Analysis of Fault Conditions in the Production of Prestressed Concrete Sleepers
Abstract
:1. Introduction
2. Characteristics of the Manufacturing Process of Prestressed Railway Concrete Sleepers in the Context of the Failure Causes
Sleeper Production Process
- The sleeper mold is loaded on a rail conveyor, cleaned of any dirt and concrete residues, and a separation emulsion is applied to its walls. In 1 mold, 4–5 sleepers are produced, depending on the length of the sleeper;
- Steel wires, stirrups, dowels, separating faces, and other equipment elements are placed in the mold. The longitudinal reinforcement consists of 40 wires with a diameter of 3 mm, which are separated and held by the jaws. The 8 × 5 matrix consists of 8 wires in each row. The jaws are tightened with two flanges, using two bolts. The bolts are tightened using a pneumatic tightener with a prescribed torque of 23 Nm. In the first step, the bolts on one side of the mold are tightened and after tensioning the reinforcement, the bolts on the other side of the mold are tightened. The range of tests for prestressing reinforcement is specified in the standard PrEN 10138-2 [34];
- The reinforcement is prestressed by a tension line to the prescribed value. The magnitude of the tensile force is recorded. Prestressed steel reinforcement must comply with the requirements of PrEN 10138-2, steel for other reinforcements must comply with EN 10 080 [35];
- The produced concrete mix is dosed into the mold and then compacted vibrating the whole mold for the prescribed time. The concrete must meet the requirements of EN 206-01 [36] and EN 13230-1 [32], it must also meet the requirements for frost resistance T 200 according to STN 73 1322 [37]. The temperature of the cement when dosing into the mixer must not exceed 60 °C. The quality of the aggregate must comply with the requirements of EN 12 620 + A1: 2008-12 [38];
- At the workstation for accelerating the hardening (hydration) of sleepers, the molds are transferred by crane from a rail conveyor into a steaming chamber with a capacity of 100 molds. The steaming process takes about 12 h. The tests must show the actual temperatures inside and around the sleeper. The temperature profile is recorded and should not exceed 45 °C.
3. Methods
4. The Results
Problem Statement: Faulty Concrete Sleeper
5. Discussion
6. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Causes of Faulty Concrete Sleeper | Total (%) |
---|---|
Fractured bolt | 41 |
Fragments on the sleeper | 24 |
The steel reinforcement defect | 15 |
Loosening of the dowel | 8 |
Front face concrete overflow | 7 |
Unsuitable concrete mixture | 3 |
Power outage/failure | 2 |
C (%wt) | Mn (%wt) | Si (%wt) | Cr (%wt) | Mo (%wt) | Ni (%wt) | Cu (%wt) | |
---|---|---|---|---|---|---|---|
STN 12 061 | 0.57–0.65 | 0.5–0.8 | 0.17–0.37 | 0.25 | 0.3 | 0.3 | |
EN ISO: C60E | 0.57–0.65 | 0.6–0.9 | <0.4 | <0.4 | <0.1 | <0.4 |
Sample | Fe | Si | Mn | Cr | Mo | Ni | Sn | Cu | S | P |
---|---|---|---|---|---|---|---|---|---|---|
1 | 97.414 | 0.283 | 0.908 | 0.069 | 0.017 | 0.108 | 0.016 | 0.229 | <LOD | 0.043 |
1 | 97.597 | 0.269 | 0.921 | 0.064 | 0.018 | 0.103 | 0.018 | 0.242 | <LOD | 0.056 |
2 | 97.455 | 0.345 | 0.807 | 0.079 | 0.019 | 0.128 | 0.017 | 0.215 | <LOD | 0.041 |
2 | 97.49 | 0.351 | 0.809 | 0.072 | 0.019 | 0.125 | 0.016 | 0.232 | <LOD | 0.047 |
Sample No. | Hardness Metallografic Surface | Hardness, Bottom Part of the Bolt | Microhardness of the Grains, Metallografic Surface | Microhardness of Ferrite Metallografic Surface | ||||||
---|---|---|---|---|---|---|---|---|---|---|
HBW | Urel (%) | HBW | Urel (%) | HV0.01 | HV0.025 | HV0.05 | HV0.1 | HV | HV0.01 | |
1 | 243 | 3.47 | 250 | 4.29 | 203 | 231 | 200 | 228 | 216 | 193 |
2 | 256 | 3.08 | - | - | 160 | 256 | 236 | 247 | 245 | 149 |
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Markulik, Š.; Petrík, J.; Šolc, M.; Blaško, P.; Palfy, P.; Sütőová, A.; Girmanová, L. Analysis of Fault Conditions in the Production of Prestressed Concrete Sleepers. Appl. Sci. 2022, 12, 928. https://doi.org/10.3390/app12020928
Markulik Š, Petrík J, Šolc M, Blaško P, Palfy P, Sütőová A, Girmanová L. Analysis of Fault Conditions in the Production of Prestressed Concrete Sleepers. Applied Sciences. 2022; 12(2):928. https://doi.org/10.3390/app12020928
Chicago/Turabian StyleMarkulik, Štefan, Jozef Petrík, Marek Šolc, Peter Blaško, Pavol Palfy, Andrea Sütőová, and Lenka Girmanová. 2022. "Analysis of Fault Conditions in the Production of Prestressed Concrete Sleepers" Applied Sciences 12, no. 2: 928. https://doi.org/10.3390/app12020928
APA StyleMarkulik, Š., Petrík, J., Šolc, M., Blaško, P., Palfy, P., Sütőová, A., & Girmanová, L. (2022). Analysis of Fault Conditions in the Production of Prestressed Concrete Sleepers. Applied Sciences, 12(2), 928. https://doi.org/10.3390/app12020928