TÜRK STANDARDI

TURKISH STANDARD

TS EN 13230-2
Ocak 2004

ICS 45.080

DEMİRYOLU UYGULAMALARI-DEMİRYOLU- BETON

TRAVERSLER VE MESNETLER- BÖLÜM 2:ÖNGERİLMELİ
YEKPARE TRAVERSLER

Railway applications - Track - Concrete sleepers and bearers

- Part 2: Prestressed monoblock sleepers

TÜRK STANDARDLARI ENSTİTÜSÜ

Necatibey Caddesi No.112 Bakanlıklar/ANKARA
 TÜRK STANDARDI

Ön söz

– Bu standard, Türk Standardları Enstitüsü tarafından ilgili Avrupa standardı esas alınarak Türk Standardı
olarak kabul edilmiştir.
EUROPEAN STANDARD EN 13230-2
NORME EUROPÉENNE
EUROPÄISCHE NORM December 2002

ICS 45.080

English version

Railway applications - Track - Concrete sleepers and bearers -

Part 2: Prestressed monoblock sleepers

Applications ferroviaires - Voie - Traverses et supports en Bahnanwendungen - Oberbau - Gleis- und

béton - Partie 2: Traverses monoblocs précontraintes Weichenschwellen aus Beton - Teil 2: Spannbeton-
Monoblockschwellen

This European Standard was approved by CEN on 9 October 2002.

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 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 Management Centre has the same status as the official
versions.

CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2002 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 13230-2:2002 E
worldwide for CEN national Members.
EN 13230-2:2002 (E)

Contents Page

Foreword .......................................................................................................................................................3
Introduction...................................................................................................................................................4
1 Scope ................................................................................................................................................4
2 Normative references .......................................................................................................................4
3 Definitions.........................................................................................................................................4
4 Product testing .................................................................................................................................4
4.1 Test arrangements ...........................................................................................................................4
4.1.1 Symbols ............................................................................................................................................5
4.1.2 Rail seat section ...............................................................................................................................6
4.1.3 Centre section ..................................................................................................................................8
4.2 Test procedures ...............................................................................................................................9
4.2.1 Test loads .........................................................................................................................................9
4.2.2 Static test........................................................................................................................................10
4.2.3 Dynamic test...................................................................................................................................14
4.2.4 Fatigue test.....................................................................................................................................15
4.3 Acceptance criteria ........................................................................................................................16
4.3.1 Static test........................................................................................................................................16
4.3.2 Dynamic test...................................................................................................................................16
4.3.3 Fatigue test.....................................................................................................................................16
4.3.4 Values of coefficients.....................................................................................................................16
4.4 Design approval tests ....................................................................................................................16
4.4.1 Bending moments evaluation ........................................................................................................17
4.4.2 Concrete .........................................................................................................................................17
4.4.3 Product inspection .........................................................................................................................17
4.4.4 Fastening system ...........................................................................................................................17
4.5 Routine tests ..................................................................................................................................17
4.5.1 Static rail seat positive load test....................................................................................................17
4.5.2 Concrete .........................................................................................................................................18
5 Manufacturing.................................................................................................................................18
5.1 Manufacturing rules .......................................................................................................................18
5.2 Position of prestressing steel........................................................................................................18
5.3 Tolerance on prestressing force....................................................................................................18
Annex A (normative) Detailed drawings of the test arrangements..........................................................19
A.1 Articulated support ........................................................................................................................19
A.2 Resilient pad...................................................................................................................................20
A.3 Tapered packing.............................................................................................................................21
Bibliography................................................................................................................................................22

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 EN 13230-2:2002 (E)

Foreword

This document EN 13230-2:2002 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 June 2003, and conflicting national standards shall be withdrawn at
the latest by June 2003.

This European Standard is one of the series EN 13230 "Railway applications -Track  Concrete sleepers and
bearers" which consists of the following parts:

 Part 1: General requirements;

 Part 2: Prestressed monobloc sleepers;

 Part 3: Twin-block reinforced sleepers;

 Part 4: Prestressed bearers for switches and crossings;

 Part 5: Special elements.

Annexe A is normative.

This document contains bibliographical references.

No other European Standard is superseded or replaced by this European Standard.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark,
Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal,
Spain, Sweden, Switzerland and the United Kingdom.

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EN 13230-2:2002 (E)

Introduction

This part of this European Standard defines the specific requirements relating to prestressed monobloc
sleepers.

These are additional requirements to EN 13230-1 and are necessary to have a complete standard dealing
with prestressed monobloc sleepers.

1 Scope

This part of this European Standard defines additional technical criteria and control procedures related to the
design and manufacture of prestressed monobloc sleepers.

2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications.
These normative references are cited at the appropriate places in the text and the publications are listed
hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to
this European Standard only when incorporated in it by amendment or revision. For undated references the
latest edition of the publication referred to applies (including amendments).

EN 206-1, Concrete – Part 1: Performance, production and conformity.

EN 13230-1:2002, Railway applications - Track – Concrete sleepers and bearers – Part 1: General
requirements.

3 Definitions

For the purpose of this standard, the definitions in EN 13230-1:2002 and the following definitions apply:

3.1
pretensioned monobloc sleeper
sleeper manufactured using pre-tensioned tendons

3.2
post-tensioned monobloc sleeper
sleeper manufactured using post-tensioned tendons

4 Product testing

4.1 Test arrangements

The test arrangements for the rail seat section and centre section tests are defined in this clause.

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 EN 13230-2:2002 (E)

4.1.1 Symbols

The following symbols are used:

Fr0 initial reference test load for the rail seat section, in kN;

Frr test load which produces first crack formation at the bottom of the rail seat section, in kN;

Fr0,05 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;

Fr0,5 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 test load at the rail seat section which cannot be increased, in kN;

Fu lower test load for the rail seat section dynamic test ; Fru = 50 kN;

Fc0 positive initial reference test load at the centre section of the sleeper, in kN;

Fc0n negative initial reference test load at the centre section of the sleeper, in kN;

Fcr positive test load which produces first crack formation at the centre of the sleeper, in kN;

Fcrn negative test load which produces first crack formation at the centre of the sleeper, in kN;

FcB positive test load at the centre section which cannot be increased, in kN;

FcBn negative test load at the centre section which cannot be increased, in 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;

Lc design distance between centre lines of the rail seat, in m.

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EN 13230-2:2002 (E)

4.1.2 Rail seat section

The arrangement for the rail seat positive load test is shown in Figure 1.

The load Fr is applied perpendicularly to the base of the sleeper.

The end of the sleeper opposite to the end being tested shall be unsupported.

Key

1 Rigid support
2 Articulated support (see annex A for details)
3 Resilient pad (see annex A for details)
4 Prestressed monobloc sleeper
5 Standard rail pad as defined by the purchaser
6 Tapered packing (see annex A for details)
7 Lateral stop

Figure 1 — Test arrangement at the rail seat section for the positive load test

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 EN 13230-2:2002 (E)

Table 1 — Value of Lr in relation to Lp

Lp in m Lr in m

Lp < 0,349 0,3

0,350 ≤ Lp < 0,399 0,4

0,5
0,400 ≤ Lp < 0,449
0,6
Lp ≥ 0,450

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EN 13230-2:2002 (E)

4.1.3 Centre section

The arrangement for the negative centre load test is shown in Figure 2.1

Key

1 Rigid support
2 Articulated support (see annex A for details)
3 Resilient pad (see annex A for details)
4 Prestressed monobloc sleeper
5 Standard rail pad as defined by the purchaser
6 Tapered packing (see annex A for details)

Figure 2.1 — Test arrangement at the centre section for the negative load test

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 EN 13230-2:2002 (E)

The test arrangement for the positive centre load test is shown in Figure 2.2

Key

1 Rigid support
2 Articulated support (see annex A for details)
3 Resilient pad (see annex A for details)
4 Prestressed monobloc sleeper

Figure 2.2 — Test arrangement at the centre section for the positive load test

4.2 Test procedures

4.2.1 Test loads

Fr0 is calculated from the geometry given in Figure 1 and values from Table 2 using the following equation:

4 Mdr
Fr0 = in kN.
Lr − 0,1

Table 2 — Value of Fr 0 in relation to Lr

Lr in m 0,3 0,4 0,5 0,6

Fr0 in kN 20 Mdr 13 Mdr 10 Mdr 8 Mdr

Fc0 and Fc0n are calculated from the geometry given in Figures 2.1 and 2.2 using the following equations:

4 Mdc 4 Mdcn
Fc 0 = in kN; Fc = in kN.
Lc − 0,1 0n L − 0,1
c

For the definitions of Mdr and Mdc : see EN 13230-1:2002 - clause 3.

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EN 13230-2:2002 (E)

4.2.2 Static test

4.2.2.1 Rail seat section

The static test procedure at the rail seat section for the design approval test and routine test is shown in
Figures 3.1 and 3.2.

Key
1 Load
2 Time
3 Crack checking
A Required part of test
B Optional part of test

Figure 3.1 - Static test procedure at the rail section for positive design approval test

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 EN 13230-2:2002 (E)

Key
1 Load
2 Time
A Required part of test
B Optional part of test

Figure 3.2 - Static test procedure at the rail section for positive routine test

Loading in the routine test may be continued to first crack to determine Frr and provide information on the
margin between Fr0 and Frr. This is not part of the pass/fail criteria.

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EN 13230-2:2002 (E)

4.2.2.2 Centre section

The static test procedure at the centre section for negative design approval test is shown in Figure
4.1.

Key
1 Load
2 Time

Figure 4.1 - Static procedure at the centre section for negative design approval test

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 EN 13230-2:2002 (E)

The test procedure at the centre section for positive design approval test is shown in Figure
4.2.

Key
1 Load
2 Time

Figure 4.2 - Static procedure at the centre section for positive design approval test

A centre routine test is not required.

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EN 13230-2:2002 (E)

4.2.3 Dynamic test

The dynamic test procedure at the rail seat section is shown in figure 5.

Key
1 Load
2 Time
3 5000 load cycles
4 Maximum time examination 5 min
5 Frequency (f) between 2 and 5 Hz
Figure 5a

Key
1 Load
2 Time
NOTE Typical cycle
Figure 5b

Figure 5 - Dynamic test procedure at the rail seat section

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 EN 13230-2:2002 (E)

4.2.4 Fatigue test

The fatigue test procedure at the rail seat section is shown in Figure 6.

Key
1 Load
2 Time
3 Frequencey (f) between 2 Hz and 5 Hz
for 2 million cycles
NOTE: First cycle (see Figure 3.1)
Figure 6a

Key
1 Load
2 Time
NOTE Typical cycle
Figure 6b

Figure 6 - Fatigue test procedure at the rail seat section

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EN 13230-2:2002 (E)

4.3 Acceptance criteria

The tests are managed according to the requirements of EN 13230-1:2002 - Clause 7. The crack width is
measured following the rules of EN 13230-1:2002 - 7.2.

4.3.1 Static test

The acceptance criteria for the static test are as follows:

4.3.1.1 Rail seat section

The acceptance criterion is: Frr > Fr0

If the non-mandatory part of the test is carried out, then Fr0,05 > k1s × Fr0

FrB > k2s × Fr0

4.3.1.2 Centre section

The acceptance criterion is: Fcrn > Fc0n

If the non-mandatory test for positive bending moment at the centre section is required, the purchaser shall
specify the acceptance criteria.

4.3.2 Dynamic test

The acceptance criteria for the dynamic test at the rail seat section are as follows:

 Fr0,05 > k1d × Fr0

 FrB > k2d × Fr0 or Fr0,5 > k2d × Fr0 (according to the requirements of the purchaser).

4.3.3 Fatigue test

The acceptance criteria for the fatigue test at the rail seat section after 2 .106 cycles are as follows:

 crack width is ≤ 0,1 mm when loaded at Fr0;

 crack width is ≤ 0,05 mm when unloaded.

 FrB > k3 × Fr0

When the load at the rail seat section is continuously increased at a rate of 120 KN/min from the unloaded
condition until failure FrB, the coefficient k3 shall be provided by the purchaser.

4.3.4 Values of coefficients

The coefficients k1 and k2 are defined in EN 13230-1:2002 - 4.3.1.

4.4 Design approval tests

The design approval tests to be carried out on the sleeper and concrete are the tests described in this
standard.

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 EN 13230-2:2002 (E)

All test results shall meet the acceptance criteria.

Each sleeper shall be used for one test only.

4.4.1 Bending moments evaluation

These tests are carried out in accordance with the test arrangements described in 4.1 and the test procedures
in 4.2.

a) static tests

rail seat section: on 6 sleepers (one rail seat per sleeper), for the positive bending moment;

centre section : 3 sleepers for the negative bending moment;

3 sleepers for the positive bending moment (optional test carried out at the request of the
purchaser).
b) dynamic test

rail seat section: on 6 sleepers (one rail seat per sleeper), for the positive bending moment.

c) fatigue test (optional test carried out at the request of the purchaser)

rail seat section: one rail seat for the positive bending moment.

4.4.2 Concrete

The properties of the concrete shall be established in accordance with EN 206-1.

4.4.3 Product inspection

Product inspection shall be carried out on all sleepers required for design approval tests including dimensions
and tolerances in accordance with EN 13230-1:2002 - Table 1 and the surface finish of the sleeper in
accordance with EN 13230-1:2002 - 6.3.

4.4.4 Fastening system

The tests shall be carried out in accordance with the European Standards on fastening systems as referenced
in EN 13230-1 or as required by the purchaser (see EN 13230-1:2002 - 4.4.1).

4.5 Routine tests

The routine tests are 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.

The routine tests to be carried out on the product and concrete are defined in this standard or another
European Standard.

4.5.1 Static rail seat positive load test

This test is carried out in accordance with the test arrangement shown in Figure 1 and the test procedures
shown in Figure 3.2.

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EN 13230-2:2002 (E)

4.5.2 Concrete

The tests are carried out in accordance with EN 13230-1:2002 - 7.4.

5 Manufacturing

5.1 Manufacturing rules

Before starting production, the supplier shall complete a production file for manufacturing data which shall be
submitted in confidence to the purchaser and shall include the following:

 water/cement ratio and tolerance;

 weight of each concrete component plus tolerance;

 grading curves for each concrete aggregate plus tolerance;

 properties of the concrete after 7 days and after 28 days;

 maximum relaxation for prestressing tendons after 1 000 h;

 description of the prestressing system including prestressing force and tolerance on each tendon;

 methods of concrete vibration;

 curing time and temperature cycle;

 minimum concrete compressive strength before releasing prestressing tendons ;

 method used for releasing prestressing force;

 stacking rules after manufacturing.

The sample sleepers submitted for design tests shall comply with the manufacturing data.

5.2 Position of prestressing steel

The position of the centroid of the prestressing tendons shall be within ± 3 mm from the design position
relative to the rail seat.

The individual prestressing tendons shall be within ± 6 mm from the design position relative to the rail seat.

Procedures shall be defined in the quality plan of the supplier.

The requirement for minimum concrete cover in EN 13230-1 shall apply to all the prestressing tendons.

5.3 Tolerance on prestressing force

The total prestressing force shall be applied within ± 5 % of the specified force.

Procedures shall be defined in the quality plan of the supplier.

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 EN 13230-2:2002 (E)

Annex A
(normative)

Detailed drawings of the test arrangements

A.1 Articulated support

This shall be as shown in Figure A.1.

Dimensions in millimetres

Key
1 Minimum length = bottom width of the concrete sleeper at the rail seat + 20 mm
2 High pressure lubricant
Material: steel: minimum Brinell hardness: HBW > 240
General tolerances: ± 0,1 mm

Figure A.1 — Articulated support

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EN 13230-2:2002 (E)

A.2 Resilient pad

This shall be as shown in Figure A.2.

Dimensions in millimetres

Key
1 Minimum length = bottom width of the concrete sleeper at the rail seat + 20 mm
Material: elastomer
Static stiffness (C) measured between 0,3 MPa and 2 MPa: 1 ≤ C ≤ 4 N/mm
3

Figure A.2 — Resilient pad

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 EN 13230-2:2002 (E)

A.3 Tapered packing

This shall be as shown in Figure A.3.

Dimensions in millimetres

Key
1 Minimum length = length of the standard rail pad + 20 mm
Material: steel: minimum Brinell hardness: HBW > 240
General tolerances: ± 0,1 mm
Note: i inclination of rail seat – see EN 13230-1

Figure A.3 — Tapered packing

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EN 13230-2:2002 (E)

Bibliography

EN ISO 9001, Quality management systems – Requirements (ISO 9001:2000)

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