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Abstract
Extending the use of continuous welded rails by eliminating the weak points (expansion joints) of a railway track
especially in sharp curves, which has resulted in increasing the operational speed and axle load of rolling stocks, enhances
the special attention to the issue of track lateral resistance. In this regard, the ballast layer interaction with sleepers plays
a crucial role in providing the track lateral stability. In many railway projects supplying the appropriate ballast materials
has encountered serious restrictions owing to the lack of qualified ore and also their long distance to the project’s site.
With the development of steel industry, the quantity of production and accumulation of steel slag as a waste material has
increased. In recent years, a great deal of attention has been paid to the use of this material as railway ballast. According
to the physical and mechanical characteristics of steel slags, such as high specific gravity and the granular roughness
respect to the limestone ballast, the usage of slag ballast can improve the track lateral stability. In this research, many field
experiments were conducted on tracks with steel slag ballast and limestone ballast materials considering the same
gradation. In this matter, several single tie push tests were carried out on both tracks with various ballast geometries.
The ballast depth was considered as 30, 40, and 50 cm and the shoulder ballast width was equal to 30 and 40 cm.
Moreover, the shoulder ballast height was chosen 0 and 10 cm. Consequently, the lateral resistance of both tracks was
measured and compared in the same conditions. In overall, the obtained results confirmed a 27% increase in lateral
resistance of track with steel slag ballast respect to that with limestone ballast.
Keywords
Ballasted railway track, lateral resistance, steel slag ballast, limestone ballast, single tie push test, ballast geometry
and fasteners, and the applied lateral forces on track track as a part of Hassan Abad-Diziche railway route
by moving trains.7,8 Typically, it is possible to provide in Isfahan province.15
sufficient lateral resistance for the track by substitut- Reviewing the technical literature reveals various
ing the ballast materials with appropriate and high methods for increasing the lateral resistance in bal-
quality materials.9 lasted tracks such as using frictional sleepers,27,28 use
Slag is a by-product material, which is produced of vertical wings in wooden and concrete sleepers29,
during the production process of metals such as steel, utilizing the Y-shaped sleepers and installation of lat-
copper, nickel, and so on. This material includes metal- eral wings and frame sleeper.30–33 As a special case,
lic and non-metallic stable oxides typically containing application of in situ polyurethane geo-composite
20% of melted form of initial metal core. Besides the beams known as Xia Track has been proposed to
economic benefits, recycling these materials reduces improve the passive shoulder resistance of a railway
environmental pollutions and preserves the natural track.34,35 On account of its high specific gravity and
rock sources. After molting the iron core, a heavy frictional specifications respect to the limestone ballast,
phase is formed that perches in a lower level and the the application of steel slag ballast in ballasted tracks
additional mine core material produces another phase increases the track lateral resistance. This issue has not
with lower specific gravity which consequently perches been studied in previous research works in the field of
over the last phase. The later phase is called slag. The ballasted railway tracks. Therefore, the present study
slag produced in this stage called blast furnace slag. was allocated to investigation of steel slag ballast
Molten materials are not pure enough. These materials effects on increasing the track lateral resistance in com-
are poured again in furnace. So, during the refine pro- parison with the limestone ballasted track.
cess, a new slag is produced which is called steel slag. In the literature, various methods have been pro-
The volume of slag produced in the USA in 2012 will posed for assessing the lateral resistance of a ballasted
be estimated to reach to 16 million tons.10 An average track comprising single tie (sleeper) push test (STPT),
production rate for both steel and blast furnace slags in panel displacement test, mechanical track displace-
Europe till 2010 was 45 million tons.11 Referring to the ment test, derailment wagon test, the continuous
last report from Australia, the rate of slag production dynamic measurement, and the lateral tensile test in
was 3.4 million tons.12 According to the latest statistics the middle of sleeper.1 Among the mentioned meth-
from Japan in 2012, 24 million tons blast furnace slag ods, the STPT is known as the most popular method
and 13.5 million tons steel slag were produced.13,14 In in railway experiments.7 In this study, for investigat-
Iran, Mobarakeh Steel Company annually produces ing the effect of steel slag ballast on the track lateral
9.5 million tons slag while the Isfahan Steel resistance in comparison with the limestone ballasted
Company production capacity is about 0.4 million track, a test track was constructed including 18 slee-
tons of blast furnace slag and 0.4 million tons steel pers nine of which were embedded in the slag ballast
slag.15 Furthermore, the annual capacity of layer and the others were located inside the limestone
Khuzestan steel company is 0.5 million tons of blast ballast layer. The middle sleeper in each part was
furnace slag. Regarding the high volume of slag pro- released from the rails for conducting the STPT.
duction in Iran and all over the world, the usage of this During the STPTs various ballast depths of 30, 40,
material seems a challenging issue. and 50 cm as well as shoulder ballast widths of 30
For this reason, nowadays, the steel slag is used as and 40 cm were examined. Moreover, the shoulder
a valuable raw material in different sections, including ballast height was set to two different values of
road infrastructure, water rivers treatment, concrete 0 and 10 cm. Finally, a detailed comparison of
and asphalt cement production.16–20 In recent years, STPTs results were accomplished for both track
the application of this waste material for railway bal- parts at the same geometrical conditions.
last production has been proposed. For instance, in
Canada and for Toronto-Montreal double railway
route, two different ballast layers of granite and slag Test track specifications and parameters
materials with 30 cm of depth were adopted.21
Steel slag and limestone ballasts specifications
Moreover, in Denver and Rio Grande railway line,
the slag ballast was executed.22,23 In Brazil, utilization In this research, the steel slag of Mobarakeh Steel
of the steel slag ballast in railway construction started Company was used. This slag was produced by elec-
from 1996.24 The Seixal Company in Portugal also tric arc furnace method. In this method, cool scrap
used steel slag to stabilize the pavement in railway steel is poured in furnace and heated by three elec-
tracks.25 In the states of America, steel slag is used trodes. The electricity passes between the electrodes
for various applications such as railways ballast, con- and creates an arc electric. The heat generated by
crete aggregates, concrete block production and road the arc melts scraps. During the melting process, the
base construction. For example, the steel slag ballast lime is added to the furnace to form a non-metallic
was used for dressing and raising the rails on major product and simultaneously the oxygen is blown
western main line near to California-Nevada border.26 into the furnace to purify the steel. At the last stage,
In Iran, the steel slag ballast was adopted in a test steel and molten slag will be poured into caldron
separately. After cooling, the steel slag is crushed to dimensions of ballast material. Sieve analyses were
appropriate sizes of 2–6 cm, which can be used as done on steel slag and limestone ballast materials
crushed ballast materials.15 according to the ASTM C136 to define their accurate
On the other hand, the limestone ballast was pro- gradation.36 Both steel slag and limestone ballasts
vided from one of the rocky mountains of Isfahan city gradations are in the category of grade four based
called Iran-kuh. This kind of ballast was extracted on the specifications of the Iran code 301 for ballasted
from limestone mine and crushed into appropriate railway track superstructure.37 Figures 1 and 2 show
the samples of the steel slag and limestone ballasts.
Mechanical and physical specifications of limestone
and steel slag ballasts were evaluated based on the
relevant ASTM standards and presented in Table 1.
According to this table, the more granular unit weight
of steel slag ballast relative to the limestone ballast
leads to the more lateral resistance in track corres-
pondingly. Regarding the abrasion resistance, the
slag steel ballast has shown more resistance than
the lime stone ballast in both Los Angeles and
Micro-Deval tests which results in less degrading
and crushing during the track operation. These tests
were carried out in accordance with ASTM stand-
ards.38,39 Furthermore, the better abrasive perform-
ance of slag ballast respect to limestone ballast
increases the maintenance period of ballast and
decreases the maintenance costs as well. As shown
in Table 1, the peak mobilized friction angle of steel
slag ballast is also more than that of limestone ballast.
Figure 1. Limestone ballast.
This parameter has been obtained from direct shear
test results conducted based on the ASTM D3080.40
The superiority of steel slag ballast parameters to
limestone ballast can be accounted as positive signs
for increasing the track lateral resistance which is the
main issue of the next section of the present study.
Lime
Feature Unit stone ballast Steel slag Standard
Figure 3. The test track plan containing limestone and steel slag ballasts parts for STPT.
Figure 4. STPT set up including: (a) loading jack, (b) displacement sensor, (c) data acquisition system with battery.
Figure 6. Geometrical dimensions of the test track section with variable parameters.
(a) 18 (b) 18
Lateral resistance - kN
Lateral resistance - kN
16 BK SH 16
14 BK SH
14
12 SB - 0 12 SB - 0
10 SB - 10 10 SB - 10
8 8
6 LB - 0 6 LB - 0
4 4
LB - 10 LB - 10
2 2
0 0
30 40 50 30 40 50
Ballast depth - cm Ballast depth - cm
Figure 7. Lateral resistance versus ballast depth for limestone and slag ballasts: (a) for shoulder width of 30 cm and (b) for shoulder
width of 40 cm. BK: ballast kind; SH: shoulder height; SB: slag ballast; LB: limestone ballast.
8 No BK BD SW SH
7 1- SB - 30 - 30 - 0
6 2- SB - 30 - 30 - 10
Lateral force - kN
5 1- LB - 30 - 30 - 0
4 2- LB - 30 - 30 - 10
3 3- SB - 30 - 40 - 0
2 4- SB - 30 - 40 - 10
1 3- LB - 30 - 40 - 0
4- LB - 30 - 40 - 10
0
0 0.5 1 1.5 2 2.5
Lateral displacement - mm
Figure 8. Force-displacement diagrams for ballast depth of 30 cm including shoulder width of 30 and 40 cm with and without
shoulder height. No: number of test; BK: ballast kind; BD: ballast depth; SW: shoulder width; SH: shoulder height; SB: slag ballast; LB:
limestone ballast.
18
No BK BD SW SH
16 5- SB - 40 - 30 - 0
14 6- SB - 40 - 30 - 10
Lateral force - kN
12
5- LB - 40 - 30 - 0
10
6- LB - 40 - 30 - 10
8
7- SB - 40 - 40 - 0
6
8- SB - 40 - 40 - 10
4
2 7- LB - 40 - 40 - 0
0 8- LB - 40 - 40 - 10
0 0.5 1 1.5 2 2.5
Lateral displacement - mm
Figure 9. Force-displacement diagrams for ballast depth of 40 cm including shoulder width of 30 and 40 cm with and without
shoulder height. No: number of test; BK: ballast kind; BD: ballast depth; SW: shoulder width; SH: shoulder height; SB: slag ballast; LB:
limestone ballast.
16
No BK BD SW SH
14
9- SB - 50 - 30 - 0
12
Lateral force - kN
10- SB - 50 - 30 - 10
10 9- LB - 50 - 30 - 0
8 10- LB - 50 - 30 - 10
6 11- SB - 50 - 40 - 0
4 12- SB - 50 - 40 - 10
2 11- LB - 50 - 40 - 0
0 12- LB - 50 - 40 - 10
0 0.5 1 1.5 2 2.5
Lateral displacement - mm
Figure 10. Force-displacement diagrams for ballast depth of 50 cm including shoulder width of 30 and 40 cm with and without
shoulder height. No: number of test; BK: ballast kind; BD: ballast depth; SW: shoulder width; SH: shoulder height; SB: slag ballast; LB:
limestone ballast.
NO BK SH
1- LB - 0
2-SB - 0
18
Sleeper lateral resistance - kN
3- LB - 10
4- SB - 10 16
5- LB - 0
6- SB - 0 14
7- LB - 10 12
8- SB - 10 10
9- LB - 0
10- SB - 0 8
11- LB - 10 6
12- SB - 10
13- LB - 0 4
14- SB - 0 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
15- LB - 10
16- SB - 10
0
17- LB - 0
18- SB - 0 SW = 30 cm SW = 40cm SW = 30 cm SW = 40cm SW = 30 cm SW = 40cm
19- LB- 10
20- SB - 10
21- LB - 0 BD = 50 cm
22- SB - 0 BD = 30 cm BD = 40 cm
23- LB - 10
24- SB - 10
Figure 11. Histograms of sleeper lateral resistances for all conditions with different geometries. No: number of test; BK: ballast kind;
BD: ballast depth; SW: shoulder width; SH: shoulder height; SB: slag ballast; LB: limestone ballast.
geometries were examined in this matter. The major (c) In the case of zero shoulder height, the ratio of lat-
quantitative findings of these experiments can be sum- eral resistance of steel slag to the limestone ballast
marized as follows: was averagely 1.28 whereas for the ballast shoulder
height of 10 cm, this ratio has been raised to 1.26.
(a) In average, in the ballast depth of 30 cm, the lat- (d) An increase in ballast shoulder width in both bal-
eral resistance of slag steel was obtained 1.13 last types led to an increase in the lateral resist-
times more than that of limestone ballast while ance. However, this increase for steel slag
these value for ballast depths of 40 and 50 cm ballasted track with 30 cm shoulder width was
were 1.38 and 1.31, respectively. 2.8 times higher than that for limestone ballasted
(b) For shoulder ballast width of 30 cm, the lateral track with 40 cm shoulder width.
resistance of steel slag has been averagely (e) Considering all STPTs results, it can be concluded
achieved 1.35 times more than that of limestone that the test track with steel slag ballast has aver-
ballast. However, in shoulder width of 40 cm this agely shown 27% more lateral resistance than the
amount was 1.19 times. track with limestone ballast.
On the basis of the obtained results, the application 15. Riva Tahghigh Company. Product information, steel
of steel slag instead of limestone ballast material is slag production for use in railway construction. Steel
suggestible from both technical and economical slag recovery, Isfahan. www.rivatahghigh.com (2014).
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Declaration of Conflicting Interests 19. Lun Y, Zhou M, Cai X, et al. Methods for improving
volume stability of steel slag as fine aggregate. J Wuhan
The author(s) declared no potential conflicts of interest with Univ Technol Mater Sci Ed 2008; 23: 737–742.
respect to the research, authorship, and/or publication of 20. Takahashi T and Yabuta K. New application of iron
this article. and steel making slag. NKK Technical Report-Japanese
Edition. 2002: 43–48.
Funding 21. Calla C. Two layered ballast system for improved per-
The author(s) disclosed receipt of the following financial formance of railway track. PhD Dissertation. Coventry
support for the research, authorship, and/or publication University, UK, 2003.
of this article: This work was supported by the Iranian 22. Canadian National, Railway Investigation Report.
Railway Research Center (S-2430). Main-Track Derailment. Report Number R07T0110.
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23. Railway Investigation Report. R03t0080. Canadian
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