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Construction and Building Materials 193 (2018) 244–254

Contents lists available at ScienceDirect

Construction and Building Materials


journal homepage: www.elsevier.com/locate/conbuildmat

Evaluation of grouting layer vibration of railway precast concrete slab


track system
Young Kyo Cho, Seong-Min Kim ⇑
Department of Civil Engineering, Kyung Hee University, 1732 Deogyeong-daero, Giheung, Yongin-si, Gyeonggi-do 17104, Republic of Korea

h i g h l i g h t s

 Grouting layer behaviors of PST are evaluated depending on bonding characteristics.


 Grouting layer vibrations are measured and analyzed using a mockup segment of PST.
 Effects of grouting layer shapes on the vibration are comprehensively examined.
 Suggestions to mitigate damages of the grouting layer of PST are proposed.

a r t i c l e i n f o a b s t r a c t

Article history: The vibration of the grouting layer of the railway precast/prefabricated concrete slab track (PST) system
Received 4 May 2018 was comprehensively evaluated by conducting numerical and experimental analyses. The behaviors of
Received in revised form 24 June 2018 the grouting layer were thoroughly analyzed numerically depending on the bonding characteristics
Accepted 28 October 2018
among the layers of the PST system. The methods to reduce the excessive stresses of the grouting layer
Available online 30 October 2018
were examined by changing the shape of the grouting layer. An experimental analysis was also
performed using a mockup segment of the PST system to find the vibration characteristics of the grouting
Keywords:
layer and to verify the effectiveness of changing the grouting layer shape for reducing stresses and
Precast slab track
Railway
associated damages. Finally, suggestions were proposed to mitigate damages of the grouting layer caused
Grouting layer by the excessive vibration.
Impact loading Ó 2018 Elsevier Ltd. All rights reserved.
Vibration
Damage
Corner shape

1. Introduction There are several different types of precast/prefabricated con-


crete slab track (PST) systems. Some of them include the Shinkan-
Concrete slab track systems are currently used widely for rail- sen system developed in Japan [8–9], the Bögl system developed in
ways because of their outstanding durability under the loads Germany [10–15], the Slab Track Austria system developed in Aus-
caused by high speed and heavyweight trains and because they tria [16], and the CRTS series systems developed in China [17–21].
require less maintenance than ballasted tracks. The railway con- The PST systems are also being applied and improved in Korea as
crete slab tracks include discrete and continuous track systems. shown in Fig. 1 [22]. To achieve the high performance of the rail-
The discrete concrete slab tracks are normally constructed using way PST systems, a number of studies have been performed in
precast concrete slabs and the continuous concrete slab tracks many countries [23–32].
are built using cast-in-place concrete slabs [1–7]. The discrete con- The PST system is generally composed of three layers. The pre-
crete slab tracks using precast concrete slabs are being applied cast concrete slab lies at the top, the grouting layer exists at the
increasingly in many countries since the factory-made concrete middle, and the basecourse is at the bottom. One of the Korean
slabs have excellent qualities and the construction of railway PST systems was constructed in a 4.8 km long tunnel of Jungang
tracks is faster. Line at Mangmiri, Gyeonggido. When the PST system was con-
structed, the precast concrete slabs were installed on the basec-
ourse and the empty space between the concrete slab and
basecourse was grouted using cement-based materials. The grout-
⇑ Corresponding author. ing layer of that PST system has the same area of the concrete slab.
E-mail addresses: brain@khu.ac.kr (Y.K. Cho), seongmin@khu.ac.kr (S.-M. Kim). The general performance of that PST system was satisfactory, but

https://doi.org/10.1016/j.conbuildmat.2018.10.216
0950-0618/Ó 2018 Elsevier Ltd. All rights reserved.
Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254 245

middle of the basecourse in the longitudinal direction and at


0.35 m inside from the outside edge of the basecourse in the trans-
verse direction. The thicknesses of the concrete slab, grouting
layer, and basecourse are 0.225 m, 0.043 m, and 0.180 m, respec-
tively. The underlying layer of the basecourse is assumed to be a
bedrock since the PST system considered in this study was con-
structed in a tunnel. The 8 noded linear rectangular solid finite ele-
ments with the element size on the horizontal plane of 0.05 m by
0.05 m are employed. The numbers of the elements in the vertical
direction of the concrete slab, grouting layer, and basecourse are 6,
3, and 4, respectively. When the layers are bonded to each other,
those are tied at the interfaces. When the layers are not bonded
at the interfaces, the hard contact is employed in the vertical direc-
tion and no friction is assumed in the horizontal direction. The
basecourse is assumed to be completely bonded to the underlying
bedrock. In order to investigate the critical responses of the system,
the loads are applied at the left and right outermost slipper loca-
Fig. 1. Precast concrete slab track (PST) system.
tions as shown in Fig. 3. The actual magnitudes of the loads vary
depending on the weight of train, speed of train, smoothness of
some damages of the grouting layer were found. Most of the dam- rail, etc. To use a load within a reasonable range, an axle load of
ages were cracking and popout of the grouting layer at the corners 250 kN (wheel load of 125 kN) is applied in this study based on
as shown in Fig. 2. Therefore, research is needed to discover the the design axle load of 220 kN, load distribution factor of 0.5,
causes of the grouting layer damages and to find strategies for mit- dynamic impact factor of 2.0, and load amplification factor of
igating these damages. 1.15. The material properties, thicknesses of the layers, and applied
The objectives of this study are to investigate the dynamic loads used for numerical analyses are summarized in Table 1.
responses of the grouting layer lying between the precast concrete The different cases of bonding characteristics among the layers
slab and basecourse when the PST system is subjected to impact of the PST system that are considered in this study are shown in
loadings, and to suggest methods to reduce the vibration of the Fig. 4. The first case represents no bonding among the layers (P-
grouting layer and associated damages. To analyze the behaviors G-B case), the second case assumes perfect bonding between the
of the grouting layer, static and dynamic analyses are performed precast concrete slab and grouting layer and no bonding between
by using numerical models of the PST system. In addition, experi- the grouting layer and basecourse (PG-B case), the third case
ments are carried out using a mockup segment of the PST system assumes no bonding between the precast concrete slab and grout-
and the measurement data are analyzed to find the vibration char- ing layer and perfect bonding between the grouting layer and
acteristics of the grouting layer. By comparing the numerical and basecourse (P-GB case), and the last case represents perfect bond-
experimental analysis results, suggestions are proposed to reduce ing among the layers (PGB case). The PST system was originally
damages of the grouting layer caused by the excessive vibration. designed as the P-GB case. However, the PGB case can occur at very
early stages of the system, and later the PG-B or P-GB cases can
develop. After a large number of load repetitions, the P-G-B case
2. Numerical analysis may develop.

2.1. Numerical modeling of PST


2.2. Static analysis
In order to find the static and dynamic responses of the grouting
layer of the PST system, a three-dimensional finite element model The behaviors of the grouting layer of the PST system under the
of the PST system has been developed [33] based on the actual PST static loading are investigated depending on the bonding charac-
system considered in this study. As shown in Fig. 3, the PST system teristics among the layers. Fig. 5 shows the typical deflected shape
is composed of three layers: precast concrete slab, grouting layer, and stress distribution of the grouting layer when the PST system is
and basecourse. The longitudinal and transverse lengths of both subjected to the static loading.
the concrete slab and the grouting layer are 3.65 m and 2.3 m, The static analysis results show that the stresses of the grouting
respectively. The transverse length of the basecourse is 3.65 m layer are affected by the bonding characteristics among the layers
and the longitudinal length used in the analysis is 10 m even as shown in Fig. 6. The longitudinal stresses at the bottom of the
though the basecourse is continuous. The concrete slab lies at the grouting layer along the longitudinal edge of the grouting layer

Fig. 2. Damages of the grouting layer.


246 Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254

(a) Outline of numerical model of PST system

(b) Finite element modeling


Fig. 3. Numerical model of PST system.

Table 1 has the largest tensile stresses. The maximum tensile stresses that
Input values for numerical analysis. occurred in the grouting layer are obtained by observing the whole
Variable Value areas and are listed in Table 2. As investigated, the largest tensile
Elastic modulus of concrete slab (GPa) 31.9
stress of the grouting layer occurs for the PG-B case. However,
Elastic modulus of grouting layer (GPa) 31.9 for all the different bonding cases, the magnitudes of the maximum
Elastic modulus of basecourse (GPa) 11.3 tensile stresses are much smaller than the tensile strength of the
Thickness of concrete slab (mm) 225 grouting layer, which is normally over 4.5 MPa, so that damages
Thickness of grouting layer (mm) 43
such as cracking may not occur in the grouting layer under the sta-
Thickness of basecourse (mm) 180
Axle load (kN) 250 tic loading.
Wheel load (kN) 125

2.3. Dynamic analysis

are shown in Fig. 6(a). It is observed that the tensile stresses are the The responses of the grouting layer of the PST system under the
largest for the PG-B case. This happens for this case because the dynamic loading are investigated according to the bonding charac-
neutral axis of the grouting layer lies in the concrete slab due to teristics among the layers. The dynamic loading used in this study
the bonding of the grouting layer to the bottom of the concrete is an impact loading with a 0.2 s load duration that has been
slab. For the transverse stresses at the bottom of the grouting layer obtained from a previous study [34]. Fig. 7 shows changes in the
along the transverse edge, shown in Fig. 6(b), the PG-B case also deflected shape of the PST system including the vibration of the

(a) P-G-B case (b) PG-B case (c) P-GB case (d) PGB case
Fig. 4. Bonding characteristics among layers of PST system.
Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254 247

magnitudes of the applied loads are the same, the stresses of the
grouting layer under the impact loading are significantly larger
than those under the static loading. The stress level of the grouting
layer under the impact loading is large enough to initiate cracking
due to a number of load repetitions, which is called fatigue
cracking.
The dynamic stress responses of the grouting layer near the cor-
Fig. 5. Deflected shape and stress distribution of grouting layer under static
loading. ner of the grouting layer are shown in Fig. 9 for the P-G-B case. The
P-G-B case shows much larger stresses compared to the other
bonding cases. For the stresses along the transverse direction
shown in Fig. 9(a), (b), (c), and (d), the maximum tensile stress of
the grouting layer occurs at 50 mm from the corner and it reaches
about 3 MPa. The stresses of the grouting layer along the longitu-
dinal direction decrease as the distance from the corner becomes
larger as shown in Fig. 9(e), (f), and (g). As investigated, if there
are no bonding among the layers of the PST system, the stresses
of the grouting layer can increase significantly near the corner.
When the PST system is subjected to moving dynamic train loads
repeatedly, the bonding among the layers can be loosened and
the stresses of the grouting layer would increase. As a result, crack-
ing would result in the grouting layer near the corner and this
cracked part of the grouting layer can pop out.

2.4. Damage mitigation of grouting layer

(a) Longitudinal stresses along longitudinal direction


The numerical analysis results show that the grouting layer is
stable under the static loading, but it is possible that the grouting
layer will be damaged at the corner under the dynamic loading. In
order to mitigate grouting layer damages, efforts have been made
to reduce the stresses of the grouting layer by changing the shape
of the grouting layer. As shown in Fig. 10, four different shapes of
the grouting layer are considered in addition to the current shape
of the grouting layer which is the same shape as concrete slab. In
case 1, the grouting layer is formed 50 mm inside the concrete slab.
In case 2, the area of the grouting layer is the same as that of the
concrete slab, but the corner of the grouting layer is rounded. In
case 3, the grouting layer is formed 50 mm inside the concrete slab
and the corner is rounded. In case 4, the grouting layer is formed
50 mm inside the concrete slab in the transverse direction and
placed continuously in the longitudinal direction.
The stress responses at the corner of different grouting layer
shapes for the P-G-B case under the impact loading are shown in
(b) Transverse stresses along transverse direction Fig. 11. Significantly lower stresses are observed for all 4 different
Fig. 6. Stresses of grouting layer under static loading.
shapes of the grouting layer compared to the stresses with the
default (current) shape of the grouting layer. Although case 4
shows relatively larger stresses and continuous vibration as shown
Table 2 in Fig. 11(d), this case still shows much smaller stresses than the
Maximum tensile stresses of grouting layer under static loading. stresses from the default shape. By comparing the magnitudes
Cases P-G-B P-GB PG-B PGB and vibrations of the stresses obtained with the different cases of
the grouting layer shapes, it can be seen that case 3, where the
Maximum tensile stress (MPa) 0.19 0.16 0.84 0.30
grouting layer is formed 50 mm inside the concrete slab and the
corner is rounded, is the most appropriate design to mitigate dam-
ages of the grouting layer. Case 2, in which the grouting layer has
grouting layer subjected to an impact loading, for instance. The the same area of the concrete slab but the corner is rounded, could
dynamic responses have been obtained every 0.0002 s. be an alternative choice if the grouting layer is not easy to be
The dynamic stress responses of the grouting layer of the PST formed inside the concrete slab during construction.
system under the impact loading at the corner of the grouting layer
are shown in Fig. 8 according to the bonding characteristics among
the layers. When all the layers are not bonded to each other (P-G-B 3. Experimental analysis
case), the largest stresses of the grouting layer are observed. The
smallest stresses can be obtained when the grouting layer is A mockup test is conducted to evaluate vibrations of the grout-
bonded to the basecourse and de-bonded from the concrete slab ing layer under the impact loading and to verify the effectiveness
(P-GB case). The other two cases of PG-B and PGB have high stres- of change in shape of the grouting layer for reducing stresses. An
ses only at the very beginning of the load application, but then experimental PST system is constructed and the dynamic
quickly decrease and become close to zero. Even though the responses of the grouting layer are measured using gages when
248 Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254

Fig. 7. Changes in deflected shape of PST system under impact loading.

(a) P-G-B (b) P-GB

(c) PG-B (d) PGB


Fig. 8. Stress responses of grouting layer at corner depending on bonding characteristics among layers.

the impact loading is applied. In addition, the curling behavior of shape that is the default shape previously shown in Fig. 10(a), and
the PST system is investigated under the environmental loading. with the other corner that has the round shape (case 2) shown in
Fig. 10(c). The other half of the grouting layer is formed 50 mm
3.1. Test setup inside the concrete slab and 2 corners are rounded, as in case 3
shown in Fig. 10(d). Polyethylene sheets in an equilateral triangu-
A mockup test PST system is built for experiments in accor- lar shape with 1 m side length are placed among the layers at the
dance with the construction process of the actual PST system as corners to prevent bonding among the layers near the corners.
shown in Fig. 12. To compare the vibration of the grouting layer To apply the impact loading to the PST system, a falling weight
depending on the shape of the grouting layer, the suggested grout- deflectometer (FWD) device shown in Fig. 13(a) is used in this
ing layer shapes of cases 2 and 3 obtained from the numerical anal- study. The FWD is widely employed for the evaluation of pave-
yses are considered with the default shape of the grouting layer in ments since the impact loadings generated by the FWD represent
this experiment. Half of the grouting layer is formed as the same heavyweight moving vehicular or aircraft loadings well [35–40].
area of the concrete slab with one corner that has the rectangular The FWD consists of an impact load application apparatus in which
Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254 249

(a) At corner

(b) 50 mm transverse (c) 100 mm transverse (d) 150 mm transverse

(e) 50 mm longitudinal (f) 100 mm longitudinal (g) 150 mm longitudinal


Fig. 9. Stress responses of grouting layer near corner for P-G-B case.

a loading plate is able to fall down to generate an impact loading crete slab move vertically depending on the time of day. At day
and isolated geophones to acquire dynamic responses of pave- times, the vertical displacements at the corners decrease and the
ments under the impact loading. The impact load application sys- concrete slab curls down because the temperatures at the upper
tem in the FWD is used in this study. The sleepers on the precast part of slab are higher than those at the lower part. On the other
concrete slab near the corners where the FWD loadings are going hand, the reverse occurs at night times. The curling behaviors are
to be applied are fabricated to have a flat surface as shown in more pronounced for the round corners 1 and 2 where the grouting
Fig. 13(b). An overview of the loading test and the load application layer is formed 50 mm inside the concrete slab. This implies that
on a loading sleeper are shown in Fig. 13(c) and (d). the concrete slab and grouting layer are de-bonded sufficiently at
To obtain the dynamic responses of the grouting layer and the the round corners 1 and 2, but the bonding between the concrete
associated behaviors of the PST system, measurements are per- slab and grouting layer is somewhat maintained near the rectangu-
formed using the experimental PST system. As shown in Fig. 14, lar corner and round corner 3 even though polyethylene sheets
the accelerometers are attached at the corners of the grouting layer exist between the layers.
to measure accelerations due to the vibration of the grouting layer The variations of gap displacements between the concrete slab
under the impact loading. The linear variable displacement trans- and grouting layer under environmental loads are shown in Fig. 17.
ducers (LVDTs) are installed at the corners of the concrete slab to At the corners of the PST system with the grouting layer 50 mm
measure the variation of vertical displacements of the concrete inside the concrete slab and round corner (Round corners 1 and
slab due to changes in temperature, which is called a curling 2), the variations of gap displacements are clearly observed and
behavior. The Pi-shape displacement transducers are also installed the shapes of variations are similar to those of curling displace-
at the corners between the concrete slab and grouting layer to ments previously shown in Fig. 16. This means that the concrete
measure the variation of gap widths between the layers. The ther- slab and grouting layer are obviously de-bonded at those areas
mocouples are installed at the top, middle, and bottom of the con- and the curling of the concrete slab forms the gap between them.
crete slab to measure the variation of temperatures through slab In addition, larger vertical displacements of the concrete slab than
depth and to find the vertical temperature gradients that induce the gap displacements between the concrete slab and grouting
curling of the PST system. Fig. 15 shows the installed gages for layer imply that there is also a gap between the grouting layer
measurements. and basecourse. At the corners of the PST system with the grouting
layer of the same area as the concrete slab (Rectangular corner and
Round corner 3), very small gap displacements are observed. This
3.2. Behavior of PST
means again that the concrete slab and grouting layer are not de-
bonded sufficiently at those corners. The interfaces between the
The curling behaviors of the concrete slab under environmental
layers at those corners, of course, will not be bonded because there
loads are measured and shown in Fig. 16. All 4 corners of the con-
250 Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254

(a) Default shape

(b) Case 1 (c) Case 2

(d) Case 3 (e) Case 4


Fig. 10. Different shapes of grouting layer.

(a) Case 1 (b) Case 2

(a) Case 3 (b) Case 4


Fig. 11. Stress responses of grouting layer at corner depending on grouting layer shape.

exist polyethylene sheets. However, the interfaces beyond those Since the curling behavior of the PST system can affect the
areas seem to be still bonded to each other so that the gaps are dynamic responses of the PST system, the impact loading tests
not clearly detected at those corners. are conducted when the PST system is in curl-up and curl-down
Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254 251

smaller as shown in Fig. 18(a), (b) and (c). The results of this exper-
iment confirm the numerical analysis results.
The accelerations of the grouting layer under the impact load-
ings when the PST system is in curl-down position are shown in
Fig. 19. The accelerations in this case are generally smaller than
those when the PST system is in curl-up position. The accelerations
of the grouting layer with the corners 50 mm inside the concrete
slab and round shape (Round corners 1 and 2) are very small, even
smaller than those with the rectangular corner and round corner of
the same area of the concrete slab (Rectangular corner and Round
corner 3). Therefore, this experiment verifies that the vibration of
the grouting layer can be reduced by changing the rectangular
shape corners with the round shape corners.

4. Conclusions and recommendations

Fig. 12. Experimental PST system.


The vibration of the grouting layer of the PST system was com-
prehensively evaluated by conducting numerical and experimental
positions. For the curl-up PST system, the impact loading tests are analyses. The static and dynamic behaviors of the grouting layer
performed at 2:00 AM, and for the curl-down PST system, the tests were thoroughly analyzed numerically depending on the bonding
are performed at 3:00 PM. At each test, the impact loadings are characteristics among the layers of the PST system. The methods
applied 9 times to each loading sleeper. The first loading is a pre- to reduce the excessive stresses of the grouting layer by changing
load, and then the test loads of 52, 76, 88, and 101 kN are each the shape of the grouting layer were examined. The experimental
applied twice. analysis was also performed using a mockup segment of the PST
The vibration of the grouting layer under the impact loading is system to find the vibration characteristics of the grouting layer
evaluated by analyzing measured accelerations at the corners of and to verify the effectiveness of changing the grouting layer shape
the grouting layer. The accelerations of the grouting layer when for reducing stresses and associated damages. The findings from
the PST system is in curl-up position are shown in Fig. 18. As this study are summarized as follows.
already mentioned, the impact loadings have been applied 9 times
with different load magnitudes. The accelerations generally  The tensile stresses of the grouting layer of the PST system
become slightly larger as the load magnitude increases. Signifi- under the static loading depend on the bonding characteristics
cantly large accelerations can be observed for the grouting layer among the layers and are largest when the grouting layer is
with the rectangular corner as shown in Fig. 18(d). The accelera- bonded to the precast concrete slab and de-bonded from the
tions of the grouting layer with the round corners, however, are basecourse. However, the maximum tensile stresses are much

(a) Falling weight deflectometer (b) Loading sleeper

(c) Impact loading test (d) Load application


Fig. 13. Impact load application.
252 Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254

Fig. 14. Gage installation plan.

(a) LVDT (b) Accelerometer and Pi-shape displacement transducer

Fig. 15. Installed gages.

Fig. 16. Curling behavior of concrete slab under environmental loads. Fig. 17. Gap displacements between concrete slab and grouting layer under
environmental loads.

smaller than the tensile strength of the grouting layer which


means damages such as cracking may not occur in the grouting
layer under the static loading.
 The dynamic stress responses of the grouting layer of the PST  The different shapes of the grouting layer are considered to find
system under the impact loading are also affected by the bond- numerically the strategies of reducing the dynamic stress
ing characteristics among the layers. The largest stresses of the responses of the grouting layer. By comparing the stresses
grouting layer are observed when all the layers are not bonded depending on the grouting layer shapes, the grouting layer
to each other. Even though the magnitudes of the applied loads formed 50 mm inside the concrete slab and rounded at the cor-
are the same, the stresses of the grouting layer under the impact ner is found to most significantly reduce the stresses of the
loading are significantly larger than those under the static load- grouting layer. The grouting layer that has the same area of
ing. The stress level of the grouting layer under the impact load- the concrete slab and rounded at the corner is an alternative
ing is large enough to initiate fatigue cracking in the grouting choice if the grouting layer is not easy to be formed inside the
layer after a number of load repetitions. concrete slab during construction.
Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254 253

(a) Round corner 1 (b) Round corner 2

(c) Round corner 3 (d) Rectangular corner


Fig. 18. Accelerations of grouting layer under impact loading with curl-up slab.

(a) Round corner 1 (b) Round corner 2

(c) Round corner 3 (d) Rectangular corner


Fig. 19. Accelerations of grouting layer under impact loading with curl-down slab.

 The vibrations of the grouting layer under the impact loading corner of the grouting layer with the round shape corner, it has
are experimentally evaluated by conducting mockup tests. The been found that the accelerations of the grouting layer decrease
accelerations of the grouting layer when the PST system is in significantly. These experimental analysis results confirm the
curl-up position are significantly large for the grouting layer numerical analysis results regarding the strategies to reduce
with the rectangular corner. By changing the rectangular shape the stresses of the grouting layer.
254 Y.K. Cho, S.-M. Kim / Construction and Building Materials 193 (2018) 244–254

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