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ARTC. This document is the confidential property of Australian Rail Track Corporation.

DisclaimerThis document is for internal use by the Australian Rail Track Corporation LTD (ARTC) only and may not be relied upon by any other party.

ARTC: 1. does not accept any liability or responsibility whatsoever for this document in respect to any use or reliance upon it by any other party;

and 2. does not provide any warranty as to the accuracy or reliability of this document.

This document is uncontrolled when printed. See ARTC Intranet for latest version.

Discipline: Engineering (Track & Civil) Category: Standard

Concrete Sleepers (Heavy Duty)

- Design

ETD-02-03

Applicability

ARTC Network Wide Western Jurisdiction

New South Wales Victoria

Primary Source

ARTC Standard ETD-02-01 Concrete Sleepers (Medium Duty) Design

Document Status

Version Date Reviewed Prepared by Reviewed by Endorsed Approved

1.1 05 Jan 07 Standards &

Systems

Standards &

Systems

Standards &

Technical Services

Engineer

Manager

Standards &

Systems05/01/2007

Amendment Record

Version Date Reviewed Clause Description of Amendment

1.0 10 May 06 First issue

1.1 05 Jan 07 4.2 Addition of text regarding tolerances for track gauge for new rail

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Engineering (Track & Civil) Standard

ETD-02-03 Concrete Sleepers (Heavy Duty) - Design

Contents

Version 1.1 Date of last revision: 05 Jan 07 Page 2 of 7


Contents

1 General Description ................................................................................ 3

2 Definitions .............................................................................................. 3

3 References.............................................................................................. 3

4 Design Requirements.............................................................................. 4

4.1 General ............................................................................................ 4

4.2 Track Details ..................................................................................... 4

4.3 Sleeper Dimensions............................................................................ 5

4.4 Design Parameters ............................................................................. 5

4.5 Installation, Handling and Maintenance................................................. 5

4.6 System Performance .......................................................................... 5

4.7 Allowance for Retrofit ......................................................................... 6

5 Sleeper Marking...................................................................................... 6

6 Product Approval Requirements ............................................................. 6

7 Previous Installation Experience ............................................................ 6

8 Sleeper Performance and Tests in Accordance with AS 1085.14............. 7

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General Description



1 General DescriptionThis Standard specifies requirements for the design of concrete sleepers having resilientfastenings and insulators designed in accordance with ARTC Standard ETD-02-04 for use ontrack having nominal 30 t axle load or less. Concrete sleepers supplied for use in Australian Rail

Track Corporation track must meet these design requirements.

Concrete sleepers for special applications including multi-gauge tracks and turnout bearers arenot covered by this Standard.

2 DefinitionsConcrete sleeper A sleeper consisting of appropriately formed reinforced concrete which,

when prestressed, includes the deformed reinforcing bars (tendons) whichare stressed before casting the concrete.

Cast in shoulder A component that prevents lateral movement of the rail foot and provides

anchorage for the resilient fastening system.

Resilient Fastenings Elastic steel clips attached to sleepers and designed to engage rail flanges.These clips fasten rails to the sleepers providing lateral support. Standard

resilient fastenings also generate toe load at the rail flange providingresistance to longitudinal movement, rail roll and rail lateral shift.

Monoblock sleeper Standard concrete sleeper cast in a single piece.

Medium Duty Pertains to track having traffic not exceeding nominal 25 t axle loads nor

more than 25 MGT annual traffic.

Heavy Duty Pertains to track having traffic not exceeding nominal 30 t axle loads normore than 100 MGT annual traffic.

3 ReferencesThe design shall be based on relevant Australian Standards and Codes of Practice and/or thereferenced standards specified in this document.

Referenced Standards include:

AS 1085.14 Prestressed Concrete Sleepers

AS 1085.19 Resilient fastening assemblies

AS 1085.1 Rails

ARTC Standard ETD-02-01 Concrete Sleepers (Medium Duty) - Design

ARTC Standard ETD-02-04 - Resilient Rail Fastenings for Heavy Duty Concrete Sleepers - Design

ARTC NSW Standard TDS 09 Mainline Track Geometry.

ARTC NSW Standard TDS 13 Base Operating Condition Standards of Track Geometry

ARTC NSW Standard TEP 01 Evaluation & Approval of Track Components

Other internationally accepted and proven standards providing these are at least equivalent to

AS 1085.14.

All references relate to the latest Standard versions, including amendments and relevant

superseding Standards.
http://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_01_concrete_sleepers_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_01_concrete_sleepers_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TDS%2009%20-%20C%202200%20-%20Mainline%20Track%20Geometry.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TEP%2001%20-%20C%205200%20-%20Evaluation%20and%20Approval%20of%20Track%20Components.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TEP%2001%20-%20C%205200%20-%20Evaluation%20and%20Approval%20of%20Track%20Components.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TDS%2009%20-%20C%202200%20-%20Mainline%20Track%20Geometry.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_01_concrete_sleepers_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdf

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Design Requirements



4 Design Requirements

4.1 GeneralSleepers shall be Monoblock type cast as pretensioned concrete designated Heavy Duty foruse with axle loads up to 30 tonne.

The design shall be in accordance with AS 1085.14 and/or the referenced standards unless

otherwise specified in this document.

Designs shall be checked by an independent competent organisation.

Fastenings, cast in shoulders, pads, spacers and insulators shall comply with ARTC Standard

ETD-02-04.

4.2 Track Details

The sleeper shall be designed for use on mainline track of 1435mm track gauge (measured 16mm from the top of rail when assembled), assuming AS 1085, 47, 50, 53 or 60 kg/m rails or

UIC 60 or UIC 54 rails are utilised. All running rails shall slope towards the track centre-line at 1in 20.

Tolerances for track gauge only apply to NEW rail. The following tolerances are applicable for

heavy duty concrete sleepers:

AS53/60kg/m rail = +4mm wide gauge, -2mm tight gauge (+4, -2)

AS47kg/m rail = +6mm wide gauge, 0mm tight gauge (+6, 0)

The railways on which the sleepers will be used include extensive lengths of sharp curves and

steep gradients where sanding is applied for improved traction. Concrete sleepers are to bedesigned to minimise potential for soffit abrasion and rail seat erosion in this type of operating

environment.Track configuration is detailed in ARTC NSW Standard TDS 09, Class 1XC track, with geometry

maintained as per ARTC NSW Standard TDS 13.

Sleepers will be installed in track both with and without signalling circuits and with and without

electrification at 1.5 kV DC and may in future be electrified at 25 kV AC.

Nominal maximum train speeds and loads may apply as detailed in Table 1.

30t Freight 25t Freight 23 t Freight 21t Freight 19t Passenger

80 km/hr 80 km/h 110 km/h 115 km/h 160 km/h

Table 1 Maximum Speeds in km/h

Track geometry assumptions (curvature, gradient, superelevation, cant deficiency etc) are to be

in accord with Table 2, TDS 09 Mainline Track Geometry for Class 1XC track, except Max Eamay be 150 mm and Max D for Heavy Freight lines may be 100 mm.

Other relevant track data includes:

Electrical Insulation - Sleeper fastening assemblies and sleepers shall ensure a minimumelectrical resistance between the running rails of 10 Ohms per track kilometre.

Sleepers and cast in components shall be designed and manufactured to provide a minimum

service life of fifty years based on annual tonnage of 100 MGT, nominal axle load of 30 t and 667mm nominal sleeper centres.
http://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TDS%2009%20-%20C%202200%20-%20Mainline%20Track%20Geometry.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TDS%2009%20-%20C%202200%20-%20Mainline%20Track%20Geometry.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TDS%2009%20-%20C%202200%20-%20Mainline%20Track%20Geometry.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TDS%2009%20-%20C%202200%20-%20Mainline%20Track%20Geometry.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TDS%2009%20-%20C%202200%20-%20Mainline%20Track%20Geometry.pdfhttp://extranet.artc.com.au/nswdocs/nsw_engineering/engineering_standards/track/TDS%2009%20-%20C%202200%20-%20Mainline%20Track%20Geometry.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdf

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Design Requirements



4.3 Sleeper Dimensions

Sleepers should be designed to a preferred length of 2.5 m, a maximum depth at the rail seat of250 mm and a width that provides a maximum pressure on ballast of 500 kPa when calculated

in accordance with AS 1085.14.

The width of the top of concrete sleepers at rail seats shall be not less than 160 mm plus any

chamfer or rounding, or such greater width as may be required for specific rail pads (refer ETD-02-04).

The sleeper base surface shall be rough cast while the top and side surfaces shall be smooth toprevent retention of moisture and foreign material.

Existing sleepers are typically 250mm wide at the base. This dimension is preferred butvariations will be considered.

4.4 Design Parameters

Design parameters for the calculation of minimum sleeper capacity are as generally detailed inAS 1085.14, except that, in clause 4.2.3, the multiple of the impact factor, j, and the static

wheel load, Q, shall be 300 kN.

The load distribution factor shall be determined in accordance with Figure 4.1 of AS 1085.14unless agreed otherwise.

4.5 Installation, Handling and Maintenance

Sleepers must be suitable for efficient transportation on rolling stock used with track laying

machines and be stable for stacking on conventional flat-bed rolling stock or on-site.

Sleepers must be suitable for installation by track laying machines and sleeper insertionequipment of a type used for partial resleepering.

Trackwork fitted with these concrete sleepers must be suitable for maintenance with trackmaintenance equipment. Such equipment may include tamping and regulating machines,

dynamic stabilisers, track adjustment jacks, track lining machines, fastening insertion/removalequipment, ballast shoulder cleaners and undercutting machines.

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-fastened on

completion of the work.

4.6 System Performance

System performance requires the concrete sleeper assembly to function as part of the trackstructure. 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.The thermal expansion and contraction forces act on the continuously welded rails with atemperature range from approximately 10 C to 65 C about a nominal neutral temperature inthe range of 25 C to 45 C. Design neutral temperature is typically 35 C to 38 C.

Pads must possess sufficient edge stiffness to prevent the sleeper tilting (about its longitudinal

axis) in order to resist longitudinal track forces arising from thermal expansion, contraction andrail creep. Pads shall be high-attenuation type as detailed in ARTC Standard ETD-02-04.

Clips must provide enough deflection capacity to accommodate rail movement on the padindefinitely without loss of toe load.

The area of the sleeper bases must be adequate to ensure an even load distribution through theballast bed up to the nominated maximum ballast pressure.
http://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdf

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Sleeper Marking



4.7 Allowance for Retrofit

The longitudinal centre line of the sleepers must have a vertical section of at least 50mm widewhich is clear of any reinforcing steel (excluding the area of fastening). This is to allow for theattachment of ancillary equipment including train stops.

5 Sleeper MarkingThe following marks shall be displayed on each sleeper, with markings being raised or indentedto suit the manufacturer. Note that some are mandatory and some are optional:

Mark of Manufacturer (Optional)

The letters ARTC (Optional)

Year of manufacture (Mandatory)

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

Lettering and marks shall be on the upper surface of the sleeper between the rail seats.

6 Product Approval RequirementsAll new sleeper designs shall be submitted to the ARTC Manager Standards and Systems forproduct approval. As part of the submission, the following data shall be provided by thesupplier:

One set of design calculations which should include the following.

Rail seat load.

Positive and negative resisting moments at the rail seat and at the centre of the sleeper.

Fastening assemblies with all cast-in components.

Tendon and/or reinforcement design stress including strain relaxation.

Tendon and/or reinforcement bond stress including losses from interface bond/anchorage.

Concrete strength including shrinkage creep and curing effects.

The effects on sleeper strength of manufacturing tolerances (eg. concrete shape and

tendon placement) and the design attrition allowance.

Independent design check of the design shall be undertaken by a competent designer, anddetails of this design check and information shall be provided.

Two sets of fully detailed drawings are to be supplied for each combination of sleeper type,fastening assembly and rail size.

The drawing should detail the following:

Sleeper and fastening system dimensions including tolerances.

Tendon type, size, material, number and location.

Cast in Shoulder type, detail and material.

Concrete mixture specification and properties.

The supplier will also be required to provide documentation of testing outcomes as specified inSection 7 and 8 below.

7 Previous Installation ExperienceAll components must be equivalent to existing designs that have been proven in track under

conditions of service similar to those detailed in this performance specification and referenceddocuments. This should include corrugation, rail flow, head check, wheel burn and weld dip rail

head conditions. Reference site details and contact persons able to objectively discuss sleepersystem performance shall be provided.

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Sleeper Performance and Tests in Accordance with AS 1085.14



8 Sleeper Performance and Tests in Accordance

with AS 1085.14

AS 1085.14 2003, Railway track material, Part 14: Prestressed concrete sleepers, Appendix Bsection 2 lists additional information to be provided by the purchaser. For completeness, thefollowing lists each item and provides the required information or cross-refers to this standard

or to referenced documents.

a) AS 1085.14 applies.

b) General information:

i. Australian Rail Track Corporation (ARTC).

ii. The sleepers may be installed anywhere on ARTCs network.

iii. The nominal track gauge is 1435 mm.

iv. Refer to section 4.2 above.

v. The maximum axle load will be 30 t

vi. The annual gross tonnage will be up to 100M.

vii. Speed will be a maximum of 160 km/h for XPT type passenger trains and 115 km/h

for freight trains refer to section 4.2.

viii. Maximum grade is 1:30.

ix. Minimum curve radius is 200 m.

x. Insulation to suit track signalling circuits is required.

xi. Track may be electrified to either 1.5 kV DC or 25 kV AC.

xii. The full range of Australian climatic conditions from alpine to desert may apply.

c) Track information:

(i), (ii), (iii), (iv) ETD-02-01 applies.

d) Sleeper design information:

i. Refer to section 4.4 above

ii. Refer to section 4.2 above.

iii. The preferred sleeper dimensions are set out in Section 4.3. The cross-sectionaldimensions shall be determined such as to meet the requirements of section 4.0above.

iv. The positive and negative moments shall be determined in accordance with section 4

of AS1085.14.

v. Other design requirements are identified in section 4.0 above and ARTC Standard

ETD-02-04 and references and amendments thereto.

e) Fastening design information:

(i) and (ii) refer to ETD-02-04 and references and amendments thereto.

f) A general description of manufacturing procedures shall be provided.
http://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_01_concrete_sleepers_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_01_concrete_sleepers_design.pdfhttp://extranet.artc.com.au/docs/engineering/common_standards/track/etd_02_04_resilient_rail_fastening_heavy_design.pdf

etd 02 03 sleeper

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