Download pdf - TRACK SPECIFICATION LOW PROFILE CONCRETE SLEEPERS · TRACK SPECIFICATION LOW PROFILE CONCRETE SLEEPERS MTSP 000003-01 Version: 3 thEffective from: 27 April 2015 L2-TRK-SPE-003 Approving

TRACK SPECIFICATION

LOW PROFILE CONCRETE SLEEPERS

MTSP 000003-01 Version: 3 Effective from: 27th April 2015

L2-TRK-SPE-003

Approving Manager: Chief Engineer Approval Date: 27/04/2015 Next Review Date: 27/04/2018

PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 1 of 17

Approval

Amendment Record

Approval Date Version Description

19/04/2013 1 Initial issue under MTM.

19/02/2014 2 Details for Train Stop sleepers added and figures updated

27/04/2015 3 Amended the design track speed vs design axle load table to

reflect current network operations.

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Table of Contents

1. Purpose ..................................................................................................................4

2. Scope ......................................................................................................................4

3. References .............................................................................................................4

4. Abbreviations .........................................................................................................5

5. Definitions ..............................................................................................................5

6. Responsibilities .....................................................................................................6

7. Safety and Environmental .....................................................................................6

8. Design Requirements ............................................................................................6

8.1 General ...............................................................................................................................6

8.2 Components .......................................................................................................................6

8.3 Design Criteria ....................................................................................................................7

8.4 Allowance for Retrofit (Train Stop Sleepers) ......................................................................9

9. Design Management ..............................................................................................9

9.1 General ...............................................................................................................................9

9.1.1 Operating Considerations ............................................................................. 9

9.2 Sleeper Design ................................................................................................................ 10

9.2.1 Design Verification ...................................................................................... 10

9.2.2 Production Validation .................................................................................. 10

9.3 Service Life ...................................................................................................................... 10

9.4 Drawings .......................................................................................................................... 10

9.4.1 Drawings Layout Requirements – General ................................................. 11

9.4.2 LPCS Drawing Details & Requirements ..................................................... 11

9.5 Design and Production .................................................................................................... 11

9.6 Sleeper Marking .............................................................................................................. 12

10. Performance Requirements ................................................................................ 12

10.1 Handling and Maintenance Performance ........................................................................ 12

11. Performance Measures and Reporting .............................................................. 12

11.1 Quality Assurance ........................................................................................................... 12

11.1.1 ISO 9001 Quality Management System ..................................................... 12

11.1.2 Retention of Documents ............................................................................. 13

11.1.3 Certificate of Conformity ............................................................................. 13

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11.1.4 Audit of Supplier .......................................................................................... 13

11.1.5 Provision of Records ................................................................................... 13

11.2 Supply and Delivery Requirements ................................................................................. 14

12. Type Approval ...................................................................................................... 14

13. Appendices .......................................................................................................... 14

List of Tables

Table 1 - Design Criteria ................................................................................................................. 7

Table 2 - Track Class and Maximum Line Speed ............................................................................ 9

List of Figures

Figure 1 - Basic Dimensions of Track Set-up ................................................................................ 15

Figure 2 - Figure identifies layout of rail seats and sleeper dimensions ......................................... 15

Figure 3 - Half Low Profile Concrete Sleeper (mirrored on other side), identifies rail seating inclination (1 in 20). Sleeper height is 150mm at C-C. ................................................................... 15

Figure 4 - Layout for Train Stop fixing bolt configuration ............................................................... 16

Figure 5 - Half Train Stop Sleeper (mirrored on other side), identifies rail seating inclination (1 in 20). Sleeper height is 210mm at D-D. ........................................................................................... 16

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1. Purpose

This specification sets out the material, design, manufacture, supply and testing requirements for Low Profile Concrete Sleepers used for the MTM railway.

2. Scope

This specification details the requirements for the design and supply of LPCS complete with resilient type fastening assemblies which will be used on MTM railway network.

Concrete sleepers for Train Stop applications are included in this specification. Concrete sleepers for special applications, including multi-gauge tracks and turnout bearers, are not covered by this specification.

System performance requires the concrete sleeper assembly to function as part of the track structure. The sleeper must be able to transfer all the relevant track forces generated by train operations and the forces of rail thermal expansion and contraction to the ballast.

3. References

AS 1085.1 (2002/Amdt 1 - 2005) – Steel Rails

AS 1085.14 (2012) – Prestressed Concrete Sleepers

AS 1085.19 (2003) – Resilient Fastening Assemblies

AS 1379 (2007) – Specification and supply of concrete

AS 3600 (2009) – Concrete Structures

ISO 9001 (2008) – Quality Management

MTST 000002-01 – Track Design and Construction Standard

MTSP 030100-01 – Track Geometry Maintenance Tolerances

MTSP 000003-02 – Supply of Resilient Rail Fastening Assemblies

L1-NAM-PRO-002 – MTM Design and Technical Review Procedure

L1-CHE-PRO-004 – Type Approval Procedure

STD_G0075 – Layout of Train Stop and Signal with Insulated Joints

STD_G0077 – Plate and Pad for top fixing of EP train stop WBS style JAH to concrete sleepers PTC2

STD_G0078 – EP Train Stop W/B&S style JAH method of fixing to top of concrete sleepers PTC2

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4. Abbreviations

LPCS – Low Profile Concrete Sleeper

MTM – Metro Trains Melbourne Pty Ltd

NAM – Network Asset Management

PTC – Public Transport Corporation

5. Definitions

Additives – A substance added to another in relatively small amounts to impart or improve desirable properties or suppress undesirable properties.

Bearer – A transverse concrete unit supporting rails

Cast in Shoulder – A component that prevents lateral movement of the rail foot and provides anchorage for the resilient fastening system

Fastening – The component, or group of components of a track system, that fixes the rail to the sleeper

Insulator – A part of the fastening that fits between the resilient clip, shoulder and the rail foot to provide electrical isolation

Monoblock Concrete Sleeper – Prestressed concrete sleeper cast in a single piece

Prestressing Tendon – A strand or wire within a sleeper, which under tension compresses the concrete

Rail Pad – The component that is located between the foot of the rail and the sleeper. Pads may include multiple layers of material

Rail Seat – The area on the top of the sleeper on which the rail sits extending between the field and gauge shoulders.

Resilient Clip – A flexible steel restraint that clamps the rail in position

Resilient Fastenings – Elastic steel clips attached to sleepers and designed to engage rail flanges. These clips fasten rails to the sleepers providing lateral support. Resilient fastenings also generate toe load at the rail flange providing resistance to longitudinal movement, rail roll and rail lateral shift.

Shall – Is to be interpreted as a requirement that is mandatory to achieve conformance to this specification.

Technical MTM Representative – The Infrastructure Delivery Manager or his delegated representative.

Track Gauge – The distance between the running face at the head of the rails measured 16mm below the top of rail head when assembled.

Train Stop – A mechanism that will automatically result in the application of the train brakes if the train passes a signal at danger.

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6. Responsibilities

All suppliers shall be responsible for conformance to this document.

The Technical Representative of MTM shall be responsible for the management of the technical requirements and ensure compliance in accordance with the MTM documented processes relevant to this specification.

7. Safety and Environmental

The design and manufacture of low profile concrete sleepers shall consider the safe application and handling of the sleepers during installation and ensure the product is safe for use with no adverse impacts on the health and safety of workers who may come in contact with the product. As part of the Type Approval evaluation criteria the product will need to demonstrate that it is suitable for use within the environment. The product shall be free of any hazardous materials and the details of all components including any additives used in the manufacture of the sleeper must be approved by MTM.

8. Design Requirements

8.1 General

The design shall be in accordance with AS 1085.14 – Prestressed Concrete Sleepers, unless otherwise noted within this document.

Alternative design techniques and materials may be used where the manufacturer can demonstrate compliance with the requirements of Sections 5 and 6 of AS 1085.14 (2012) and other requirements, to the satisfaction of MTM. In this instance, a Type Approval Application will be required by the MTM Network Asset Manager.

The sleepers shall be designed to operate as specified in Table 1 and Table 2, which provide design information relating to track and rail operations where the prestressed sleepers will be used. Designs shall be verified by a competent independent third party organisation that has prior approval and endorsement by MTM / NAM.

8.2 Components

For all specified requirements to achieve adequate load transfer, which includes details on fastenings, insulation, rail pads, etc. can be found in the MTM document MTSP 000003-02 ‘Track Specification – Supply of Resilient Rail Fastening Assemblies’.

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8.3 Design Criteria

Sleepers shall be designed to operate in the environment detailed in Table 1 and Table 2.

Table 1 - Design Criteria

General Track Conditions Description / Detail

Maximum Track Grade 1 in 30 (3.33%)

Minimum Curve Track Radius 120m

Maximum Track Cant Deficiency 85mm

Maximum Track Cant

Application Rate 15mm/10m (1:667)

Nominal Ballast Depth 300mm

Minimum Ballast Depth 150mm

Sleeper Spacing 685mm

Additives Requires prior approval by MTM

Curing Method Proposed by

Supplier Requires prior approval by MTM

Design Criterion Description / Detail

Sleeper Type Monoblock, pre-stressed low-profile concrete sleepers for

general use with axle loads up to 23 tonnes.

Operating Class Passenger and Freight Line

Track Gauge 1600mm (gauge face to gauge face, measured 16mm from top

of the rail)

Length from outside of shoulder

to outside of shoulder at 6

Months

1848.8mm ± 1.5mm (Refer Appendix 1)

Rail Size Capable of Supporting 47kg/m, 50kg/m, 53kg/m, 60kg/m

which are used on the network

Estimated Track Gauge at 6

Months per Rail

47kg 50kg 53kg 60kg

1602.1mm 1600.8mm 1600.5mm 1599.2mm

Rail Seat Width at 6 months 164.5mm ± 1mm

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General Track Conditions Description / Detail

Rail Seating Inclination 1 in 20 (5%) ±1 in 250, all running rails shall incline towards

the track centre-line at this rate.

Design Line Speed 160km/hr 115km/hr 100km/hr

Design Axle Load 19 tonne 21 tonne 23 tonne

Signalling Track circuited Signalling. Insulation between rail legs is

required.

Nominal track Modulus 28MPa

Annual Tonnage 20 MGT

Minimum Service Life 50 years

Electrical Insulation

Rail/Sleeper fastening assemblies and sleepers shall ensure a

minimum electrical resistance between running rails of 10 Ω

per track km

Dimensions Description / Detail

Nominal Sleeper Length

2600mm ± 6mm – Standard Sleeper

2695mm ± 6mm – Train Stop Sleeper

Nominal Sleeper Base Width 250mm ± 3mm

Maximum Sleeper Height at Rail Seat

150mm ± 3mm(at centreline of rail seat) – Standard Sleeper

210mm ± 3mm(at centreline of rail seat) – Train Stop Sleeper

Maximum Sleeper Height

165mm – Standard Sleeper

220mm – Train Stop Sleeper

Note:

1. Shoulders shall be positioned at locations on axis B-B. Refer to Appendix 1 for details.

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Table 2 - Track Class and Maximum Line Speed

Track Class1 1/HP 2M 2 3 4 5

Maximum Speed 160

km/hr

130

km/hr

115

km/hr

100

km/hr

80

km/hr

50

km/hr

Maximum Cant (2)

120 100 100 80 80 40

Maximum Cant Deficiency (2)

85 85 85 85 85 85

Note:

1. For explanation of Track Classes, refer to Appendix 1 of MTSP 030100-01 - Track Geometry Maintenance Tolerances.

2. Values extracted from MTST 000002-01 - Track Design and Construction Standard.

8.4 Allowance for Retrofit (Train Stop Sleepers)

The longitudinal centre line of train stop sleepers must have an area which is clear of any reinforcing steel (excluding the area of fastening) to allow for the attachment of train stop equipment.

9. Design Management

The design of the required low profile concrete sleeper shall satisfy the key elements set out below.

9.1 General

The design shall achieve a LPCS that has the following characteristics:

Suitable for installation into track with minimum variation to the ballast depth while maintaining track level.

Facilitate easy operation of all track tamping and ballast regulation using machines compatible with timber sleepered track.

Better track stability than timber sleepers.

Better control of gauge.

Service life longer than for a timber sleeper – Approximately twice the life.

Reduction in track maintenance effort and costs.

Capable of inserting amongst existing timber sleepers at a rate of 1 in 5 through to 1 in 1 replacement.

9.1.1 Operating Considerations

The LPCS shall perform in compliance with this specification under general operating conditions. These conditions include ambient temperatures of -10°C to +50°C and in the presence of rail traffic operating with 1500 Voltage (V) Direct Current (DC).

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9.2 Sleeper Design

The Supplier shall describe the sleeper design process that is to be applied. The design shall be based on proven structural design principles, incorporating finite analysis techniques and consider fatigue as well as ultimate capacity.

9.2.1 Design Verification

The Supplier shall document the process used for the design and MTM shall approve the design before the manufacture and supply of concrete sleepers.

The Supplier shall document the process for the design process and the independent validation of the design by a third party. The design and validation of the concrete sleeper shall be in accordance with the MTM Engineering Design Procedure attached to this specification: ‘L1-NAM-PRO-002 – MTM Design and Technical Review Procedure’.

The Supplier shall provide a Design Report detailing any non compliance to Australian Standards and any Design Limitations to be considered during installation and train operation as detailed in Table 1 – Design Criteria.

The Design report shall describe the range of operating conditions and practices that would apply to the track where LPCS are used. Where there are restrictions on the use of the sleeper these shall be highlighted in the report i.e. curved radius track, concrete sleepers interspersed with timber or heavy duty PTC concrete sleepers and track grades etc.

9.2.2 Production Validation

The Supplier shall demonstrate that the loadings used in the sleeper design are valid. A batching sample of 10 no. sleepers shall be supplied to MTM for checking against the final Supplier approved drawings to be used for the manufacture of sleepers. MTM shall arrange for independent testing to ensure compliance to MTM standards and operating requirements. The Supplier shall undertake their own validation testing and provide MTM with the test results. This validation by MTM and the Supplier must be completed prior to the commencement of full production of sleepers.

9.3 Service Life

The Supplier shall provide the theoretical service life for the proposed sleeper when used under a range of track conditions. The track geometry parameters for the various track classes and speeds as detailed in Appendix 1 of MTSP 030100-01 – Track Geometry Maintenance Tolerances including potential increase in axle loads, change in rail size, change in ballast support conditions and any change in the impact characteristics of rolling stock shall be considered.

9.4 Drawings

MTM reserves the right, and will give reasonable notice, to request further information not contained or included in delivered drawings to ensure adequate description of supplied LPCS, in accordance with this specification.

The Supplier shall provide a dimensioned (together with tolerances applied to the external and internal dimensions) drawing or drawings of the LPCS. Accordingly, the Supplier shall ensure that all pertinent information listed below has been included on the drawings.

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9.4.1 Drawings Layout Requirements – General

All Dimensions and their units in millimetres (mm)

All writing in English

Signatures provided by designer, reviewer and approver and dates

Drawing number and title

Drawing version number and details

Explanatory Notes

Supplier title block / name

9.4.2 LPCS Drawing Details & Requirements

The details shall include but not be limited to:

Type and Grade of Steel

Pre-Tensioning of Steel bars

Number and Size of Steel Reinforcing/Stressing Bars

Strength of Concrete

Details of Aggregates in Concrete (i.e. sand, gravel, etc.)

Type of Cement

Details of Additives used, if any

Branding description

Gauge measurements and details

Rail Seat measurements

Cast in shoulder details

Reinforcement details

List of conforming standards relevant to the above

9.5 Design and Production

The Supplier is required to keep records detailing each batch that is manufactured. These records are to be available for MTM upon request at anytime. They shall serve as a Quality Assurance tool and also a quality check for the supplier.

The records shall include details on:

Dimensional Report

Defect Summary

Batch Report

Cylinder/Beam Test Results (Reference AS 1379 clause 6.2.5)

Casting Report

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Wire Stressing Report

Manufacture Report

Wire Preparation Report

9.6 Sleeper Marking

The following marks shall be displayed on each sleeper, with markings to meet the requirements as specified in AS 1085.14. Note that some are mandatory and some are optional:

Mark of Manufacturer (Mandatory)

The letters “MTM” (Optional)

Year of manufacture (Mandatory)

Batch number (including a design type designator) (Mandatory)

Lettering and marks shall be on the upper sleeper surface.

10. Performance Requirements

10.1 Handling and Maintenance Performance

Sleepers must be suitable for efficient and safe transportation on flat top Rail Wagons or road semi-trailers and be stable for stacking on site. Refer to Section 11.2 for Supply and Delivery Requirements. LPCS must also be suitable for installation by conventional track laying equipment of a type used for partial resleepering.

Track work fitted with these concrete sleepers must be suitable for maintenance with conventional track maintenance equipment. Such equipment may include tamping machines, track adjustment jacks, track lining machines and fastening insertion/removal equipment.

For the purpose of track adjustment, rails must move freely on the rail seats. To achieve this, fastening systems must be able to be released for the adjustment and re-fastening to meet specified tolerances on completion of the work.

11. Performance Measures and Reporting

11.1 Quality Assurance

11.1.1 ISO 9001 Quality Management System

The Supplier shall have either

a) A quality management system third party certified per AS/NZS ISO 9001 (2008), or

b) Be compliant with the requirements of AS/NZS ISO 9001 (2008).

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11.1.2 Retention of Documents

The Supplier shall retain documents verifying the testing and compliance certification, as set out at AS 1085.14, for the manufacture of each production batch of LPCS. These documents shall be available for review by MTM’s Representative at or after the time of dispatch of shipment of sleepers. Inspection and Test Plans (ITP) must comply with AS 1085.14-2012 Section 2 Performance Requirements and Testing. Details on the following should also be Included in the ITP:

Material Composition

Concrete Strength

Details of Additives used, if any

Details on Concrete Curing

Dimensions

Torque Resistance

Steel Reinforcement Characteristics

11.1.3 Certificate of Conformity

A Certificate of Conformity must be presented by the Supplier with the following statement attached:

“It is certified that the Supplies detailed hereon have been designed, manufactured, tested, inspected, quality controlled/quality assured and, unless otherwise stated above, are strictly in accordance with AS 1085.14 requirements, MTM specifications and proper packaging, marking and material use standards as specified in the Contract or Purchase Order. The required inspection, analysis and/or test records in compliance with the Contract or Purchase Order are traceable from this document and will be made available for review by MTM at mutually agreed times or as specified in the Contract or Purchase Order.”

It shall be signed by a senior contractor’s management representative such as Quality Manager, Production or Manufacturing Manager.

11.1.4 Audit of Supplier

Metro Trains Melbourne Pty Ltd or its appointed agent has the right to audit the Supplier at a mutually agreed time to ensure the Suppliers compliance to Section 11.1 of this specification.

11.1.5 Provision of Records

The records to be provided by the Supplier are:

Steel Testing Records conforming with requirements of AS 1085.14-2012 Section 5.6

Concrete Testing Records conforming with requirements of AS 1085.14-2012 Section 5.7

Fastener Testing Records conforming with requirements of AS 1085.14-2012 Section 2.6

Sleeper Testing Records conforming with requirements of AS 1085.14-2012 Section 2.8

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Electrical Testing Records conforming with requirements of AS 1085.14-2012 Section 2.8

The Inspection and Test Plans shall be submitted to MTM for review and approval prior to commencing manufacture.

11.2 Supply and Delivery Requirements

The Supplier shall be responsible for all the materials being supplied and their storage, loading and transport until they are properly stacked at the delivery site and accepted by MTM in accordance with the terms specified in the purchase order/contract. Any materials not accepted by MTM after inspection shall be removed from the site by the Supplier at his own cost and such materials shall be replaced with acceptable materials by the Supplier at his own cost.

The point of handover and delivery site will be specified by the MTM Representative.

During transport and stockpiling, the sleepers shall be stacked on timber, or other suitable material bearer which shall be located in the rail seat area of the sleeper. Sleepers will be stacked in a way to maintain the integrity of units capable of access by conventional means. Sleepers shall be stacked so that they can be loaded, unloaded, secured and transported with no loss, damage or deterioration.

The Supplier shall provide methodology and drawings detailing the safe storage and stacking of concrete sleepers, including the dunnage, during shipping and delivery and storage on site.

12. Type Approval

The Type Approval process shall be in compliance with the MTM document ‘Type Approval Procedure’. It will consist of but not limited to testing performed by an independent qualified party and involve a review period involving sleepers used in-situ. The process will be regulated and approved by MTM’s Chief Engineer.

13. Appendices

Appendix 1 - Figures showing basic Sleeper dimensions and Layout

Appendix 2 - Current MTM Accepted Fastening Systems

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Appendix 1 - Figures showing basic Sleeper dimensions and Layout

Figure 1 - Basic Dimensions of Track Set-up

Figure 2 - Figure identifies layout of rail seats and sleeper dimensions

Figure 3 - Half Low Profile Concrete Sleeper (mirrored on other side), identifies rail seating inclination (1 in 20). Sleeper height is 150mm at C-C.

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Figure 4 - Layout for Train Stop fixing bolt configuration

Figure 5 - Half Train Stop Sleeper (mirrored on other side), identifies rail seating inclination (1 in 20). Sleeper height is 210mm at D-D.

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Appendix 2 - Current MTM Accepted Fastening Systems

Fastclip FE

Pandrol Type E-2003 Fastener