EN 13230-1:2016
(Main)Railway applications - Track - Concrete sleepers and bearers - Part 1: General requirements
Railway applications - Track - Concrete sleepers and bearers - Part 1: General requirements
This part of the EN 13230 series defines technical criteria and control procedures which need to be satisfied by the constituent materials and the finished concrete sleepers and bearers, i.e.: precast concrete sleepers, twin-block reinforced sleepers, bearers for switches and crossings, and special elements for railway tracks.
The main requirement of concrete sleepers and bearers is the transmission of vertical, lateral and longitudinal loads from the rails to the ballast or other support. In use, they are also exposed to frost damage and to moisture, which can result in detrimental chemical reactions within the sleeper.
In this standard mechanical tests are defined which provide assurance of the capability of sleepers or bearers to resist repetitive loading and provide sufficient durability. In addition, controls are placed on manufacturing processes and tests to ensure that the concrete will not suffer degradation in service through chemical reaction and frost damage.
Bahnanwendungen - Oberbau - Gleis- und Weichenschwellen aus Beton - Teil 1: Allgemeine Anforderungen
Dieser Teil der Normenreihe EN 13230 legt die technischen Kriterien und Kontrollverfahren fest, denen die Baustoffe und Fertigerzeugnisse, d. h. aus Beton gefertigte Gleis- und Weichenschwellen, bewehrte Zweiblockschwellen, Schwellen für Weichen und Kreuzungen und spezielle Schwellen (Sonderformen) für Eisenbahngleise, genügen müssen.
Die Hauptaufgabe von Gleis- und Weichenschwellen aus Beton ist die Übertragung vertikaler, horizontaler und longitudinaler Lasten von den Schienen auf den Schotter oder eine andere Tragschicht. Während des Einsatzes sind sie sowohl Frost als auch Feuchtigkeit, die zu schädlichen chemischen Reaktionen innerhalb der Gleisschwellen führen kann, ausgesetzt.
In dieser Norm werden mechanische Prüfungen festgelegt, die die Gebrauchstauglichkeit und Dauer-haftigkeit von Gleis- und Weichenschwellen aus Beton gegenüber wiederholten Belastungen sicherstellen. Zusätzliche Kontrollen sind für die Herstellungsverfahren erforderlich und Prüfungen sind durchzuführen, um sicherzustellen, dass der Beton im Laufe der Nutzung keine Festigkeitsverluste durch chemische Reaktion und Frostschäden erfährt.
Applications ferroviaires - Voie - Traverses et supports en béton - Partie 1 : Prescriptions générales
La présente partie de la série EN 13230 traite des prescriptions générales relatives aux traverses et supports en béton et est utilisée conjointement avec les parties suivantes :
— Partie 2 : Traverses monoblocs précontraintes
— Partie 3 : Traverses biblocs en béton armé
— Partie 4 : Supports précontraints pour appareil de voie
— Partie 5 : Éléments spéciaux
— Partie 6 : Conception
Les traverses et les supports en béton, du fait de la sécurité, sont des constituants spécifiques du domaine ferroviaire. Ils ne sont couverts par aucune autre norme.
En tant que constituants de sécurité un accord est nécessaire entre client et fournisseur pour la mise en œuvre d’un système qualité en production.
Cette position a toujours été mise en exergue par les résolutions prises au CEN/TC 256/SC 1 « Applications ferroviaires – Infrastructure » et des informations détaillées figurent dans l’Annexe ZA.
Železniške naprave - Zgornji ustroj proge - Betonski pragi in kretniški betonski pragi - 1. del: Splošne zahteve
Ta del standarda EN 13230 določa tehnične kriterije in kontrolne postopke, ki jih morajo izpolnjevati sestavni materiali ter končni betonski pragi in kretniški betonski pragi, npr. montažni betonski pragi, kretniški betonski pragi za kretnice in križišča ter posebne oblike pragov za železniške proge.
Glavna zahteva za betonske prage in kretniške betonske prage je prenos navpičnih, stranskih in vzdolžnih obremenitev s tračnic na gramozno gredo ali drugo podporo. Med uporabo so izpostavljeni tudi poškodbam zaradi zmrzovanja in vlage, kar lahko povzroči škodljive kemične reakcije v betonskem pragu.
V tem standardu so določeni mehanski preskusi, s katerimi se lahko zagotovita odpornost betonskih pragov in kretniških betonskih pragov proti ponavljajočim se obremenitvam ter zadostna vzdržljivost. Prav tako se izvaja kontrola proizvodnih postopkov in preskusov, s čimer se zagotovi, da ne pride do uničenja betona zaradi kemičnih reakcij in poškodb zaradi zmrzovanja.
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
01-julij-2016
1DGRPHãþD
SIST EN 13230-1:2009
Železniške naprave - Zgornji ustroj proge - Betonski pragi in kretniški betonski
pragi - 1. del: Splošne zahteve
Railway applications - Track - Concrete sleepers and bearers - Part 1: General
requirements
Bahnanwendungen - Oberbau - Gleis- und Weichenschwellen aus Beton - Teil 1:
Allgemeine Anforderungen
Applications ferroviaires - Voie - Traverses et supports en béton - Partie 1 : Prescriptions
générales
Ta slovenski standard je istoveten z: EN 13230-1:2016
ICS:
45.080 7UDþQLFHLQåHOH]QLãNLGHOL Rails and railway
components
91.100.30 Beton in betonski izdelki Concrete and concrete
products
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
EN 13230-1
EUROPEAN STANDARD
NORME EUROPÉENNE
May 2016
EUROPÄISCHE NORM
ICS 91.100.30; 93.100 Supersedes EN 13230-1:2009
English Version
Railway applications - Track - Concrete sleepers and
bearers - Part 1: General requirements
Applications ferroviaires - Voie - Traverses et supports Bahnanwendungen - Oberbau - Gleis- und
en béton - Partie 1 : Prescriptions générales Weichenschwellen aus Beton - Teil 1: Allgemeine
Anforderungen
This European Standard was approved by CEN on 4 March 2016.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this
European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2016 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 13230-1:2016 E
worldwide for CEN national Members.
Contents Page
European foreword . 5
Introduction . 6
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 8
4 Common characteristics . 10
4.1 General . 10
4.2 Loading. 10
4.2.1 Loads . 10
4.2.2 Load distribution . 10
4.3 Characteristic bending moments . 11
4.4 Data to be supplied . 11
4.4.1 General . 11
4.4.2 Data to be supplied by the purchaser . 11
4.4.3 Data to be provided by the supplier . 12
5 Materials . 12
5.1 General requirements . 12
5.2 Cement . 13
5.3 Aggregates . 13
5.4 Mixing water . 14
5.5 Admixtures . 14
5.6 Concrete . 14
5.6.1 Material requirements . 14
5.6.2 Information to be provided by the supplier . 14
5.6.3 Changes for the material and processes . 15
5.7 Steel . 15
5.7.1 Prestressing tendons . 15
5.7.2 Reinforcing steel . 15
5.7.3 Steel connecting bar . 15
5.8 Embedded components. 15
6 General requirements . 15
6.1 Design . 15
6.1.1 Geometrical design . 15
6.1.2 Concrete cover . 18
6.1.3 Prestressing system design . 18
6.1.4 Reinforcing steel design . 18
6.2 Manufacturing process . 18
6.2.1 General requirements . 18
6.2.2 Natural curing. 19
6.2.3 Accelerated curing . 19
6.3 Surface finish . 21
6.4 Marking . 21
7 Product testing . 21
7.1 General . 21
7.2 Mechanical parameters . 22
7.3 Tests on product . 22
7.4 Tests on concrete . 22
7.5 Tests in combination with the fastening system . 23
7.6 Additional tests . 23
8 Quality control . 23
8.1 General . 23
8.2 Quality control during design approval tests . 24
8.3 Quality control during manufacturing . 24
Annex A (informative) Test method to determine the Taber Wear index for a fine aggregate . 25
A.1 General . 25
A.2 Apparatus . 25
A.3 Preparation of Mortar Tiles . 25
A.3.1 Sampling . 25
A.3.2 Mortar Tile preparation . 25
A.3.3 Mortar Tile curing . 26
A.3.4 Grinding of Mortar Tiles . 26
A.4 Test procedure . 26
A.5 Calculation of Taber Wear Index. 26
Annex B (informative) Test method for freeze–thaw resistance . 27
Annex C (informative) Test method for measuring the water absorption of concrete at
atmospheric pressure . 28
C.1 Introduction. 28
C.2 Samples . 28
C.3 Sequence of test . 28
C.4 Results . 28
C.5 Requirements . 28
Annex D (informative) Definition and recommendation for measurement of rail seat
inclination and twist between rail seats . 29
Annex E (informative) Surface finish . 30
E.1 General . 30
E.2 General information for surface finish . 30
E.3 Surface finish of the rail seat . 30
E.4 Surface finish of all other surfaces . 31
E.5 Detailed procedure for remedial work . 31
Annex F (informative) Quality control during manufacturing – Routine tests and frequency
of testing . 32
F.1 General . 32
F.2 Data of the sleeper to be checked . 32
F.3 Examples for frequency of testing . 34
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 2008/57/EC. 35
Bibliography . 37
European foreword
This document (EN 13230-1:2016) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This document supersedes EN 13230-1:2009.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by November 2016, and conflicting national standards
shall be withdrawn at the latest by November 2016.
This document has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive 2008/57/EC.
For relationship with EU Directive 2008/57/EC, see informative Annex ZA, which is an integral part of
this document.
This European Standard is one of the EN 13230 series “Railway applications – Track – Concrete sleepers
and bearers”, which consist of the following parts:
— Part 1: General requirements;
— Part 2: Prestressed monoblock sleepers;
— Part 3: Twin-block reinforced sleepers;
— Part 4: Prestressed bearers for switches and crossings;
— Part 5: Special elements;
— Part 6: Design.
This European Standard is used as the technical basis for transaction between corresponding parties
(purchaser – supplier).
Annexes A to F are informative; they can be used as normative requirements by completion of a
contract, if agreed by the contracting parties.
The Annex E of EN 13230-1:2009 is deleted and is shifted into EN 13230-6.
There is a change in the wording of the documents of EN 13230 (series) “design bending moment” is
replaced by “characteristic bending moment” and “test bending moment”.
According to the CEN/CENELEC Internal Regulations, the national standards organisations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria,
Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta,
Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Turkey and the United Kingdom.
Introduction
This part of the EN 13230 series covers the general requirements for concrete sleepers and bearers and
is used in conjunction with the following parts:
— Part 2: Prestressed monoblock sleepers;
— Part 3: Twin-block reinforced sleepers;
— Part 4: Prestressed bearers for switches and crossings;
— Part 5: Special elements;
— Part 6: Design.
Concrete sleepers and bearers are safety critical components for railway applications. They are not
covered by any other standards.
As safety critical components, an agreement is needed between purchaser and supplier to operate a
factory Quality System.
This position about safety critical relevance has always been highlighted by decisions from
CEN/TC 256/SC 1 “Railway applications / Infrastructure” and Annex ZA provides detailed information.
1 Scope
This part of the EN 13230 series defines technical criteria and control procedures which need to be
satisfied by the constituent materials and the finished concrete sleepers and bearers, i.e.: precast
concrete sleepers, twin-block reinforced sleepers, bearers for switches and crossings, and special
elements for railway tracks.
The main requirement of concrete sleepers and bearers is the transmission of vertical, lateral and
longitudinal loads from the rails to the ballast or other support. In use, they are also exposed to frost
damage and to moisture, which can result in detrimental chemical reactions within the sleeper.
In this standard mechanical tests are defined which provide assurance of the capability of sleepers or
bearers to resist repetitive loading and provide sufficient durability. In addition, controls are placed on
manufacturing processes and tests to ensure that the concrete will not suffer degradation in service
through chemical reaction and frost damage.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
EN 206, Concrete - Specification, performance, production and conformity
EN 934-2, Admixtures for concrete, mortar and grout – Part 2: Concrete admixtures – Definitions,
requirements, conformity, marking and labelling
EN 1008, Mixing water for concrete - Specification for sampling, testing and assessing the suitability of
water, including water recovered from processes in the concrete industry, as mixing water for concrete
EN 10080, Steel for the reinforcement of concrete - Weldable reinforcing steel - General
FprEN 10138 (all parts), Prestressing steels
EN 12620, Aggregates for concrete
EN 13146-5, Railway applications - Track - Test methods for fastening systems - Part 5: Determination of
electrical resistance
EN 13230-2:2016, Railway applications – Track – Concrete sleepers and bearers – Part 2: Prestressed
monobloc sleepers
EN 13230-3:2016, Railway applications – Track – Concrete sleepers and bearers – Part 3: Twin-block
reinforced sleepers
EN 13230-4:2016, Railway applications – Track – Concrete sleepers and bearers – Part 4: Prestressed
bearers for switches and crossings
prEN 13230-6:2015, Railway applications – Track – Concrete sleepers and bearers – Part 6: Design
EN 13481-2, Railway applications - Track - Performance requirements for fastening systems - Part 2:
Fastening systems for concrete sleepers
EN 13481-5, Railway applications - Track - Performance requirements for fastening systems - Part 5:
Fastening systems for slab track with rail on the surface or rail embedded in a channel
EN 13481-7, Railway applications - Track - Performance requirements for fastening systems - Part 7:
Special fastening systems for switches and crossings and check rails
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
purchaser
body responsible for purchasing the product on the user’s behalf
3.2
supplier
body responsible for the use of the European Standard in response to the purchaser’s requirement, and
for requirements which apply to the producer or manufacturer
3.3
sleeper
transverse component of the track which controls the gauge and transmits loads from the rail to the
ballast or other sleeper support
3.4
bearer for switches and crossings
transverse component of switches and crossings which controls the relative geometry of two or more
stretches of running rails and different pieces of special track work, and transmits loads from the rails
to the ballast or other bearer support
3.5
bending moment
moment applied on the concrete sleeper or bearer which produces tension and compression in the
element
3.6
positive bending moment
moment which produces tension or reduces compression at the bottom of the concrete sleeper or
bearer
3.7
negative bending moment
moment which produces tension or reduces compression at the top of the concrete sleeper or bearer
3.8
rail seat
area on which a running rail rests
3.9
rail seat area
rail seat and the immediate area around the fastening system
3.10
rail seat bending moment
moment under the centre line of the rail
3.11
centre bending moment
moment at the centre part of a monoblock sleeper
3.12
prestressed monoblock sleeper
monoblock sleeper using pre-tensioned or post-tensioned tendons for prestressing the concrete
3.13
twin-block reinforced sleeper
sleeper in which two reinforced concrete blocks are connected by a steel connecting bar
3.14
prestressed concrete bearer
monoblock bearer using pre-tensioned or post-tensioned tendons for prestressing the concrete
3.15
test load
load applied during testing
3.16
crack
partial split in concrete due to an external bending moment
3.17
crack under loading
crack measured during a test with an external bending moment applied
3.18
residual crack
crack measured during a test after an external bending moment has been applied and has been
removed
3.19
minimum concrete cover
minimum cover given by the nominal cover reduced by the tolerance
Note 1 to entry: Construction tolerances do not apply to the anchorage system of prestressed sleepers, in which
case only the ordinary construction tolerances indicated by the manufacturer are applied.
3.20
dynamic rail seat load
P
k
characteristic load on a rail seat of the sleeper for normal service dynamic loading
3.21
characteristic bending moment
M
k
bending moment from dynamic rail seat load P
k
3.22
characteristic positive bending moment for rail seat section
M
k,r,pos
positive bending moment at rail seat from dynamic rail seat load P
k
3.23
characteristic negative bending moment for rail seat section
M
k,r,neg
negative bending moment at rail seat from dynamic rail seat load P
k
3.24
characteristic negative bending moment for centre section
M
k,c,neg
negative bending moment at centre section from dynamic rail seat load P
k
3.25
characteristic positive bending moment for centre section
M
k,c,pos
positive bending moment at centre section from dynamic rail seat load P
k
4 Common characteristics
4.1 General
The track is an assembly of transverse sleepers or bearers secured to the rails by means of a fastening
system and supported by ballast or other support. It is characterized by the gauge of the track, the rail
profile, the inclination of the rails and the spacing of the concrete sleepers and bearers.
4.2 Loading
4.2.1 Loads
The track is subjected to repeated loads in three different directions, generally applied simultaneously:
a) vertical loads from axle load and service conditions;
b) transverse loads from guiding forces;
c) longitudinal loads from acceleration and braking, thermal stresses in continuous welded rail, etc.
Under all loading conditions, the track has to retain its geometry including gauge, top level and
alignment.
The characteristic load is calculated by applying a dynamic coefficient to the static wheel load.
The dynamic coefficient takes into account the normal dynamic effects of wheel and track irregularities.
Loads and the corresponding bending moments are the responsibility of the purchaser.
4.2.2 Load distribution
The assembled rail, fastening system and concrete sleepers and bearers on ballast or other support
shall be considered as a beam on a continuous resilient support.
The moment of inertia of the rail profile, the spacing of the concrete sleepers and bearers and the
elasticity of the whole assembly on its support, have an influence on the longitudinal distribution of the
vertical loads applied on the rail. As a result, the rail seat load applied on the concrete element is only a
proportion of the wheel load.
4.3 Characteristic bending moments
The characteristic bending moments are defined in kNm by the concrete sleeper and bearer design
criteria and are used to calculate test loads.
Characteristic bending moments are seldom reached in the life time of the sleeper.
See prEN 13230-6:2015, 4.2.
4.4 Data to be supplied
4.4.1 General
The purchaser can require all the data from the supplier before the design approval tests.
4.4.2 Data to be supplied by the purchaser
The purchaser shall specify the following data:
a) all characteristic bending moments (M ; M ; M , ) and when required (M );
k,r,pos k,c,pos k c,neg k,r,neg
b) impact coefficients (k ) and (k ), and when required (k ) and (k ) as defined in
1d 2d 1s 2s
prEN 13230-6:2015;
c) test coefficient (k ) as defined in prEN 13230-6:2015;
t
d) required tests and choice of options (see for example Annexes A, B, C);
e) drawings and specifications necessary to define:
1) critical dimensions (distance between sleeper gauge points L1 – length – width – depth at rail
seat – etc.);
2) fastening system interface and geometric lay-out (6.1);
3) particular tolerances (6.1, Table 1);
4) conductor rail insulator supports;
5) scope of the test arrangements and procedures indicating whether the options are used;
f) absolute maximum and minimum weight of the concrete sleeper and bearer (kg/sleeper or kg/m);
g) any additional technical specification, e.g. electrical insulation;
h) rail profile definition;
i) minimum strength class of concrete (optional).
4.4.3 Data to be provided by the supplier
4.4.3.1 Before the design approval tests
a) Detailed drawings of the concrete sleeper and bearer;
b) characteristics of materials;
c) description of manufacturing process;
d) description of the prestress anchoring system (if any) for prestressed sleepers and bearers:
1) for bonded anchoring systems, the adherence specification of the tendons, for example
indentation;
2) how prestress is applied to sleeper;
3) characteristics of chemical, dimensional and mechanical tolerances for anchor devices.
4.4.3.2 After the design approval tests
— Design approval test report.
4.4.3.3 Prior to start-up of production
a) All data required in Clause 8 “Quality control”;
b) production file for manufacturing data as defined in the following:
1) EN 13230-2:2016, Clause 5;
2) EN 13230-3:2016, 7.1;
3) EN 13230-4:2016, 6.1.
5 Materials
5.1 General requirements
All materials shall comply with European standards or if no European Standards exist, with appropriate
national standards. Materials other than those specified below shall only be used with the agreement of
the purchaser.
Great care shall be exercised in the selection of materials to ensure the long term durability of the
concrete. Consideration shall be given to the requirements for freeze–thaw resistance, porosity and
abrasion resistance.
Where aggregates contain varieties of silica susceptible to attack by alkalis (Na2O and K2O originating
from cement or other sources) and as the concrete is exposed to humid conditions, precautions in the
choice of constituents shall be taken. Typical precautions are stated below. Other precautions may
include provisions which are valid in the place of use of the concrete taking into account previous long-
term experience using the particular combination of cement and aggregate and agreed by the
purchaser.
The supplier shall provide a document including all precautions about Alkali Silica Reaction for
agreement by the purchaser.
Typical precautions are the following:
a) use of low-alkali cement with total alkali content, stated as Na O equivalent, less than or equal to
0,60 %;
b) where national recommendations exist, use of additions allowed by EN 206 as partial cement
replacement;
c) use of only non-reactive aggregates, regularly confirmed by ex-quarry petrographic analysis (see
5.3);
d) the total mass of reactive alkalis in the concrete not exceeding 3,0 kg/m or being in accordance
with national recommendations where available.
5.2 Cement
Use of Portland cement type CEM I with minimum strength-grade class 42.5 complying with EN 197-1 is
recommended.
Cement other than type CEM I shall only be used if the durability of the sleepers can be demonstrated
and approval is obtained from the purchaser.
The maximum SO content and the curing procedure shall comply with 6.2.
The total alkali content expressed as Na O equivalent shall comply with national recommendations
unless European standards exist.
The manufacturer shall obtain certificates from the cement supplier detailing the chemical and physical
properties of the cement at a sufficient frequency to comply with the quality plan.
5.3 Aggregates
Aggregates shall comply with EN 12620 unless a specific criterion is not within its scope, in which case
national standards shall be used.
The manufacturer shall supply the following information to the purchaser concerning aggregates to be
used:
a) grading curve;
b) petrographic analysis including:
1) susceptibility to alkali-silica-reaction and alkali-carbonate-reaction;
2) presence of particles leading to poor abrasion resistance;
3) presence of absorbent particles leading to frost damage;
c) chemical analysis including:
1) maximum chloride content;
2) maximum sulfate content;
3) maximum organic material content.
The petrographic analysis shall be carried out at least every two years and each time the source (quarry
face or strata) changes.
Aggregates not occurring naturally shall only be used with the agreement of the purchaser.
The maximum size of aggregates shall be determined taking into account the minimum cover and
minimum spacing of reinforcement.
The properties of the fine aggregates shall not allow unacceptable abrasion of the concrete element on
the parts in contact with the ballast or on the rail seat (7.6).
Use of recycled aggregates is permitted, subject to the agreement of the purchaser, when the supplier
can provide evidence of origin and suitable quality of materials.
5.4 Mixing water
In general, potable water is suitable for concrete.
If non-potable water is used, it shall be tested according to EN 1008 unless a specific criterion is not
within its scope, in which case national standards shall be used.
5.5 Admixtures
Admixtures shall comply with EN 934-2 unless a specific criterion is not within its scope, in which case
national standards shall be used.
Calcium chloride setting acceleration admixtures shall not be used.
The supplier shall offer a solution for durability. The purchaser has the authority to accept it or not.
5.6 Concrete
5.6.1 Material requirements
The concrete shall generally comply with EN 206 plus the following requirements:
a) minimum compressive strength shall be class C45/55 MPa unless otherwise required by the
purchaser;
b) water/cement ratio shall be less than 0,45 in mass;
c) minimum cement content shall be 300 kg/m ;
d) compaction of the concrete shall be sufficient to minimize water penetration (7.6, c));
e) heat treatment may be used (6.2.3).
5.6.2 Information to be provided by the supplier
The supplier shall submit to the purchaser the following information about the concrete:
a) description of the constituent materials including origin, composition, shape and size;
b) mix design;
c) full description of the production process for the concrete including cold weather working, and the
storage and measurement of materials;
d) technical report on the following requirements:
1) alkali content according to national standards;
2) design test on the concrete, according to 7.4;
3) the following tests if required:
i) abrasion resistance, see Annex A;
ii) freeze–thaw resistance, see Annex B;
iii) water absorption, see Annex C.
5.6.3 Changes for the material and processes
No change shall be made to the materials and processes used without the agreement of the purchaser.
5.7 Steel
5.7.1 Prestressing tendons
Prestressing tendons shall consist of wires, strands or bars according to the FprEN 10138 series.
5.7.2 Reinforcing steel
Reinforcing steel shall comply with EN 10080 and provisions valid in the place of use. It may be smooth,
indented or deformed and shall be of weldable quality where required for reinforcement assembly.
Welds shall only be used to aid assembly and shall not affect the fatigue performance of the sleeper.
5.7.3 Steel connecting bar
See EN 13230-3:2016, Clause 5.
5.8 Embedded components
The fastening inserts are defined by the fastening system used by the purchaser and shall comply with
the technical specifications and drawings of the system.
The surface of these components in contact with concrete shall be free of mud, oil, loose rust and scale
or other contamination.
6 General requirements
6.1 Design
6.1.1 Geometrical design
Typical concrete envelopes for concrete sleepers and bearers are shown in Figures 1, 2 and 3.
Key
1 gauge points
NOTE L1: Distance between sleeper gauge points taking into account the fastening system, the rail and the
track gauge.
Figure 1 — Typical prestressed monoblock sleeper
Key
1 gauge points
NOTE L1: Distance between sleeper gauge points taking into account the fastening system, the rail and the
track gauge.
Figure 2 — Typical twin-block reinforced sleeper
Figure 3 — Typical prestressed concrete bearer
The values of the main dimensions shall be determined by the purchaser.
The maximum tolerances specified in Table 1 apply to ballasted track and can be varied by the
purchaser in the case of special requirements such as dedicated concrete elements for ballastless track
or use of a sleeper laying machine, etc.
Table 1 — Maximum tolerances
Symbols Description Tolerances
L Overall length of the concrete element ±10 mm
b , b Top and bottom width of the concrete element ±5 mm
1 2
hr Depth at any position along the total length of the reinforced
+10
mm
concrete element measured in accordance with the quality plan
−3
hp Depth at any position along the total length of the prestressed
+5
mm
concrete element measured in accordance with the quality plan
−3
L Distance between the rail fastening gauge points
+2
mm
−1
L Position of the rail fastening gauge point with regard to the end ±8 mm
of the concrete element
L Total length of reinforced concrete block ±8 mm
i Inclination of the rail seat (see Annex D) ±0,25°
f Planeness of each rail seat area: with regard to 2 points 150 mm 1 mm
apart (monoblock and twin-block sleepers only)
T Relative twist between rail seats for monoblock sleepers (see 0,5°
Annex D)
T Relative twist between rail seats for twin-block sleepers (see 0,8°
Annex D)
T Relative twist between rail seats from same track for concrete 0,5°
bearers (see Annex D)
a
m Mass of the sleeper (variation with regard to nominal weight) ±5 %
a
The purchaser shall indicate if all or part of the fastening system is included in the mass of the concrete element.
The design, dimensions and tolerances of the fastening system shall be defined by the purchaser.
The purchaser shall specify the minimum clearances between rail fastening component and
reinforcement according to the fastening system to be used, and between reinforcement and connecting
bar for twin-block sleepers.
For abbreviations, see Table 1.
6.1.2 Concrete cover
Unless there is an alternative agreement by the purchaser, the minimum concrete cover for
prestressing tendons shall be 30 mm from the bottom surface and 20 mm from the other surfaces
except at the ends of sleepers and bearers.
The minimum concrete cover for reinforcing steels shall be 25 mm from the bottom surface and 15 mm
for the rail seat area and 20 mm from the other surfaces, except for the end of spacing bars.
6.1.3 Prestressing system design
The supplier shall define all data in relation with the nominal prestressing force, nominal position of
each tendon, anchorage system.
The vertical position of the centroid of the prestressing shall be within ± 3 mm of the nominal vertical
position relative to the rail seat.
The vertical position of each individual prestressing tendon shall be within ± 6 mm of the nominal
position relative to the rail seat.
The horizontal position of each individual prestressing tendon shall be within ± 6 mm of the nominal
position relative to the sleeper axis.
The total prestressing force shall be applied within ± 5 % of the specified nominal force.
6.1.4 Reinforcing steel design
The supplier shall define all data in relation with the design of the reinforcing steel and nominal
position in the concrete element.
The reinforcing steel shall be within ± 5 mm of the nominal position in all directions.
6.2 Manufacturing process
6.2.1 General requirements
Details of production plant and equipment are the responsibility of the supplier. The supplier shall
supply to the purchaser a description of the manufacturing process.
The processes for curing, mould removal and handling conditions of the concrete sleepers and bearers
are part of the manufacturing process. They shall be submitted to the purchaser for approval.
Any change in the manufacturing process shall be submitted to the purchaser for approval. The
purchaser is entitled to verification that such changes will have no adverse effect on the concrete
sleepers and bearers.
The concrete temperature shall be monitored.
When the temperature is measured in the concrete, it shall be measured as near as possible at the mid
depth and mid width of the sleeper.
When the manufacturer can provide evidence of the relationship between concrete and air temperature
at all stages throughout the curing cycle, it is permissible for the air temperature within the immediate
curing environment to be measured instead of the concrete temperature.
6.2.2 Natural curing
Curing and protection should start as soon as possible after the compaction of the concrete.
Curing is prevention against premature drying, particularly by solar radiation and wind. The curing
method shall be approved by the purchaser.
The principal measures for curing concrete are:
a) keeping the formwork in place;
b) covering with plastic films;
c) placing of wet coverings;
d) sprinkling with water;
e) application of curing compounds which form protective membranes.
The methods can be used separately or in combination.
To avoid surface cracking caused by heat generated in the concrete under normal conditions, the
temperature difference between the centre and the surface of the concrete shall be less than 20 °C.
The maximum permitted temperature shall not exceed those shown in Figure 4 and shall be reduced if
the sulfur trioxide content of the cement expressed as a percentage of the cement by weight exceeds
2 % (see Figure 5).
6.2.3 Accelerated curing
The introduction of heat to the concrete, in addition to the heat of hydration, shall be allowed to
increase the rate of gain of strength of the concrete. The maximum permitted temperature shall not
exceed those shown in Figure 4 and shall be reduced if the sulfur trioxide content of the cement
expressed as a percentage of the cement by weight exceeds 2 % (see Figure 5).
Any change in the curing process, such as maximum temperature of concrete and supported by results
from additional design tests shall be submitted to the purchaser f
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