Overbygning/Komposittsviller
| Fagområde / Discipline | Overbygning / Permanent way |
| Tilhører rammeavtale / Frame agreement | K.xxxxxxxxx |
| Utarbeidet av / Prepared by | Frode Teigen |
| Godkjent av / Approved | Christopher Schive |
| Revisjon / Revision | 01 |
| Utgitt / Issued | 02.02.2024 |
Innhold
- 1 Scope
- 2 Functional requirements
- 3 Resistance to environmental conditions
- 4 Dimensions
- 5 Mechanical and physical requirements
- 6 Machining
- 7 Disposal and recyclability
- 8 Design approval
- 9 Production routine testing
- 10 Quality system
- 11 Marking
- 12 Documentation
- 13 Storage and transport
- 14 Reference document
- 15 Compliance list
- 16 Change log
1 Scope
This specification describes objective requirements to the supplier for construction, production, control and deliveries of composite plastic sleepers in accordance with requirements and expectations of Bane NOR.
This specification is applicable to composite plastic sleepers for the following applications:
- Normal track
- Heavy haul track
- Switches and crossings
- Bridges with open steel deck without ballast layer (Open deck bridges)
This specification applies to sleepers with, and without preinstalled baseplates for rail fastening.
2 Functional requirements
2.1 Fastening system
- Sleepers for normal traffic and heavy haul traffic shall be delivered with complete fastening system preinstalled
- Sleepers can be delivered with direct fastening system if the sleeper material can withstand the contact pressure on the sleeper-rail interface
2.1.1 Fastening for normal traffic
- Sleepers for normal traffic shall be preinstalled with Pandrol Fastclip FE fastening system
- Sleepers for normal traffic shall be delivered with fastening which comply with category C and D according to EN 13481-2
2.1.2 Fastening for heavy haul traffic
- Fastening for heavy haul application shall comply with category E according to EN 13481-2
- Fastening for heavy haul application shall be designed for minimum 35 ton axle load
- Any protruding parts of the fastening system shall be designed to withstand impacts from snow and ice removal equipment and tamping tools.
- Any embedded cast iron parts shall not protrude the sleeper surface
- The fastening system shall be able to accomodate temporary installation of 54E4 rails.
- 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.
2.2 Track gauge
a) For normal traffic sleepers, delivered with preinstalled fastening, the design track gauge when the rails are installed shall be 1437 mm with a tolerance of +/- 2 mm.
b) For heavy Haul sleepers, the design track gauge when the rails are installed shall be 1437 mm with a tolerance of +0 /- 2 mm.
2.3 Axle load and speed
a) Sleepers for normal track and switches & crossings shall be designed to accommodate the following combinations of axle loads and speed in track with sleeper distance 60 cm c-c and a ballast layer depth of 30 cm below the sleeper:
- Axleload = 22,5 tonnes at speed = 160 km/h
- Axleload = 25 tonnes at speed = 120 km/h
b) Sleepers for heavy haul application shall be designed to accommodate the following combinations of axle loads and speed in track with sleeper distance 52 cm c-c and a ballast layer depth of 20 - 30 cm below the sleeper:
- Axleload = 35 tonnes at speed = 50 km/h
c) Sleepers for open deck bridges shall be designed to accommodate the following combinations of axle loads and speed when fastened directly to steel girders with sleeper distance 45 cm c-c :
- Axleload = 22,5 tonnes at speed = 160 km/h
2.4 Electrical resistance between the rails
a) The electrical resistance between the two fastened rail strings shall be not less than 5 kΩ when measured in accordance with EN 13146-5
2.5 Design service life
a) The sleepers for normal traffic shall be designed for a service lifetime of at least 40 years taking into account an annual traffic load 10 MGT and the combinations of axle load and speed given in this specification.
b) The sleepers for Heavy Haul traffic shall be designed for a service lifetime of at least 40 years taking into account an annual traffic load 30 MGT and the combinations of axle load and speed given in this specification.
3 Resistance to environmental conditions
3.1 Temperature range
a) The sleepers shall meet all functional requirements over the entire ambient temperature interval -400C to + 350C.
3.2 Weathering resistance
a) Weathering resistance shall be demonstrated according to ISO 12856-1:2022, clause 4.1.2.1
3.3 Chemical resistance
a) The sleeper material shall not be adversely affected by exposure to diesel, grease, herbicides or lubricants found in the railway environment.
b) Chemical resistance shall be demonstrated according to ISO 12856-1:2022, clause 4.1.1
3.4 Resitance to water and frost
a) The sleepers shall be designed so that any penetrating water can not cause frost damage to the sleepers.
b) The manufacturer shall prove the basic non-water absorbing capacity of the material according to ISO 12856-1:2022, clause 4.1.2.3
3.5 Temperature resistance
a) The manufacturer shall ensure that, the influence of temperature during the design service life, does not lead to such embrittlement of the sleeper material that the requirements in Physical and mechanical requirements are no longer kept.
4 Dimensions
4.1 Cross section and length
a) Sleepers and bearers shal have a rectangular cross section as shown in Figur 1
Tabell 1 shows the dimensions of the sleepers
| Sleeper | Dimensions (mm) | ||
|---|---|---|---|
| Length | w (width) | h (height) | |
| Normal track sleeper | 2500 | 240-260 | max 150 |
| Heavy haul track sleeper | 2500 | min 260 | max 160 |
| Switches & crossing bearer | 2300 - 7500 | 240-260 | 140 - 160 |
| Open deck bridge bearer | 2500 - 5000 | 230 | variable |
b) For bridge bearers, the cross section height may vary along the length of the bearer.
4.2 Dimensional tolerances
a) Dimensonal tolerances shall be within limits given in Tabell 2
| Sleeper | Tolerances (mm) | ||||
|---|---|---|---|---|---|
| Length | w (width) | h (height) | Camber and bend | Torsion | |
| Normal track sleeper | ± 10 | ± 6 | ± 3 | ≤ 2/1000 | ≤ 1/1000 |
| Heavy haul track sleeper | ± 10 | ± 6 | ± 3 | - | - |
| Switches & crossing bearer | ± 10 | ± 6 | ± 3 | ≤ 2/1000 | ≤ 1/1000 |
| Open deck bridge bearer | ± 10 | ± 6 | ± 3 | ≤ 2/1000 | ≤ 1/1000 |
b) The sleeper dimensions shall be measured in accordance with ISO 12856-3:2022, clause 5.2.
4.3 Surface finish
The rail seat area shall be free of any large voids
5 Mechanical and physical requirements
5.1 Characteristic bending moments
5.1.1 Characteristic bending moments Normal traffic
Sleepers for normal traffic shall be designed to the following characteristic bending moments:
- Positive characteristic bending moment for rail seat section Mk,r,pos:15,1 kNm
- Positive characteristic bending moment for centre section Mk,c,pos:16,3 kNm
- Negative characteristic bending moment for rail seat section Mk,r,neg:-7,5 kNm
- Negative characteristic bending moment at centre section Mk,c,neg:-23,2 kNm
5.1.2 Characteristic bending moments for Heavy Haul traffic
Sleepers for Heavy Haul traffic shall be designed to the following characteristic bending moments:
- Positive characteristic bending moment for rail seat section Mk,r,pos:18,5 kNm
- Positive characteristic bending moment for centre section Mk,c,pos:20,2 kNm
- Negative characteristic bending moment for rail seat section Mk,r,neg:-9,2 kNm
- Negative characteristic bending moment at centre section Mk,c,neg:-28,9 Knm
5.1.3 Characteristic bending moments for Switches and crossings
a) Sleepers with length=2300 mm for use in Switches and Crossings shall be designed to the following characteristic bending moments:
- Positive characteristic bending moment for rail seat section Mk,r,pos:10,8 kNm
- Positive characteristic bending moment for centre section Mk,c,pos:22,2 kNm
- Negative characteristic bending moment for rail seat section Mk,r,neg:-5,4 kNm
- Negative characteristic bending moment at centre section Mk,c,neg:-31,7 Knm
b) Sleepers with length=2500 mm for use in Switches and Crossings shall be designed to the following characteristic bending moments:
- Positive characteristic bending moment for rail seat section Mk,r,pos:15,3 kNm
- Positive characteristic bending moment for centre section Mk,c,pos:16,3 kNm
- Negative characteristic bending moment for rail seat section Mk,r,neg:-7,7 kNm
- Negative characteristic bending moment at centre section Mk,c,neg:-23,2 Knm
5.1.4 Characteristic bending moments for open deck bridges
a) Sleepers with cross section 230x140 mm for use on Bridges with open steel deck without ballast layer shall be designed to the following characteristic bending moments:
- Positive characteristic bending moment Mk,b,pos:10,4 kNm
b) Sleepers with cross section 230x230 mm for use on Bridges with open steel deck without ballast layer shall be designed to the following characteristic bending moments:
- Positive characteristic bending moment Mk,b,pos:24 kNm
5.2 Shear strength
a) Sleepers with cross section 230x140 mm for use on Bridges with open steel deck without ballast layer shall be designed to accomodate shear forces of minimum 44,8 kN
5.3 Screw pull-out strength
a) The sleeper screw pull-out strength shall be minimum 30 kN when measured in accordance with EN 13146-10
5.4 Surface friction
a) Sleepers on steel girder bridges shall have non-skid surface
5.5 Mass density
a) The sleeper material shall have a minimum mass density of 0,72 g/cm3 when measured in accordance with ISO 12856-1:2014, clause 4.10
5.6 Expansion coefficient
a) The linear expansion coefficient shal not exceed 6x10-5 m/m0C when measured in accordance with ISO 12856-2:2020
5.7 Flame resistance
a) When testet according to ISO 12856-1:2014, clause 4.12 - Option 1, the flame shall not penetrate any of the five test specimens.
b) When testet according to ISO 12856-1:2014, clause 4.12 - Option 2, the test specimen shall not burn completely and the time of after-flame and after-glow shall not exceed 60 minutes on any of the five specimens.
6 Machining
6.1 Drilling
a) All sleepers shall allow for in-track predrilling of sleeper screw holes using standard sleeper drilling machines for wooden sleepers.
6.2 Length adjustment
a) Switches & crossing sleepers and open deck bridge sleepers shall allow for in-track trimming of the sleeper length using cutting and sawing tools for wood.
6.3 Height adjustment
a) Open deck bridge sleepers shall allow for in-track trimming of sleeper height using cutting and sawing tools for wood.
7 Disposal and recyclability
a) After end of life, it shall be possible to recycle minimum 85% of the sleeper material (excluding fastening components) into new sleepers or other usable products.
8 Design approval
a) Prior to design approval, tests in Tabell 3 shall be carried out to demonstrate compliance with the requirements in this specification.
| Test | Reference in ISO 12856-3:2022 | Test method |
|---|---|---|
| Stiffness at centre section for negative bending moments | 8.2.2.1.1 | ISO 12856-2:2020, 5.2.3.1 |
| Fatigue test and ultimate load at centre section for negative bending moments | 8.2.2.1.2 | ISO 12856-2:2020, 5.2.3.2 |
| Strength test at centre section for negative bending moments | 8.2.2.1.4 | ISO 12856-2:2020, 5.2.3.4 |
| Stiffness at rail seat | 8.2.2.3.1 | ISO 12856-2:2020, 5.2.5.1 |
| Fatigue test at rail seat | 8.2.2.3.2 | ISO 12856-2:2020, 5.2.5.2 |
| Strength at rail seat | 8.2.2.3.3 | ISO 12856-2:2020, 5.2.5.3 |
| Thermal expansion | 8.2.3 | ISO 12856-2:2020, 5.4 |
| Permanent deformation of screw/insert in function of temperature | 8.2.4 | ISO 12856-2:2020, 5.5.1 |
| Electrical resistance | 8.2.6 | EN 13146-5 |
| Flame resistance | 8.2.8 | ISO 12856-1:2014, clause 4.12 |
| Environmental resistance | 8.3.2 | ISO 12856-1:2022, 4.1.2 |
| Chemical resistance | 8.3.1 | ISO 12856-1:2022, 4.1.1 |
| Sleeper screw pull-out strength | - | EN 13146-10 |
| Mass density | - | ISO 12856-1:2014, clause 4.10 |
9 Production routine testing
a) Prior to start of manufacturing, a quality plan shall be provided to Bane NOR.
b) The quality plan shall give the frequency of testing and actions to be taken in case of defects or deviation from the requirements being found.
c) Test requirements and acceptance criteria shall be in accordance with ISO 12856-1:2014, ISO 12856-1:2022, ISO 12856-2:2020, EN 13146-5 and EN 13146-10.
10 Quality system
a) The supplier shall operate a quality system, which is defined and maintained in a quality manual. This manual shall address all actions, functions and resources, procedures and practices concerned with achieving and providing documentary evidence that the quality of the delivered sleepers and bearers are to the agreed requirements.
11 Marking
Each sleeper shall be marked with the following data:
- Model description
- Production date
- Batch number
- Supplier
12 Documentation
12.1 Drawings
a) Detailed drawings of the sleepers shall be provided to Bane NOR prior to delivery
b) All drawings must be supplied in both of the following electronic formats:
- dwg (Autocad)
c) The supplier has an obligation to supply files that are compatible with the version of Autocad currently used by Bane NOR.
d) All drawings must be approved by Bane NOR before production commences.
12.2 Materials certificates
a) The supplier must maintain comprehensive records of each order of sleepers. These records must include materials certificates for the following components:
- Raw material
- Rail fastening baseplate if supplied
- Rail fastening clip if supplied
b) 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.
12.3 BIM model
- The supplier must prepare a BIM model 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
12.4 Test records
a) Test records from design approval testing shall be provided to Bane NOR prior to delivery
b) Test records from routine approval testing shall be retained by the supplier, but must be available for inspection by Bane NOR at any time.
12.5 Safety data sheet
a) The supplier shall submit a safety data sheet according to REACH annex 2.
13 Storage and transport
a) Sleepers shall be stored and transported in such a manner that neither sleepers nor fastening components are damaged.
b) During storage and transportation wooden or plastic shims with min. 50 mm thickness shall be used between the sleepers.
14 Reference document
- ISO 12856-1:2014 Plastics - Plastic railway sleepers for railway applications - Part 1: Material characteristics
- ISO 12856-1:2022 Railway applications - Polymeric composite sleepers, bearers and transoms - Part 1: Material characteristics
- ISO 12856-2:2020 Railway applications - Polymeric composite sleepers, bearers and transoms - Part 2: Product testing
- ISO 12856-3:2022 Railway applications - Polymeric composite sleepers, bearers and transoms - Part 3: General requirements
- EN 13146-5: 2012 Railway applications - Track - Performance requirements for fastening systems - Part 5: Determination of electrical resistance
- EN 13146-10:2017 Railway applications - Track - Test methods for fastening systems - Part 10: Proof load test for pull-out resistance
- REACH Annex 2:2015 (Guidance on compilation of Safety Data Sheet)
