrete blocks with USP

Temperature and frequency (23 ± 3)°C 5 Hz, 10 Hz, 20 Hz, 30 Hz

(0 ± 3)°C, (-20 ± 3)°C 10 Hz

Load application The concrete block with USP is placed on top of the profiled plate

(NSP). The pad is in contact with the plate. The weight of the

concrete block has to be taken into account for the applied force.

Type of load harmonic excitation between u and o

Test rig servo-hydraulic tensile-compression testing machine with 100 kN

cylinder, see Table 8-4

Table 5-5: Low-frequency bedding modulus - Loading range

Loading range for main line

railway

u = 0.01 N/mm², o = 0.10 N/mm²

The results of the low-frequency bedding modulus Cdyn1 (f) for three different materials are

shown in Table 8-13 and Table 8-14 and in Figure 5-9.

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Figure 5-9: Low-frequency bedding modulus

5.2.4 Low-frequency stiffening ratio Kdyn1(10Hz)

The low-frequency stiffening ratio Kdyn1 was calculated for 10 Hz due to the standard

DIN 45673-6 [1]. It is calculated as the quotient of the lower frequency bedding modulus at

10 Hz and the static bedding modulus with the following formula:

The values of both bedding moduli must be determined on the same specimen. The results

for all materials are summarized in Table 8-15.

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5.2.5 High-frequency bedding modulus Cdyn2 (f)

The high-frequency bedding modulus Cdyn2 (f) is determined for under-sleeper pads to

characterise their mitigation potential.

In comparison to the low-frequency bedding modulus the test procedure of the

high-frequency bedding modulus Cdyn2 (f) is carried out with a static preload, only with the

single pad without bonding layer and concrete block and with a smaller vibration amplitude.

Therefore the values of low and high-frequency bedding modulus at the same frequency are

not the same and cannot be compared. For the test conditions see Table 5-6.

Table 5-6: High-frequency bedding modulus - Test condition


Specimen single USP, 300 * 300 mm²

3 specimens: SLN1010 and SLN 0315

2 specimens: SLN 0613

Temperature (23 ± 3)°C

Load application The USP is placed between a flat loading plate (above) and the

profiled loading plate NSP. The tests are carried out under preload.

preload: main-line railway network: σv = 0,12 N/mm²

Type of load Harmonic excitation with a particle velocity amplitude of 7 mm/s

Frequency fj : 10 Hz to 160 Hz in octave intervals

Test rig servo-hydraulic tensile-compression testing machine with

7 kN cylinder see Table 8-5

The results of the high-frequency dynamic bedding moduli are summarized in Table 8-16 and

in Figure 5-10.

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Figure 5-10: High-frequency bedding modulus

5.2.6 High-frequency dynamic stiffening ratio Kdyn2 (80Hz)

The high-frequency dynamic stiffening ratio Kdyn2 was calculated for a frequency of 80 Hz due

to the standard DIN 45673-6 [1]. It is calculated as the quotient of the high-frequency

bedding modulus at a frequency of 80 Hz and the static bedding modulus with the following

formula:

The values of both bedding moduli must be determined on the same specimen. The results

for all materials are summarized in Table 8-17.

0,00

0,05

0,10

0,15

0,20

0,25

0,30

0,35

0,40

0 50 100 150 200

be

dd

ing

mo

du

lus

[N

/mm

³]

frequency [Hz]

high frequency bedding modulus(structure borne noise)

SLN1010

SLN613

SLN315

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5.3 SERVICEABILITY

5.3.1 Mechanical fatigue strength

The mechanical fatigue strength test shall characterize the long term functionality of the USP

and the bonding layer. One very soft type of USP was planned to test according to the

simulation [7].

Test conditions:

For the mechanical fatigue strength test a total of 8 million load cycles were applied on a

concrete block with bonded USP which was placed on the ballast in a ballast trough, see

Figure 8-7. The load cycles were applied in two 2 load levels. The loadings are induced

according to DIN 45673-6 (5.2) for main-line railways, Table 5-7.

Table 5-7: Mechanical fatigue strength – test conditions




Load application The concrete block with the sleeper pad is placed on top of the

ballast in a ballast trough. The USP is in contact with the ballast.

The weight of the concrete block has to be taken into account for

the applied force.

Type of load Harmonic excitation at f = 3 Hz

Loading range: Load level 1 (5 mill. load cycles):

preload FU = 1 kN upper load F0 = 21 kN

Load level 2 (3 mill. load cycles):

preload FU = 1 kN upper load F0 = 28 kN

Test rig see Table 8-6

Results:

There were several pressure areas after the first and the second load level as documented

after a manually evaluation in Figure 8-22 and Figure 8-23 after the first and the second load

level. The depth of the pressure areas were up to 11 mm after the first load level and up to

12 mm after the second load level, Table 8-18. At one place the USP was perforated by the

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ballast up to the concrete. The edges of the USP were cracked at several places especially

at the corners.

In addition an evaluation by the system ATOS from GOM (GOM - Gesellschaft für Optische

Messtechnik mbH, Optical Measuring Techniques) was made. Using that system the surface

of the USP was photographed after both load steps out of two directions and so the structure

of the surface could be illustrated in colours with the relative depth to a self chosen area, see

Figure 8-24. The absolute depth couldn’t be determined because the ballast contact felt

didn’t allow defining an exact zero area before the loadings.

5.3.2 Bond strength by pull-off

The bond strength by pull-off shall be determined to ensure the required degree of the

bonding between under sleeper pad and concrete. For the test conditions see Table 5-8.

Table 5-8: Bond strength by pull-off – test conditions



3 test areas each with a tear chip Ø 50 mm, drilled through the USP

in the concrete of the specimen, Figure 8-25


Load application steel stud glued to the USP with a polyurethane glue defined from

the manufacturer of the USP Getzner Werkstoffe GmbH, Macroplast

UK 8303 B60

vertically to the bonded surface

Loading rate /t = 0.01 N/mm²/s


Results

The collapse area was the bonding layer between the concrete and the USP in the majority

of cases, 27 tests of 30 tests, Figure 8-26. The load deformation curves are given in Figure

8-26 and Figure 5-11. The values of the bond strength are documented in Table 8-19.

The Specimen SLN1010 A11 shows the highest maximum load and the lowest maximum

displacement. The bonding layer for the USP is a geogrid with different denseness, Figure

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8-1 to Figure 8-2. The different bonding layer and the different materials had an influence on

the bond strength.

Figure 5-11: Bond strength, SLN1010, SLN0613, SLN0315 and SLN0613 after freeze thaw test

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

0 2 4 6 8 10 12 14 16

stre

ss [

N/m

m²]

Displacement [mm]

SLN 1010 A 11

Sample 1

Sample 2

Sample 3

Sample 4

Sample 50

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

0 2 4 6 8 10 12 14 16

stre

ss [

N/m

m²]

Displacement [mm]

SLN 0613 B 05

Sample 1

Sample 2

Sample 3

Sample 5

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

0 2 4 6 8 10 12 14 16

stre

ss [

N/m

m²]

Displacement [mm]

SLN 0315 C 09

Sample 1

Sample 2

Sample 3

Sample 4

Sample 5

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

0 2 4 6 8 10 12 14 16

stre

ss [

N/m

m²]

Displacement [mm]

SLN 0613 B 08 - after freeze thaw test

Sample 1

Sample 2

Sample 3

Sample 4

Sample 5

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5.3.3 Shear strength

Table 5-9: Shear strength – test conditions


Specimen for each material 3 concrete cubes with USP on two sides,

200 * 200 * 200 mm³

only SLN0613 and SLN0315


Load application The two USP sides of the specimen were glued onto steel plates

and the steel plates were fixed vertically in the testing machine,

load applied in the middle of the concrete cube with a 30-mm-wide

loading blade

parallel to the bonded surface

Loading rate /t = 0.01 N/mm²/min


Results

All specimens had the breakdown within the USP material, see Figure 8-27 to Figure 8-29.

The stress-deformation curves are documented in Figure 5-12 and Figure 5-13. The values

of the shear strength are documented in Table 8-20.

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Figure 5-12: Shear strength, SLN0613

Figure 5-13: shear strength, SLN0315

VII.2 Ingenieurbau

SLN0613

Layout: AbSch_SLN0615.TDR

Datei: SLN0613_AbSch.TDM

0 5 10 15 20 25

displacement [mm]

0.00

0.10

0.20

0.30

0.40

0.50

0.60

str

es

s [

N/m

m²]

B31

B32

B33

VII.2 Ingenieurbau

SLN0315

Layout: AbSch_SLN0315.TDR

Datei: SLN0315_AbSch_korr.TDM

0 5 10 15 20 25

displacement [mm]

0.00

0.10

0.20

0.30

0.40

0.50

0.60

str

es

s [

N/m

m²]

C31

C32

C33

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5.3.4 Freeze-thaw resistance

One type of USP was foreseen for the freeze-thaw resistance test. The USP type SLN 0613

was chosen for the test, since this type has been preselected as potential useful soft USP

type for main line according to the simulation [7].

Figure 5-14: Test routine freeze-thaw test

Table 5-10: Freeze-thaw resistance - Test conditions

Conditions: dry test object before conditioning,

Specimen 1 concrete block with USP, 300 * 300 * 100 mm³

Test medium distilled water

Temperature (23 ± 3)°C, (-20 ± 3)°C, (30 ± 3)°C

Preparation USP of the concrete block 24 h in distilled water on the

German-NSP

Load application first 2 hours in water bath

pulsed load with u = 0,05 N/mm² and o = 0,15 N/mm²

Loading rate 30 strokes per hour

Temperature application 50 freeze-thaw cycles -20°C to 30°C, 1 day for each cycle

Temperature rate -20°C to 30°C in 1 hour

Before and after the test determine the low-frequency bedding modulus at 10 Hz

time

T

2h 24h

-20°C

30°C

RT

Test-cycle 50x1h + 11h + 1h + 11h = 24h

11h

u

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Results

The curve of the low-frequency bedding modulus before and after the freeze-thaw-test is

shown in Figure 5-15 and the values are given in Table 8-21. The bedding modulus after the

test is in the maximum 3% higher than before the test.

The curve of the pull-off strength before and after the freeze-thaw-test is shown in Figure

5-11 and the values are given in Table 8-19. The arithmetic average of the maximum stress

is about 8% lower than before the freeze thaw resistance test and the standard variance is

21% higher.

The visual inspection after the freeze-thaw cycles didn’t show any damage.

Figure 5-15: Freeze-thaw resistance, SLN0613, low-frequency bedding modulus, before and

after the test

0,00

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0 10 20 30 40

be

dd

ing

mo

du

lus

[N/m

m³]

frequency [Hz]

Freeze-thaw resistance,low frequency bedding modulus

SLN0613

before the test

after the test

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6. EXAMINATION OF THE SLEEPERS B90.2 –

BALLASTED TRACK

The test procedure was carried out according to DIN EN 13230-2 “Railway applications –

Track – Concrete sleepers and bearers – Part 2: Prestessed monoblock sleeper, English

version of [3].

The test program includes four different tests: The static and dynamic test for positive

moment at the rail seat section, the static test at the centre section for negative moment and

the fatigue test for positive moment at the rail seat section. All tests carried out are

summarized in Table 8-24. The loadings according to DBS 918 143 [6] as provided by

RAIL.ONE GmbH are summarized in Table 8-25. Photos of all tested sleepers are given in

Figure 8-39 to Figure 8-44.

6.1 MATERIAL AND SPECIMEN

The tested sleepers were of the type B90.2 as shown in Figure 8-31 and Figure 8-32. In total

16 + 4 sleepers, 16 for the tests and 4 in reserve, were delivered by RAIL.ONE GmbH.

The material of the sleepers is concrete C50/60 with an aggregate of iron ore. Therefore one

sleeper has got a weight of 600 kg, without fastening. In comparison, a standard sleeper B90

has a weight of 333 kg. The main dimensions of one sleeper are: Length 2600 mm, Width

320 mm.

6.2 STATIC TEST RAIL SEAT

The static test on the rail seat section with positive load was carried out with 6 sleepers and

additionally with 4 sleepers. The test set-up is shown in Figure 8-34 and Figure 8-35. The

test routine is shown in Figure 6-1. For the test conditions see Table 6-1.

There were two test sequences. In the first sequence the sleepers were dry during the tests

and in the second one wet. Four sleepers were additionally tested because in the first

sequence 2/3 of the sleepers failed the tests. In tests afterwards the sleepers had been put

under water for a minimum of two days prior the testing according to the technical supply

specitication of the DB-AG.

http://www.dict.cc/englisch-deutsch/technical.html

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Figure 6-1: Test routine, rail seat section, static test

Table 6-1: Static test rail seat (+) – test conditions

Conditions: dry test object (sleeper 1 to sleeper 6)

wet test object (sleeper 21 to sleeper 24) according to the DB-AG

technical supply specification [6]

Specimen 6 prestressed monobloc sleepers, B90.2

Temperature and frequency (23 ± 3)°C

Load application The load was applied perpendicular to the base of the sleeper in

middle of the rail seat section. The sleeper opposite shall be

unsupported

Loading rate Fmax/time = 2 kN/s

Type of load quasi static

Procedure preparation Choice of the sleeper – no cracks and spalling in the test area,

because the crack detection will be difficult

Marking of the evaluation area, 15 mm parallel to the bottom of the

sleeper

Procedure test Position the piston on the sleeper, set point 20 kN

Raise the force until Fro=176kN, loading rate 2kN/s

Search for the first crack under load

increase the force in steps of 10kN up to the first crack

Further increase of the force, steps of 10kN up to 356 kN

time

force

10s < t < 5min

max. 120 kN/min

detecting of the crack max. 5min

10 k

N

10 k

N

Fro

Frr

Fr0,05

FrB


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Unloading of the sleeper and search for cracks

Repeat the loading and unloading up to a crack with a width of

0.05mm at the bottom of the sleeper

Further increase of the force up to the break of the sleeper

Crack detection Cracks are searched at the side of the sleeper in an area 15 mm

from the bottom and under the sleeper between the support

Detection equipment includes crack loupe, mirror, acetone (only

initial crack inspection prior testing)

The results for the static test at the rail seat section are shown in Table 8-26 and Figure 6-2.

For the dry sleeper two of six sleepers passed the first pass/fail criteria with Frr > Fr0, the

others had got the first crack at Frr = Fr0. All sleepers passed the second and third criteria.

For the wet sleeper all four sleepers passed the first, second and third criteria. Only the

testing of wet sleepers is in accordance with DB specification [6] and thus governing, testing

on dry sleepers is on the conservative side, when criteria are met.

Pass/fail criteria: 1. Frr > Fr0 with Fr0 = 176 kN

2. Fr0,05 > k1s * Fr0 = 264 kN with k1s = 1,5

3. FrB > k2s * Fr0 = 369,6 kN with k2s = 2,1

Figure 6-2: Static test, rail seat, B90.2

0

100

200

300

400

500

600

700

1 2 3 4 5 6 21 22 23 24

forc

e [

kN]

number of the sleeper

sleeper tests B90.2static, rail seat

Fr0

Frr

F r0.05

FrB

testcondition dry testcondition wet

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6.3 STATIC TEST CENTRE

The static test at the centre section with negative load was carried out with three sleepers.

The test set-up is shown in Figure 8-36 and Figure 8-37. The test routine is shown in Figure

6-3. For the test conditions see Table 6-2.

Figure 6-3: Test routine, centre section, negative bending moment, static test

Table 6-2: Static test centre (-) – test conditions

Conditions: dry test object




middle of the centre section. The sleeper lies upside down in the

test rig.

Loading rate Fmax/time = 2 kN/s

Type of load quasi static

Procedure preparation Choice of the sleeper – no cracks and spalling in the test area,

because the crack detection will be difficult

Marking of the evaluation area, 15 mm parallel to the base (top in

fact) of the sleeper

time

force

10s < t < 5min

max. 120 kN/min 5 k

N

Fcon

Fcrn

FcBn

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Raise the force until Fc0n = 48 kN, Loading rate 2kN/s

Search for cracks under load

Further increase of the force, steps of 5kN up to Fcrn

Repeat further increase of the force, steps of 5kN up to the break of

the sleeper


from the bottom (top in fact) and under the sleeper between the

support



The results for the static tests in the centre section are shown in Table 8-29. All three

sleepers passed the pass/fail criterion. Only the testing of wet sleepers is in accordance with

DB specification [6] and thus governing, testing on dry sleepers is on the conservative side,

when criteria are met.

Pass/fail criterion: Fcrn > Fc0n = 48 kN

6.4 DYNAMIC TEST RAIL SEAT

The dynamic test at the rail seat section with positive load was carried out with six sleepers.

The test set-up was the same as for the static test rail seat section. The test routine is shown

in Figure 6-4. For the test conditions see Table 6-3.

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Figure 6-4: Test routine, rail seat section, dynamic test

Table 6-3: Dynamic test rail seat (+) – test conditions




Load application The load was applied perpendicular to the base of the sleeper in the

middle of the rail seat section of the sleeper.

Load levels see Table 8-27: Load steps B90.2, dynamic test rail seat (+)

Type of load Harmonic excitation at f = 5 Hz

Procedure preparation Choice of the sleeper – no spalling in the test area, because the

crack detection will be difficult


sleeper


Raise the force until Frmiddle = 113 kN, Loading rate 2kN/s

Search for cracks under load

20 kN

50 kN

176 kN = Fro

176 x 1,3 kN = 228,8 kN

176 * 1,7 kN = 299,2 kN

5.000load cycles

2Hz< f <5Hz max. 5 min time

force

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Start the harmonic excitation

Further increase of the force, steps for Frmiddle ≤ 10kN up to

Fr0 = 319,2 kN, 10 kN over the 2nd

pass/fail criteria

Search for cracks after every load step





The results for the dynamic test at the rail seat section are shown in Table 8-28. All six

sleepers passed the pass/fail criteria.

Pass/fail criteria: 1. Fr0,05 > k1d * Fr0 = 228,8 kN with k1d = 1,3

2. FrB > k2d * Fr0 = 299,2 kN with k2d = 1,7

6.5 FATIGUE TEST

The fatigue test at the rail seat section with positive load was carried out with one sleeper.

The test set-up is shown in Figure 8-38. The test routine is shown in Figure 6-5. For the test

conditions see Table 6-4.

Figure 6-5: Test routine, rail seat section, fatigue test (source [3])

Load rate 2 kN/s

time

force

2 mill cycles, f = 5 Hz

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Table 6-4: Fatigue test 2 Mio LC (+) – test conditions





middle of the rail seat section. The overhanging sleeper opposite

shall be unsupported

Loading rate Fmax/time = 2 kN/s to the set point and after the harmonic excitation

up to FrB

Load levels Fru = 50 kN, Fr0 = 176 kN

Type of load harmonic excitation f = 3 Hz, 2 mill load cycles

Procedure preparation Choice of the sleeper – no spalling in the test area, because the

crack detection will be difficult


sleeper


Raise the force until Frr like in the static test rail seat section

start the harmonic excitation, 2 mill load cycles

Raise the force until Fr0 and then until FrB





The results for the fatigue test in the rail seat section are given in Table 8-30. The sleeper

passed all three pass/fail criteria.

Pass/fail criteria after the 2 mill

load cycles:

1. Crack width is < 0,1 mm when loaded at Fr0

2. Crack width is < 0,05 mm when unloaded

3. FrB > k3 * Fr0 = 299,2 kN; k3 = k2d = 1,7

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7. CONCLUSION

A possible mitigation measure at track has been found and intensely tested, a heavy sleeper

and soft under sleeper pads. The expected benefit of the heavy sleeper and soft sleeper

pads can be concluded from the results of the parametric study in [7] and the measured

characteristics of the track elements in the present report. The under sleeper pads yield a

reduction of the high-frequency dynamic loads. Therefore, the high-frequency bedding

modulus is of interest. The performance at the track depends on the stiffness per sleeper

which is calculated from the high-frequency bedding modulus multiplied by the sleeper base

area.

The three different under sleeper pads have the following values:

Table 7-1: Overview Results USP parametric study and laboratory tests

Type SLN1010 SLN0613 SLN0315

Dynamic bedding modulus (109 N/m

3)* 0.332 0.146 0.082

Stiffness per standard sleeper (109 N/m) 0.236 0.104 0.058

Resonance frequency standard sleeper (Hz)** 64 50 35

Resonance frequency heavy sleeper (Hz)** 57*** 42*** 28***

* The dynamic bedding modulus is the mean value of the frequencies 40, 80 and 160 Hz (see Table 8-16).

** The resonance frequencies are taken from the parametric study [7].

*** The frequencies with three asterisk are taken from the simulation results of the isolated wide sleeper track as a first

approximation since it has almost the same weight than the tested B90.2 sleeper type.

The reduction of the dynamic train loads starts at a frequency which is 1.4 times the

resonance frequency. The lowest resonance frequency yields the best mitigation of ground

vibrations. The heavier sleeper always yields a better reduction than the standard sleeper,

and the softer under sleeper pads yield better reduction than the stiffer under sleeper pads.

So, it can be concluded that efficient mitigation measures for train induced ground vibration

have been found. The soft under sleeper pads can be combined with the heavy or normal

sleepers, and the new heavy sleeper can be used with the tested or other soft under sleeper

pads. The results of the laboratory tests help to adjust the mitigation measures to the specific

site conditions.

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8. ANNEX

8.1 REFERENCES

[1] DIN 45673-6:2010-08 (E) „Mechanical vibration - Resilient elements used in railway

tracks - Part 6: Laboratory test procedures for under-sleeper pads of concrete

sleepers”; DIN Institute; Beuth Verlag; August 2010

[2] DIN 45673-7:2010-08 (E) „Mechanical vibration - Resilient elements used in railway

tracks - Part 7: Laboratory test procedures for resilient elements of floating slab track

systems”; DIN Institute; Beuth Verlag; August 2010

[3] DIN EN 13230-2:2009-10 (E) “Railway applications Track – Concrete sleepers and

bearers – Part 2: Prestressed monoblock sleepers”; DIN Institute Beuth Verlag;

October 2009

[4] Draft CEN/TC 256: Railway applications – Track – Concrete sleepers and bearers –

concrete sleepers and bearers with under sleeper pads, 2012-02

[5] „Railway Induced Vibration Abatement Solutions“, Description of Work. Collaborative

project for theme SST.2010.1.1-3. “Attenuation of ground-borne vibration affecting

residents near railway lines” in the seventh framework programme, European

Commission, 2010-11

[6] DBS 918 143: Concrete sleepers and bearers for ballast superstructure and slab

track, Technical supply specification of DB-AG; January 2012

[7] Auersch L: Mitigation measures for ballasted tracks - sleepers, sleeper pads and

substructure - Results from the finite-element boundary element method. Report for

RIVAS Deliverable D3.2, BAM, Berlin, January 2012

8.2 ABBREVIATIONS

8.2.1 Terms and definitions

Bonding layer The bonding layer is a grid to connect concrete and USP. It can be

manufactured of felt or geogrid


http://www.dict.cc/englisch-deutsch/delivery.html

http://www.dict.cc/englisch-deutsch/condition.html

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Elastomer Material of the USP

Felt Protective layer for the elastomer of the USP, one side or both sides

Tear chip test area for the bonding test

NSP German ballast plate, in German: Normschotterplatte

GBP geometric ballast plate

gauge block ceramic slices with a defined thickness to validate the displacement sensors

8.2.2 Symbols

Examination of the USP

USP under sleeper pad

NSP German ballast plate

GBP geometric ballast plate

A area

C12 secant modulus

Cdyn(f) dynamic bedding modulus

Cstat static bedding modulus

Cstat 0 at-rest value of the static bedding modulus

stress

s1, s2 displacement

f test frequency

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Examination of the sleepers

k1s Static coefficient to be used for calculation of Fr0,05 test load

k2s Dynamic coefficient to be used for calculation of Fr0,5 or FrB test load

Mdr Positive design bending moment at rail seat, in kNm

Fr0 Positive initial reference test load for the rail seat section in kN

for all tests: Fr0 = 176 kN

Frr

Positive test load which produces first crack formation at the bottom of the

rail seat section

The first crack is a crack with a length of 15 mm from the bottom of the

sleeper, detected at lateral surface

Fr0,05

Load where the crack gets a width of 0.05 mm in the unloaded state

Maximum test load for which a crack width of 0,05 mm at the bottom of rail

seat section

FrB Maximum positive test load at the rail seat section which cannot be

increased in kN, Breaking of the sleeper

Mdcn Negative design bending moment at centre section, in kNm

Fc0n Negative initial reference test load at the centre section of the sleeper in kN

Fcrn Negative test load which produces first crack formation at the centre of the

sleeper in kN

FcBn Maximum negative test load at the centre section which cannot be

increased in kN

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8.3 TABLES – EXAMINATION OF THE USP

Table 8-1: Specimens, arrival, SLN 1010

Type Sample Weight L X B H = concrete H = USP* test

[g] [mm] [mm] [mm]

SLN 1010G A-01 22947,0 300x300 103 12 bedding modulus



SLN 1010G A-04 22728,0 300x300 103 12

SLN 1010G A-05 23267,0 300x300 103 12

SLN 1010G A-06 22913,5 300x300 105 12

SLN 1010G A-07 23418,0 300x300 105 12

SLN 1010G A-08 23013,5 300x300 105 12

SLN 1010G A-09 23131,5 300x300 105 12

SLN 1010G A-10 22964,0 300x300 103 12

SLN 1010G A-11 22793,0 300x300 103 12 bond strength

average 23021,2

SLN1010 P01 P-01 565,5 300 x 300 only USP 10,0 high-frequency bedding modulus



* Height H includes 2 mm ballast contact felt

Vh 7243_Rivas_schwellenbesohlung\Tabellen\Probeneingang\[Probeneingang_pieringer_bis_MAERZ13.xlsx]SLN-en

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Type Sample Weight L X B H = concrete H = USP test

[g] [mm] [mm] [mm]

SLN 0613 B-01 22501,5 300x300 102 15 bedding modulus



SLN 0613 B-04 22400,0 300x300 100 15

SLN 0613 B-05 22114,0 300x300 102 15 bond strength

SLN 0613 B-06 21998,5 300x300 100 15

SLN 0613 B-07 21734,5 300x300 100 15

SLN 0613 B-08 22078,5 300x300 102 15 freeze-thaw resistance, bond strength

SLN 0613 B-09 22448,5 300x300 100 15

SLN 0613 B-10 22448,5 300x300 103 15

SLN 0613 B-11 22056,0 300x300 100 15

SLN 0613 B-12 22466,5 300x300 102 15

average 22189,4

SLN 0613 B-21 42600,0 300x300 195 15 fatigue test

SLN 0613 B-31 20015,0 200x200 200 2x15 shear test



average 20036,2

SLN0613 P01 P-01 484,3 300 x 300 only USP 13 high-frequency bedding modulus



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Type Sample Weight L X B H = concrete H = USP test

[g] [mm] [mm] [mm]

SLN 0315 C-01 21855,0 300x300 100 17 bedding modulus



SLN 0315 C-04 21744,5 300x300 100 17

SLN 0315 C-05 21695,0 300x300 100 16

SLN 0315 C-06 22281,0 300x300 100 15

SLN 0315 C-07 21563,0 300x300 98 17

SLN 0315 C-08 21607,0 300x300 100 16

SLN 0315 C-09 22054,0 300x300 100 15 bond strength

SLN 0315 C-10 22110,0 300x300 100 15 bond strength

SLN 0315 C-11 22107,0 300x300 100 16

average 21879,8






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8.3.1 Measuring System

Table 8-4: Measuring system static and at-rest value of the static bedding modulus, low-

frequency bedding modulus

Test rig static and at-rest value of the static bedding modulus and low-frequency bedding modulus

Designation KPM - testing machine for small components 100 kN

Type: servo-hydraulic tensile-compression testing machine

Producer: Carl Schenck AG, Darmstadt

Piston stroke: smax = 125 mm

Force measurement

Designation Load cell PM 100 Rn; suitable for testing machines class 1


Maximum static force Fmax = 100 kN

Maximum dynamic force Fdyn = 80 kN

Calibration periodically, test certificate MPA

Displacement measurement (external), because the piston stroke is not sufficient

Designation inductive displacement sensors WA 10 HBM

Quantity 2

Measuring range: 0 – 10 mm

Output signal: 80 mV/V

Linearity error: ≤ ±0.2 %

Temperature range: -20 to +80°C

Validation made by gauge blocks

Climatic chamber

Temperature range: – 40 °C to + 180 °C

Dimensions inside: height 1000 mm, width 1200 mm, depth 700 mm

Electronic control and measuring technique

type Instron series 8400

control computer

measurement amplifier separate, every single channel can be recorded digitally

Maximum measuring frequency per channel: 5 kHz

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Table 8-5: Measuring system high-frequency bedding modulus

Test rig High-frequency bedding modulus of elastomer pads

Designation

Type: servo-hydraulic tensile-compression testing machine with 7 kN cylinder

Producer: BAM/ Instron Systems

Piston stroke: smax = ±50 mm

Force measurement


Producer: Instron

Maximum static force Fmax = ±7 kN




Designation inductive displacement sensors WA05

Quantity 3


Output signal: 80 mV/V


Temperature range: -20 to +80°C

Validation made by gauge blocks


type Instron series 8800

control computer


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Table 8-6: Measuring system fatigue test

Test rig fatigue test

Designation ballast test rig with 400kN cylinder (ballast trough)

Type: fatigue test of elastomer pads in ballast

Producer: BAM/ Instron Systems, test area

Piston stroke: smax = ±200 mm

Force measurement





Calibration Displacement measurement (external), because the piston stroke is not sufficient

Designation laser displacement sensors

Type Micro-Epsilon optoNCDT 1401

Quantity 4


Output signal: 12.5 mm/V


Temperature range: Validation made by gauge blocks


electronic control system type Instron series 8500

control computer

analogous signals sampled by 16 bit A-D converter

measuring system Cronos, IMC


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Table 8-7: Measuring system bond strength by pull-off

Test rig bond strength by pull-off

Designation „RK Toni“ 25 kN

Type: Producer: MFL/ Toni-Technik


Force measurement

Designation Load cell suitable for testing machines class 1

Producer: Maximum static force Fmax = 25 kN



Displacement measurement (internal), piston stroke


Output signal: Linearity error: ≤ ±0.2 %

Validation Electronic control and measuring technique

type MTS Serie TestStar

control computer


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Table 8-8: Measuring system shear test

Test rig shear test

Designation test rig with 400 kN cylinder

Type: Producer: BAM/ Instron Systems, test area


Force measurement







Designation rope displacement sensors ASM 1410

Quantity 2


Output signal: 5 mm/V


Validation by incremental linear encoder system Heidenhain


electronic control system type Instron series 8500

control computer

analogous signals sampled by 16 bit A-D converter

measuring system Cronos, IMC


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8.3.2 Results USP

Table 8-9: SLN1010 – static and at-rest value of the static bedding modulus - DIN 45673-6; 23°C,

0°C, -20°C

SLN1010 – static bedding modulus - DIN 45673-6; 23°C; NSP

sample C01 [N/mm³]

C02 [N/mm³]

C03 [N/mm³]

average [N/mm³]

Cstat medium ballast compaction 0,0991 0,0935 0,0945 0,0957

Cstat high ballast compaction 0,1322 0,1258 0,1264 0,1281

Cstat0 medium ballast compaction 0,0825 0,0787 0,0792 0,0801

Cstat0 high ballast compaction 0,1121 0,1076 0,1080 0,1092


sample C01 [N/mm³]

C02 [N/mm³]

C03 [N/mm³]

average [N/mm³]





SLN1010 – static bedding modulus - DIN 45673-6; -20°C; NSP

sample C01 [N/mm³]

C02 [N/mm³]

C03 [N/mm³]

average [N/mm³]





\Vh7243_Rivas_schwellenbesohlung\Messdaten\T6_Ergebnisse_Excel\[1_Bericht_SLN-Getzner_Bettungsmodul-alle_B.xlsx]A_StatBett

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Table 8-10: SLN0613 – static and at-rest value of the static bedding modulus - DIN 45673-6;

23°C, 0°C, -20°C


sample B01 [N/mm³]

B02 [N/mm³]

B03 [N/mm³]

average [N/mm³]






sample B01 [N/mm³]

B02 [N/mm³]

B03 [N/mm³]

average [N/mm³]






sample B01 [N/mm³]

B02 [N/mm³]

B03 [N/mm³]

average [N/mm³]






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Table 8-11: SLN0315 – static and at-rest value of the static bedding modulus - DIN 45673-6

(4.1); 23°C, 0°C, -20°C


sample C01 [N/mm³]

C02 [N/mm³]

C03 [N/mm³]

average [N/mm³]






sample C01 [N/mm³]

C02 [N/mm³]

C03 [N/mm³]

average [N/mm³]






sample C01 [N/mm³]

C02 [N/mm³]

C03 [N/mm³]

average [N/mm³]






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Table 8-12: static and at-rest value of the static bedding modulus – different loading plates

SLN1010 – static bedding modulus - DIN 45673-6, different profiled plates

C EU-GBP [N/mm³] German-NSP [N/mm³] variance EU-GBP / German-NSP

Cstat medium ballast compaction 0,0894 0,0992 -10 %

Cstat high ballast compaction 0,1212 0,1322 -8 %

Cstat0 medium ballast compaction

0,0746 0,0825 -10 %

Cstat0 high ballast compaction 0,1030 0,1121 -8 %



Cstat medium ballast compaction 0,0515 0,0468 10 %

Cstat high ballast compaction 0,0646 0,0568 14 %


0,0425 0,0399 7 %

Cstat0 high ballast compaction 0,0546 0,0493 11 %



Cstat medium ballast compaction 0,0346 0,0293 18 %

Cstat high ballast compaction 0,0415 0,0374 11 %


0,0265 0,0251 6 %

Cstat0 high ballast compaction 0,0338 0,0331 2 %

\\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Messdaten\StatEUdeu\[StatEUdeu.xls]Tabelle1

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Table 8-13: low-frequency bedding modulus - DIN 45673-6 (4.2); 23°C

SLN1010 – low-frequency bedding modulus - DIN 45673-6 (4.2); 23°C; NSP

frequency [Hz] A01 [N/mm³]

A02 [N/mm³]

A03 [N/mm³]

average [N/mm³]

5 0,1236 0,1176 0,1174 0,1195

10 0,1280 0,1212 0,1220 0,1237

20 0,1316 0,1249 0,1252 0,1272

30 0,1350 0,1294 0,1282 0,1309


frequency [Hz] B01 [N/mm³]

B02 [N/mm³]

B03 [N/mm³]

average [N/mm³]

5 0,0572 0,0582 0,0528 0,0561

10 0,0593 0,0600 0,0546 0,0580

20 0,0612 0,0620 0,0568 0,0600

30 0,0628 0,0636 0,0581 0,0615


frequency [Hz] C01 [N/mm³]

C02 [N/mm³]

C03 [N/mm³]

average [N/mm³]

5 0,0369 0,0357 0,0371 0,0366

10 0,0380 0,0370 0,0382 0,0377

20 0,0395 0,0386 0,0401 0,0394

30 0,0410 0,0402 0,0422 0,0411 \\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Messdaten\Körperschall\Körperschall_Excel\[1_Bericht_Oct24Oct25Körperschall.xls]DatenBericht

Table 8-14: low-frequency bedding modulus - DIN 45673-6 (4.2)

SLN1010 – low-frequency bedding modulus - DIN 45673-6 (4.2); NSP, sample A3

Temperatur -20°C 0°C 23°C

Cdyn1 (10Hz) [N/mm³] 0,1649 0,1236 0,1220

SLN0613 – low-frequency bedding modulus - DIN 45673-6 (4.2); NSP, sample B01

Temperature -20°C 0°C 23°C

Cdyn1 (10Hz) [N/mm³] 0,1068 0,0635 0,0593

SLN0315 – low-frequency bedding modulus - DIN 45673-6 (4.2); NSP, sample C01

Temperature -20°C 0°C 23°C

Cdyn1 (10Hz) [N/mm³] 0,0824 0,0413 0,0380 \\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Messdaten\Körperschall\Körperschall_Excel\[1_Bericht_Oct24Oct25Körperschall.xls]DatenBericht

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Table 8-15: Low-frequency dynamic stiffening ratio on NSP

SLN1010 Low-frequency dynamic stiffening ratio DIN 45673-6 (4.3), NSP

Cdyn1(10 Hz) [N/mm³] Cstat [N/mm³] kdyn1(10 Hz)

SLN1010 medium ballast compaction 0,1237 0,0957 1,29

SLN1010 high ballast compaction 0,1237 0,1281 0,97









\\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Messdaten\T6_Ergebnisse_Excel\[SLN_Dyn_Vers_T6.xls]Tabelle1

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Table 8-16: high-frequency bedding modulus (under preload) - DIN 45673-6 (4.4) on NSP

SLN0315 – high-frequency bedding modulus - DIN 45673-6 (4.4); 23°C; NSP; 7,0 mm/s

frequency [Hz] P01 [N/mm³]

P02 [N/mm³]

P03 [N/mm³]

average [N/mm³]

average [N/mm³]

10 0,0718 0,0733 0,0731 0,0727

20 0,0757 0,0772 0,0764 0,0764

40 0,0796 0,0806 0,0802 0,0801

80 0,0817 0,0844 0,0826 0,0829 0,0822

160 0,0825 0,0818 0,0862 0,0835



P02 [N/mm³]

P03 [N/mm³]

average [N/mm³]

average [N/mm³]

10 0,1230 0,1260 0,1245

20 0,1324 0,1337 0,1331

40 0,1397 0,1418 0,1408

80 0,1452 0,1480 0,1466 0,1462

160 0,1480 0,1546 0,1513



P02 [N/mm³]

P03 [N/mm³]

average [N/mm³]

average [N/mm³]

10 0,2653 0,2773 0,2651 0,2692

20 0,2929 0,3067 0,2926 0,2974

40 0,3089 0,3288 0,3116 0,3164

80 0,3232 0,3489 0,3323 0,3348 0,3319

160 0,3342 0,3656 0,3333 0,3444

\\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Messdaten\Körperschall\Körperschall_Excel\[1_Bericht_Oct24Oct25Körperschall.xls]DatenBericht

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Table 8-17: Higher-frequency dynamic stiffening ratio on NSP

SLN1010 High-frequency dynamic stiffening ratio DIN 45673-6 (4.3); NSP












\\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Messdaten\T6_Ergebnisse_Excel\[SLN_Dyn_Versteifung_T6.xls]Tabelle1

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Table 8-18: Mechanical fatigue strength - Minute of the damage - DIN 45673-6 (5.2)

Minute of the damages

5 Mio 09.11.2012 specimen: SLN 0613 B - 21

Nr. depth [mm] size or length [mm] comment

1 6 45 on the right side of [1]

2 3 25 three damages in the area of [2]

3 3 40 * 50 big area

4 5 20

5 9 45 perforated USP up to the concrete!

6 2,5 40 - 50

7 6 45 slender

8 11 40 broken off on the border (b) damage under [8] 5mm depth)

9 11 30 edge broken off up to the concrete

10 6 50 on the right side of [10]

\\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Bilder\Schotterstand\2012_11_08_ 5M Lastwechsel\[Schadenaufnahmen.xlsx]Bericht-en

Minute of the damages 8 Mio 04.12.2012 specimen: SLN 0613 B - 21

Nr. depth [mm] size or length [mm] comment

1 7,5 50 pressure area

2 6 20 cut

3 3 45 cut

4 6 20 pressure area
















20 3 40 pressure area \\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Tabellen\Schotter_dauerversuch\[Schadenaufnahme01.xlsx]Bericht-en

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Table 8-19: bond strength by pull of - DIN 45673-6 (5.3)

Pull-off strength SLN 1010 A 11, DIN 45673-6

Sample Load Stress Displacement Position

- [N] [N/mm2] [mm] -

01 1595,3 0,812 4,50 bonding layer

02 1433,0 0,730 3,98 bonding layer

03 1225,5 0,624 3,71 bonding layer

04 1403,4 0,715 3,62 bonding layer

05 1285,8 0,655 3,28 bonding layer

Pull-off strength SLN 0613 B 05, DIN 45673-6


- [N] [N/mm2] [mm] -

01 841,1 0,428 8,60 bonding layer

02 788,8 0,402 8,27 bonding layer

03 760,2 0,387 7,28 bonding layer

04 649,2 0,331 7,74 bonding layer

05 891,4 0,454 9,07 bonding layer

arithmetic average 0,400

standard deviation 0,042

Pull-off strength SLN 315 C 09, DIN 45673-6


- [N] [N/mm2] [mm] -

01 758,4 0,386 10,18 bonding layer

02 747,5 0,381 9,97 bonding layer

03 845,0 0,430 12,94 Elastomer + bonding layer

04 939,2 0,478 14,85 Elastomer

05 854,5 0,435 12,65 Elastomer

Pull-off strength SLN 0613 B 08, DIN 45673-6, after freeze thaw test


- [N] [N/mm2] [mm] -

01 848,3 0,432 9,42 bonding layer

02 825,1 0,420 7,48 bonding layer

03 680,9 0,347 8,41 Elastomer + bonding layer

04 609,5 0,310 5,37 bonding layer

05 633,6 0,323 5,72 bonding layer

arithmetic average 0,366

standard deviation 0,050

Vh 7243_Rivas_schwellenbesohlung\Messdaten\Abreißfestigkeit\Tabellen\[Abreißverhalten_Alle_Einfach_Tabellen.xlsx]Tabelle1

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Table 8-20: shear strength - DIN 45673-6 (5.4)

Shear strength SLN0613 – DIN 45673-6 (5.4)

specimen stress [N/mm²]

B31 0,558

B32 0,567

B33 0,563

Shear strength SLN0315 – DIN 45673-6 (5.4)

specimen stress [N/mm²]

C31 0,407

C32 0,459

C33 0,457

Comment: SLN1010 was not requested (no specimen were delivered and no tests were carried out) \\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Messdaten\AbSch\[Tabelle_Abscherfestigkeit_korr.xlsx]Tabelle1

Table 8-21: Freeze-thaw resistance - DIN 45673-6 (5.5)

SLN0613 – freeze-thaw resistance - DIN 45673-6 (5.5); 23 °C; NSP low-frequency bedding modulus

frequency [Hz]

before the test after the test variance

Hz [N/mm³] [N/mm³]

5 0,0520 0,0524 1%

10 0,0537 0,0546 2%

20 0,0556 0,0566 2%

30 0,0570 0,0587 3% \\scl1\Service31\720SERV\02_Vorhaben\Vh 7243_Rivas_schwellenbesohlung\Messdaten\FrostTau\FrostTau-Tabellen\[SLN0613_B05_FrostTau.xls]SLN0613_B05_FrostTau

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8.4 FIGURES - EXAMINATION OF THE USP

8.4.1 Specimen



SLN 1010

SLN 0315

5 cm

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8.4.2 Test rig

Figure 8-3: Test rig for small components (KPM), static and low-frequency bedding modulus

Figure 8-4: Test rig for small components (KPM), static and low-frequency bedding modulus,

detail

Concrete block with

USP

German ballast plate

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Figure 8-5: Test rig for high-frequency bedding modulus (structure-borne noise)

Figure 8-6: Test rig for high-frequency bedding modulus (structure-borne noise), detail

Spring for preload

German ballast plate

Under sleeper pad

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Figure 8-7: Test rig fatigue test for USP in ballast trough

Figure 8-8: Test rig fatigue test for USP in ballast trough, detail

Ballast trough

USP

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Figure 8-9: Test rig bond strength

Figure 8-10: Test rig bond strength, detail

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Figure 8-11: Test rig shear test

Figure 8-12: Test rig shear test, detail

USP

Concrete cube

200 * 200 * 200 mm

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8.4.3 Evaluation static bedding modulus

Figure 8-13: SLN0315 static bedding modulus, stress and displacement during the test

Figure 8-14: SLN0315 static bedding modulus

SLN315 sample C01

7.2 IngenieurbauLayout: SLN0314_C01_demo_quad.TDR

File: SLN0314_C01_demo.TDM

0 500 1000 1500 2000 2500

time [s]

0.00

0.05

0.10

0.15

0.20

0.25

Str

es

s [

N/m

m²]

SLN315 sample C01

7.2 IngenieurbauLayout: SLN0314_C01_demo_quad.TDR

File: SLN0314_C01_demo.TDM

0 500 1000 1500 2000 2500

time [s]

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

dis

pla

ce

me

nt

[mm

]

SLN0315

7.2 Ingenieurbau Layout: SLN0315_C01_report.TDR

File: SLN0315_C_statBett_T6.TDM

0 2 4 6 8

displacement [mm]

0.00

0.05

0.10

0.15

0.20

0.25

Str

es

s [

N/m

m²]

SLN0315_C01_statBett_T6



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SLN0613

7.2 IngenieurbauLayout: SLN0613_report.TDR

File: SLN0613_B_statBett_T6.TDM

0 500 1000 1500 2000 2500

time [s]

0.00

0.05

0.10

0.15

0.20

0.25

Str

es

s [

N/m

m²]

SLN0613



0 500 1000 1500 2000 2500

time [s]

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

dis

pla

ce

me

nt

[mm

]

SLN0613

7.2 Ingenieurbau Layout: SLN0613_report.TDR


0 1 2 3 4 5 6

displacement [mm]

0.00

0.05

0.10

0.15

0.20

0.25

Str

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s [

N/m

m²]

SLN0613_B01_statBett_T6



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SLN1010


File: SLN1010_A_statBett_T6.TDM

0 500 1000 1500 2000 2500

time [s]

0.00

0.05

0.10

0.15

0.20

0.25

Str

ess

[N

/mm

²]

SLN1010



0 500 1000 1500 2000 2500

time [s]

0.00

1.00

2.00

3.00

4.00

dis

pla

ce

me

nt

[mm

]

SLN1010

7.2 Ingenieurbau Layout: SLN1010_report.TDR


0 1 2 3 4

displacement [mm]

0.00

0.05

0.10

0.15

0.20

0.25

Str

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s [

N/m

m²]

SLN1010_A01_statBett_T6



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Figure 8-19: Static bedding modulus – comparison German-NSP and GBP – SLN1010 – A01

Figure 8-20: Static bedding modulus – comparison German-NSP and GBP – SLN0613 – B01

Stat. bet. EU/DE

7.2 Ingenieurbau Layout: SLN1010_vergleich_EU_DE.TDR

File: StatEUdeu.TDM

0 0.5 1 1.5 2 2.5 3 3.5 4

displacement [mm]

0.00

0.05

0.10

0.15

0.20

0.25

Str

es

s [

N/m

m²]

SLN1010_A01_statBett_EU


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Stat. bet. EU/DE


File: StatEUdeu.TDM

0 1 2 3 4 5 6 7 8

displacement [mm]

0.00

0.05

0.10

0.15

0.20

0.25

Str

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s [

N/m

m²]

SLN613_B01_statBett_EU


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Figure 8-21: Static bedding modulus – comparison German-NSP and GBP – SLN0315 – C01

Stat. bet. EU/DE


File: StatEUdeu.TDM

0 1 2 3 4 5 6 7 8

displacement [mm]

0.00

0.05

0.10

0.15

0.20

0.25

Str

es

s [

N/m

m²]

SLN0315_C01_statBett_EU


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Figure 8-22: Fatigue test specimen after 5 mio load cycles

Figure 8-23: Fatigue test, overview pressure marks, after 5 mio (l) and 8 mio (r) load cycles

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Figure 8-24: Pressure marks (relative) on the fleece after 5 Mio (a) and 8 Mio (b) load cycles,

measuring system ATOS

a) after 5 mio load cycles

Relative

dimensions

b) after 8 mio load cycles

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Figure 8-25: Bond strength, prepared specimen

Figure 8-26: Bond strength, SLN1010-A11-1 (left), SLN0613-B05 (right)

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Figure 8-27: Shear strength, SLN0613 B-33, SLN0315 C-32, during the test

Figure 8-28: Shear strength, SLN0613 B-31, SLN0315 C-33, after the test

Figure 8-29: Shear strength,

SLN0315 C-32, after the test

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8.5 DATA SHEETS USP FIRM GETZNER WERKSTOFFE GMBH

Figure 8-30: Product data sheet, SLN 0315, source Getzner Werkstoffe GmbH

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