In a railway track, reinforced concrete sleepers are laid on the ballast layer of the upper structure of the track and ensure that the relative position of the rail threads remains constant, they receive pressure directly from the rails or from intermediate fastenings and transfer it to the undersleeper base (usually the ballast layer).

Reinforced concrete sleeper Ш-1-1 - Drawing

Reinforced concrete sleepers

Reinforced concrete sleepers are divided into several categories depending on the possibilities of their use. What is common is the production principle. Ready-made reinforced concrete sleepers are beams made of reinforced concrete that have previously undergone a tension procedure (to increase strength). Sleepers are produced taking into account resistance to cracking and are frost-resistant. The design life of reinforced concrete sleepers is approximately 50 years.

Reinforced concrete sleeper Ш-1-1 (grade 1)– element of the upper structure of the railway track. It is a beam made of stressed reinforced concrete. Heavy concrete of the highest category is used in production.

Compared to wooden sleepers, a reinforced concrete product has the highest performance characteristics: increased strength, resistance to cracking, frost resistance, long service life (up to 50 years).

This type of sleeper Ш-1-1 designed for terminal-bolt rail fastening of the design unit with bolted fastening of the lining to the sleeper. Used for laying broad gauge railways (1520 mm), with rails P50, P65, P75.

Reinforced concrete sleepers Ш-1-1 are much heavier and stronger than wooden ones, therefore they are used in the construction of highways and other routes with high traffic.

The only drawback of such products is their high cost.

During the existence of railways, supports for sleepers were made from various materials. There were stone ones, but stone is difficult to process, quickly cracks and becomes unusable. Durable wooden sleepers are tarred to protect against the negative effects of weather conditions. But after a while they also demanded either replacement or repair of the railway tracks. Today, reinforced concrete structures are rightfully considered the material of the future for the manufacture of supports for sleepers and foundations for buildings and structures. A foundation made of reinforced concrete sleepers is used for buildings of all possible complexity and number of storeys on any type of soil. However, it is worth considering that this product weighs a lot.

Definition

Reinforced concrete sleepers have the form of a rail support, the manufacture of which will require beams with varying sizes and cross-sectional shapes. Concrete rail supports are reinforced with steel wire, the diameter of which depends on the modification. When working with reinforced concrete sleepers, the following requirements are imposed on their production technology:

preparing concrete mortar requires a uniform consistency;
for the necessary transmission of stress, the material must have appropriate strength;
When manufacturing products, they adhere to the exact dimensions and shapes that are important for reinforced concrete sleepers at the junction with the rails.

Where are they used?

Nowadays, everyone wants to save money - used sleepers provide this opportunity when building your own home.

Reinforced concrete sleepers are used in the construction of foundations and railway tracks. Due to different natural operating conditions and varied mechanical loads on products, increased requirements are adhered to in the manufacture of reinforced concrete supports. This will increase the service life, which under favorable conditions of use will reach sixty years. Posts made using prestressed concrete outshine common wood posts everywhere due to their strength, durability and speed of installation.

Advantages and disadvantages

Reinforced concrete sleepers have the following advantages:

long service life;
sufficient resistance to the negative effects of environmental factors;
no possibility of rotting during operation;
resistance to various mechanical loads;
low price category;
installation and installation do not require large physical costs;
do not require large maintenance costs during operation;
Due to the fact that the width and length of the product are perfectly even, convenient transportation and unloading is ensured.

Reinforced concrete sleepers have the following disadvantages:

The need for periodic inspection of railway tracks due to fatigue failure of a structure made of concrete.
The sleeper weighs 0.27 tons, which means that manual installation of the products is impossible. Thus, due to the heavy weight, there is a need for specialized equipment. Concrete structures, unlike wood products, which weigh less, are mounted with special mechanisms - sleeper layers.
The need to use elastic pads that reduce the rigidity of the product.
Reinforced concrete sleepers have high electrical conductivity, which requires the use of insulation.

Types

Reinforced concrete sleepers are divided into the following types, which depend on resistance to possible cracks, quality and the exact width, length and other dimensions of the product:

First class support.
Second grade support. It is characterized by a low degree of resistance to cracks, geometric dimensions do not require high requirements.

Depending on the type of rail fastening, there are the following types:

Ш-1, with a separate type clamp-bolt connection, which is fixed to the support using a gasket and a bolt.
Sh-2 of an inseparable type of fastening.
Sh-3 are similar to Sh-2 supports, but differ in the method of fastening.

Reinforced concrete sleepers vary in class, the presence of electrical insulation and the type of reinforcement used. Reinforced concrete sleepers have differences in electrical insulation parameters:

isolated;
non-insulated, without insulating liners.

Production technology

Regardless of the area of use, reinforced concrete supports are made with the same strength and performance properties. There are four types of support manufacturing technology:

Carousel type followed by mold removal. It consists of preparing the mixture and pouring it into molds, where it is further compacted. Remove the supports from the container after the solution has completely hardened and reached its maximum strength. For manufacturing, cassette structures are used, which accommodate six supports. To achieve the required adhesion and provide prestress, reinforcement is used, with the help of which the stress is transferred to the surface of the concrete. Upon completion of the product, the mold is removed and started for the next production.
Linear. This type of manufacturing a reinforced concrete support involves a linear technology, which requires a conveyor on which the forms are placed in a certain sequence. The length of the installed forms reaches one hundred meters. The sides of the container are covered with specially designed devices, which are also capable of transmitting voltage to the reinforcement. As the mortar sets, stress is transferred to the surface of the concrete.
Dismantling of forms with further stress. This type of manufacturing of reinforced concrete supports requires the installation of templates, with the help of which the location of steel reinforcement is determined. The containers are filled with concrete mortar and compacted. While the solution is setting, the pins are immersed in it. After some time, the mold and template are removed.
Dismantling forms with prestressing is the same technology as when dismantling forms with further tension, only instead of pins, frames are used that provide a tension force in the product.

A sleeper is a support for railway rails that maintains their relative position unchanged. It takes the pressure from their weight and transfers it to the sleeper base, consisting of a layer of ballast made of crushed stone or concrete, then to the ground. It is made of wood, plastic, steel, reinforced concrete. They are installed on every kilometer of tracks in quantity (three options): 1600 on secondary roads, 1840 or 2000.

Precast concrete products have found particularly wide application in the construction of continuous (velvet) railway tracks. These are roads on which the distance between rail joints is much greater than the length of a standard rail (25 m). Such tracks differ from conventional ones in the higher cost of installation work due to the weight of the elements, but they provide maximum train speed, convenience for passengers, and reduced maintenance costs.

Sleepers are solid beams (bars) of variable cross-section with platforms for installing rails. They are made from stressed reinforced concrete. This is a structure with prestressed (prestressed) steel reinforcement inside. It differs from conventional reinforced concrete products in its ability to withstand significant tensile loads and prevent the appearance of cracks and splits under their influence. This material is also called prestressed (labeled polyconcrete reinforced concrete). Its use allows the use of smaller products, saving on reinforcement, concrete and transportation costs, and simplifies installation. Weight of 1 piece - 270-285 kg (depending on the weight and number of reinforcing bars).

The production of rail supports is carried out in accordance with the requirements of GOST 10629-88 and 54747-2011. Standard dimensions of a reinforced concrete support: length - 2700 mm, width - 300, height - 230, height in the middle section - 160 mm, height at the ends - 185 mm.

Concrete is used with strength grades from B40 (M500) and higher, frost resistance grades of at least F200. As a filler for the mixture, only crushed stone from natural stone or gravel with a grain size of 5-20 mm is used. By agreement with the buyer, in order to reduce the cost per unit, it is allowed to add a fraction of 20-40 mm in an amount of no more than 10% of the volume of the main one (5-20).

For reinforcement in the production of these reinforced concrete structures, periodic or smooth carbon steel products are used:

cold-deformed wire with a diameter of 3 to 8 mm;
cold-deformed rod reinforcement with a diameter of 8 to 10;
hot-rolled and heat-treated rod reinforcement from 8 to 10;
reinforcing ropes from 6 to 14.

Smooth reinforcement can only be used in conjunction with end anchors.

Advantages and disadvantages

Advantages of reinforced concrete sleepers:

long service life - at least 30 years;
no rotting or corrosion;
resistance to atmospheric and mechanical influences;
high resistance to movement;
simplicity of installation technology;
dimensional accuracy, weight stability;
possibility of use on the busiest sections of tracks;
dismantling and reinstallation.

Disadvantages of reinforced concrete supports:

weight of 1 piece - not less than 270 kg;
the need to use special equipment;
relatively high price of a new product;
increased rigidity, require special elastic gaskets;
the possibility of destruction of concrete, the need for periodic inspection;
high electrical conductivity, use of insulation.

Kinds

On the platform for installing rails (under-rail platform) there are holes for fastening to the rail and connections to the adjacent support.

Sleepers are classified according to the type of rail fastening:

Ш-1-1 - separate terminal-bolt fastening type KB, with an angle of inclination of the thrust edges of the under-rail platforms of 55°;
Ш-1-2 - separate terminal-bolt type, with an angle of inclination of the thrust edges of the under-rail platforms of 72°;
Sh-2 - inseparable terminal-bolt fixation with bolted fastening to the gasket or rail;
Ш-3 - continuous terminal-bolt fixation with bolt fastening to the rail;
Sh-5-DF - screw-dowel fastening;
ShS-ARS - anchor rail;
Pandarol-350 (Fastclip) - have a special anchor fastening developed by the British company of the same name for high-speed (350 km/h) and heavy-duty railway traffic.

According to the features of application and installation, the following types of reinforced concrete rail supports are distinguished:

pavement (M) - for laying on bridges;
shuttle (CH) - for shuttles on bridges;
for curved sections (K) - radius less than 350°;
Sh-3-D 750 - for children's railway (for a track width of 750 mm with rails of type R-43);
transformer - for constructing transfer paths for power transformers at electrical substations, differs from other types in that it has a rectangular cross-section along the entire length;
bars for turnouts;
half sleeper - for rail tracks intended for moving cranes along them;
for sections with a combination of two different track widths - two varieties: for three or four rail lines.

To ensure insulation, sleeper manufacturers offer products with special void-forming liners.

Depending on the dimensional accuracy, quality of the concrete surface and resistance to cracking, rail supports are classified into two grades. The products of the second can be purchased for use on access roads, stations, other lightly loaded tracks of class 5 and internal roads of industrial enterprises.

Before purchasing a batch of reinforced concrete rail supports, it is recommended to inspect several sleepers. There should be a stamp with markings on the top surface of a quality product. It contains the trademark or abbreviated name of the manufacturer. The end part is marked with a quality control inspection mark and the batch number. Every fifth element indicates the last two digits of the year of manufacture.

Products of the second grade (in terms of crack resistance and geometry) are supplied only at the request of the buyer. A transverse line 1.5-2 cm wide is applied at both ends with indelible paint. If there are two such stripes on each side, it means that the sleeper does not meet the standard requirements even for the second grade.

Be sure to evaluate the number and nature of defects. Allowed presence:

imprints from welds on the longitudinal edges of under-rail areas;
traces at the ends - no more than 5 mm deep.

Not allowed:

sagging in the bolt channels, preventing their installation and free rotation;
surges on under-rail areas;
turning bolts;
cracks;
protruding reinforcement rods (if wire was used for reinforcement, then its ends should extend beyond the end by no more than 2 cm).

Maximum permissible dimensions of cavities and beads on reinforced concrete sleepers of the first grade:

For the second grade, defects with dimensions twice as large as those of the first are allowed.

Definition

preparing concrete mortar requires a uniform consistency;
for the necessary transmission of stress, the material must have appropriate strength;
When manufacturing products, they adhere to the exact dimensions and shapes that are important for reinforced concrete sleepers at the junction with the rails.

Where are they used?

Nowadays, everyone wants to save money - used sleepers provide this opportunity when building your own home.

Advantages and disadvantages

Reinforced concrete sleepers have the following advantages:

long service life;
sufficient resistance to the negative effects of environmental factors;
no possibility of rotting during operation;
resistance to various mechanical loads;
low price category;
installation and installation do not require large physical costs;
do not require large maintenance costs during operation;
Due to the fact that the width and length of the product are perfectly even, convenient transportation and unloading is ensured.

Reinforced concrete sleepers have the following disadvantages:

The need for periodic inspection of railway tracks due to fatigue failure of a structure made of concrete.
The sleeper weighs 0.27 tons, which means that manual installation of the products is impossible. Thus, due to the heavy weight, there is a need for specialized equipment. Concrete structures, unlike wood products, which weigh less, are mounted with special mechanisms - sleeper layers.
The need to use elastic pads that reduce the rigidity of the product.
Reinforced concrete sleepers have high electrical conductivity, which requires the use of insulation.

Types

Reinforced concrete sleepers are divided into the following types, which depend on resistance to possible cracks, quality and the exact width, length and other dimensions of the product:

First class support.
Second grade support. It is characterized by a low degree of resistance to cracks, geometric dimensions do not require high requirements.

Depending on the type of rail fastening, there are the following types:

Ш-1, with a separate type clamp-bolt connection, which is fixed to the support using a gasket and a bolt.
Sh-2 of an inseparable type of fastening.
Sh-3 are similar to Sh-2 supports, but differ in the method of fastening.

isolated;
non-insulated, without insulating liners.

Production technology

Regardless of the area of use, reinforced concrete supports are made with the same strength and performance properties. There are four types of support manufacturing technology:

Carousel type followed by mold removal. It consists of preparing the mixture and pouring it into molds, where it is further compacted. Remove the supports from the container after the solution has completely hardened and reached its maximum strength. For manufacturing, cassette structures are used, which accommodate six supports. To achieve the required adhesion and provide prestress, reinforcement is used, with the help of which the stress is transferred to the surface of the concrete. Upon completion of the product, the mold is removed and started for the next production.
Linear. This type of manufacturing a reinforced concrete support involves a linear technology, which requires a conveyor on which the forms are placed in a certain sequence. The length of the installed forms reaches one hundred meters. The sides of the container are covered with specially designed devices, which are also capable of transmitting voltage to the reinforcement. As the mortar sets, stress is transferred to the surface of the concrete.
Dismantling of forms with further stress. This type of manufacturing of reinforced concrete supports requires the installation of templates, with the help of which the location of steel reinforcement is determined. The containers are filled with concrete mortar and compacted. While the solution is setting, the pins are immersed in it. After some time, the mold and template are removed.
Dismantling forms with prestressing is the same technology as when dismantling forms with further tension, only instead of pins, frames are used that provide a tension force in the product.

Installation, repair and disposal of sleepers

The installation of railway tracks has the following features:

Reinforced concrete supports and rails are installed on a pre-prepared surface, which consists of soil, sand and crushed stone. To preserve the sleepers during operation and the passage of trains over them, it is important to preserve the top layer of earth by installing sand strips.
A reinforced concrete support weighs a lot, and an ordinary worker cannot lift such a weight of the structure; installation is carried out using mechanized equipment. This approach reduces the use of physical force and reduces the cost of installing products. The mechanized complex also reduces the time for laying the railway.
To use reinforced concrete sleepers for fifty years, it is important to diagnose the tracks, which will identify deformations and breakdowns. The fastening elements are checked to ensure that there is no breakage, as this could lead to disruption of the fixation of the lining, which makes sounds as the train passes along the tracks.
Failure to timely detect the failure of fasteners leads to the appearance of cracks and partial or complete breakage of the sleeper.
When the service life of the product has expired or the reinforced concrete support has become unusable due to possible destruction, the sleeper is disposed of. Disposal occurs with a jaw crusher, with the help of which the product is crushed to the size of crushed stone of a small fraction or medium fraction. The recycled products are subsequently used to fill holes.

Repairing reinforced concrete sleepers involves identifying and eliminating defects and damage. Seal chips, potholes, sinkholes and cracks. When a breakdown is repaired, train traffic does not stop; the workplace is fenced off with a special signal sign. Major repairs are carried out between repairs, where sleepers do not need to be changed, repairs are carried out using track machine stations according to prepared individual projects and calculations. Repair of reinforced concrete supports is divided into:

capital;
average;
lifting;
reconstruction.

By type of top installation: laying on new crushed stone or on old crushed stone. To enhance the power and durability of tracks, in the process of repairing damaged parts, under-rail bases of various designs are used.

Conclusion

The use of reinforced concrete supports is relevant all over the world; the demand for such products is constantly growing. After all, supports made of reinforced concrete, despite their heavy weight, have incomparable strength, reliability and durability.

And the cost of materials and ease of manufacturing products increases the popularity of using reinforced concrete sleepers in the world of construction.

kladembeton.ru

Reinforced concrete sleepers

Reinforced concrete sleepers are reinforced concrete beams of variable cross-section.

Such beams have platforms for installing rails, as well as holes for rail and sleeper fastening bolts. The main advantage of reinforced concrete sleepers is their almost unlimited service life. The products are characterized by high mechanical strength and are not subject to rotting. They can be reused, as well as on heavily loaded sections of the track.

Flaws:

high cost and weight
insufficient rigidity
possibility of fatigue failure of concrete.

Reinforced concrete sleeperDESCRIPTIONPRICE

APPENDIX 2

SPACER

Material - St 3.

Thickness - 1 mm.

Weight - 0.037 kg.

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APPENDIX 3

Information

LIST OF DEVICES, INDICATORS AND TEMPLATES

TO CONTROL THE GEOMETRICAL PARAMETERS OF SLEEPERS

To control the geometric parameters of reinforced concrete sleepers, it is recommended to use a set of devices, indicators and templates developed by the Industroyproekt Institute and adopted by the USSR Ministry of Construction Materials Industry.

Ш1-1 naked GOST 32.152-2000

Request a price

Sh1-1 used bare GOST 32.152-2000

Dimensions (L/W/H) mm 2700/300/230 Weight 250. kg

Request a price

Reinforced concrete anchor sleeper subtype ShS-ARS

Dimension (D) mm 2700 Weight 259 kg

Request a price

Reinforced concrete anchor sleeper with counter-angle fastening elements for bridges of the Sh-ARS-M subtype

Dimension (D) mm 2700

GOST 10629-88

Group Zh83

INTERSTATE STANDARD

REINFORCED CONCRETE SLEEPERS, PRESTRESSED

FOR 1520 mm GAUGE RAILWAYS

Specifications

Prestressed reinforced concrete sleepers for 1520 mm gauge railways.

Specifications

MKS 91.080.40

OKP 58 6411

Date of introduction 1990-01-01

INFORMATION DATA

1. DEVELOPED AND INTRODUCED by the USSR Ministry of Railways

2. APPROVED AND ENTERED INTO EFFECT by Resolution of the State Construction Committee of the USSR dated November 21, 1988 N 228

3. INSTEAD GOST 10629-78

4. REFERENCE REGULATIVE AND TECHNICAL DOCUMENTS


Designation of the referenced technical document	Item number
GOST 8.326-89	3.13
GOST 7348-81	1.3.8
GOST 7392-2002	1.3.7
GOST 10060.0-95 - GOST 10060.4-95	3.2
GOST 10180-90	3.1
GOST 13015-2003	1.3.3, 1.4.1, 2.1, 3.4, 3.7, 4.1
GOST 16017-79	3.8
GOST 18105-86	3.1
GOST 22362-77	3.3
GOST 23009-78	1.2.3
GOST 23616-79	2.4
GOST 25706-83	3.11
GOST 26633-91	1.3.2, 1.3.7
TU 14-4-1471-87	1.3.8

5. EDITION (July 2004) with Amendment (IUS 5-90)

This standard applies to reinforced concrete prestressed sleepers for railway tracks with a rail gauge of 1520 mm width and rails of types P75, P65 and P50, on which the standard rolling stock of the general railway network of the USSR operates.

1. TECHNICAL REQUIREMENTS

1.1. Sleepers should be manufactured in accordance with the requirements of this standard according to technological documentation approved in the prescribed manner.

1.2. Main parameters and dimensions

1.2.1. Depending on the type of rail fastening, sleepers are divided into:

Ш1 - for separate terminal-bolt rail fastening (KB type) with bolted attachment of the lining to the sleeper;

Ш2 - for inseparable terminal-bolt rail fastening (BPU type) with bolted attachment of the lining or rail to the sleeper.

1.2.2. The shape and dimensions of the sleepers must correspond to those indicated in Figures 1-4 and Table 1. Indicators of material consumption of sleepers are given in Appendix 1.

1 - embedded washer; 2 - wire reinforcement

Section 3-3 is shown in Fig. 3

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UNDER-RAIL PART OF SLEEP SH1-1

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UNDER-RAIL PART OF SLEEPER Ш1-2

Sections 4-4, 5-5 and 6-6 are shown in Fig. 2

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UNDER-RAIL PART OF SLEEP SH2-1

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Table 1


Sleeper brand	Distance between the thrust edges of different ends of the sleeper, mm	Distance between thrust edges of one end of the sleeper, mm	Distance between axes of bolt holes, mm	Distance between the hole axis and the stop edge, mm	Angle of thrust edges	The direction of the larger side of the bolt hole relative to the longitudinal axis of the sleeper
Ш1-1	2012	404	310		55°	Transverse
Ш1-2	2000	392	310		72°
Ш2-1	2012	404	236		55°	Longitudinal

Notes:

1. On the edges adjacent to the sole and ends of the sleepers, chamfers with a width of no more than 15 mm are allowed.

2. By agreement between the manufacturer and the consumer, it is allowed to produce sleepers in which the dimensions and location of the recesses on the sole differ from those indicated in Figure 1, and the shape and dimensions of the vertical channels for embedded bolts differ from those indicated in Figures 2-4.

1.2.3. Sleepers are designated by marks in accordance with the requirements of GOST 23009. The sleeper mark consists of two alphanumeric groups separated by a dash.

The first group contains the designation of the type of sleeper (clause 1.2.1). In the second group, the design option for the under-rail platform is indicated (Table 1).

An example of a symbol (brand) of sleeper type Ш1, the first version of the under-rail platform:

Ш1-1

1.2.4. Depending on crack resistance, accuracy of geometric parameters, and quality of concrete surfaces, sleepers are divided into two grades: first and second.

Second grade sleepers are intended for laying on low-traffic, station and access roads. Second grade sleepers are supplied only with the consent of the consumer.

1.3. Characteristics

1.3.1. Sleepers must meet the crack resistance requirements adopted during their design and withstand the test loads specified in Table 2.

table 2

1.3.2. Sleepers should be made of heavy concrete in accordance with GOST 26633, compressive strength class B40.

1.3.3. The actual strength of concrete (at design age, transfer and tempering) must comply with the requirements of GOST 13015.

1.3.4. The normalized transfer strength of concrete should be taken equal to 32 MPa (326 kgf/cm ).

1.3.5. The tempering strength of concrete is taken to be equal to the transfer strength of concrete.

1.3.6. The frost resistance grade of concrete must be at least F200.

1.3.7. For concrete sleepers, crushed stone from natural stone or crushed stone from gravel of a fraction of 5-20 mm should be used in accordance with GOST 26633. It is allowed, by agreement between the manufacturer and the consumer, to use:

crushed stone of the 20-40 mm fraction in an amount of no more than 10% of the mass of crushed stone of the 5-20 mm fraction according to GOST 26633;

crushed stone from natural stone of fraction 5-25 mm in accordance with GOST 7392, subject to its compliance with all other requirements of GOST 26633.

1.3.8. As reinforcement for sleepers, periodic steel wire of class BP with a diameter of 3 mm should be used according to GOST 7348 and TU 14-4-1471.

1.3.9. The nominal number of reinforcing wires in a sleeper is 44. The location of the wires, controlled at the ends of the sleeper, must correspond to that indicated in Figure 5. The vertical clear distance between pairs or individual wires, in case of their deviation from the design position, should not be less than 8 mm. It is allowed to rotate pairs of wires by 90° while maintaining the above distance.

PLACEMENT OF FITTINGS

at the end of the sleeper

in the middle section of the sleeper

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To ensure the design arrangement of the wires, spacers that remain in the body of the sleeper concrete can be used (see Appendix 2). It is allowed, by agreement between the manufacturer and the consumer, to use spacers that differ from those specified in Appendix 2.

1.3.10. The total initial tension force of all reinforcing wires in the package must be at least 358 kN (36.4 tf). The average value of the initial tension force of one wire with their nominal number should be 8.12 kN (827 kgf). The tension force of individual wires should not differ from the average value by more than 10%.

A decrease in the tension force of individual wires in excess of 10%, caused by wire slipping in the gripper, should not occur for more than one wire in sleepers of the first grade and for two wires in sleepers of the second grade.

1.3.11. Deviations from the nominal number of reinforcing wires are allowed, provided that the total tension force of the existing wires is not less than that specified in clause 1.3.10. In this case, maximum deviations in the number of wires should not exceed ±2 pcs.

1.3.12. The ends of the prestressing reinforcement should not protrude beyond the end surfaces of the first grade sleepers by more than 15 mm and the second grade by more than 20 mm.

1.3.13. Embedded washers - according to the technical documentation.

1.3.14. The values of actual deviations of the geometric parameters of sleepers should not exceed the limits specified in Table 3.

Table 3


mm
Name of deviation geometric parameter	Name geometric parameter	Prev. off for sleepers
		first varieties	second varieties
Deviation from linear size	Distance	±2	3; -2
	Distance	2; -1	3; -1
	Distances and	±1	±1
	Depth of embedded washer in concrete	6; -2	6; -2
	Sleeper length	±10	±20
	Sleeper width	10; -5	20; -5
	Sleeper height	8; -3	15; -5
Deviation from straightness of the profile of under-rail platforms over the entire length or width

Note. Dimensions for which maximum deviations are not indicated are for reference only.

1.3.15. The slope of the under-rail platforms to the longitudinal axis of the sleeper in a vertical plane passing through the axis (slope) should be in the range of 1:18 - 1:22 for sleepers of the first grade and 1:16 - 1:24 for sleepers of the second grade.

1.3.16. The difference in the slopes of the under-rail areas of different ends of the sleeper in the direction transverse to the sleeper axis (propeller ratio) should not exceed 1:80.

1.3.17. The values of actual deviations in the thickness of the protective layer of concrete to the top row of reinforcement should not exceed, mm:

For sleepers of the first grade;

For sleepers of the second grade.

1.3.18. The dimensions of cavities on concrete surfaces and concrete edges of ribs near sleepers should not exceed the values specified in Table 4.

Table 4

	shells				around concrete ribs
	Depth		Diameter (largest size)		Depth		Edge length
	First grade sleepers	Second grade sleepers	First grade sleepers	Second grade sleepers	First grade sleepers	Second grade sleepers	First grade sleepers	Second grade sleepers
Under-rail platforms			10*	15*
Thrust edges of under-rail platforms			10**	15**
Upper surface of the middle part of the sleeper
Other areas of the upper surface							Not regulated
Side and end surfaces							Same

________________

* No more than three sinks on one platform.

**Limit one sink.

Notes:

1. It is allowed to have marks from welds between the permanent under-rail plates and the mold on the longitudinal edges of the under-rail pads.

2. The presence of imprints of diaphragm stiffening elements with a depth of no more than 5 mm at the ends of the sleepers is allowed.

1.3.19. The depth of the gaps between the wires and concrete at the ends of the sleepers should not exceed 15 mm for sleepers of the first class and 30 mm for sleepers of the second class.

1.3.20. The following are not allowed in sleepers:

sagging of concrete in the bolt channels, preventing the free installation and rotation of these bolts into their working position;

local flows of concrete on under-rail areas;

turning the rail fastening bolts in the sleeper channels while screwing the nuts;

cracks in concrete.

To form channels for bolts, it is allowed to install internal elements, the design and material of which are agreed upon with the consumer.

1.4. Marking

1.4.1. The marking of sleepers must comply with the requirements of GOST 13015 and this standard.

1.4.2. On the upper surface of the sleepers the following is applied by stamping during molding:

trademark or short name of the manufacturer - on each sleeper;

year of manufacture (last two digits) - for at least 20% of sleepers of each batch.

At the end of each sleeper the following is applied with paint:

quality control stamp;

batch number.

1.4.3. The locations for markings are indicated in Figure 6.

SLEEP MARKING

1 - batch number; 2 - trademark or short name of the manufacturer;

3 - year of manufacture; 4 - second grade sleeper sign

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It is allowed to apply a trademark or short name of the manufacturer and the year of manufacture on one half of the sleeper.

(Amendment).

1.4.4. Markings should be made in a font with a height of at least 50 mm.

1.4.5. At both ends of the second grade sleepers, a transverse strip 15-20 mm wide is applied with paint (see Figure 6).

2. ACCEPTANCE

2.1. Sleepers are accepted in batches in accordance with the requirements of GOST 13015 and this standard.

2.2. Sleepers accept:

according to the results of periodic tests - in terms of frost resistance of concrete and the accuracy of the geometric parameters of sleepers, with the exception of the size of type Sh1-2 sleepers;

based on the results of acceptance tests - in terms of crack resistance of sleepers, concrete strength (class of concrete in terms of compressive strength, transfer and tempering strength), condition of the bolt channels, size accuracy of sleepers type Ш1-2, quality of concrete sleeper surfaces

2.3. Periodic testing of sleepers in terms of frost resistance of concrete is carried out once a year, and in terms of the accuracy of geometric parameters - once a month.

2.4. The accuracy of the geometric parameters of the sleepers is accepted based on the results of random inspection. With the volume of the batch of sleepers St. 3200 pcs. The sampling plan should be adopted in accordance with GOST 23616.

2.5. To test for crack resistance, control sleepers are selected from each batch in the amount of 0.3%, but not less than 3 pieces. The batch is accepted for crack resistance if the sleepers selected for testing have withstood the test loads. The sleeper is considered to have passed the crack resistance test if, under control loads, no visible cracks are detected in the under-rail and middle sections. A transverse crack in concrete with a length of more than 30 mm from the edge of the sleeper and an opening at the base of more than 0.05 mm is taken as visible.

If the result of the crack resistance test is unsatisfactory, it is allowed to divide the batch into smaller ones and submit them for repeated crack resistance tests. If the result of the repeated test is unsatisfactory, it is allowed to carry out a continuous test of all sleepers in the batch.

2.6. Acceptance of sleepers based on the condition of the bolt channels and the quality of concrete surfaces is carried out based on the results of continuous inspection.

3. CONTROL METHODS

3.1. The compressive strength of concrete is determined according to GOST 10180 on a series of samples made from a concrete mixture of the working composition, stored under the conditions established by GOST 18105.

3.2. Frost resistance of concrete is determined according to GOST 10060.0 - GOST 10060.4.

3.3. The total tension force of the reinforcement is monitored using pressure gauge readings in accordance with GOST 22362 with a parallel connection of a recorder to record the tension force.

The tension force of individual reinforcement wires is measured by the transverse guy method according to GOST 22362.

3.4. To measure the linear dimensions of sleepers, as well as shells and edges of concrete, metal measuring instruments are used in accordance with GOST 13015. The depth of shells, as well as the gaps between the wires and concrete at the ends of the sleepers, are measured with a caliper with a pointed rod.

3.5. The distance between the thrust edges of the recesses of the under-rail platforms of different ends of the sleeper is measured with a template applied simultaneously to both under-rail areas of the sleeper (Fig. 7).

SIZE ACCURACY CONTROL SCHEME ( ) AND UNDER-RAIL PLATES ( AND )

1 - template or indicator device

Damn.7

The distances between the edges of the recess of one end of the sleeper, between the axes of the holes for bolts and from the axis of the hole to the thrust edge are ensured by checking these dimensions on the form of metal plates that form recesses in the under-rail area when forming sleepers

3.6. The slope of the under-rail platforms in the longitudinal and transverse directions to the sleeper axis (slope and propeller) is measured with an indicator applied simultaneously to both under-rail areas of the sleepers (Figures 7 and 8).

SLEEP PROPELLER CONTROL SCHEME ( )

1 - measuring device

Damn.8

3.7. Deviation from straightness of under-rail platforms is determined according to GOST 13015 by measuring the largest gap between the surface of the platform and the edge of a metal straight edge.

3.8. The depth of embedding of the embedded washers into the concrete is controlled by a device inserted into the sleeper channel and rotated 90° (Fig. 9).

DIAGRAM OF A DEVICE FOR MEASURING THE DEPTH OF WASHERS

1 - handle; 2 - rod; 3 - scale; 4 - pointer; 5 - body; 6 - head

Damn.9

The absence of concrete sagging in the sleeper channels, preventing installation and rotation of the bolt into the working position, as well as turning the bolt when screwing the nut, is checked with a embedded bolt in accordance with GOST 16017 with maximum positive deviations of the head dimensions. Check all four channels of the controlled sleeper

3.9. The thickness of the protective layer of concrete over the top row of reinforcement is controlled in the middle of the sleeper using the method indicated in Figure 10. It is allowed, by agreement between the manufacturer and the consumer, to control the thickness at the ends of the sleepers with a metal ruler.

SCHEME FOR MEASURING THE THICKNESS OF CONCRETE PROTECTIVE LAYER

ABOVE THE TOP ROW OF REINFORCEMENT IN THE MIDDLE OF THE SLEEPER

1 - rail; 2 - wire of the upper row of reinforcement

Damn.10

3.10. The height of the sleeper is checked with a caliper in cross sections in the middle of each under-rail platform and in the middle of the sleeper.

3.11. Each sleeper selected for crack resistance testing is tested with static load sequentially in the under-rail and middle sections according to the diagrams shown in Figure 11.

SCHEME FOR TESTING SLEEPERS FOR CRACK RESISTANCE

in the under-rail section

in the middle section

1 - steel plate with a lower base slope of 1:20, size 250x100 mm, average thickness 25 mm;

2 - steel plate measuring 250x100x25 mm; 3 - rubber gasket measuring 250x100x10 mm;

4 - steel roller with a diameter of 40 and a length of 250 mm

Damn.11

The load is evenly increased with an intensity of no more than 1 kN/s (100 kgf/s) and brought to the control value indicated in Table 2. This load is maintained constant for 2 minutes, after which the side surfaces on both sides of the sleeper at the tested section are inspected in order to detect visible cracks in the tension zone of the concrete. The surface of the concrete is not wetted. Illumination of the concrete surface is at least 3000 lux. To measure the length of cracks, a metal ruler is used, and for the width of cracks, a measuring magnifying glass is used in accordance with GOST 25706 with a division value of 0.05 mm.

3.12. The list of devices, indicators and templates for monitoring the geometric parameters of sleepers is given in Appendix 3.

3.13. All non-standardized measuring and testing instruments must undergo metrological certification in accordance with GOST 8.326*.

________________

* PR 50.2.009-94 applies on the territory of the Russian Federation.

4. TRANSPORTATION AND STORAGE

4.1. Transportation and storage of sleepers should be carried out in accordance with the requirements of GOST 13015 and this standard.

4.2. Sleepers should be transported and stored in stacks in horizontal rows in the working position (sole down). The stack height should be no more than 16 rows.

Pads for sleepers and spacers between them in a stack should be placed in the recesses of the under-rail areas of the sleepers. The thickness of wooden linings and gaskets must be at least 50 mm. It is allowed, by agreement between the manufacturer and the consumer, to use wooden spacers with a cross-section of at least 40x40 mm when located at a distance of 30-40 mm from the thrust edges of the recesses in the under-rail areas of the sleepers.

4.3. Sleepers are transported in gondola cars or cars. Transportation of sleepers of different brands and varieties in one gondola car or vehicle is not allowed.

5. MANUFACTURER WARRANTY

5.1. The manufacturer guarantees that sleepers comply with the requirements of this standard provided that the consumer complies with the rules for their operation, transportation and storage.

5.2. The warranty period for sleepers is three years from the date of their installation. The calculation of the warranty period begins no later than 9 months from the date of receipt of the sleepers by the consumer.

ANNEX 1

Mandatory

INDICATORS OF MATERIAL CONSUMPTION OF SLEEPERS

Indicators of material consumption of sleepers manufactured using standard flow-aggregate technology in ten-cavity molds (without taking into account technological and production losses outside the mold):

embedded washers

11.8 kg


Name of geometric parameter	Name of the device, indicator or template	Cipher project
The distance between the thrust edges of the recesses in the under-rail areas of different ends of the sleeper	Size control template for railway sleepers with an edge angle of 55°	3477/10
Slope of under-rail platforms in the longitudinal and transverse directions to the sleeper axis	Indicator for monitoring the slopes and propellers of under-rail platforms of railway sleepers	3477/4-A
Depth of embedding washers into concrete	Device for controlling the embedding depth of embedded washers	3633/4
Thickness of the protective layer of concrete in the middle part of the sleeper	Device for monitoring the thickness of the protective layer of concrete	3633/3
Depth of sinks and gaps between wire and concrete	Measuring device	3633/5

Electronic document text

prepared by Kodeks JSC and verified against:

official publication

M.: IPK Standards Publishing House, 2004