AS 1085.14-1997

1 - AS 1085.14-1997 RAILWAY PERMANENT WAY MATERIAL - PRESTRESSED CONCRETE SLEEPERS
4 - PREFACE
5 - CONTENTS
7 - FOREWORD
8 - SECTION 1 SCOPE AND GENERAL
8 - 1.1 SCOPE
8 - 1.2 ALTERNATIVE DESIGN TECHNIQUES AND MATERIALS
8 - 1.3 REFERENCED DOCUMENTS
8 - 1.4 DEFINITIONS
8 - 1.4.1 Administrative definitions
8 - 1.4.2 Technical definitions
9 - 1.5 NOTATION
11 - SECTION 2 MATERIALS
11 - 2.1 CEMENT
11 - 2.2 SUPPLEMENTARY CEMENTITIOUS MATERIALS
11 - 2.2.1 Fly ash
11 - 2.2.2 Slag
11 - 2.2.3 Silica fume
11 - 2.3 AGGREGATES
11 - 2.3.1 General
11 - 2.3.2 Durability
11 - 2.3.3 Alkali aggregate reactivity
11 - 2.4 WATER
11 - 2.5 ADMIXTURES
11 - 2.5.1 Chemical admixtures
11 - 2.5.2 Chlorides
11 - 2.6 PRESTRESSING TENDONS
11 - 2.6.1 Wire tendons
11 - 2.6.2 Strand tendons
12 - 2.7 CONCRETE
12 - 2.7.1 General
12 - 2.7.2 Use of potentially alkali reactive aggregates
12 - 2.7.3 Characteristic compressive strength
12 - 2.7.4 Minimum compressive strength
12 - 2.7.5 Saturated surface-dry density of the concrete
12 - 2.7.6 Total chloride content
13 - SECTION 3 MANUFACTURE OF SLEEPERS
13 - 3.1 GENERAL
13 - 3.2 TOLERANCES
13 - 3.3 MOULDS
13 - 3.3.1 Specifications
13 - 3.3.2 Mould surfaces
13 - 3.4 WORKMANSHIP AND FINISHES
14 - 3.5 BONDING OF TENDONS
14 - 3.6 CONCRETING
14 - 3.6.1 Concrete consistency
14 - 3.6.2 Construction joints
14 - 3.6.3 Curing
15 - 3.7 TRANSFER OF PRESTRESS TO SLEEPERS
15 - 3.7.1 Releasing the tendons
15 - 3.7.2 Cutting of tendons where required
15 - 3.8 MARKING OF SLEEPERS
15 - 3.9 RECORDS OF MANUFACTURE
15 - 3.9.1 Records
15 - 3.9.2 Concrete test results
15 - 3.9.3 Prestressing tendon certificates or test results
15 - 3.9.4 Sleeper load tests
16 - 3.10 STACKING OF SLEEPERS
17 - SECTION 4 DESIGN OF SLEEPERS
17 - 4.1 GENERAL CONDITIONS
17 - 4.1.1 Type and spacing
17 - 4.1.2 Shape and dimensions
17 - 4.1.3 Clear tendon cover
17 - 4.2 DESIGN FORCES
17 - 4.2.1 Vertical wheel load
18 - 4.2.2 Load distribution
19 - 4.2.3 Rail seat load
20 - 4.2.4 Ballast and ballast pressure
20 - 4.2.5 Lateral loads
20 - 4.2.6 Longitudinal loads
20 - 4.3 DESIGN MOMENTS
20 - 4.3.1 General
20 - 4.3.2 Moments at rail seat
21 - 4.3.3 Moments at centre
22 - 4.4 DESIGN SHEARS
22 - 4.5 PERMISSIBLE STRESSES
22 - 4.5.1 Concrete stresses
22 - 4.5.2 Prestressing tendons
23 - 4.6 LOSS OF PRESTRESS
23 - 4.7 DEVELOPMENT LENGTH AND END ZONE
25 - SECTION 5 RAIL FASTENING SYSTEMS
25 - 5.1 SERVICE CONDITIONS
25 - 5.2 FASTENING SYSTEM DESCRIPTION
25 - 5.2.1 Proprietary fastenings
25 - 5.2.2 Type
25 - 5.2.3 Fixing
25 - 5.2.4 Expected life of components
25 - 5.2.5 Materials
26 - 5.2.6 Design
26 - 5.3 FASTENING COMPONENTS
26 - 5.3.1 General
26 - 5.3.2 Marking
26 - 5.3.3 Tolerance
26 - 5.3.4 Rail fastening clips
26 - 5.3.5 Cast-in components
26 - 5.3.6 Insulators
26 - 5.3.7 Rail pads
28 - SECTION 6 TESTING
28 - 6.1 GENERAL
28 - 6.2 TYPE AND PROOF TESTING
28 - 6.2.1 Type tests
28 - 6.2.2 Proof tests
28 - 6.2.3 Test loads
29 - 6.3 CONCRETE TESTING
29 - 6.3.1 General
29 - 6.3.2 Concrete cylinder compressive tests
29 - 6.4 FASTENING SYSTEM TESTING
29 - 6.4.1 Type tests
29 - 6.5 SLEEPER TESTING
29 - 6.5.1 Type tests
30 - 6.5.2 Proof tests
30 - 6.5.3 Failure to pass testing
30 - 6.5.4 Trial assembly of track panel
31 - 6.6 CRITERIA FOR ACCEPTANCE
31 - 6.6.1 Fastening uplift test
31 - 6.6.2 Fastening longitudinal restraint test
31 - 6.6.3 Fastening repeated load test
31 - 6.6.4 Lateral load restraint test
31 - 6.6.5 Fastening insert pull-out test
31 - 6.6.6 Fastening insert torque test
31 - 6.6.7 Fastening insert repeated lateral load test for screwed inserts
31 - 6.6.8 Electrical impedance test
32 - 6.6.9 Electrical short test
32 - 6.6.10 Rail seat vertical load test
32 - 6.6.11 Rail seat repeated load test
32 - 6.6.12 Development length and ultimate load test
32 - 6.6.13 Centre negative bending moment test
32 - 6.6.14 Centre positive bending moment test
33 - APPENDIX A - SPECIAL SLEEPERS AND FASTENINGS
33 - A1 SCOPE
33 - A2 SPECIAL SLEEPER TYPES
33 - A2.1 Dual gauge sleepers
33 - A2.2 Turnout bearers
33 - A2.3 Sleepers with additional rails
35 - A3 MANUFACTURING DETAILS
35 - A4 LOADINGS AND DESIGN
35 - A4.1 Dual gauge sleepers
36 - A4.2 Turnouts and crossovers
36 - A4.3 Sleepers with additional rails (other than dual gauge sleepers)
37 - A5 FASTENINGS
37 - A6 TESTING
37 - A6.1 General
37 - A6.2 Additional fastening tests
39 - APPENDIX B - PURCHASING GUIDELINES
39 - B1 SCOPE
39 - B2 INFORMATION TO BE SUPPLIED BY THE PURCHASER
40 - B3 ADDITIONAL INFORMATION
41 - APPENDIX C - MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD
41 - C1 SCOPE
41 - C2 STATISTICAL SAMPLING
41 - C3 PRODUCT CERTIFICATION
41 - C4 SUPPLIER’S QUALITY SYSTEM
42 - C5 OTHER MEANS OF ASSESSMENT
43 - APPENDIX D - REFERENCED DOCUMENTS
45 - APPENDIX E - BACKGROUND ON DESIGN OF PRESTRESSED CONCRETE SLEEPERS
45 - E1 GENERAL CONDITIONS
45 - E1.1 General track conditions
45 - E1.2 Spacing
46 - E1.3 Shape and dimensions
46 - E2 DESIGN FORCES
46 - E2.1 Vertical load determination
47 - E2.2 Lateral loads
47 - E2.3 Longitudinal loads
47 - E3 DESIGN MOMENTS
48 - E4 SHEAR STRESSES
48 - E5 CONCRETE STRENGTHS
48 - E6 PERMISSIBLE STRESSES
48 - E7 LOSS OF PRESTRESS
48 - E8 BOND AND END ZONE
49 - APPENDIX F - DYNAMIC EFFECTS
49 - F1 INTRODUCTION
49 - F2 TRACK LOADS
49 - F3 TYPES OF LOAD
50 - F4 LOAD LEVELS
50 - F5 CRITERION FOR FAILURE
50 - F6 RAILHEAD IRREGULARITY
50 - F7 ALTERNATIVE SPECIFICATION
51 - F8 TESTING APPARATUS
51 - F9 TEST DATA
51 - REFERENCES
53 - APPENDIX G - TYPICAL FASTENING EVALUATION AND DATA SHEETS
55 - APPENDIX H - FASTENING UPLIFT TEST
55 - H1 SCOPE
55 - H2 APPARATUS
55 - H3 PROCEDURE
55 - H4 REPORT
57 - APPENDIX I - FASTENING LONGITUDINAL RESTRAINT TEST
57 - I1 SCOPE
57 - I2 APPARATUS
57 - I3 PROCEDURE
57 - I4 REPORT
59 - APPENDIX J - FASTENING REPEATED LOAD TEST
59 - J1 SCOPE
59 - J2 APPARATUS
59 - J3 PROCEDURE
59 - J4 REPORT
61 - APPENDIX K - LATERAL LOAD RESTRAINT TEST
61 - K1 SCOPE
61 - K2 APPARATUS
61 - K3 PROCEDURE
61 - K4 REPORT
63 - APPENDIX L - FASTENING INSERT PULL-OUT TEST
63 - L1 SCOPE
63 - L2 APPARATUS
63 - L3 PROCEDURE
63 - L4 REPORT
65 - APPENDIX M - TORQUE TEST
65 - M1 SCOPE
65 - M2 APPARATUS
65 - M3 PROCEDURE
65 - M4 REPORT
66 - APPENDIX N - ELECTRICAL IMPEDANCE AND SHORT TESTS
66 - N1 SCOPE
66 - N2 ELECTRICAL IMPEDANCE TEST
66 - N2.1 Apparatus
66 - N2.2 Procedure
66 - N3 ELECTRICAL SHORT TEST
66 - N3.1 Apparatus
66 - N3.2 Procedure
67 - N4 REPORT
68 - APPENDIX O - FASTENING INSERT LATERAL REPEATED LOAD TEST
68 - O1 SCOPE
68 - O2 APPARATUS
68 - O3 PROCEDURE
68 - O4 REPORT
69 - APPENDIX P - RAIL SEAT VERTICAL LOAD TEST
69 - P1 SCOPE
69 - P2 APPARATUS
69 - P3 PROCEDURE
69 - P4 REPORT
71 - APPENDIX Q - RAIL SEAT REPEATED LOAD TEST
71 - Q1 SCOPE
71 - Q2 APPARATUS
71 - Q3 PROCEDURE
71 - Q4 REPORT
72 - APPENDIX R - DEVELOPMENT LENGTH AND ULTIMATE LOAD TEST
72 - R1 SCOPE
72 - R2 APPARATUS
72 - R3 PROCEDURE
72 - R4 ULTIMATE LOAD
72 - R5 REPORT
73 - APPENDIX S - CENTRE NEGATIVE BENDING MOMENT TEST
73 - S1 SCOPE
73 - S2 APPARATUS
73 - S3 PROCEDURE
73 - S4 REPORT
74 - APPENDIX T - CENTRE POSITIVE BENDING MOMENT TEST
74 - T1 SCOPE
74 - T2 APPARATUS
74 - T3 PROCEDURE
74 - T4 REPORT

Specifies requirements for design, manufacture and installation of prestressed concrete sleepers, and their fastening components for use in railway permanent way. Several test methods are given in appendices, including sleeper bending, fastening tests, electrical impedance and repeated load tests. Information is also given for design of special sleepers.

This Standard sets out requirements for the design, manufacture, testing and installation of prestressed concrete sleepers and their fastening components for use in main line railway systems. It also sets out requirements for electrical performance of rail fastener and sleeper combinations.This Standard also gives requirements and information in Appendix A for special sleepers such as turnout bearers, sleepers with additional rails and dual gauge sleepers and their fastenings for use in special sleepered track.This Standard does not cover -(a) the design of post-tensioned concrete sleepers;(b) the design of duo block concrete sleepers; and(c) the techniques and equipment for the manufacture of concrete sleepers or fastenings.NOTE: Purchasing guidelines are given in Appendix B. Guidance on means for demonstrating compliance with this Standard is given in Appendix C.

First published as AS 1085.14-1990.
Second edition 1997.