Overbygning/Sporvekselsviller
| Fagområde / Discipline | Overbygning / Permanent way |
| Tilhører rammeavtale / Frame agreement | K.xxxxxxxxx |
| Utarbeidet av / Prepared by | Frode Teigen |
| Godkjent av / Approved | Christopher Schive |
| Revisjon / Revision | 07 |
| Utgitt / Issued | 13.01.2021 |
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 prestressed concrete bearers for switches and crossings with rail profiles 54E3 and 60E1.
Requirements for switches and crossing bearers are based on EN 13230-4 "Railway Application - Track- Concrete sleepers and bearers, Part 4-prestressed bearers for switches and crossings"
This specification applies to two traffic conditions:
- Switches&Crossing bearers for normal traffic
- Switches&Crossings bearers for heavy haul traffic
3 Functional requirements
3.1 Rail profiles
Switches and crossing bearers shall be delivered for two different S&C types regarding rail profiles (according to EN 13674-1):
- 60E1 bearers - Concrete prestressed bearers for switches and crossings with rail profile 60E1
- 54E3 bearers - Concrete prestressed bearers for switches and crossings with rail profile 54E3
3.2 Switches and crossing types
Bearers shall be delivered to all switches and crossing types listed in appendix 1
3.3 Track gauge
- Nominal track gauge is 1435 mm
- The design track gauge shall be 1437 mm for S&C with rail inclination 1:20
3.4 Axle load and speed
3.4.1 Axle load and speed for normal traffic S&C bearers
Bearers for switches and crossings with rail profile 60E1 shall be designed to accommodate the following combinations of axle loads and speed (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
Bearers for switches and crossings with rail profile 54E3 shall be designed to accommodate the following combinations of axle loads and speed in track (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 Axle load and speed for heavy haul traffic S&C bearers
Bearers for switches and crossings with rail profile 60E1 shall be designed to accommodate the following combinations of axle loads and speed (sleeper distance 60 cm c-c):
- Axleload = 22.5 tonnes at speed = 130 km/h
- Axleload = 25 tonnes at speed = 70 km/h
- 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
4.1 Dimensions
- The bearers shall have a uniform cross section throughout the entire length of the bearer.
- Exception: Provision for rail inclination may be integrated in the design of the bearer.
- The bearers shall be delivered with lengths to accomodate a track distance up to 5 meter.
- Height: The design height shall be between 200 and 210 mm
- Bottom width: The design bottom width shall be between 260 and 300 mm
- Top width: The design top width shall be between 240 - 280 mm
4.1.1 Tolerances
The maximum tolerances for the dimensions and straightness of the bearers shall be in accordance with EN 13230-4
4.2 Characteristic bending moments
4.2.1 Characteristic bending moments for normal traffic S&C bearers
The bearers shall be designed to the following characteristic bending moments:
- Positive characteristic bending moment :22 kNm
- Negative characteristic bending moment :15 kNm
- Factor for calculating test bending moments kt = 1,45
- Impact coefficient for positive static test kb = 1,96
- Impact coefficient for negative static test kbn = 1,96
4.2.2 Characteristic bending moments for heavy haul traffic S&C bearers
The bearers shall be designed to the following characteristic bending moments:
- Positive characteristic bending moment :25 kNm
- Negative characteristic bending moment :25 kNm
- Factor for calculating test bending moments kt = 1,45
- Impact coefficient for positive static test kb = 1,96
- Impact coefficient for negative static test kbn = 1,96
4.3 Surface finish
- The top and side surfaces of the sleepers must be free of pores to the maximum possible extent.
- There must be no cavities in which water can accumulate.
- The underside of the sleepers must have a rough surface.
- The lower side edges of the sleepers must not contain large burrs or fracture marks.
- Minor irregularities must be removed by grinding.
4.4 Anchors for fastening
- Bearers shall incorporate embedded sleeper anchors for Pandrol Fastclip FC fastenings (Pandrol Ltd drawing no. 7532) and Pandrol e2039 fastenings .
- The sleeper anchors shall accommodate the use of 10 mm thick elastic pads between rail base and sleeper.
- A detailed list of which sleepers are to incorporate anchors for Pandrol Fastclip FC fastenings and which sleepers are to incorporate anchors for Pandrol e2039 fastenings will be given from Bane NOR
- Bane NOR will prepare a coordinates list for the positioning of the embedded components. The length of the sleeper will be indicated in addition to the coordinates.
- Tolerances for positioning of the anchors shall comply with EN 13230-4
- The reinforcement shall be designed to provide sufficient area for positioning of the anchors without any risk of interference with the prestressing tendons.
- Any traces of concrete on the sleeper anchors that might prevent them from functioning properly shall be removed.
5 Materials
All materials shall comply with EN 13230-1 with the following additional specification:
- Minimum compressive strength of the concrete shall be class C60
6 Under sleeper pads
6.1 General
Manufacturing, bonding and testing of under sleeper pads shall comply with the requirements in EN 16730:2016.
6.2 Stiffness classification
- Determination of static and dynamic stiffness properties of the USP along the turnout shall take into account the elastic properties of the fastening components and traffic loads given in Overbygning/Sporveksler, kryss og sporforbindelser#Maximum_permissible_loads
6.3 Dimensions
- Under sleeper pads shall cover the entire base area of the sleeper with maximum distance to the sleeper base edges = 10 mm.
6.4 Bond strength
The bonding of the under sleeper pads shall be tested by pull-out tests according to EN 16730:2016.
Acceptance criteria:
- Minimum bond strength = 0,4 N/mm2
- Average bond strength ≥ 0,5 N/mm2
6.5 Durability
The durability of the under sleeper pads shall be tested according to EN 16730:2016 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 %
6.6 Resistance to environmental conditions
The effect of severe environmental conditions shall be tested in accordance with EN 16730:2016 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.
7 Manufacturing process
- The manufacturing process shall comply with the requirements of EN 13230-1 and EN 13230-4
- The supplier shall complete and submit a production file for manufacturing data in accordance with EN 13230-4
8 Design approval
The following tests shall be carried out to demonstrate compliance with the design.
- Static bending test
- Fatigue test
- Concrete properties
- Geometrical dimension test
Test requirements and acceptance criteria shall be in accordance with EN 13230-1 and EN 13230-4
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 13230-4
10 Quality system
The supplier shall operate a quality system in accordance with EN 13230-1
11 Marking
- The sleepers must be marked with a simple identification mark indicating the manufacturer, year of manufacture and mould number.
- This mark must be on the top of the sleeper at the left-hand end when looking from the switch blades towards the crossing
- Each sleeper shall be marked with a sleeper number in accordance with the switch diagram, to facilitate assembly of the switch.
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)
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 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
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 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 4: Prestressed bearers for switches and crossings
- EN 13674-1 Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above
- EN 16730 Railway applications - Track - Concrete sleepers and bearers with under sleeper pads
