Professional Documents
Culture Documents
TRACK SLABS
Version 1.3
Issued February 2011
Owner:
Approved
by:
John Stapleton
Principal Engineer Technology
& Standards
Authorised
by:
Richard Hitch
Chief Engineer Civil
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Page 1 of 14
Engineering Standard
Engineering Standard
Civil
ESC 362
Document control
Version
1.3
Date
February, 2011
1.2
July, 2010
1.1
November,
2009
1.0
October, 2007
RailCorp
Issued February 2011
Summary of change
Section 5.7.1 - specify minimum thickness of rail pad when
using epoxy grouts
Correct internal section references throughout; Section 4.12
- change reference to TMC 304 to SPC 301; Section
5.7.4.2 - add guard rail insulation requirements from CTN
08/06
Change of format for front page, change history and table of
contents; minor editing and formatting throughout
First issue of this standard.
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Version 1.3
ESC 362
Contents
1
2
2.1
2.2
2.3
References...............................................................................................................................4
Australian and International Standards.....................................................................................4
RailCorp Documents .................................................................................................................4
Other References......................................................................................................................5
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
General Requirements............................................................................................................5
Use of Track Slabs....................................................................................................................5
Design Standards......................................................................................................................5
Integrated Designs ....................................................................................................................6
Approved Materials ...................................................................................................................6
Clearances ................................................................................................................................6
Safety ........................................................................................................................................6
Protection of the Environment...................................................................................................6
Heritage.....................................................................................................................................6
Services.....................................................................................................................................6
Design Procedure New or Infrequently Used Products .........................................................7
Drawing Standards....................................................................................................................7
Construction ..............................................................................................................................7
Maintenance..............................................................................................................................7
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
Prohibited Configurations....................................................................................................14
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ESC 362
References
2.1
2.2
RailCorp Documents
ESC 100 - Civil Technical Maintenance Plan
ESC 200 - Track System
ESC 210 - Track Geometry and Stability
ESC 215 - Transit Space
ESC 302 - Defect Limits
ESC 310 - Underbridges
ESC 340 - Tunnels
ESC 420 - Track Drainage
SPC 234 - Resilient Fastenings
SPC 235 - Resilient Baseplates
SPC 301 - Structures Construction
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ESC 362
2.3
Other References
Workcover Code of Practice - Tunnels under Construction
Environment Protection Authority NSW - Interim Guideline for the Assessment of Noise
from Rail Infrastructure Projects
Track Slab:
Rigid Track
Slab:
Floating Track
Slab:
General Requirements
4.1
4.2
Design Standards
Designs are to comply with the requirements of the relevant Australian Standards,
specific site geotechnical parameters and the requirements of this Document.
Relevant standards and documents include:
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4.3
ESC 362
Integrated Designs
The design of each track slab is to be integrated taking into account all associated
requirements such as drainage, track, overhead wiring, signalling infrastructure,
communications services, fire safety equipment and platforms.
4.4
Approved Materials
Approved construction material for main structural elements is concrete.
The use of polymer concrete sleepers embedded into track slabs is approved.
Fibre reinforced concrete is not to be used without the approval of the Chief Engineer
Civil.
Timber and masonry materials shall not be used.
Materials in tunnels shall generally be non-flammable and shall comply with specific
requirements for fire safety detailed in RailCorp Engineering Standard ESC 340 Tunnels.
4.5
Clearances
Horizontal and vertical clearances from slabs to structures adjacent to and over the track
are to comply with RailCorp Engineering Standard ESC 215 - Transit Space.
4.6
Safety
The design of track slabs is to take into account safety considerations for construction
and maintenance personnel, and any other parties including operations personnel who
may be required to use the structure.
Designs are to incorporate the requirements of the RailCorp Safety Management System,
particularly SMS-12-PR-0371 Managing Engineering Design Control.
Designs of track slabs in tunnels are also to comply with the requirements of Workcover
NSW Code of Practice - Tunnels under Construction.
4.7
4.8
Heritage
Heritage considerations and classifications must be observed in track slab designs. This
may have particular application in circumstances where an existing structure is being
refurbished or modified, or where a new structure is being proposed in the vicinity of
existing heritage items.
4.9
Services
Provision must be made in the design and installation of track slabs for services as
required, e.g. signalling, electrical, communications.
Services are to be positioned in accordance with the following requirements:
Transit space standard ESC 215;
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ESC 362
Clear of any walking areas where they might present a trip hazard;
Not to interfere with or obstruct emergency walkways;
Not to obstruct access to or reduce the capacity of refuge areas:
Not to obstruct drainage
Not to obstruct Track Control Marks.
The location of any services is also to be selected so that future access for maintenance
of the services is facilitated.
4.10
4.11
Drawing Standards
Construction drawings are to comply with RailCorps standard procedures and formats,
and are to detail the design loadings, horizontal and vertical clearances, and any other
information that is relevant to ensuring that the new structure is constructed and
maintained in accordance with the design.
4.12
Construction
The design of track slabs is to take into account construction constraints, particularly live
road and rail operating conditions and track possession constraints.
RailCorp has a suite of technical specifications covering various aspects of civil
construction. The specifications are detailed in RailCorp Engineering Specification SPC
301 - Structures Construction and are to be incorporated in design and construction
documentation.
Construction methods include top down, bottom up or a combination of both.
Top down construction involves setting the rails in place with temporary supports and
casting the concrete slab in situ.
Bottom up involves installing a slab(s) and attaching the rails.
Track slab configurations include:
4.13
monolithic slab
base slab and top slab
sleepers embedded in a slab
base slab with kerb walls and an infill slab
concrete monoblocks embedded in concrete.
Maintenance
The design of track slabs is to take into account the ability to access key components for
inspection and maintenance purposes.
The design shall also consider provision for safe egress from maintenance plant and
vehicles onto the track slab.
Components, materials and finishes should be chosen to minimise future maintenance.
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ESC 362
Maintenance requirements are to be specified in all design documentation for track slabs.
Requirements are to include examination tasks and frequencies, damage limits, and
repair standards, and be supported by documentation showing the basis for these
requirements.
Design Requirements
5.1
General
Track slab design is a system design taking into account the stiffness of the:
sub-base
slab(s)
rail fastening assemblies
rail.
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ESC 362
The maximum height of grout bed under the rail fixings shall be 60 mm. Packers are not
to be used.
High impact epoxy grouts/mortars or specially developed grouts are to be used under the
rails to accommodate the high dynamic effects and movement of the slab. There shall be
no metallic elements in the epoxy. Standard cementitious grouts shall not be used.
The grout bed shall provide sufficient edge distance to the bolt to avoid cracking of the
grout.
Where different trackforms are used on a particular project, the geometric tolerances
specified at the wheel/ rail interface should be the same. Different slab trackforms are to
be effectively bonded at the interface.
The design of track slabs shall provide for easy access to bearings for inspection,
maintenance and replacement. Procedures shall be specified in Technical Maintenance
Plans.
The design shall mitigate against debris getting into gaps around floating slabs. All gaps
shall be effectively sealed to prevent debris from entering gaps between structural
elements.
Non-resilient fastening assemblies are not to be used on track slabs.
Where the track slab consists of a base slab and a top slab, the top slab shall be tied to
the base slab with anchors.
5.2
Design Loads
Track slabs shall be designed to accommodate the train loadings as specified below:
Operating Class
Passenger Main Line / Light Line
The loading is based on the railway traffic load in AS 5100 - Bridge design. The
Reference Load is 300LA. For the other loadings, all axles are to be proportioned by the
ratio of the nominated LA load divided by 300.
Operating Classes are defined in RailCorp Engineering Standard ESC 200 - Track
System.
For loadings less than 300LA, future loading requirements need to be considered. Final
approval of the design loads shall be obtained from the Chief Engineer, Civil.
The impact factor shall be in accordance with the dynamic load allowance in AS 5100
with the characteristic length based on either deck slabs or direct rail fixation.
Track slabs shall also be designed for the derailment load requirements of AS 5100.
Track slabs shall be designed for earthquake forces in accordance with AS 5100. The
earthquake design category shall be Type III i.e. essential to post-earthquake recovery.
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5.3
ESC 362
Infill Slabs
Where track slabs are constructed using top down methods in which a concrete infill
section is provided to connect the track fixings to the base slab, the concrete infill shall be
designed and detailed to ensure structural adequacy and durability to give a 100 year
design life to AS 5100.
In particular the construction joint between the infill concrete and track slab shall be
prepared by removing laitance to expose the aggregate using appropriate mechanical
equipment.
The reinforcement provided in the infill shall be designed to limit cracking due to early
thermal and shrinkage effects. Cracks shall not exceed 0.2 mm in width.
The infill slab shall be adequately tied down to the main track slab to ensure that debonding does not occur due to dynamic effects or thermal/shrinkage effects. The
maximum spacing of the bars shall be 500 mm in any direction.
The minimum thickness of the concrete infill shall be 250 mm.
5.4
5.5
Allowable Movements
The design of the track slab shall provide for allowable movements of the slab that do not
adversely affect the integrity of other infrastructure such as track and signalling.
Movements shall not result in the track geometry being outside the limits as specified in
RailCorp Engineering Standard ESC 210 - Track Geometry and Stability.
The design shall provide for construction, expansion and contraction joints as
appropriate.
5.6
Drainage
Provision must be made for adequate surface drainage by efficiently directing water into
the track drainage system. The track drainage system shall be cleanable as specified in
RailCorp Engineering Standard ESC 420 - Track Drainage.
Baseplates and fastenings must remain above water at all times.
Ponding must not occur on slabs or in the void beneath any floating slab. The drainage
design shall ensure that depth of run-off water on track slabs does not interfere with
signalling and electrical equipment.
5.7
Track Interface
5.7.1
General
The design of the track slab shall take of account of the interaction with the track
including longitudinal effects, thermal effects, concrete shrinkage and traction/braking
loads. The design shall consider the effect on both the track and the track slab, including
interaction of slab expansion and rail expansion.
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ESC 362
5.7.2
Slab Construction
Where rails are to be fixed to the completed slab, the finished surface of the slab shall be
constructed to a tolerance of + 0 mm, - 5 mm from the design level.
Where top down construction is used, the construction method shall ensure track
fastenings are fully supported with no voids under the track fastenings. This is especially
important on superelevated track.
5.7.3
Turnouts
Where turnouts are planned in the track slab, full base plate fixings shall be installed to
allow installation of the turnout.
The rail must be straight railed through the turnout location without joints.
5.7.4
Guard Rails
5.7.4.1
General
Guard rails may be required to be provided along track slabs where it is determined to be
appropriate for providing protection to adjacent structures.
Concrete upstands may be provided as an alternative to standard guard rail sections.
Upstands are to be installed in the four foot, not on the outside of the track. The upstands
shall be designed for a 80 kN lateral load.
Guard rail installations are to comply with the following requirements:
Guard rail shall be new rail or recycled rail Category 1 (White rail).
Guard rail section is to be the same as the running rail or one section size less
than the running rail.
Top of guard rail is to be no higher than the adjacent running rail and no more than
50 mm below the running rail.
Each guard rail is to be plated and fastened on both sides at the same spacing as
the running rail fasteners.
Guard rails are to extend parallel for a minimum 20 metres in advance of the area
being protected on the train approach side.
Guard rails are to extend parallel for a minimum of 3 metres beyond the area being
protected on the train departure side.
A tapered nose section (vee), minimum 3.6 metres long, is to be installed on the
train approach side of the guard rail. The design of the vee shall be in accordance
with Drawing Number 785-570. The nose of the vee shall be bolted.
Where rail traffic is bi-directional, the guard rail is to extend 20 metres beyond the
area being protected on both approach and departure sides.
Where traffic is bi-directional, the tapered nose section is to be installed on both
ends of the guard rails.
Clearance between gauge face of running rail and adjacent face of guard rail is to
be 380 mm.
Block-out holes for guard rail fastenings in concrete sleepers/slab shall be grouted
with a high strength grout.
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For fixing details, dimensional set-out and componentry detail and sizes, standard guard
rail drawings are available:
5.7.4.2
785-568
785-569
785-570
785-571
Signalling Interface
Suitable isolation arrangements are to be made, where required, in track circuited and
electrified areas.
The tapered nose section (Vee) is to be insulated with an approved component - refer to
Figure 1. This insulation requirement applies to new installations and where
refurbishment of the guard rails is undertaken.
Figure 1
Where guard rails exceed 50 metres in length, additional insulation and bonding
arrangements may be required. Design drawings are to specify that insulation and
bonding arrangements shall be in accordance with the requirements of the Chief
Engineer Signals. See RailCorp Engineering Standard ESG 100.17 - Signal Design
Principles Track Circuits.
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5.8
ESC 362
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5.9
Prohibited Configurations
The following track slab configurations are prohibited:
Embedded rail systems.
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