Steel sleepers

Steel sleepers Introduction

Designing and making steel sleepers for over 100 years

Steel sleepers from Tata Steel are high quality, engineered products used across the world. Choosing steel sleepers means your project benefits from quicker and lower cost installation.
Steel sleepers are stackable so can be transported using fewer wagons than concrete sleepers. Image courtesy of Pandrol.

Steel sleepers are high quality products Steel sleepers can be designed to suit most track specifications Expected lower maintenance costs over a typical lifetime of 50 years
Improves track quality and stability by reducing wet spots. There is a reduction in wet spots using steel sleepers and studies demonstrate benefits in longer term track quality and stability because the contact surface of steel sleepers is higher on the ballast layer and remains drier. Where fines accumulate under concrete sleepers they become waterlogged and degradation of the ballast is accelerated. Steel sleepers provide greater stability under moving vehicles. Tests in the USA have shown that steel sleepers provide greater stability under moving vehicles and experience in the UK has shown track with steel sleepers is less susceptible to track buckles. Once installed steel sleepers do not rot and are resistant to insect attack. Steel sleepers survive well in wet tropical climates where wood decays rapidly. Steel sleepers can be reused and steel has the capability to be endlessly recycled. In many countries steel sleepers are refurbished and reused after decades in track. Steel sleepers can be designed to overcome some major engineering challenges. Tata Steel sleepers have a very high load capability the load factors used mean that in tests the standard sleeper withstands nearly twice the static axle load for 5 million cycles. Our experience and research in steel sleepers and rail means that we can advise on specific issues and provide customised designs where necessary. For example, we have designed sleepers with a removable spade, for spot replacements of sleepers, and a longer spade to give more stability, for clients with specific requirements. Can achieve lower height construction enabling levels to be matched especially for bridges, stations and tunnel works. Steel sleepers require less ballast so can be used where clients need to achieve lower height construction. This has solved problems for level adjustments in tunnels, over underpasses and has accommodated platform constraints. Using BS 500:2000, steel sleepers are designed for unlimited tonnage and typically 50 years life. Steel sleepers are designed and tested to load levels that are 20-30% higher than the required duty to avoid fatigue. This means that the sleepers have a significant margin of life under normal conditions. Steel has survived well in harsh climates in Africa which have reduced the life of concrete sleepers, and in corrosive environments steel can be protected whilst concrete reinforcing bars will fail. Modern pads and insulators for steel sleepers means signalling works well. Pads and insulators for Tata Steel sleepers are tested in accordance with CEN 131455:2002, ensuring very high electrical resistance and compliance with track circuit signalling requirements. A more durable replacement for wood on structures because steel sleepers are the same weight as timber. Steel sleepers are a similar weight to wood, so they can be used to replace wooden sleepers on a ballasted bridge, providing a stronger, more durable solution without increasing bridge load.

Quicker, lower cost installation using lighter equipment

Significant savings can be made when renewing track with steel sleepers Reductions in ballast quantities also lead to reduced logistics costs, both for imported ballast and for spoil disposal. Installation cost benefits of using steel sleepers vs concrete
Total Lab, Plant, Manage Sleepers Spoil Disposal Ballast Delivery Ballast Rail Delivery Rail 0% Key Concrete Steel 20% 40% 60% 80% 100%

Steel sleepers are stackable and light enough to be manually handled. Steel sleepers are relatively light weight and stackable meaning they can be manually handled on site or moved in bundles by a forklift. Steel sleepers require about one third fewer vehicle movements compared to concrete. Steel sleepers require less ballast. Steel sleepers need less depth of ballast than concrete sleepers, because the body of ballast within the sleeper provides the necessary spring to distribute load. Steel sleepers can be replaced without excavating the old ballast. Tata Steel sleepers can be laid on existing ballast because of their unique control of the ballast bed and improved long term drainage. Concrete sleepers require more excavation and preparation; up to 450mm of the old ballast and formation has to be removed to achieve the greater depth needed for concrete.

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Steel sleepers Research

Extensive research means that we have a detailed understanding of the dynamic loads sleepers are subject to. This enables each sleeper to be designed and tested with confidence that they meet the standards for modern track design.

Hydraulic actuator

Sleeper fatigue resistance

Rigorous research and testing

Our rail experts will work with you to evaluate the requirements for your railway and design your steel sleepers for you.

Forces from the wheels of rail traffic are passed down to the sleepers and each type of sleeper material, wood, concrete or steel, responds differently. The dynamic response of the vehicle axle mass to small variations in the rail/wheel contact area leads to increased forces as speed increases, so requiring each sleeper material to be considered differently. For example concrete sleepers may fracture under impact loads if not sufficiently cushioned, and a high dead load is required to resist uplift and ensure stability. For steel sleepers, testing focuses on understanding fatigue behaviour. The method for calculating the test load for steel sleepers, based on vehicle parameters and track geometry, is detailed in British Standard BS500. Steel sleepers are tested by applying the calculated load through arms angled at 21 to simulate the lateral and vertical forces for 5 million cycles. The table below shows typical parameters used to calculate sleeper duty to BS500 for a mainline application using a 436 profile. This detailed technical approach results in sleepers which can withstand very high dynamic loads the test score for the current UK mainline sleeper is 238 kN, a clear margin over the requirement shown in the table.
Speed mph/kph Axle load tonne Rail joint dip angle radians Rail centres m Cant deficiency m Height of vehicle centre of gravity m Cant effect Po = Static wheel load kN Sleeper spacing m Unsprung mass on axle kg Kt = Track stiffness factor
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Loading beam

Polymer support Conforming steel block Support beam Sleeper fatigue test for British Standard BS500

forming a circuit will operate just as well with these modern steel sleeper systems as any other form of track. The electrical resistance test simulates severe conditions rails are subjected to an intense salt spray during testing, which represents the worst possible conditions of contamination with conducting fluids. In addition to this the test is repeated after the assembly has been subjected to 3 million load cycles to ensure that the properties remain satisfactory over time. Our sleeper system has been tested in conjunction with other electrical equipment to ensure compatibility for example automatic warning systems using electromagnetic switching equipment is installed in track with steel sleepers and verified to function satisfactorily. Track circuitry with 2kHz AC excitation has a fine tune adjustment facility which enables operation with steel sleepered track. Steel sleepers also operate very satisfactorily with AC overhead line electrified track, and have been installed in different networks in Europe with the purpose of maintaining the running gauge height when installing OHL without having to lower the track base, for example in tunnels.

60/98.4 25.5 0.01 1.485 0.15 2.1 0.29 160.81 0.654 1500 55.91 CEN 56 216.76 2336.00 1.28 90.62 217.5

The chemistry is carefully controlled by adding precise amounts of alloying elements and close control of the deoxidation process ensures a very high level of steel cleanliness. The sophisticated steel making process controls the steel chemistry to consistently tight tolerances. Steel blooms are rolled into their final profile using modern process technology to achieve outstanding results. Computer modelling and computer-controlled heating and cooling processes utilise novel roll pass design and modern process technology to ensure consistent product dimensions. Surface quality is controlled using high pressure water descaling twice, before and after going through the rollers.

Rail size P = Dynamic rail seat reaction kN Rail moment of inertia I cm^4
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We have developed and optimised sleeper design

The Tata Steel sleeper design is a step change from the slow evolution of the past. Our rail and sleeper technology experts work with clients during design and construction so they understand the challenges of installation and in service. They also have access to, and expertise in, the latest design software, for example finite element analysis has been used to refine the design details of the sleepers to optimise the profile so that it has a very efficient strength to weight ratio and performs well in fatigue testing. The length and width of the spade is greater than in previous designs, and test results have showed this improved lateral resistance is comparable to that of concrete sleepers and significantly better than timber sleepers.
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Load sharing factor Rail seat reaction kN Minimum sleeper test load kN including 1.2 corrosion allowance

Signalling and overhead line electrification

The standard range of Tata Steel sleepers is available with todays most advanced fastening systems, which have a very high insulation resistance. This means they perform, as well as or better than concrete sleepers from the point of view of rail-to-rail electrical resistance. Signalling systems which depend on the train
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Our sleepers are manufactured in the same advanced mill that produces high quality rail
The process of refining iron to make steel is precisely controlled by highly skilled operators using intelligent process control equipment.

Steel sleepers Design

WE design sleepers to meet each customers specification

Our sleepers are designed and configured to suit your project requirements. Your Tata Steel contact will be pleased to discuss your specifications and will go through the following section with you.

Tata Steel sleeper property table Section ID Principle dimensions

Rail seat thickness Rail seat width Leg thickness Section width B Section height A mm mm mm mm mm

202
7.5/1.2 160 6.75 240 82.5

300
12 160 7 254 92

436
11.8 168 7.125 260 100.75

600
14.25 168 7.6 280.5 115.25

Section properties
Moment of Inertia Ixx Section modulus Height of neutral axis from base Plate weight cm4 cm3 mm kg/m 200 34.4 58.1 22.1 283.3 42.3 67.0 29.45 452.79 65.85 68.76 31.69 655 81.3 80.5 39.53

Rail size, gauge and inclination

Sleepers can be supplied for all rail sizes, and with the inclination required for your network. The sleeper designs can be tailored to any rail gauge 1000mm, 1067mm (3' 6") , standard and broadgauge.

Specify the fastening system to be used

Steel sleepers can be supplied with fastenings to suit your railway. For speed of installation they can be delivered pre-assembled. Vossloh and Pandrol represent the most widely used modern fastening systems and both come insulated for use with signalling.

Speed and axle load 

We supply four profiles which cover the full range of railway applications. For narrow gauge traffic applications where low axle loads and moderate line speeds are typically used, the 202 profile is recommended. For heavier narrow gauge applications, 300 profile sleepers are capable of carrying axle loads up to 20 tonnes at a line speed of 80km/h. The 436 profile is recommended for use for standard gauge mainline traffic. These sleepers have been tested and validated for 25 tonnes axle loads travelling up to 160km/hr. For heavier axle load applications like mining or dedicated freight lines, the 600 profile includes additional load capability which means they can be used for heavier axle loads up to 35 tonnes. For new applications of steel sleepers, our experts will analyse your vehicle characteristics and track design to ensure the best system solution is obtained. We have detailed knowledge of the relationship between traffic speeds, track configurations and permitted axle loads, and so can advise on the most economic design.

There are a number of spade options available:

lateral resistance and efficient design

Standard spade: For normal track offers good Deep spade: This is an extended spade which
gives higher lateral resistance, for use in tight curves with long welded rail

We can make sleepers designed for the requirements of specific situations in track

Guard rail sleepers Dual gauge sleepers Bearers for switches and crossings Insertion sleepers for spot replacement Sleepers for tight curves

Getting your sleepers where you need them

We have delivered over one million tonnes of rail and sleepers worldwide over the last 10 years. From just in time deliveries to Germany and whole projects in Northern Ireland, to bulk shipment of sleepers for railway rehabilitation projects in West Africa, we have the expertise to project manage delivery where you need it and when you need it.

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Steel sleepers Installation

Before tamping

Easy installation

After first tamp

After second tamp

Filling and ballast

Steel sleepers can be laid onto existing ballast that has been scarified and, because steel sleepers are relatively light, can be installed manually or by machine. Steel sleepers can also be supplied with fastening systems already in place, ready for immediate clipping-up. A typical track renewal using steel sleepers will proceed as follows: Run the ballast regulator to level the shoulder and smooth off surplus ballast Remove existing rails and sleepers Scarify, but do not compact the ballast bed, using a tractor mounted agricultural harrow Level with laser controlled bulldozer. Minimum ballast depth: 200mm / 150mm according to category Lay sleepers at required spacing

Thread rails onto rail seat (insert pads Clip up manually or using machine Weld joints Run ballast train to push sleepers into ballast Tamp the track to acceptable track geometry Test each sleeper for track circuit integrity The track may be opened at 20mph De-stress the track to a stress-free temperature The track may be opened at line speed. Re-tamp after approximately six weeks of
running at line The diagram (above) shows measured flow of ballast into the body of a sleeper after each stage of tamping. The diagram also shows that a void is required at the centre of the sleeper to prevent centre-binding. of 27C and add stone to top of sleeper level if not pre-assembled)

Refurbishment of steel sleepers

In many countries sleepers that have been in track for an extended period can be refurbished and reused. The process is simple and can be carried out in the railways workshops. Improvements can include welding on of base-plated shoulders, correction of holes, re-establishment of cant through pressing, and joining sleeper sections through welding.

Image courtesy of Pandrol 08 09

Steel sleepers Examples

Worldwide application
We have used our expertise to advise and supply customers in Europe, Africa and Asia on mainline, urban and freight railways, and in difficult terrain through jungle, desert and mountain.
Steel sleepers are ideal for renewal projects in areas where track levels are dictated by bridges, platforms or other structures. This is because the height occupied by the old track with wooden sleepers does not provide sufficient space for concrete sleepers and the necessary additional ballast. Track built with Tata Steel sleepers has a lower construction height, so that changes of track design are more easily accommodated without resorting to major re-builds. When these steel sleepers were laid the steel sleepers they replaced were over 70 years old. We provided new trial sleepers which allowed the railway to become familiar with the installation of steel sleepers, inspected the track conditions and provided technical advice for the engineering design and methods to be used. We also worked with our customer to develop a new sleeper with extended spades. Full scale tests of lateral resistance validated their performance in tight curves. The steel sleepers were particularly beneficial in not requiring heavy equipment where track access was poor in the mountains. In Africa steel sleepers are more easily laid by local labour and the sleepers are more tolerant of poor track conditions, because the ballast within the sleeper provides additional cushioning to the track. Timber sleepers may last as little as 15 years in some African climates, and concrete sleepers are difficult to manufacture because of the need to control water content and temperature of the mix, so that easily transported and installed steel sleepers are a major help for the development and sustainability of African railways. Working with a customer who needed to replace individual concrete sleepers, we developed a sleeper that could be changed quickly and easily using light equipment. The new sleeper has a removable spade, so that the sleeper could be pushed under the rails from one side retaining the ballast fill after which the spade was reinserted.

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Steel sleepers xxxxxx

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Care has been taken to ensure that this information is accurate, but Tata Steel Europe Ltd, including its subsidiaries, does not accept responsibility or liability for errors or information which is found to be misleading. Copyright 2013 Tata Steel

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SS/LJ/ENG/V2/04.13