Overbygning/Betongsviller

Fagområde / Discipline Overbygning / Permanent way
Tilhører rammeavtale / Frame agreement K.xxxxxxxxx
Utarbeidet av / Prepared by Frode Teigen
Godkjent av / Approved Christopher Schive
Revisjon / Revision 08
Utgitt / Issued 26.11.2024

Innhold

1 Purpose

This specification sets out objective requirements concerning the units to be supplied, to enable suppliers to design, manufacture and deliver sleepers that meet the expectations of Bane NOR.

2 Scope

This specification applies to monoblock concrete sleepers in ballasted track suitable for rail profiles 49E1 / 54E3 and 60E1.

This specification applies to monoblock concrete sleepers for use on bridges suitable for rail profiles 49E1 / 54E3 and 60E1 together with guard rails in profile 49E1

This specification applies to monoblock concrete sleepers delivered with elastic under sleeper pads (USP) as well as without under sleeper pads.

Requirements for concrete sleepers are based on EN 13230 "Railway Application - Track- Concrete sleepers and bearers"

This specification applies to concrete sleeper for two different applications:

  1. Concrete sleepers for normal traffic applications with axle loads up to 25 ton
  2. Concrete sleepers for heavy haul traffic with axle loads up to 35 ton

3 Functional requirements

3.1 Rail profiles

Concrete sleepers shall be delivered in two versions regarding rail profiles (according to EN 13674-1):

  1. 60E1 sleeper - Concrete monoblock sleeper for rail profile 60E1
  2. 54E3 sleeper - Concrete monoblock sleeper for rail profile 54E3 and 49E1

3.2 Track gauge

The design track gauge shall be 1437 mm

The design track gauge is here defined as the track gauge measured when the rails are positioned hard to the field side with no clearance between the rail foot and the field side shoulder/side post insulator.

3.3 Rail inclination

The sleepers shall be designed to give a rail inclination 1:20

3.4 Axle load and speed

3.4.1 Concrete sleepers for normal traffic

Concrete sleepers for rail profile 60E1 shall be designed to accommodate the following combinations of axle loads and speed in track with sleeper distance 60 cm c-c:

  • Axleload = 17 tonnes at speed = 300 km/h
  • Axleload = 18 tonnes at speed = 250 km/h
  • Axleload = 20 tonnes at speed = 200 km/h
  • Axleload = 25 tonnes at speed = 120 km/h

Concrete sleepers for rail profile 54E3 shall be designed to accommodate the following combinations of axle loads and speed in track with sleeper distance 60 cm c-c::

  • Axleload = 20.5 tonnes at speed = 160 km/h
  • Axleload = 22,5 tonnes at speed = 90 km/h

3.4.2 Concrete sleepers for heavy haul traffic

Concrete sleepers for rail profile 60E1 shall be designed to accommodate the following combinations of axle loads and speed in track with sleeper distance 60 cm c-c:

  • Axleload = 35 tonnes at speed = 50 km/h

3.5 Electrical resistance of fastening system and sleeper

The electrical insulation of fastening system and sleeper shall be not less than 5 kΩ when measured in accordance with EN 13146-5

4 Design

The design of the sleepers shall comply with the requirements in EN 13230-1 and the following requirements.

4.1 Dimensions

4.1.1 60E1 sleeper for normal traffic

a) 60E1 sleepers for normal traffic shall be designed according to Figur 1

Figur 1: Dimensions of 60E1 sleeper

b) minimum mass of one sleeper (wmin): 265 kg

c) maximum mass of one sleeper: (wmax): 350 kg

4.1.2 54E3 sleeper for normal traffic

a) 54E3 sleepers for normal traffic shall be designed according to Figur 2

Figur 2: Dimensions of 54E3 sleeper

b) minimum mass of one sleeper (wmin): 230 kg

c) maximum mass of one sleeper: (wmax): 300 kg

4.1.3 60E1 sleeper for heavy haul traffic

a) maximum overall length (L): 2610 mm

b) maximum width (w): 340 mm

c) minimum bottom width at sleeper ends (b1): 300 mm

d) minimum top width at rail seat (b2): 170 mm

e) maximum height at rail seat (h): 225 mm

f) minimum bottom area (A) 650 000 mm2

g) minimum mass of one sleeper (wmin): 300 kg

h) maximum mass of one sleeper: (wmax): 400 kg

4.2 Characteristic bending moments

4.2.1 Characteristic bending moments for 60E1 sleeper - normal traffic

60E1 sleeper shall be designed to the following characteristic bending moments:

  • Positive characteristic bending moment for rail seat section Mk,r,pos:16,80 kNm
  • Positive characteristic bending moment for centre section Mk,c,pos:7,80 kNm
  • Negative characteristic bending moment at centre section Mk,c,neg:10,50 kNm
  • Positive test bending moment for rail seat section Mt,r,pos:21,38 kNm
  • Negative test bending moment at centre section Mt,c,neg:14,30 kNm
  • Static impact coefficient due to exceptional and random load k1s: 2,20
  • Dynamic impact coefficient due to exceptional and random load k1d: 1,83
  • Static impact coefficient due to accidental load k2s: 3,05
  • Dynamic impact coefficient due to accidental load k2d: 2,68
  • Fatigue test coefficient: k3: 3,05

4.2.2 Characteristic bending moments for 54E3 sleeper - normal traffic

54E3 sleeper shall be designed to the following characteristic bending moments:

  • Positive characteristic bending moment for rail seat section Mk,r,pos:7,59 kNm
  • Positive characteristic bending moment for centre section Mk,c,pos:8,22 kNm
  • Negative characteristic bending moment at centre section Mk,c,neg:11,73 Knm
  • Positive test bending moment for rail seat section Mt,r,pos:12,87 kNm
  • Negative characteristic bending moment at centre section Mk,c,neg:14,83 Knm
  • Static impact coefficient due to exceptional and random load k1s: 2,34
  • Dynamic impact coefficient due to exceptional and random load k1d: 1,96
  • Static impact coefficient due to accidental load k2s: 3,26
  • Dynamic impact coefficient due to accidental load k2d: 2,86
  • Fatigue test coefficient: k3: 3,26

4.2.3 Characteristic bending moments for 60E1 sleeper - heavy haul traffic

60E1 sleeper for heavy haul traffic shall be designed to the following characteristic bending moments:

  • Positive characteristic bending moment for rail seat section Mk,r,pos:18 kNm
  • Negative characteristic bending moment at centre section Mk,c,neg:12 kNm
  • Positive test bending moment for rail seat section Mt,r,pos:26 kNm
  • Negative test bending moment at centre section Mt,c,neg:18 kNm
  • Static impact coefficient due to exceptional and random load k1s: 2,20
  • Dynamic impact coefficient due to exceptional and random load k1d: 1,83
  • Static impact coefficient due to accidental load k2s: 3,05
  • Dynamic impact coefficient due to accidental load k2d: 2,68
  • Fatigue test coefficient: k3: 3,05

4.3 Fastening

  • Sleepers for normal traffic shall be preinstalled with Pandrol Fastclip FE fastening system

4.3.1 Fastening for 60E1 sleepers - normal traffic

  • 60E1 sleepers to be delivered in the following versions regarding fastening components:
  1. Fastening for standard application which comply with category D according to EN 13481-2
  2. Fastening adapted for installation of 54E3 and 49E1 rail profiles which at a later stage can be reconfigured to suit 60E1 rail profile

4.3.2 Fastening for 54E3 sleepers - normal traffic

  • 54E3 sleepers to be delivered in the following versions regarding fastening components:
  1. Fastening for standard application which comply with category C according to EN 13481-2
  2. Fastening adapted for installation of NSB40 and 35kg rail profiles which at a later stage can be reconfigured to suit 54E3 and 49E1 rail profiles

4.3.3 Fastening for 60E1 sleepers - heavy haul traffic

  • Requirements for fastening components for heavy haul concrete sleepers:
  1. Fastening for heavy haul application which comply with category E according to EN 13481-2
  2. Fastening shall be designed for minimum 35 ton axle load
  3. Any protruding parts of the fastening system shall be designed to withstand impacts from snow and ice removal equipment and tamping tools.
  4. Any embedded cast iron parts shall not protrude the concrete surface
  5. The fastening system shall be able to accomodate temporary installation of 54E4 rails.
  6. Resistance to wear and deformation in the fastening components shall ensure a maximum track gauge variation of 5 mm from the design track gauge after 20 MGT traffic load in a 300 meter radius curve.

4.3.4 Fastening for 60E1 sleepers and 54E3 sleepers to be used on bridges

  • In addition to the above fastening versions, sleepers to be used on bridges shall also incorporate fastening for guard rails.
  1. 60E1 sleeper bridge Type A with embedded sleeper anchors for Pandrol e2039 fastenings (Pandrol Ltd drawing no. 6162) according to Figur 3
  2. 60E1 sleeper bridge Type B with sdÜ9 dowels according to Figur 4
  3. 54E3 sleeper bridge Type A with embedded sleeper anchors for Pandrol e2039 fastenings (Pandrol Ltd drawing no. 6162) according to Figur 3
  4. 54E3 sleeper bridge Type B with sdÜ9 dowels according to Figur 4
  • Sleepers shall have through holes for drainage at dowels.
Figur 3: Positioning of anchors for guard rails
Figur 4: Positioning of dowels for guard rail set of plates

5 Materials

All materials shall comply with EN 13230-1 with the following additional specification:

  • Minimum compressive strength of the concrete shall be class C50/60

6 Manufacturing process

  • The manufacturing process shall comply with the requirements of EN 13230-1
  • The supplier shall complete and submit a production file for manufacturing data in accordance with EN 13230-1

7 Under sleeper pads

7.1 General

Manufacturing, bonding and testing of under sleeper pads shall comply with the requirements in EN 16730.

7.2 Stiffness classification

7.2.1 Under sleeper pads for 60E1 sleepers - normal traffic

60E1 sleepers to be delivered with 3 alternative under sleeper pad types according to Tabell 1

Tabell 1: USP stiffness classification 60E1 sleepers normal traffic
Track category (EN 16730) Bedding Modulus Cstat Thickness
min [N/mm3] max [N/mm3] min [mm] max [mm]
TC3 0,10 0,15 10 15
TC3 0,25 0,30 7 13

7.2.2 Under sleeper pads for 60E1 sleepers - heavy haul traffic

60E1 sleepers to be delivered with under sleeper pad type according to Tabell 2

Tabell 2: USP stiffness classification 60E1 sleepers heavy haul traffic
Track category (EN 16730) Bedding Modulus Cstat Thickness
min [N/mm3] max [N/mm3] min [mm] max [mm]
TC4 0,30 0,35 5 10

7.2.3 Under sleeper pads for 54E3 sleepers

54E3 sleepers to be delivered with 2 alternative under sleeper pad types according to Tabell 3

Tabell 3: USP stiffness classification 54E3 sleepers
Track category (prEN 16730) Bedding Modulus Cstat Thickness
min [N/mm3] max [N/mm3] min [mm] max [mm]
TC3 0,15 0,20 7 15
TC3 0,25 0,30 7 13

7.3 Dimensions

  • Thickness of the under sleeper pads shall be in accordance with Tabell 1, Tabell 2 and Tabell 3
  • Under sleeper pads shall cover the entire base area of the sleeper with maximum distance to the sleeper base edges = 10 mm.

7.4 Bond strength

The bonding of the under sleeper pads shall be tested by pull-out tests according to EN 16730.

Acceptance criteria:

  • Minimum bond strength = 0,4 N/mm2
  • Average bond strength ≥ 0,5 N/mm2

7.5 Durability

The durability of the under sleeper pads shall be tested according to EN 16730-Annex L

Acceptance criteria:

  • USP shall not show any sign of perforations, cracking or other damage
  • The mass of the sleeper shall not be reduced by more than 0.5 %.
  • The static and low frequency dynamic stiffness of USP shall not change by more than 15 %

7.6 Resistance to environmental conditions

The effect of severe environmental conditions shall be tested in accordance with EN 16730-Annex N

Acceptance criteria:

  • The static and low frequency dynamic stiffness of USP shall not change by more than 15 %
  • The minimum value of pull-out of USP, after the climatic test, should not be less than 0,4 N/mm2.

8 Design approval

The following tests shall be carried out to demonstrate compliance with the design.

  • Static bending test
  • Dynamic bending test
  • Fatigue test
  • Concrete properties
  • Geometrical dimension test

Test requirements and acceptance criteria shall be in accordance with EN 13230-1 and EN 13230-2

9 Production routine testing

  • Prior to start of manufacturing, a quality plan shall be provided to Bane NOR in accordance with EN 13230-1
  • The quality plan shall give the frequency of testing and actions to be taken in case of defects being found.
  • Test requirements and acceptance criteria shall be in accordance with EN 13230-1 and EN 13230-2

10 Quality system

The supplier shall operate a quality system in accordance with EN 13230-1

11 Marking

Each concrete sleeper shall be marked in accordance with EN 13230-1

12 Documentation

12.1 Drawings

Detailed drawings of the sleepers shall be provided to Bane NOR prior to delivery

All drawings must be supplied in both of the following electronic formats:

  • dwg (Autocad)
  • pdf

The supplier has an obligation to supply files that are compatible with the version of Autocad currently used by Bane NOR.

All drawings must be approved by Bane NOR before production commences.

12.2 BIM model

  • The supplier must prepare a BIM model for every expansion joint type prior to delivery.
  • The BIM model shall be based on Bane NORs requirements - GEN-00-A-00005
  • The BIM model shall be based on open standard, IFC version 4.3 or newer as described in ISO 16739
  • The Model shall include all details in the sleepers, including fastening components.
  • Object libraries shall be available to Bane NOR and 3rd party suppliers
  • Structured information shall be connected to the BIM model

12.3 Materials certificates

The supplier must maintain comprehensive records of each order of sleepers. These records must include materials certificates for the following components:

  • Reinforcing steel
  • Rail fastening anchor
  • Rail fastening clip
  • Rail fastening insulator
  • Rail fastening pad
  • Under sleeper pad

The records are to be retained by the supplier, but must be available for inspection by Bane NOR at any time. On request, the supplier must submit materials certificates to Bane NOR.

12.4 Test records

  • Test records from design approval testing shall be provided to Bane NOR prior to delivery
  • Test records from routine approval testing shall be retained by the supplier, but must be available for inspection by Bane NOR at any time.

13 Storage and transport

  • Sleepers shall be stored and transported in such a manner that neither sleepers or fastening components are damaged.
  • During storage and transportation wooden shims with min. 50 mm thickness shall be used between the sleepers.

14 Reference documents

  • EN 13230-1 Railway applications - Track - Concrete sleepers and bearers - Part 1: General requirements
  • EN 13230-2 Railway applications - Track - Concrete sleepers and bearers - Part 2: Prestressed monoblock sleepers
  • EN 13674-1 Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above
  • EN 13481-2 Railway applications - Track - Performance requirements for fastening systems - Part 2: Fastening systems for concrete sleepers
  • EN 13146-5 Railway applications - Track - Test methods for fastening systems - Part 5: Determination of electrical resistance
  • prEN 16730 Railway applications - Track - Concrete sleepers and bearers with under sleeper pads

15 Compliance list

16 Change log

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