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William W. Hay Railroad Engineering Seminar Concrete Crossties and Fastening Systems: Previous Experiences, Current Research, and Future Advances J. Riley Edwards Senior Lecturer RailTEC University of Illinois at Urbana-Champaign 12:00 - 1:30 PM • 1 March 2013 2311 Yeh Center NCEL Sponsored by National University Rail Center A US DOT RITA University Transportation Center

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Page 1: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

William W. Hay Railroad Engineering Seminar

Concrete Crossties and

Fastening Systems:

Previous Experiences,

Current Research, and

Future Advances

J. Riley Edwards

Senior Lecturer – RailTEC

University of Illinois

at Urbana-Champaign

12:00 - 1:30 PM • 1 March 2013

2311 Yeh Center NCEL

Sponsored by

National University Rail Center

A US DOT RITA University Transportation Center

Page 2: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team

William W. Hay Railroad Engineering Seminar

Urbana, IL, USA

1 March 2013

Concrete Crossties and Fastening Systems:

Previous Experiences, Current Research, and

Future Advances

Page 3: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 3 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and

Summary of Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

Page 4: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 4 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and Summary of

Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

Page 5: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 5 Concrete Crossties and Fastening Systems – Hay Seminar

Concrete Crossties – Overview of Use

• Typical Usage:

– Freight Heavy tonnage

lines, steep grades, and

high degrees of curvature

– Passenger High density

corridors (e.g. Amtrak’s

Northeast Corridor [NEC])

– Transit applications

• Number of concrete ties in

North America*:

– Freight 25,000,000

– Passenger 2,000,000

– Transit Significant

quantities (millions)

*Approximate

Page 6: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 6 Concrete Crossties and Fastening Systems – Hay Seminar

Concrete Crosstie and Fastening System Components

Rail Pads

Clips

Fastening Insulators

Concrete Crossties

Shoulder

Page 7: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 7 Concrete Crossties and Fastening Systems – Hay Seminar

Fastening System Components

Shoulder

Insulator

Field Gauge

Rail Pad

Assembly

Clip

Concrete Crosstie

Rail

Page 8: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 8 Concrete Crossties and Fastening Systems – Hay Seminar

Complete System

8-9 ft

56.5 in

8-13 in

6-10 inPrestress

wire or strand

Insulator

Clip

Shoulder insert Tie pad between

rail base and

rail seat

Page 9: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 9 Concrete Crossties and Fastening Systems – Hay Seminar

2012 International Survey Results – Criticality of Problems

Problem (higher ranking is more critical) Average Rank

International Responses

Tamping damage 6.14

Shoulder/fastening system wear or fatigue 5.50

Cracking from center binding 5.36

Cracking from dynamic loads 5.21

Cracking from environmental or chemical degradation 4.67

Derailment damage 4.57

Other (e.g. manufactured defect) 4.09

Deterioration of concrete material beneath the rail 3.15

North American Responses

Deterioration of concrete material beneath the rail 6.43

Shoulder/fastening system wear or fatigue 6.38

Cracking from dynamic loads 4.83

Derailment damage 4.57

Cracking from center binding 4.50

Tamping damage 4.14

Other (e.g. manufactured defect) 3.57

Cracking from environmental or chemical degradation 3.50

Page 10: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 10 Concrete Crossties and Fastening Systems – Hay Seminar

2012 International Survey Results – Research Needs

Research topic (higher ranking is more important) Average Rank

International Responses

Track system design 4.08

Optimize crosstie design 3.93

Fastening system design 3.50

Materials design 2.23

Prevention or repair of rail seat deterioration (RSD) 1.58

North American Responses

Prevention or repair of rail seat deterioration (RSD) 3.60

Fastening system design 3.60

Materials design 3.00

Optimize crosstie design 2.80

Track system design 2.00

Page 11: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 11 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and

Summary of Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

Page 12: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 12 Concrete Crossties and Fastening Systems – Hay Seminar

Concrete Crosstie and Fastener

Research Levels (and Examples)

Materials

Concrete Mix

Design

Rail Seat Surface

Treatments

Pad / Insulator Materials

Components

Fastener Yield Stress

Insulator Post Compression

Concrete

Prestress Design

System

Finite Element Modeling

Full-Scale Laboratory

Experimentation

Field Experimentation

Page 13: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 13 Concrete Crossties and Fastening Systems – Hay Seminar

Current Research Sponsors

• Federal Railroad Administration (FRA)

(Fastening System Design, Performance,

Wear, Fatigue, Cracking, Environmental, etc.)

• Amsted RPS / Amsted Rail, Inc. (Fastening

System Wear and Fatigue)

• Association of American Railroads (AAR)

Technology Scanning Program (RSD and

Fastening System Wear and Fatigue)

• Kansas City Southern (KCS) (Crosstie Design)

• NEXTRANS Region 5 Transportation Center

(RSD)

• National University Rail (NURail) (Fastening

System Wear and Fatigue)

• CN Fellowship in Rail Engineering (RSD)

National University Rail Center

Page 14: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 14 Concrete Crossties and Fastening Systems – Hay Seminar

Materials Experimentation

Large Scale Abrasion Test:

Used to investigate abrasion as a

mechanism leading to rail seat deterioration

(RSD) while varying load magnitude,

displacement, pad material, etc.

Small Scale Abrasion Resistance

Test (SSART):

Evaluate various approaches to

increasing the abrasion resistance of

concrete and determine wear rates

Page 15: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 15 Concrete Crossties and Fastening Systems – Hay Seminar

Component Experimentation

Static Tie Tester:

Used to study the rail seat compression and

bending moment behavior of the concrete

crosstie under static loading conditions

Rail Bending Test:

Used to prove the concept of using the

rail as a built-up load cell using

strain gauges

Page 16: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 16 Concrete Crossties and Fastening Systems – Hay Seminar

System Experimentation - Laboratory

Static Load Testing Machine (SLTM):

Provides a means to study the behavior

of the crosstie and fastening system

under static load

Pulsating Load Testing Machine (PLTM):

Conduct full-scale concrete tie and

fastening system Testing by simulating

various L/V ratios under repeated loads

Page 17: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 17 Concrete Crossties and Fastening Systems – Hay Seminar

System Experimentation - Field

Field installation at

Monticello Railway

Museum (MRM):

Full-scale concrete tie and

fastening system field

preparation testing site

Field Installation at the Transportation

Technology Center (TTC):

Conduct full-scale concrete tie and fastening

system testing in field while varying track

geometry, train type, and speed

Page 18: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 18 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and

Summary of Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

Page 19: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 19 Concrete Crossties and Fastening Systems – Hay Seminar

Current Design Process • Found in AREMA Manual on Railway Engineering

• Based largely on practical experience:

– Lacks complete understanding of failure

mechanisms and their causes

– Empirically derives loading conditions

(or extrapolates existing relationships)

• Can be driven by production and installation practices

• Improvements are difficult to implement without

understanding complex loading environment

Page 20: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 20 Concrete Crossties and Fastening Systems – Hay Seminar

Principles of Mechanistic Design

1. Quantify track system input loads (wheel loads)

2. Qualitatively establish load path (free body diagrams,

basic modeling, etc.)

– Establish the locations for load transfer

3. Quantify loading conditions at each interface /

component (including displacements)

a. Laboratory experimentation

b. Field experimentation

c. Analytical modeling (basic → complex/system)

4. Link quantitative data to component geometry and

materials properties (materials decision)

Page 21: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 21 Concrete Crossties and Fastening Systems – Hay Seminar

Principles of Mechanistic Design (cont.)

5. Relate loading to failure modes (e.g., how does

lateral loading relate to post insulator wear?)

6. Investigate interdependencies through modeling

7. Run parametric analyses

– Materials, geometry, load location

8. Development and testing of innovative designs

– Novel rail pad, sleeper, insulator designs

– Geometry and materials improvements

9. Establish mechanistic design practices

10. Adoption into AREMA Recommended Practices

Page 22: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 22 Concrete Crossties and Fastening Systems – Hay Seminar

Determining System Input Loads

• Quantitative methods of data collection (Step 1):

– Wheel Impact Load Detectors (WILD)

– Instrumented Wheel Sets (IWS)

– Truck Performance Detectors (TPD)

– UIUC Instrumentation Plan (FRA Tie BAA)

• Most methods above are used to monitor rolling stock

performance and assess vehicle health

• Can provide insight into the magnitude and

distribution of loads entering track structure

– Limitations to WILD: tangent track (still need lateral

curve data), good substructure (not necessarily

representative of the broader rail network)

Page 23: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 23 Concrete Crossties and Fastening Systems – Hay Seminar

0 25 50 75 100 125 150 175 200 225 250 275 300

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70

Peak Vertical Load (kN)

Pe

rce

nt

Ex

ce

ed

ed

Peak Vertical Load (kips)

LocomotivesPassenger CoachesFreight WagonsAll Wheels

Vertical Wheel Loads – Shared Infrastructure

Source: Amtrak, Edgewood, MD – November 2010

90%

Page 24: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 24 Concrete Crossties and Fastening Systems – Hay Seminar

UNLOADED FREIGHT CARS

PASSENGER COACHES

LOADED FREIGHT CARS

Source: Amtrak – Edgewood, MD (November 2010)

Effect of Traffic Type on Peak Wheel Load

Page 25: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 25 Concrete Crossties and Fastening Systems – Hay Seminar

Impact Loads and Percent Exceedance

0.1%

𝑰𝒎𝒑𝒂𝒄𝒕 𝑭𝒂𝒄𝒕𝒐𝒓 (𝑰𝑭) =𝑷𝒆𝒂𝒌 𝑳𝒐𝒂𝒅

𝑺𝒕𝒂𝒕𝒊𝒄 𝑳𝒐𝒂𝒅

Amtrak, Edgewood, MD – November 2010

Page 26: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 26 Concrete Crossties and Fastening Systems – Hay Seminar

So What is Our Design Threshold?

Fre

qu

en

cy

Load (e.g. Rail Seat Load)

Threshold #2 Threshold #1

*Need curves for each component / interface and failure mode

Page 27: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 27 Concrete Crossties and Fastening Systems – Hay Seminar

Development of Quantitative Loading Model

Speed

Pe

ak V

ert

ica

l W

he

el L

oa

d

Confidence

interval

Page 28: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 28 Concrete Crossties and Fastening Systems – Hay Seminar

Locomotives

Development of Quantitative Loading Model Conceptual Sketch

Nominal Wheel Load

Pe

ak V

ert

ica

l W

he

el L

oa

d

286k

Freight

Car (Load)

315k

Freight

Car (Load)

Pass.

Coach 1

Pass.

Coach 2

286k

Freight

Car (Empty)

315k

Freight

Car (Empty)

Page 29: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 29 Concrete Crossties and Fastening Systems – Hay Seminar

Establishment of the Qualitative Load Path

Page 30: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 30 Concrete Crossties and Fastening Systems – Hay Seminar

Rail Seat Load Calculation Methodologies

0 5 10 15 20 25 30 35 40 45 50 55

0

2

4

6

8

10

12

14

16

18

20

22

0

10

20

30

40

50

60

70

80

90

100

0 25 50 75 100 125 150 175 200 225 250

Wheel Load (kips)

Ra

il S

ea

t L

oa

d (

kip

s)

Ra

il S

ea

t L

oa

d (

kN

)

Wheel Load (kN)

AREMA

USACE

Average

Kerr

Talbot

Analysis courtesy of Christopher Rapp

Page 31: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 31 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and

Summary of Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

Page 32: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 32 Concrete Crossties and Fastening Systems – Hay Seminar

Large Scale Abrasion Test –

Deterioration Test Results • Consistently able to cause deterioration of concrete due to abrasion

• Concrete deterioration initiated near pad edges and propagates inward

• Heat build up in pad materials at local contact points lead to softening

• Difficult to correlate severity of abrasion to input variables

– Heterogeneity of concrete surface

– Contact angle and pressure distribution

Page 33: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 33 Concrete Crossties and Fastening Systems – Hay Seminar

Mean Coefficient of Friction (COF) – Nylon 6/6

3 kips

5 kips

10 kips

Page 34: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 34 Concrete Crossties and Fastening Systems – Hay Seminar

Mean Coefficient of Friction (COF) –

Nylon 6/6 and Polyurethane (5 kip load)

Polyurethane

Nylon 6/6

Page 35: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 35 Concrete Crossties and Fastening Systems – Hay Seminar

Small-Scale Test for Abrasion Resistance (SSTAR):

Test Setup Overview

• Consists of a powered

rotating steel wheel with

3 lapping rings

– Lapping rings permitted

to rotate about their

own axis

– Vertical load applied

using the dead weights

(4.5 pounds)

– Abrasive sand and

water dispensed

during testing

Page 36: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 36 Concrete Crossties and Fastening Systems – Hay Seminar

Effect of Mineral Admixtures

0

1

2

3

4

5

6

0 20 40 60 80 100

We

ar

Dep

th (m

illi

me

ters

)

Test Duration (minutes)

30% Fly ash

Control

10% Silica fume

5% Silica fume

15% Fly ash

Page 37: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 37 Concrete Crossties and Fastening Systems – Hay Seminar

Effect of Other Variations in Mix Design

0

1

2

3

4

5

6

0 20 40 60 80 100

We

ar

De

pth

(M

illim

ete

rs)

Test Duration (Minutes)

ControlSCC

FRC

MFA

Page 38: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 38 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and

Summary of Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

Page 39: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 39 Concrete Crossties and Fastening Systems – Hay Seminar

FRA Tie and Fastening System

BAA Objectives and Deliverables

• Program Objectives

– Conduct comprehensive international literature review

and state-of-the-art assessment for design and

performance

– Conduct experimental laboratory and field testing,

leading to improved recommended practices for design

– Provide mechanistic design recommendations for

concrete sleepers and fastening system design in the

US

• Program Deliverables

– Improved mechanistic design recommendations for

concrete sleepers and fastening systems in the US

– Improved safety due to increased strength of critical

infrastructure components

– Centralized knowledge and document depository for

concrete sleepers and fastening systems

FRA Tie and Fastener BAA

Industry Partners:

Page 40: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 40 Concrete Crossties and Fastening Systems – Hay Seminar

Data Collection

Document Depository

Groundwork for

Mechanistic Design

International Survey Report

Load Path Map

Parametric Analysis

State of Practice Report

Validated Tie and

Fastening System Model

Laboratory

Study

Modeling

Field

Study

Impro

ved R

ecom

mend

ed P

ractic

es

Comprehensive Literature

Review

International Tie and

Fastening System Survey

Loading Regime (Input)

Study

Rail Seat Load Calculation

Methodologies

Involvement of Industry

Experts

FRA Tie and Fastener Project Structure

Inputs Outputs/Deliverables

Page 41: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 41 Concrete Crossties and Fastening Systems – Hay Seminar

Data Collection

Document Depository

Groundwork for

Mechanistic Design

International Survey Report

Load Path Map

Parametric Analysis

State of Practice Report

Validated Tie and

Fastening System Model

Data Collection

Document Depository

Groundwork for

Mechanistic Design

International Survey Report

Load Path Map

Parametric Analysis

State of Practice Report

Validated Tie and

Fastening System Model

Laboratory

Study

Modeling

Field

Study

Impro

ved R

ecom

mend

ed P

ractic

es

Comprehensive

Literature Review

International Tie and

Fastening System Survey

Loading Regime (Input)

Study

Rail Seat Load

Calculation

Methodologies

Involvement of Industry

Experts

Laboratory

Study

FRA Tie and Fastener Project Structure

Inputs Outputs/Deliverables

Page 42: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 42 Concrete Crossties and Fastening Systems – Hay Seminar

Quantification of Lateral Loads Entering the

Shoulder Face (Insert) • Instrumented shoulder face insert

– Original shoulder face is removed

– Small beam insert replaces removed section

– 4-point bending beam experiment

• Beam strategy is a well-established, successful technology

Page 43: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 43 Concrete Crossties and Fastening Systems – Hay Seminar

Transfer of Lateral Load to Shoulder Face 32.5 kip vertical load, 0.5 L/V ratio

Time (Seconds)

Page 44: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 44 Concrete Crossties and Fastening Systems – Hay Seminar

Percent of Lateral Load Transferred to Shoulder Preliminary Data

Page 45: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 45 Concrete Crossties and Fastening Systems – Hay Seminar

Railseat Pressures Under Different Rail Pads

• Load Applied: 32.5 kip vertical, 16.9 kip lateral (0.52 L/V)

Contact Area (in2) 25.8 19.0 23.9

Max Pressure (psi) 2,925 3,721 2,990

MDPE TPV Two-Part

Pad Assembly

FIELD

GAUGE

Page 46: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 46 Concrete Crossties and Fastening Systems – Hay Seminar

Laboratory Instrumentation • Development and refinement of field instrumentation

• Research with controlled variables to investigate

– Displacement of rail and fastening system

components

– Pressure distribution under different L/V ratios,

support conditions, and fastening system

components

– The effect of dynamic load

• Make recommendations to refine future laboratory tests

Page 47: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 47 Concrete Crossties and Fastening Systems – Hay Seminar

Full Scale Track Response Experimental System

Page 48: William W. Hay Railroad Engineering Seminarrailtec.illinois.edu/wp/.../pdf-archive/Edwards_Hay... · J. Riley Edwards and the entire UIUC Concrete Crosstie Research Team William W

Slide 48 Concrete Crossties and Fastening Systems – Hay Seminar

Full Scale Track Response Experimental System

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Slide 49 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and

Summary of Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

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Slide 50 Concrete Crossties and Fastening Systems – Hay Seminar

Data Collection

Document Depository

Groundwork for

Mechanistic Design

International Survey Report

Load Path Map

Parametric Analysis

State of Practice Report

Validated Tie and

Fastening System Model

Data Collection

Document Depository

Groundwork for

Mechanistic Design

International Survey Report

Load Path Map

Parametric Analysis

State of Practice Report

Validated Tie and

Fastening System Model

Laboratory

Study

Modeling

Field

Study

Impro

ved R

ecom

mend

ed P

ractic

es

Comprehensive

Literature Review

International Tie and

Fastening System Survey

Loading Regime (Input)

Study

Rail Seat Load

Calculation

Methodologies

Involvement of Industry

Experts

Field

Study

FRA Tie and Fastener Project Structure

Inputs Outputs/Deliverables

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Slide 51 Concrete Crossties and Fastening Systems – Hay Seminar

• Lay groundwork for mechanistic design of concrete

sleepers and elastic fasteners

• Quantify the demands placed on each component within

the system

• Develop an understanding into field loading conditions

• Provide insight for future field testing

• Collect data to validate the UIUC concrete sleeper and

fastening system FE model

Goals of Field Instrumentation

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Slide 52 Concrete Crossties and Fastening Systems – Hay Seminar

Areas of Investigation Fasteners/ Insulator

• Strain of fasteners

• Stresses on insulator

• Moments at the

rail seat

• Stresses at rail seat

• Vertical

displacements of

sleepers

Concrete Sleepers

Rail

• Stresses at rail seat

• Strains in the web

• Displacements of web/base

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Slide 53 Concrete Crossties and Fastening Systems – Hay Seminar

Field Instrumentation Map (July 2012) • Full Instrumentation

– Lateral, vertical, and chevron strain gauges on rail

– Embedment and external concrete strain gauges on crosstie

– Matrix based tactile surface sensors at rail seat (at rail seat W)

– Linear potentiometers on rail and crosstie

• Partial Instrumentation

– Vertical strain gauges on rail

– Matrix based tactile surface sensors (at rail seats G and Y)

– Linear potentiometers on crosstie (at rail seats C and G)

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Slide 54 Concrete Crossties and Fastening Systems – Hay Seminar

Instrumented Crosstie Construction

Embedment gauge installed between shoulders on prestress wire

Prestress Wire

Strain Gauges

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Slide 55 Concrete Crossties and Fastening Systems – Hay Seminar

Instrumented Crosstie Construction

Placement and protection of

surface strain gauges

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Slide 56 Concrete Crossties and Fastening Systems – Hay Seminar

TTCI Field Testing Locations

5 degree curve spiral

Balance Speed = 33 mph

Tangent

Speeds up to 105 mph Railroad Test

Track (RTT)

High-Tonnage Loop (HTL)

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Slide 57 Concrete Crossties and Fastening Systems – Hay Seminar

Objectives of Field Experimental Program

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Slide 58 Concrete Crossties and Fastening Systems – Hay Seminar

Loading Environment

• Track Loading Vehicle (TLV)

– Static

– Dynamic

• Track modulus

• Freight Consist

– 6-axle locomotive (393k)

– Instrumented car

– Nine cars

• 263, 286, 315 GRL Cars

• Passenger Consist

– 4-axle locomotive (255k)

– Nine coaches

• 87 GRL

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Slide 59 Concrete Crossties and Fastening Systems – Hay Seminar

Installation of Clip by Professors (“experts”)

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Slide 60 Concrete Crossties and Fastening Systems – Hay Seminar

Fully Instrumented Rail Seats

Instrumented

Low Rail

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Slide 61 Concrete Crossties and Fastening Systems – Hay Seminar

Instrumented Low Rail

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Slide 62 Concrete Crossties and Fastening Systems – Hay Seminar

Field-side Instrumentation

Vertical Sleeper

Displacement

Base Displacement

Vertical Web

Strain

Clip Strain

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Slide 63 Concrete Crossties and Fastening Systems – Hay Seminar

Gauge-side Instrumentation

Lateral Rail

Displacement

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Slide 64 Concrete Crossties and Fastening Systems – Hay Seminar

Data Acquisition System

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Slide 65 Concrete Crossties and Fastening Systems – Hay Seminar

Tangent Track (RTT) – Passenger Train

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Slide 66 Concrete Crossties and Fastening Systems – Hay Seminar

Tangent Track (RTT) – Freight Train

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Slide 67 Concrete Crossties and Fastening Systems – Hay Seminar

0

2

4

6

8

10

12

14

16

18

0

10

20

30

40

50

60

70

80

24 (15) 48 (30) 66 (45) 97 (60)

Late

ral Load (

kip

s)

Late

ral Load (

kN

)

Train Speed, km/h (mph)

Lateral Loads on Tangent Track (Freight)

Lateral

Loads

Max

Median Lower quartile

Upper quartile

Leading axles of a 10-car freight

train (30, 33, and 36t axle loads).

Minimum

Left Right

Tangent

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Slide 68 Concrete Crossties and Fastening Systems – Hay Seminar

0

2

4

6

8

10

12

14

16

18

0

10

20

30

40

50

60

70

80

24 (15) 48 (30) 66 (45) 97 (60)

Late

ral Load (

kip

s)

Late

ral Load (

kN

)

Train Speed, km/h (mph)

Lateral Loads on Tangent Track (Freight)

Lateral

Loads

- No correlation

between lateral loads

and train speed on

tangent track.

Leading axles of a 10-car freight

train (30, 33, and 36t axle loads).

Left Right

Tangent

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Slide 69 Concrete Crossties and Fastening Systems – Hay Seminar

RTT Curved Instrumentation – Train Pass

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Slide 70 Concrete Crossties and Fastening Systems – Hay Seminar

Lateral Loads Acting on a Curve Track

HIGH LOW

Lateral

Loads

5° curve

Leading axles of a 10-car freight

train (30, 33, and 36t axle loads).

0

2

4

6

8

10

12

14

16

18

0

10

20

30

40

50

60

70

80

3 (2) 24 (15) 48 (30) 66 (45)

Late

ral Load (

kip

s)

Late

ral Load (

kN

)

Train Speed, km/h (mph)

- Median load is ~5.5

times larger than

what was recorded in

tangent track.

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Slide 71 Concrete Crossties and Fastening Systems – Hay Seminar

Global Track Deflections Under

Passage of Freight Train

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Slide 72 Concrete Crossties and Fastening Systems – Hay Seminar

Vertical Displacements of Crossties (HTL)

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0 10 20 30 40

Ver

tica

l Dis

pla

cem

en

t (i

n)

Vertical Load (kips)

HIGH

LOW

U

S

W

E

C

G

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Slide 73 Concrete Crossties and Fastening Systems – Hay Seminar

0 10 20 30 40 50 60

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0 50 100 150 200 250 300

Vertical Load (kips)

Ver

tica

l Tie

Def

lect

ion

(in

)

Ver

tica

l Sle

eper

Def

lect

ion

(cm

)

Vertical Load (kN)

24 km/h (15mph)

48 km/h (30mph)

97 km/h (60mph)

100% (Static Deflection)

90%

80%

60%

70%

50%

Deflections from train passes do not

exceed static response: typically

60% (passenger) and 75% (freight)

Effect of Train Speed on Sleeper

Deflection (cont.)

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Slide 74 Concrete Crossties and Fastening Systems – Hay Seminar

0 20 40 60 80 100

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0 50 100 150

Speed (mph)

Ve

rtic

al T

ie D

eflection (

in)

Vert

ical S

leeper

Deflection (

cm

)

Speed (km/h)

Freight

Passenger

No significant relationship between

train speed and sleeper deflection

Effect of Train Speed on

Sleeper Displacement

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Slide 75 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and

Summary of Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

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Slide 76 Concrete Crossties and Fastening Systems – Hay Seminar

Data Collection

Document Depository

Groundwork for

Mechanistic Design

International Survey Report

Load Path Map

Parametric Analysis

State of Practice Report

Validated Tie and

Fastening System Model

Data Collection

Document Depository

Groundwork for

Mechanistic Design

International Survey Report

Load Path Map

Parametric Analysis

State of Practice Report

Validated Tie and

Fastening System Model

Laboratory

Study

Modeling

Field

Study

Impro

ved R

ecom

mend

ed P

ractic

es

Comprehensive

Literature Review

International Tie and

Fastening System Survey

Loading Regime (Input)

Study

Rail Seat Load

Calculation

Methodologies

Involvement of Industry

Experts

Modeling

FRA Tie and Fastener Project Structure

Inputs Outputs/Deliverables

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Slide 77 Concrete Crossties and Fastening Systems – Hay Seminar

Concrete Sleeper and Fastening System

Rail

Concrete Sleeper

Clip Insulator

Shoulder

Pad &

Abrasion

frame

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Slide 78 Concrete Crossties and Fastening Systems – Hay Seminar

Component Modeling

Rail Clip Rail Clip model

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Slide 79 Concrete Crossties and Fastening Systems – Hay Seminar

Component Modeling: Validation

• Clip Model

Mises stress contour

( Clamping force = 11.6 kN) Clamping force-displacement curves

Stress concentration due

to support 0

5000

10000

15000

20000

25000

30000

35000

0 0.02 0.04Rail

seat

Cla

mp

ing

fo

rce (

N)

Displacement (m)

Clip Model

Manufacturer Data

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Slide 80 Concrete Crossties and Fastening Systems – Hay Seminar

Static loading of the model

Deformation contour

Component Modeling: Concrete Sleeper

and Ballast

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Slide 81 Concrete Crossties and Fastening Systems – Hay Seminar

System Modeling - COF Estimation

Clip & Insulator: 0.25

Shoulder & Insulator: 0.25

Rail & Pad: 0.50

Plate and Tie: 0.25

Pin Support

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Slide 82 Concrete Crossties and Fastening Systems – Hay Seminar

Laboratory Test Validation

System Modeling: Single-Sleeper Modeling

Fixed at bottom

Symmetric

BC in the

middle

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Slide 83 Concrete Crossties and Fastening Systems – Hay Seminar

System Model: Multiple-Sleeper Modeling

• Track loading vehicle (TLV) applying vertical and lateral loads to the

track structure in field

• The symmetric model including 5 Sleepers

Simplified model:

Fastening system were replaced

by BCs and pressure

Detailed model with the fastening system

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Slide 84 Concrete Crossties and Fastening Systems – Hay Seminar

System Modeling: Lateral Load Path

0

2000

4000

6000

8000

10000

12000

14000

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Forc

e (

lb)

L/V Ratio

Friction (F1)

Insulator

Post (F2)

Lateral

Load

Friction + Insulator Post

+Shoulder to Pad

Shoulder

to Pad

(F3)

F1F3

F2

Lateral Load

36 Kip

Vertical Load

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Slide 85 Concrete Crossties and Fastening Systems – Hay Seminar

Future System-Level Modeling Work

• Additional comparisons: More measurements on the lab

testing set-ups will be deployed and compared with the models

• Large-scale modeling: More Models will be built to look into

the distribution of loading among multiple ties and the discrete

support condition of rail

• Realistic loading: More load types (vertical, lateral, and

longitudinal loads) and load forms (static and dynamic load) will

be applied to the track system to better simulate the actual

loading environment

• Parametric studies: Parametric studies about material

properties and geometric dimensions will be conducted using

the model

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Slide 86 Concrete Crossties and Fastening Systems – Hay Seminar

Outline • Background and Research Justification

• RailTEC Concrete Crosstie Research

• Mechanistic Design Introduction

• Key Research Thrust Areas and

Summary of Results

– Materials Research

– Laboratory Instrumentation

– Field Instrumentation

– Analytical Methods (FEA)

• Future Work

• Acknowledgements

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Slide 87 Concrete Crossties and Fastening Systems – Hay Seminar

Current Research Thrust Areas

• Continued data analysis to understand the governing mechanics

of the system by investigating the:

– elastic fastener (clamp) strain response

– number of ties effected simultaneously

– bending modes of the sleepers

– pressure magnitude and distribution at the rail seat

• Continued comparison and validation of the UIUC tie and

fastening system finite element model (Chen, Shin)

• Preparation for instrumentation trip (May 2013)

– Focus on lateral load path by gathering

• relative lateral sleeper displacements

• global lateral sleeper displacements

• load transferred to the clamp, insulator-post, and shoulder

• Small-scale, evaluative tests on Class I Railroads

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Slide 88 Concrete Crossties and Fastening Systems – Hay Seminar

The Future of Concrete Crossties and

Fastening Systems…

• Mechanistic design and materials choices

– Concrete materials (e.g. mineral and chemical admixtures, coatings, etc.)

– Improved plastics (e.g. Nylon abrasion frame, polyurethane rail pad, etc.)

– Other advanced materials (e.g. tie armor)

• Considerations of friction at all system interfaces, and how it relates to overall system design

– Improved understanding of component interaction

• Lowering the stress state of the tie and fastening system:

– Larger rail seats

– Under Sleeper Pads (USP)

• Improved design validation tests (AREMA C-30 Modifications)

• System level design, once components are better optimized

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Slide 89 Concrete Crossties and Fastening Systems – Hay Seminar

RailTEC Concrete Tie Research Team

• Previous Personnel

– 3 Graduate Research Assistants

– 6 Undergraduate Research Assistants

• Current Personnel

– 9 Graduate Research Assistants

– 1 Post Doctoral Researcher

– 1 Visiting Scholar

– 6 Undergraduate Research Assistants

– 2 Research Engineers

– 4 Professors

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Slide 90 Concrete Crossties and Fastening Systems – Hay Seminar

Acknowledgements

FRA Tie and Fastener BAA Industry Partners:

National University Rail Center

Research Sponsors:

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Slide 91 Concrete Crossties and Fastening Systems – Hay Seminar

Other Supporting Organizations

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Slide 92 Concrete Crossties and Fastening Systems – Hay Seminar

Key Industry Experts and Individuals

– Amsted RPS / Amsted Rail, Inc.: Jose Mediavilla, Dave Bowman, Brent Wilson, Thai

Nguyen, Chase Nielsen, Brent Wilson

– BNSF Railway: John Bosshart, Tom Brueske, Hank Lees, Seth Ogan, Hal

Lewandoski,

– Union Pacific Railroad: Kevin Hicks, Eric Gehringer, Dwight Clark, Steve Ashmore

– Vossloh: Winfred Boesterling, Michael Steidl, Rigi Chackanad, Chris Kenyon

– Pandrol Track Systems: Bob Coats, Scott Tripple, Dave Kangas, Frank Brady

– CXT Concrete Ties: Pelle Duong, Jim Parsley, Mark Hammons, Vince Petersen

– VAE Nortrak: Steve Mattson

– Rocla Concrete Tie: Al Smith (retired), Rusty Crowley, Pedro Lemmertz

– GIC: Mauricio Gutierrez, Carlos Gutierrez

– TTCI: Dave Davis, Richard Reiff, Michael Brown, Ken Laine

– Engis Corporation: Peter Kuo, Steven Griffin

– Others: Jerry Rose, Tim Johns, Bill Riehl, Brandon Hunter, Al Smith, Fabian

Weber, John Clark, Jim Gauntt, Michael Land, Rob Loomis, Jeff DeGross

– UIUC: Tim Prunkard, Don Marrow, Darold Marrow, Marc Killion, Ernie Barenberg,

Greg Banas, Jim Meister, Dauren Kumarbekov, Josh Brickman, Steven

Jastrzebski, Michael Wnek, Andrew Kimmle, Calvin Nutt, Alex Ng, Kris Gustafson,

Chris Naranjo, Matthew Greve, Brad Jones, Dan Rivi, Alex Schwarz, Matthew

Jarrett, Scott Schmidt, Andrew Stirk

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Slide 93 Concrete Crossties and Fastening Systems – Hay Seminar

Questions?

Riley Edwards

Senior Lecturer

Department of Civil and Environmental Engineering

University of Illinois, Urbana-Champaign

Email: [email protected]