RAILWAY ENGINEERING

CHAPTER 3
RAILWAY TRACK STRUCTURES
Contents
1. Component and
function of track
structure
2. Rail support:
sleepers/ties, ballast
3. Ballasted track
4. Slab track
5. Rail fastening system
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3.1 Component and function of track structure

In contrast to road transport, where vehicles merely run on a
prepared surface, rail vehicles are also directionally guided
by the tracks they run on.
Track usually consists of steel rails installed on sleepers/ties
and ballast, on which the rolling stock, usually fitted
with metal wheels, moves.

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 TRACK LOADS
Components of track structure The bearing strength and quality of the track are largely
influenced by the following load parameters:
• Axle Load: The static vertical load per axle.
• Tonnage Borne: The total sum of the axle loads.
• Running Speed: The speed at which the train operates.
• The static axle load, along with the dynamic increment,
primarily determines the required strength of the track.
• Accumulated Tonnage measures track deterioration and
indicates when maintenance and renewal are necessary.
• The Dynamic Load Component, influenced by speed and
track geometry (both horizontal and vertical), plays a crucial role
5 in the track's performance. 6

Upper structures
Structural design of track
Rail Track Components (Upper)
• Rails: Two parallel steel rails form the upper part of the track, providing a
The Principle:-
smooth surface for train wheels.
– Components do not function independently!
• Fasteners: Secure the rails to the ties, ensuring stability and alignment.
– Each component layer must protect the one below.
• Ties (Sleepers): Made from timber, concrete, steel, or plastic, ties support
the rails and maintain consistent spacing (gauge).
Main design components
• Ballast: The material beneath the ties (typically gravel or crushed stone)
1. Rail
helps with drainage and track stability.
2. Rail pad/plate
3. Sleeper
4. Ballast

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 1. Rail…
Rail b) Functions:

• The rail guides the conical, flanged wheels, Functions of Rail Track
ensuring the vehicles stay on track without the • Supports the weight of vehicles and locomotives, guiding
need for active steering, which allows trains to be their movement.
much longer than road vehicles. • Determines wheel loads, speeds, safety, and reliability of

a) Characteristics of Rail Track train operations.

• Supports and guides the wheels.
• Rigidity: Resists deformation under load.
• Provides a smooth surface with minimal resistance.
• Tenacity (toughness): Withstands • Bears the force from the wheels and transfers it to the
stress without breaking. sleepers.

• Hardness: Resists wear and damage. • Used in electrified railways for track circuits and automatic
block segments.
• Roughness: Affects grip between rail and Rail
wheels.
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1. Rail… 1. Rail…
C) Rail Profile
• The rail profile refers to the cross-sectional shape of a
railway rail, which is perpendicular to its length.
• A railway rail is made from hot-rolled steel and features
a specific cross-sectional profile, typically resembling an
asymmetrical I-beam. This profile is designed to be the
fundamental component of a railway track.
Components of a Rail Profile:
• Rail Head: The top part of the rail that comes into direct
contact with the train wheels.
rail head
• Rail Web: The vertical section between the rail head and
base, providing strength and stability. rail web

• Rail Base: The bottom part of the rail, wider and thicker for
rail base CN 60 kg/m rail (unit: mm)
added support on the track. CN 75 kg/m rail (unit: mm)

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 1. Rail… 1. Rail…
d) Types and length
• Rail strength, which determines the support it provides for axle loads
and speeds, is primarily based on its weight per unit length.
 In China, rails are categorized by their unit weight, measured in kilograms
per meter (kg/m). Common rail types include:75 kg/m, 60 kg/m, 50 kg/m,
43 kg/m
• Rails can also be expressed in pounds per yard (lbs./yd)
• Standard Rail Lengths:
12.5 meters
25 meters
• Rail types like 75 kg/m, 60 kg/m, and 50 kg/m are widely used in China for
various railway applications.
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1. Rail…
Rail Forms in Use
The following rail forms are commonly in use today: grooved rails
Vignoles Rail
• Vignoles Rail: The standard railway rail, featuring
a head, web, and foot. grooved rails

• Double-Head Rails: These rails have heads, Tram

web, and foot but are now considered obsolete.

Crane rails
• Grooved Rails: Used primarily for tramways,
designed with a groove to accommodate tram
wheels.
• Switch Rails: Used in railway switches for
guiding trains from one track to another. Switch rails
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 1. Rail… 1. Rail…
e) Rail gap
e) Continuous welded track (CWR)
• To accommodate the expansion and contraction of rails
due to temperature changes, the rail gap must be carefully The 25 m rail is welded into a 100-200m long rail in the factory
regulated. and then welded again into 1000-2000 m long rail in the laid place
• It should neither be too large nor too small, ensuring
proper adjustment for heat expansion and cold contraction. Advantages:

 smooth driving
Typically, the rail gap is set  low maintenance cost
between 0.5 to 1.5 cm (5 to 15
mm) in warmer climates, but it can  long life
vary based on environmental The main disadvantage is limited freedom of
conditions and the type of rail used. expansion and contraction of the rails due to
temperature changes. Which leads to rail
deformation and lateral and longitudinal
17 displacements of the track 18

1. Rail… 1. Rail…
f) Rail requirement
• The rail is running surface, carrier, and guiding element at the g) Composition
same time. Unlike some other uses of iron and steel, railway rails are subject to
• It is subject to static and dynamic stress. very high stresses and have to be made of very high-quality steel.
• Rails have to bear very high lateral forces exerted by the wheel It took many decades to improve the quality of the materials,
flange striking against the gauge corner of the outer rail. including the change from iron to steel.

To be able to withstand manifold and high forces, the rails must

meet the following requirements: Minor faults in the steel that pose no problems in reinforcing rods
for buildings, can, however, lead to broken rails and dangerous
derailments when used on railway tracks
 high resistance to wear,  good weld ability,
 high resistance to compression, high degree of purity
 high resistance to fatigue good surface quality
 high yield strength, tensile strength evenness and observance of profile and
and hardness low residual stress after manufacturing
 high resistance to brittle fracture 19 20
 2. Sleeper…
2. Sleeper (b) Characteristic
(a) Function • Solid and durable structure
• Flexible to accommodate loads and vibrations
 Bear the force of the track
• Cost-effective solution
 Act as an elastic medium to absorb impacts
• Convenient for both manufacturing and maintenance
and vibrations
 Provide longitudinal and lateral stability
 Distribute the force to the ballast bed and
 Supporting signal
roadbed
engineering and other safety-
 Maintain the direction, position, and gauge related equipment
of the track  Supporting conductor rails,
electrical bonds and feeder
 Support wheels and/or hydraulic jacks cables.
directly in the event of a derailment  Reducing noise and vibration on
non-ballasted bridge decks
 Function as transverse beams when placed
on temporary way beams 21 22

2. Sleeper… 2. Sleeper…
c) Requirements
（c）Types
• Moderate weight – easy to handle during installation and maintenance
• Simple fastening system – easy to fix and remove Traditional Materials:
• Sufficient bearing area – to distribute loads effectively • Wooden ties – historically the most common
• Ease of maintenance and gauge adjustment • Concrete ties – now widely used due to durability
• Track circuiting compatibility – must allow proper electrical conductivity • Steel and plastic composite ties – used less frequently
• Resistance to shocks and vibrations – ensures durability and safety Based on Material:
• Low initial and maintenance cost – cost-effective over the long term • Reinforced concrete sleeper
• Wooden sleeper
• Steel sleeper
Based on Usage:
• Regular sleeper – used in standard track sections
• Switch sleeper – used in turnout or switch areas
• Bridge sleeper – designed specifically for use on bridges
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 2. Sleeper… 2. Sleeper…

1. Wooden Sleeper
• Made primarily from hardwoods, with oak being a popular
choice
• Easily treated with preservatives, enhancing durability
• Commonly treated with creosote to prevent insect damage
and rot
• Creosote-treated sleepers resist decay but pose
environmental and health risks (carcinogenic)
• Some hardwoods are naturally durable and may be used
untreated
• While cost-effective and flexible, they are more susceptible
to wear over time 25 26

2. Sleeper… 2. Sleeper…
2. Concrete Sleeper
• Widely used due to better performance under high-speed and heavy traffic

• Provide greater stability and rail support compared to wooden sleepers

• Offer longer service life and lower maintenance requirements

• More economical in the long run despite higher initial cost

• Resistant to weathering, fire, and decay

• Ideal for modern railways with demanding load and speed conditions

Wooden sleeper
27 concrete sleeper 28
 2. Sleeper… 2. Sleeper…
3. Steel sleeper
• Ideal where wooden or concrete sleepers
aren't suitable
• Commonly used on sharp curves to prevent
gauge widening
• May cause interference with signal control
systems
• Prone to fatigue cracking over time
• Preferred today due to wood shortages and
economic factors

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2. Sleeper…steel sleepers 2. Sleeper…steel sleepers

Advantages:
– Long life
– Better lateral rigidity
– Free from decay and fire hazards
– Good scrap value
– Lesser damage during handling /transportation
– Less maintenance problems
– Easy to maintain gauge
Disadvantages:
• Liable to corrosion
• Unsuitable to track circuiting
• Becomes center bound due to sloping ends
• Rail specific 31 32
 Other sleepers 2. Sleeper…
Switch sleeper Wide sleeper
Bridge sleeper
 Concrete monoblock sleepers can be produced in wider forms (e.g., 57
cm or 22 inches)

 No ballast is placed between the sleepers

 Increase lateral resistance, improving track stability

 Reduce ballast pressure, minimizing wear and tear on the underlying

track structure
Wide sleepers are used in high-speed, heavy traffic areas or on
Short sleeper long sleeper unstable subgrades to improve track stability and reduce ballast pressure.

33 34

2. Sleeper… 2. Sleeper…
Y-shaped sleepers
• Developed in 1983, Y-shaped
sleepers reduce ballast volume due
to their load-spreading design
• They distribute the load over a
wider area
• Higher noise levels compared to
conventional sleepers
• Excellent resistance to track
movement
• Challenges in curves: Three-point
contact prevents an exact geometric
fit with a fixed attachment point
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 2. Sleeper…Bi-block
Bi-block sleepers 2. Sleeper…
Consists of two concrete rail supports joined by steel.
Advantages:
• Increase lateral resistance
• Lighter than monoblock concrete sleepers
• Eliminate damage from torsional forces due to flexible
steel connections
• Used in ballast less track systems for improved track
stability

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2. Sleeper… 2. Sleeper…
Mono-block vs. twin block sleepers d) Arrangement
• Wooden Sleepers:
The advantages of the twin-block The advantages of the mono-
• Maximum: 1920 per km
sleeper block sleeper
• Well-defined bearing surfaces • low price • Minimum: 1440 per km
in the ballast bed; • less susceptibility to • Reinforced Concrete Sleepers:
• high lateral resistance in the cracking • Maximum: 1840 per km
ballast bed • can be pre-stressed
• Minimum: 1440 per km

The configuration is determined by factors like traffic volume, speed, and

line level.
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 2. Sleeper… 2. Sleeper…
Tie Analysis and Design(size and spacing)
Railroad Tie Plates
• Action under load
–Earlier tie reaction was considered as uniform Two basic types
• Single shoulder
• Double shoulder
Size
• Width: Matches the width of the
tie–
• Length: Chosen to keep stress on
–Talbot found that stress concentrated under rail seat
wood tie < 200 psi
–Stress = Qo/Plate Area

This insight led to more precise tie size and spacing designs to accommodate
stress variations. 41 42

3. Ballast and sub ballast

3. Ballast and sub ballast a) Functions
1. Ballast
• A layer of broken stones, gravel, or other gritty material Key Functions of Ballast

• Placed and packed below and around sleepers 1. Resist vertical and longitudinal forces and hold track in

Functions: position
• Distributes load from sleepers to the formation 2. Absorb energy from dynamic train loads
• Provides drainage
• Ensures longitudinal and lateral stability of the track 3. Provide voids for storage and movement of fouling materials

A loose, coarse-grained layer that 4. Allow for adjustment of track geometry

resists compressive stresses 5. Ensure immediate drainage of water from the track
through internal friction but
cannot resist tensile stresses. 6. Distribute loads to reduce pressure on subgrade materials
Tensile forces are resisted by:
• Rails, which are strong in tension
• Fastenings and sleepers 43 44
 3. Ballast and sub ballast 3. Ballast and sub ballast
(b) Requirements Minimum depth of ballast
– Tough and resist wear
– Hard enough
– Cubical with sharp edge
– Non porous, non-water absorbent
– Resist attrition
– Durable
– Good drainage
– Cheap and economical
Minimum Depth of Ballast • Thickness depends on:
• Stress assumed to spread at 45° • Sleeper spacing
• Must consider stress overlap area • Sleeper size
• Ensure adequate depth for load distribution • Axle load and traffic volume
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3. Ballast and sub ballast 3. Ballast and sub ballast

2. Sub ballast Sub Ballast Required When:
• Subgrade contains 85% or more of silt and clay-sized particles
Definition:
• Subgrade material has a liquid limit > 50 and a plasticity index > 20
• A layer between the top ballast and subgrade, with a finer gradation
Material
than top ballast but coarser than subgrade.
• Hard, angular, and non-cementing material
Functions:
• Primarily sand-sized particles
• Reduces total ballast cost
Particle Size Range:
• Filters fine subgrade particles from entering the ballast
From the smallest ballast particles to the largest subgrade particles
• Distributes loads effectively and prevents ballast from penetrating into
the subgrade Sub Ballast Depth
Application: • Considered as part of the total ballast depth during structural analysis

• Recommended for most new construction to maintain track stability • May comprise up to 40% of the total ballast thickness on main tracks and

and prevent fouling of the ballast. 50% on auxiliary/terminal tracks

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 4. Rail fastening system/ Union piece
a) Function:
• A Rail fastening system is a means of fixing rails to The purpose of the rail fastenings:
railroad sleepers.  To maintain the track gauge
• The terms rail anchors, tie plates, chairs and track fasteners  Offer sufficient resistance in a vertical direction, each pair
are used to refer to parts or all of a rail fastening system. of rail fastening elements has to be able to take over the
Various types of fastening have been used over the years. weight of the concrete sleeper and the respective rail
section without excess deformation.
 To transmit forces acting on and in the rails to the
• Union pieces are divided into rail joint sleepers (cross, longitudinal, concrete plates etc.)
fastenings and middle joint fastenings.  Electrically insulate the sleeper against the remaining
track grid, to minimize the loss of signals of the direct-
current circuits

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b) Types
Fishplates (Rail Joint Bars) (1) rail joint fastenings
Rail joint fastenings are used at the end of the two tracks.
• Purpose: Connect the ends of two rails to maintain alignment
and continuity

•Key Functions:
• Transfer longitudinal forces across rail joints
• Maintain gauge and vertical alignment
• Allow for thermal expansion/contraction

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(2) Middle joint fastenings
• They are used to connect the track with the sleeper wooden joint fastenings

• According to the character of sleeper, middle joint fastenings

can divided into reinforced concreted joint fastenings and

wooden joint fastenings .

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Reinforced concreted joint fastenings

Reinforced concreted
joint fastenings

55 56
 Ballasted track…
5. Ballasted and slab track Disadvantages
a) Ballasted track In comparison to slab track:
Advantages:  Track "floating" in both longitudinal and lateral directions over
time
• Lower cost compared to other track types  Limited lateral resistance causes problems with lateral acceleration
• Reduced noise emission in curves
• Short construction period  Ballast pulverization damages rails and wheels
• Easy repairs when failure occurs
 Ballast shaking at high speeds
 Reduced permeability due to contamination and fine particle
• High efficiency in maintenance due to
intrusion
mechanization
• Easy adjustment of geometrical
"Floating" refers to the track's tendency to shift or move slightly in both
unevenness longitudinal and lateral directions, losing stability over time.

Ballast pulverization refers to the gradual breakdown of ballast particles

into finer material
57 58

Slab track design

b) Slab track

Ballast replacement: Concrete or asphalt replaces ballast for load

distribution.

Elasticity provided: Through elastic elements below the rail or

sleeper. (inserting elastic elements such as rubber pads,
mats, or elastic bearings)

Advantages:

Reduced maintenance

Higher track stability compared to ballasted track

59 60
 Slab track Advantages:

• Lower maintenance cost (20%–30% less)

• Better line evenness and increased service life
• Increased lateral resistance and stability
• Reduced structure height and weight
• Potential for full replacement at the end of service life
• No track position alteration with mixed freight and passenger traffic
• Better accessibility for road vehicles
• Prevents dust release from ballast into the environment

61 62

Disadvantages: Types
Main types of non-ballasted track:
• Higher construction costs – Embedded in concrete
• Higher airborne noise reflection – Prefabricated slabs
• Longer repair time in case of derailment – Monolithic slab
• Challenges in transitions between ballasted and slab track – AC(asphalt concrete)-road bed
• Significant effort required for track position and super elevation – Embedded rail
adjustments
• Limited adaptability to large sinking in embankments
• Requires extensive foundation preparation and homogenous
sub-layers to avoid settlements

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 LVT (Sonneville Company)
Practical uses of slab track

• Metro, urban rail transit

• Bridge
Rheda (Germany)- sleepers
embedded in concrete • Repair inconvenience, small
space, traffic density
• Tunnels, subways, elevated
crossing, stations & terminals
Floating Slab Track on springs
(Gerb Company) • High speed railway

Slab track (Japan)- prefabricated

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Thanks!

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