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Bs en 13230 3 2009
Bs en 13230 3 2009
BRITISH STANDARD BS EN
13230-3:2009
Railway applications
— Track — Concrete
sleepers and bearers
Part 3: Twin-block reinforced sleepers
BS EN 13230-3:2009
National foreword
English Version
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 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 Management Centre has the same status as the
official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
© 2009 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 13230-3:2009: E
worldwide for CEN national Members.
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BS EN 13230-3:2009
EN 13230-3:2009 (E)
Contents Page
Foreword ..............................................................................................................................................................4
Introduction .........................................................................................................................................................5
1 Scope ......................................................................................................................................................6
2 Normative references ............................................................................................................................6
3 Terms and definitions ...........................................................................................................................6
4 Product testing.......................................................................................................................................6
4.1 Test arrangements .................................................................................................................................6
4.1.1 Symbols ..................................................................................................................................................6
4.1.2 Rail seat section.....................................................................................................................................7
4.2 Test procedures .....................................................................................................................................9
4.2.1 Test loads ...............................................................................................................................................9
4.2.2 Static test ............................................................................................................................................. 10
4.2.3 Dynamic test........................................................................................................................................ 12
4.3 Acceptance criteria ............................................................................................................................. 14
4.3.1 General ................................................................................................................................................. 14
4.3.2 Static test ............................................................................................................................................. 14
4.3.3 Dynamic test........................................................................................................................................ 14
4.3.4 Value of coefficients ........................................................................................................................... 15
4.4 Design approval tests ........................................................................................................................ 15
4.4.1 General ................................................................................................................................................. 15
4.4.2 Bending moment evaluation.............................................................................................................. 15
4.4.3 Concrete .............................................................................................................................................. 15
4.4.4 Product inspection ............................................................................................................................. 15
4.4.5 Fastening system................................................................................................................................ 15
4.5 Routine tests ....................................................................................................................................... 15
4.5.1 General ................................................................................................................................................. 15
4.5.2 Static rail seat positive load test ....................................................................................................... 16
4.5.3 Concrete .............................................................................................................................................. 16
5 Steel connecting bar .......................................................................................................................... 16
5.1 General ................................................................................................................................................. 16
5.2 Steel ..................................................................................................................................................... 16
5.2.1 Chemical composition ....................................................................................................................... 16
5.2.2 Mechanical properties ........................................................................................................................ 16
5.3 Geometry ............................................................................................................................................. 17
5.4 Appearance of the steel connecting bar .......................................................................................... 17
6 Design criteria for incorporating the steel connecting bar ............................................................ 17
6.1 Length of the connecting bar ............................................................................................................ 17
6.2 Orientation of the connecting bar ..................................................................................................... 18
6.3 Position of the connecting bar .......................................................................................................... 18
7 Manufacturing ..................................................................................................................................... 18
7.1 Manufacturing rules............................................................................................................................ 18
7.2 Other manufacturing rules ................................................................................................................. 18
Annex A (normative) Details of the test arrangement components ........................................................... 19
A.1 Articulated support ............................................................................................................................. 19
A.2 Resilient pad........................................................................................................................................ 20
A.3 Tapered packing ................................................................................................................................. 21
Annex B (normative) Steel connecting bar defects ...................................................................................... 22
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EN 13230-3:2009 (E)
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BS EN 13230-3:2009
EN 13230-3:2009 (E)
Foreword
This document (EN 13230-3:2009) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
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 December 2009, and conflicting national standards shall be withdrawn
at the latest by December 2009.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
This European Standard is one of the series EN 13230 "Railway applications – Track – Concrete sleepers and
bearers", which consists of the following parts:
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 EC Directive 2008/57/EC.
For relationship with EC Directive 2008/57/EC, see informative Annex ZA, which is an integral part of this
document.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.
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EN 13230-3:2009 (E)
Introduction
This part of the standard defines the specific requirements dedicated to twin-block reinforced sleepers.
These are additional requirements to EN 13230-1:2009 and are necessary to have a complete standard
dealing with twin-block reinforced sleepers.
The document specifies the test arrangements and the test procedures to implement and also the
corresponding acceptance criteria just as the design approval tests
It also specifies the steel connecting bar characteristics and the design criteria for incorporating the steel
connecting bar within the twin-block reinforced sleepers.
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1 Scope
This part of EN 13230 defines technical criteria and control procedures for designing and manufacturing
twin-block reinforced concrete sleepers.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
EN 10002-1, Metallic materials – Tensile testing – Part 1: Method of test at ambient temperature
EN 13230-1:2009, Railway applications – Track – Concrete sleepers and bearers – Part 1: General
requirements
EN ISO 6506-1, Metallic materials – Brinell hardness test – Part 1: Test method (ISO 6506-1:1999)
3.1
steel connecting bar
steel profile which connects reinforced concrete blocks
4 Product testing
This section defines the testing regime and rules for acceptance of twin-block concrete sleepers.
The layout of test arrangements for the rail seat section tests are defined in this section.
4.1.1 Symbols
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Table 1 — Symbols
Symbol Designation
Fr0 Positive initial reference test load for the rail seat section, in kN
Fr0n Negative initial reference test load at rail seat section, in kN; Fr0n = ½· Fr0
Frr Positive test load which produces first crack formation at the bottom of the rail seat section,
in kN
Frrn Negative test load which produces first crack formation at the top of rail seat, in kN
Fr0,05 Maximum test load for which a crack width of 0,05 mm at the bottom of the rail seat section
persists after removal of the load, in kN
Fr0,05n Maximum test load for which a crack width of 0,05 mm at the top of rail seat section persists
after removal of the load, in kN
Fr0,5 Maximum test load for which a crack width of 0,5 mm at the bottom of the rail seat section
persists after removal of the load, in kN
FrB Maximum positive test load at the rail seat section which cannot be increased, in kN
FrBn Maximum negative test load on the top of rail seat section which cannot be increased, in kN
Fru Lower test load for the rail seat section dynamic test; Fru = 50 kN
Lp Design distance between the centre line of the rail seat to the edge of the sleeper at the
bottom, in m
Lr Design distance between the articulated support centre lines for the test arrangement at the
rail seat section, in m
Mdr Positive design bending moment at rail seat, in kNm
k1s Static coefficient to be used for calculation of Fr0,05 or Fr0,05n test load
k2s Static coefficient to be used for calculation of Fr0,5 or FrB test load
k2d Dynamic coefficient to be used for calculation of Fr0,5 or FrB test load
The arrangement for the rail seat positive load test is shown in Figure 1.
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Key
1 Rigid support
2 Articulated support (see Annex A for details)
3 Resilient pad (see Annex A for details)
4 Reinforced concrete block
5 Standard rail pad as defined by the purchaser
6 Tapered packing (see Annex A for details)
7 Lateral stop and base plate when used. To be agreed by the purchaser
Figure 1 — Test arrangement at the rail seat section (positive bending moment)
The test arrangement for the rail seat negative load test is shown in Figure 2, the value of Lr in relation to Lp.is
detailed in Table 2.
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Key
1 Rigid support
2 Articulated support (see Annex A for details)
3 Resilient pad (see Annex A for details)
4 Reinforced concrete block
5 Special tapered packing
6 Special tapered packing
Figure 2 — Test arrangement at the rail seat section (negative bending moment)
Lp in m Lr in m
Fr0 is calculated from the geometry given in Figure 1 and values from Table 3 using the following equation:
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4 Mdr
Fr0 = in kN (1)
Lr − 0,1
The static test procedure at the rail seat section for design approval and routine tests is shown in Figures 3, 4
and 5.
Key
1 Load
2 Time
3 Crack checking (maximum duration 5 min)
4 120 kN/minute maximum
5 From 10 s minimum to 5 min maximum
A Required part of test
B Optional part of test
Figure 3 — Static test procedure at the rail seat section for positive design approval test
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EN 13230-3:2009 (E)
Key
1 Load
2 Time
3 Crack checking (maximum duration 5 min)
4 120 kN/min maximum
5 From 10 s minimum to 5 min maximum
A Required part of test
B Optional part of test
Figure 4 — Static test procedure at the rail seat section for negative design approval test
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EN 13230-3:2009 (E)
Key
1 Load
2 Time
3 Crack checking (maximum duration 5 min)
4 120 kN/min maximum
5 From 10 s minimum to 5 min maximum
A Required part of test
B Optional part of test
Figure 5 — Static test procedure at the rail seat section for positive routine test
Loading in the routine test may be continued to Fr0,05 and provide information on the margin between
k1s × Fr0 and Fr0,05. This is not part of the pass/fail criteria.
The dynamic test procedure at the rail seat section is shown in Figures 6 and 7. The dynamic test
arrangement is shown in Figure 1. The test is carried out on only one block after cutting the steel connecting
bar.
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Key
1 Load
2 Time
3 5000 load cycles
4 Maximum time examination 5 min
5 Frequency (f ) between 2 Hz and 5 Hz (identical frequency maintained during duration of test)
6 Load step before k1d × Fr0 and k2d × Fr0 smaller than 20 kN
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EN 13230-3:2009 (E)
Key
1 Load
2 Time
4.3.1 General
The tests shall be managed according to the rules of EN 13230-1:2009. The crack width shall be measured
following the rules of EN 13230-1:2009, sub-clause 7.2.
The acceptance criterion for the static tests at the rail seat section is as follows:
The acceptance criterion for the dynamic test at the rail seat section is as follows:
FrB > k2d × Fr0 or (according to the requirements of the purchaser) Fr0,5 > k2d × Fr0
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4.4.1 General
The design approval tests to be carried out on the sleeper and concrete comprise the tests already defined in
this standard.
Each concrete sleeper block shall be used for one test only.
These tests shall be carried out in accordance with the test arrangements shown in Figures 1 and 2 and the
test procedures in 4.2.
a) Static test
1) both rail seat sections on 3 sleepers for the positive bending moment;
2) both rail seat sections on 3 sleepers for the negative bending moment (optional test carried out at the
request of the purchaser).
b) Dynamic test
4.4.3 Concrete
Product inspection shall be carried out on all sleepers required for design approval tests including dimensions
and tolerances in accordance with EN 13230-1:2009, Table 1 and the surface finish of the sleeper in
accordance with EN 13230-1:2009, 6.3.
Test shall be carried out in accordance with the European standards on fastenings systems as referenced in
EN 13230-1:2009 or as required by the purchaser (see EN 13230-1:2009, 4.4.1).
4.5.1 General
The routine tests shall be carried out in order to find any variation in the quality of the concrete sleeper leading
to an unacceptable quality level.
The number of samples and rates of tests are given in the quality plan for the manufacturing unit.
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The routine tests to be carried out on the product and concrete are defined in this standard.
This test shall be carried out in accordance with the test arrangement shown in Figure 1 and the test
procedures shown in Figure 5.
4.5.3 Concrete
5.1 General
This section specifies the properties and the quality control requirements for the hot rolled steel connecting
bar for twin-block reinforced sleepers.
5.2 Steel
The chemical composition of the steel shall be within the following limits:
0,28 % ≤ C ≤ 0,80 %
0,45 % ≤ Mn ≤ 1,40 %
P ≤ 0,08 %
S ≤ 0,08 %
Si ≤ 0,50 %
The mechanical properties (conventional yield strength at 0,2 % plastic strain, percentage elongation at
fracture) shall be maintained within the following limits:
where
Brinell hardness (HBW) to be 160 ≤ HBW ≤ 300 when tested according to EN ISO 6506-1.
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5.3 Geometry
When determining the dimensions, the following criteria shall be taken into account:
a) corrosion of steel;
c) avoidance of any excessive negative moment in the steel connecting bar due to the bearing of its centre
part on the ballast;
Criteria for the acceptance of steel connecting bar are defined in Annex B.
Connecting bar length (Lcb) shall be at least greater than the distance L1 (EN 13230-1:2009, Figure 2), unless
approved by the purchaser.
Key
he Distance between bottom surface of the sleeper to steal connecting bar
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If the connecting bar is not protected against corrosion, the orientation and shape shall avoid retention of
water.
Unless otherwise prescribed for handling purposes, the distance "he" (Figure 8) shall be a minimum of 40 mm.
7 Manufacturing
Before starting production, the manufacturer shall complete a production file for manufacturing data, which
shall be submitted in confidence to the purchaser and shall include the following:
d) characteristic compressive and tensile strength of concrete samples after 7 days and after 28 days;
The sample sleepers submitted for design approval tests shall comply with the manufacturing data.
Welding to a connecting bar is not allowed unless the welding procedures, including controlled heating and
cooling of the whole section of the connecting bar, have been approved by the purchaser.
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Annex A
(normative)
Key
Steel: Minimum hardness Brinell: HBW > 240
General tolerances: ± 0,1 mm
1 Minimum length = bottom width of the concrete sleeper at the rail seat + 20 mm
2 High pressure lubricant
Figure A.1 — Articulated support
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Dimensions in millimetres
Key
Material : Elastomer
3
Static stiffness measured between 0,3 MPa and 2 MPa: 1 ≤ C ≤ 4 N/mm
1 Minimum length = bottom width of the concrete sleeper at the rail seat + 20 mm
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Dimensions in millimetres
Key
Steel: Minimum hardness Brinell: HBW > 240
General tolerances: ± 0,1 mm
i : inclination of rail seat – see EN 13230-1:2009
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Annex B
(normative)
Superficial burn is accepted if its depth does not exceed 3 mm over a maximum length of 500 mm at each end,
which is embedded in the concrete.
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Tear at the end is accepted, if its depth does not exceed 20 mm and it is not present on more than 5 % of the
bars in the same batch.
This kind of cut is accepted for the same conditions as the tear at the end is accepted (B.2).
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The surface defect is accepted if it appears only on the external faces of the bar and if its dimension E is
greater or equal to the minimum tolerance of the thickness and:
The surface defect is not permitted if it is on the interior faces of the bar.
B.5 Splitting
Splitting is a line affecting the square edge of the bar.
Splitting at the extremities of the bars can be accepted if its length does not exceed 500 mm at each extremity
of the bar and if its depth is less than 5 mm.
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Deformation of the extremities of the bar is accepted if on a length of 500 mm at each extremity (the part
embedded in the concrete) it does not exceed a deformation d of 5 mm on length l less than 100 mm.
Except for the part embedded in concrete scaling must be removed by grinding and the depth must not
exceed 0,5 mm.
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Annex ZA
(informative)
This European Standard has been prepared under a mandate given to CEN/CENELEC/ETSI by the European
Commission and the European Free Trade Association to provide a means of conforming to Essential
Requirements of the Directive 2008/57/EC.
Once this standard is cited in the Official Journal of the European Communities under that Directive and has
been implemented as a national standard in at least one Member State, compliance with the clauses of this
standard given in Table ZA.1 for High Speed Rail Infrastructure and Table ZA.2 for Conventional Rail confers,
within the limits of the scope of this standard, a presumption of conformity with the corresponding Essential
Requirements of that Directive and associated EFTA regulations.
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Table ZA.1 —Correspondence between this European Standard, the Infrastructure TSI for the trans-
European high-speed rail system, dated 20 December 2007 (published in the Official Journal L77,
19.03.2008, p.1), and Directive 2008/57/EC
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Table ZA.2 —Correspondence between this European Standard, the ERA draft of Conventional Rail
System TSI Infrastructure (version 2.71 dated 07/10/2008), and Directive 2008/57/EC
5.3.3.
Interoperability constituents –
Constituents performances and
specifications – Track sleepers
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6.2.4.5.
Assessment of conformity
and/or suitability for use of the
constituents and verification of
the subsystem – Infrastructure
sub-system – Requirements for
conformity assessment –
Assessment of minimum value
of mean track gauge
WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling
within the scope of this standard.
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Bibliography
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