IL(dB) IL(dB) IL(dB) RIVAS 16 IL PTQ AceSB_FL GPvsGS 14 12 10 8 6 4 2 0-2 10 0 10 1 10 2 f(hz) 6 IL FTQ AceSB_FL GPvsGS 5 4 3 2 1 0-1 -2-3 -4 10 0 10 1 10 2 f(hz) 15 IL DFT AceSB_FL GPvsGS 10 5 0-5 -10-15 10 0 10 1 10 2 f(hz) 1/3 octave subballast-form layer acceleration insertion loss graphs for passenger train (upper graph), freight vehicle (middle graph) and dynamic load time history (lower graph) of TS3 track system compared to TS2 with ballast tamped and stabilized. RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 237 of 241 07/06/2013
IL(dB) IL(dB) IL(dB) RIVAS 20 IL PTQ AceFL_E GPvsGS 15 10 5 0-5 10 0 10 1 10 2 f(hz) 8 IL FTQ AceFL_E GPvsGS 6 4 2 0-2 -4-6 10 0 10 1 10 2 f(hz) 15 IL DFT AceFL_E GPvsGS 10 5 0-5 -10-15 10 0 10 1 10 2 f(hz) 1/3 octave form layer-embankment acceleration insertion loss graphs for passenger train (upper graph), freight vehicle (middle graph) and dynamic load time history (lower graph) of TS3 track system compared to TS2 with ballast tamped and stabilized. RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 238 of 241 07/06/2013
IL(dB) IL(dB) IL(dB) RIVAS 18 IL PTQ AceE142 GPvsGS 16 14 12 10 8 6 4 2 0-2 10 0 10 1 10 2 f(hz) 5 IL FTQ AceE142 GPvsGS 4 3 2 1 0-1 -2-3 -4-5 10 0 10 1 10 2 f(hz) 15 IL DFT AceE142 GPvsGS 10 5 0-5 -10-15 10 0 10 1 10 2 f(hz) 1/3 octave middle embankment acceleration insertion loss graphs for passenger train (upper graph), freight vehicle (middle graph) and dynamic load time history (lower graph) of TS3 track system compared to TS2 with ballast tamped and stabilized. RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 239 of 241 07/06/2013
IL(dB) IL(dB) IL(dB) RIVAS 14 IL PTQ AceE062 GPvsGS 12 10 8 6 4 2 0-2 -4-6 10 0 10 1 10 2 f(hz) 6 IL FTQ AceE062 GPvsGS 4 2 0-2 -4-6 10 0 10 1 10 2 f(hz) 10 IL DFT AceE062 GPvsGS 5 0-5 -10-15 10 0 10 1 10 2 f(hz) 1/3 octave bottom embankment acceleration insertion loss graphs for passenger train (upper graph), freight vehicle (middle graph) and dynamic load time history (lower graph) of TS3 track system compared to TS2 with ballast tamped and stabilized. RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 240 of 241 07/06/2013
RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 241 of 241 07/06/2013
RIVAS Railway Induced Vibration Abatement Solutions Collaborative project Results of laboratory tests for ballasted track mitigation measures Under Sleeper Pads (USP) and heavy sleepers Deliverable D3.7 (Part B) Submission date: 10/06/2013 Project Coordinator: Bernd Asmussen International Union of Railways (UIC) asmussen@uic.org RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 1 of 89 10/06/2013
Title Results of laboratory tests for ballasted track mitigation measures Under Sleeper Pads (USP) and heavy sleepers Domain WP3, Task 3.2, D3.7 (Part B) Date 10/06/2013 Author/Authors Partner Document Code Version Status Dipl. Ing. E. Knothe BAM RIVAS_BAM_ WP3_D3_7_PartB_final.docx V02 Final Dissemination level: Project co-funded by the European Commission within the Seventh Framework Programme Dissemination Level PU Public PP Restricted to other programme participants (including the Commission Services) RE Restricted to a group specified by the consortium (including the Commission) Services) CO Confidential, only for members of the consortium (including the Commission Services) X Document history Revision Date Description 1 29/04/2013 First Draft 2 03/06/2013 Second Draft 3 10/06/2013 Final RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 2 of 89 10/06/2013
1. EXECUTIVE SUMMARY The laboratory tests of under sleeper pads and sleepers were carried out within the research project RIVAS Railway Induced Vibration Abatement Solutions, Grant Agreement Number 265754, of the European Union EU. This report describes the measurement of under sleeper pads and sleepers for ballasted tracks, work package 3 Mitigation measures track of RIVAS, task 3.2 Mitigation measures for ballasted tracks [5]. The tests for under sleeper pads have been performed in accordance with DIN 45673-6 Mechanical vibration Resilient elements used in railway tracks Part 6: Laboratory test procedures for under sleeper pads of concrete sleepers, [1]. The tests for the sleepers have been performed in accordance with DIN EN 13230-2 Railway applications Track Concrete sleepers and bearers Part 2: Prestressed monoblock sleepers. Three different types of under sleeper pads (SLN1010, SLN0613 and SLN0315) and one sleeper type (B90.2) were investigated. For the examination of the under sleeper pads for ballasted tracks tests for the static and dynamic bedding modulus, fatigue strength, bond strength, shear strength and the freeze-thaw resistance were carried out. For the sleepers static tests, dynamic tests and in a fatigue test were carried out. The results of the measurements are documented in detail among others in stressdisplacement diagrams for the different static bedding moduli, bond strength and shear strength. The so called low-frequency bedding modulus was determined for 5 Hz, 10 Hz, 20 Hz and 30 Hz at 23 C and in addition for 10 Hz at 0 C and -20 C. The so called highfrequency bedding modulus was determined at 10 Hz, 20 Hz, 40 Hz, 80 Hz and 160 Hz at room temperature. Two standards for tests of USP with different profiled loading plates exist, the German standard DIN 45673-6 [1] and the draft European standard CEN/TC 256 [4]. The static bedding modulus was determined at the same specimen with the test procedure of the German standard with the two different loading plates. Looking at the influence of the loading plates the static bedding modulus differs depending on the material between 10% and 18% for medium ballast compaction. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 3 of 89 10/06/2013
2. TABLE OF CONTENTS 1. Executive Summary... 3 2. Table of contents... 4 3. Introduction... 6 4. Test Laboratory and Staff... 7 5. Examination of the under sleeper pads for ballasted track... 8 5.1 Material and Specimen... 8 5.1.1 Material... 8 5.1.2 Specimen... 9 5.2 Characteristic Values...12 5.2.1 Static bedding modulus C stat and at-rest value C stat0 of the static bedding modulus 12 5.2.2 Different profiled loading plates (German-NSP and EU-GBP) - Static bedding modulus 15 5.2.3 Low-frequency bedding modulus C dyn1 (f)...17 5.2.4 Low-frequency stiffening ratio K dyn1 (10Hz)...19 5.2.5 High-frequency bedding modulus C dyn2 (f)...20 5.2.6 High-frequency dynamic stiffening ratio K dyn2 (80Hz)...21 5.3 Serviceability...22 5.3.1 Mechanical fatigue strength...22 5.3.2 Bond strength by pull-off...23 5.3.3 Shear strength...25 5.3.4 Freeze-thaw resistance...27 6. Examination of the Sleepers B90.2 ballasted track...29 6.1 Material and specimen...29 6.2 Static test rail seat...29 6.3 Static test centre...32 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 4 of 89 10/06/2013
6.4 Dynamic test rail seat...33 6.5 Fatigue test...35 7. Conclusion...37 8. Annex...38 8.1 References...38 8.2 Abbreviations...38 8.2.1 Terms and definitions...38 8.2.2 Symbols...39 8.3 Tables Examination of the USP...41 8.3.1 Measuring System...44 8.3.2 Results USP...49 8.4 Figures - Examination of the USP...60 8.4.1 Specimen...60 8.4.2 Test rig...61 8.4.3 Evaluation static bedding modulus...66 8.5 Data sheets USP firm Getzner Werkstoffe GmbH...75 8.6 Tables Examination of the sleepers...76 8.6.1 Measuring system and test forces...77 8.6.2 Results sleepers...79 8.7 Figures Examination of the sleepers...81 8.7.1 Test rig...82 8.7.2 Tested sleepers...85 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 5 of 89 10/06/2013
3. INTRODUCTION Railway induced vibrations are a growing problem in Europe. Therefore the European Commission installed the research project RIVAS Railway Induced Vibration Abatement Solutions, Grant Agreement Number 265754. The aim of RIVAS project is to reduce railway induced ground-borne vibrations with mitigation measures on the track, the propagation path and of the vehicles. The subjects investigated in this report aims for the measures in track only. Under sleeper pads (USP) and sleepers are investigated within the work package 3 Mitigation measures track of RIVAS, task 3.2 Mitigation measures for ballasted tracks [5]. The numerical study [7] in RIVAS-Deliverable 3.2 showed the mitigation potential of soft under sleeper pads and heavy sleeper. Therefore, laboratory tests were carried out with soft under sleeper pads and with a newly designed heavy sleeper. The tests include the determination of characteristic values, which are necessary to predict the mitigation effect, as well as serviceability tests which are necessary for the installation new elements in commercial tracks. During the laboratory tests three different materials from Getzner Werkstoffe GmbH for USP were examined: SLN1010, SLN0613 and SLN0315. One sleeper type B90.2 was examined. All tests were planned in corporation with RAIL.ONE GmbH and all tested materials were delivered as well by RAIL.ONE GmbH. The report is subdivided into chapter 1 to 4 with the executive summary, the table of contents, the introduction and the test laboratory and staff. The examination of the USP is described in chapter 5 and the examination of the sleepers in chapter 6. The conclusions are given in chapter 7. Additional information are given in chapter 8. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 6 of 89 10/06/2013
4. TEST LABORATORY AND STAFF The measurements were carried out at BAM Federal Institute for Materials Research and Testing Division 7.2 Buildings and Structures Unter den Eichen 87 12205 Berlin Germany The tests were carried out between August 2012 and Mai 2013. The measuring staff was: Dipl. Ing. E. Knothe Dipl. Ing. E. Kretzschmar Dipl.-Ing. R.Makris Dipl.-Ing. H.-J. Peschke Project Management, Report Evaluation Test organisation Evaluation M. Peuschel Evaluation with ATOS I. Feick N. Neumann Test setup and procedure RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 7 of 89 10/06/2013
5. EXAMINATION OF THE UNDER SLEEPER PADS FOR BALLASTED TRACK For the examination of the under sleeper pads for ballasted tracks the characteristic values the static and dynamic bedding modulus were determined. The high-frequency bedding moduli are the values which characterise the mitigation potential of the USP. In addition tests for the serviceability the fatigue strength, bond strength, shear strength and the freeze-thaw resistance were carried out. The test procedure was carried out according to DIN 45673-6 [1] Mechanical vibration Resilient elements used in railway tracks Part 6: Laboratory test procedures for under sleeper pads of concrete sleepers, English version of [1]. 5.1 MATERIAL AND SPECIMEN 5.1.1 Material Three different elastomer materials of USP from the company Getzner Werkstoffe GmbH were examined. Table 5-1 gives the declaration of the USP as delivered by Getzner Werkstoffe GmbH. Additional information are given in the data sheet exemplarily for the material SLN 0315, Figure 8-30. Table 5-1: USP, declaration of the manufacturer Getzner Werkstoffe GmbH material thickness [mm] declaration manufacturer bedding modulus, declaration manufacturer SLN 1010 SLN 10 0.10 SLN 0613 SLN 13 0.06 SLN 0315 SLN 15 0.03 The single USP SLN 0613 is shown exemplarily in Figure 5-1. The USP consist of a felt layer at the bottom, the elastomer and a geogrid. The felt layer protects the elastomer against spiky ballast and the geogrid as a bonding layer to connect the USP with the concrete. Pictures of USP SLN1010 and SLN0613 are shown in Figure 8-1 and Figure 8-2 in the annex. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 8 of 89 10/06/2013
SLN 0613 5 cm geogrid elastomer d = 15 mm felt Figure 5-1: Under-sleeper pad SLN0613 5.1.2 Specimen The specimens were concrete blocks with bonded USP as a substitute for the sleeper and single USP, see Figure 5-2. The dimensions of the concrete blocks differ depending on the kind of tests. The concrete blocks with bonded USP and the single USP were provided by RAIL.ONE GmbH. An overview of all delivered specimen is given in Table 8-1 to Table 8-3, page 41ff. Every specimen had his own notation. Material SLN1010 Material SLN0613 Material SLN0315 notation C-xx notation B-xx notation A-xx Single USP P-01, P-02 or P-03 The supplier s notation e.g. SLN 0613 means a Material Sylodyn (SLN) with 0.06 N/mm³ nominal modulus and a thickness of 13 mm. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 9 of 89 10/06/2013
b) a) c) Figure 5-2: Specimen, concrete blocks with USP, material Getzner Werkstoffe GmbH SLN, a) + b) for different tests 300 * 300 * 100 mm³, 300 * 300 * 200 mm³, c) for the shear test 200 * 200 * 200 mm³ Static and dynamic Bedding modulus: For the static and at-rest value of the static bedding modulus the specimens were concrete blocks with bonded USP with the dimensions 300 * 300 * 100 mm³ (only concrete block), see Figure 5-2. The area of the specimens was 90 000 mm². The height was reduced versus the requirement of the German standard DIN 45673-6 [1] because of a better handling in the laboratory. The lower mass was considered in the test. The low-frequency bedding modulus was measured directly after the static bedding modulus with the identical specimen as those for the static bedding modulus. For the high-frequency bedding modulus single USP without bonding layer were used. One side of the USP was plain and the other side had got the normal felt layer at the ballast contact surface. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 10 of 89 10/06/2013
Fatigue test: The specimen for the fatigue test was a concrete block with USP with the dimensions 300 * 300 * 200 mm³ (only concrete block) as provided in the German standard DIN 45673-6. The area of the specimen was 90 000 mm². Bond strength by pull-off: For the bond strength a specimen with a test area with a diameter of 50 mm has to be prepared. The tear chips were drilled out of a concrete block with bonded USP. The drill was made through the USP and about 10 mm down into the concrete block, see Figure 5-3. \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Bilder\ Haftabzug\bonding test USP ballasted track\jan13\ Figure 5-3: Bond strength by pull-off, preparation of specimen, 5 test areas Shear test: For the shear tests concrete cubes with USP on two opposite sides were used. The dimensions of the cubes are 200*200*200 mm³ (only concrete cube) as provided in the German standard DIN 45673-6. Frost-thaw test: The specimen for the frost-thaw test is the same (identical in construction) as for the static bedding modulus, concrete block with USP, 300 * 300 * 100 mm³. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 11 of 89 10/06/2013
5.2 CHARACTERISTIC VALUES 5.2.1 Static bedding modulus C stat and at-rest value C stat0 of the static bedding modulus The static bedding modulus is used for the calculation of the static deformation of the rail under the service load. It is calculated with the following formula: It is a reference parameter for the USP. For the determination three load cycles were applied. The third cycle was analysed and the secant modulus between stress and and the displacements s 2 and s 1 was calculated, see Figure 5-4. The at-rest value of the static bedding modulus shows the static compression under the dead load of a train. It is calculated between stress and, measured after a resting time of 10 minutes, see Figure 5-4, with the following formula: Test parameters: The static bedding modulus was determined with 3 specimens. The at-rest value of the static bedding modulus was determined with exactly the same specimen directly after the static bedding modulus for each condition in accordance with [1]. The test routine for both bedding moduli is shown in Figure 5-4. The test conditions for the static bedding modulus are summarized in Table 5-2 and the evaluation range in Table 5-3. The test conditions for the at-rest value of the static bedding modulus are the same as for the static bedding modulus but the loading range is different. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 12 of 89 10/06/2013
stress RIVAS o 2* 2 middle ballast pres. high ballast pressure resting value resting value u = 1 0 test for static bed. modulus 5 min resting value 10 min 10 min 10 min time test for at-rest value of the static bed. modulus Figure 5-4: Test routine static and at-rest value of the static bedding modulus Table 5-2: Static bedding modulus - Test conditions Conditions: Specimen Temperature Load application Loading and unloading rate dry test object, test temperature must be achieved 16 h before the test 3 concrete blocks with USP, 300 * 300 * 100 mm³ (23 ± 3) C, (0 ± 3) C, (-20 ± 3) C The concrete block with the USP is placed on top of the profiled plate (NSP). The USP is in contact with the plate. The weight of the concrete block has to be taken into account for the applied force. /t = 0.01 N/mm²/s Loading range: u = 0.01 N/mm², o = 0.25 N/mm² Test rig servo-hydraulic tensile-compression testing machine with 100 kn cylinder, see Table 8-4 Table 5-3: Static bedding modulus - evaluation ranges Evaluation range for medium ballast compaction: Evaluation range for high ballast compaction: 1 = 0.01 N/mm², 1 = 0.01 N/mm², 2 = 0.10 N/mm² 2 = 0.20 N/mm² RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 13 of 89 10/06/2013
The results of the static and at-rest value of the static bedding modulus for the three different materials are shown in Table 8-9 to Table 8-11. As an example the static bedding modulus for different temperatures and for high ballast compaction is presented in Figure 5-5. The static bedding modulus for all different USP increases while the temperature decreases. Figure 5-5: static bedding modulus for high ballast compaction RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 14 of 89 10/06/2013
5.2.2 Different profiled loading plates (German-NSP and EU-GBP) - Static bedding modulus The tests for the static and at-rest value of the static bedding modulus, for the low-frequency bedding modulus and for the high-frequency bedding modulus are carried out with the German ballast plate (NSP, in German Normschotterplatte), Figure 5-6. Surface area of the German ballast plate is 300 x 300 mm². It is produced from a ballast cast from real ballast. Figure 5-6: German ballast plate (NSP) The other ballast plate is the European or Geometric ballast plate (GBP) with a pyramidal structure instead of the real ballast and with the same surface area, Figure 5-7, according to CEN [4]. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 15 of 89 10/06/2013
Figure 5-7: European or Geometric ballast plate (GBP) For the different USP the static bedding modulus was determined with the German ballast plate and in addition with the geometric ballast plate to compare the influence of both profiled plates. The tests with the NSP and the GBP were performed on the identical specimen for each material and with the same test procedure. The test procedure was chosen according to DIN 45673-6, [1]. It is described in chapter 5.2. Results: The results are shown in Table 8-12 and in Figure 8-19 for SLN1010, in Figure 8-20 for SLN0613 and in Figure 8-21 for SLN 0315. The static bedding modulus for medium ballast compaction differs for the three materials as follows: USP type variance in modulus measured with EU-GBP / German-NSP SLN1010-10 % SLN0613 10 % SLN0315 18 % The results are not the same and the test method has to be noted with every bedding modulus. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 16 of 89 10/06/2013
stress RIVAS 5.2.3 Low-frequency bedding modulus C dyn1 (f) The low-frequency bedding modulus C dyn1 (f) is used for the calculation of the time depending bending deformation of the rail under a rolling wheel. It determines the superstructure dynamics. The tests are carried out without preload. The low-frequency bedding modulus is calculated with the following formula: The low-frequency bedding modulus C dyn1 (f) is determined at 23 C for f = 5 Hz, 10 Hz, 20 Hz and 30 Hz and in addition for 10 Hz at 0 C and -20 C. The test routine is presented in Figure 5-8. The test conditions are summarized in Table 5-4 and the loading range was chosen for main-line-railways, Table 5-5. max 5 Hz 10 Hz 20 Hz 30 Hz m min ~ 3 min ~ 10 s 10 cycles time Figure 5-8: Test routine dynamic bedding modulus; 5, 10, 20, 30 Hz RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 17 of 89 10/06/2013
Table 5-4: Low-frequency bedding modulus - Test conditions Conditions: Specimen dry test object, test temperature must be achieved 16 h before the test 3 concrete blocks with USP Temperature and frequency (23 ± 3) C 5 Hz, 10 Hz, 20 Hz, 30 Hz (0 ± 3) C, (-20 ± 3) C 10 Hz Load application Type of load Test rig The concrete block with USP is placed on top of the profiled plate (NSP). The pad is in contact with the plate. The weight of the concrete block has to be taken into account for the applied force. harmonic excitation between u and o servo-hydraulic tensile-compression testing machine with 100 kn cylinder, see Table 8-4 Table 5-5: Low-frequency bedding modulus - Loading range Loading range for main line railway u = 0.01 N/mm², o = 0.10 N/mm² The results of the low-frequency bedding modulus C dyn1 (f) for three different materials are shown in Table 8-13 and Table 8-14 and in Figure 5-9. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 18 of 89 10/06/2013
Figure 5-9: Low-frequency bedding modulus 5.2.4 Low-frequency stiffening ratio K dyn1 (10Hz) The low-frequency stiffening ratio K dyn1 was calculated for 10 Hz due to the standard DIN 45673-6 [1]. It is calculated as the quotient of the lower frequency bedding modulus at 10 Hz and the static bedding modulus with the following formula: The values of both bedding moduli must be determined on the same specimen. The results for all materials are summarized in Table 8-15. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 19 of 89 10/06/2013
5.2.5 High-frequency bedding modulus C dyn2 (f) The high-frequency bedding modulus C dyn2 (f) is determined for under-sleeper pads to characterise their mitigation potential. In comparison to the low-frequency bedding modulus the test procedure of the high-frequency bedding modulus C dyn2 (f) is carried out with a static preload, only with the single pad without bonding layer and concrete block and with a smaller vibration amplitude. Therefore the values of low and high-frequency bedding modulus at the same frequency are not the same and cannot be compared. For the test conditions see Table 5-6. Table 5-6: High-frequency bedding modulus - Test condition Conditions: Specimen dry test object, single USP, 300 * 300 mm² 3 specimens: SLN1010 and SLN 0315 2 specimens: SLN 0613 Temperature Load application Type of load Frequency (23 ± 3) C The USP is placed between a flat loading plate (above) and the profiled loading plate NSP. The tests are carried out under preload. preload: main-line railway network: σv = 0,12 N/mm² Harmonic excitation with a particle velocity amplitude of 7 mm/s fj : 10 Hz to 160 Hz in octave intervals Test rig servo-hydraulic tensile-compression testing machine with 7 kn cylinder see Table 8-5 The results of the high-frequency dynamic bedding moduli are summarized in Table 8-16 and in Figure 5-10. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 20 of 89 10/06/2013
bedding modulus RIVAS 0,40 high frequency bedding modulus (structure borne noise) 0,35 0,30 0,25 0,20 SLN1010 SLN613 SLN315 0,15 0,10 0,05 0,00 0 50 100 150 200 frequency [Hz] Figure 5-10: High-frequency bedding modulus 5.2.6 High-frequency dynamic stiffening ratio K dyn2 (80Hz) The high-frequency dynamic stiffening ratio K dyn2 was calculated for a frequency of 80 Hz due to the standard DIN 45673-6 [1]. It is calculated as the quotient of the high-frequency bedding modulus at a frequency of 80 Hz and the static bedding modulus with the following formula: The values of both bedding moduli must be determined on the same specimen. The results for all materials are summarized in Table 8-17. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 21 of 89 10/06/2013
5.3 SERVICEABILITY 5.3.1 Mechanical fatigue strength The mechanical fatigue strength test shall characterize the long term functionality of the USP and the bonding layer. One very soft type of USP was planned to test according to the simulation [7]. Test conditions: For the mechanical fatigue strength test a total of 8 million load cycles were applied on a concrete block with bonded USP which was placed on the ballast in a ballast trough, see Figure 8-7. The load cycles were applied in two 2 load levels. The loadings are induced according to DIN 45673-6 (5.2) for main-line railways, Table 5-7. Table 5-7: Mechanical fatigue strength test conditions Conditions: Specimen Temperature Load application Type of load dry test object, 1 concrete blocks with USP, 300 * 300 * 200 mm³ (23 ± 3) C The concrete block with the sleeper pad is placed on top of the ballast in a ballast trough. The USP is in contact with the ballast. The weight of the concrete block has to be taken into account for the applied force. Harmonic excitation at f = 3 Hz Loading range: Load level 1 (5 mill. load cycles): preload F U = 1 kn Load level 2 (3 mill. load cycles): preload F U = 1 kn upper load F 0 = 21 kn upper load F 0 = 28 kn Test rig see Table 8-6 Results: There were several pressure areas after the first and the second load level as documented after a manually evaluation in Figure 8-22 and Figure 8-23 after the first and the second load level. The depth of the pressure areas were up to 11 mm after the first load level and up to 12 mm after the second load level, Table 8-18. At one place the USP was perforated by the RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 22 of 89 10/06/2013
ballast up to the concrete. The edges of the USP were cracked at several places especially at the corners. In addition an evaluation by the system ATOS from GOM (GOM - Gesellschaft für Optische Messtechnik mbh, Optical Measuring Techniques) was made. Using that system the surface of the USP was photographed after both load steps out of two directions and so the structure of the surface could be illustrated in colours with the relative depth to a self chosen area, see Figure 8-24. The absolute depth couldn t be determined because the ballast contact felt didn t allow defining an exact zero area before the loadings. 5.3.2 Bond strength by pull-off The bond strength by pull-off shall be determined to ensure the required degree of the bonding between under sleeper pad and concrete. For the test conditions see Table 5-8. Table 5-8: Bond strength by pull-off test conditions Conditions: Specimen dry test object, 1 concrete blocks with USP, 300 * 300 * 100 mm³ 3 test areas each with a tear chip Ø 50 mm, drilled through the USP in the concrete of the specimen, Figure 8-25 Temperature Load application (23 ± 3) C steel stud glued to the USP with a polyurethane glue defined from the manufacturer of the USP Getzner Werkstoffe GmbH, Macroplast UK 8303 B60 vertically to the bonded surface Loading rate /t = 0.01 N/mm²/s Test rig see Table 8-7 Results The collapse area was the bonding layer between the concrete and the USP in the majority of cases, 27 tests of 30 tests, Figure 8-26. The load deformation curves are given in Figure 8-26 and Figure 5-11. The values of the bond strength are documented in Table 8-19. The Specimen SLN1010 A11 shows the highest maximum load and the lowest maximum displacement. The bonding layer for the USP is a geogrid with different denseness, Figure RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 23 of 89 10/06/2013
stress [N/mm²] stress [N/mm²] stress [N/mm²] stress [N/mm²] RIVAS 8-1 to Figure 8-2. The different bonding layer and the different materials had an influence on the bond strength. SLN 1010 A 11 SLN 0613 B 05 0,9 0,8 0,7 0,6 0,9 0,8 0,7 0,6 0,5 0,5 0,4 0,4 0,3 0,3 0,2 0,1 0 Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 0 2 4 6 8 10 12 14 16 Displacement [mm] 0,2 0,1 0 Sample 1 Sample 2 Sample 3 Sample 5 0 2 4 6 8 10 12 14 16 Displacement [mm] SLN 0315 C 09 SLN 0613 B 08 - after freeze thaw test 0,9 0,9 0,8 0,8 0,7 0,7 0,6 0,6 0,5 0,5 0,4 0,4 0,3 0,3 0,2 0,1 0 Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 0 2 4 6 8 10 12 14 16 Displacement [mm] 0,2 0,1 0 Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 0 2 4 6 8 10 12 14 16 Displacement [mm] Figure 5-11: Bond strength, SLN1010, SLN0613, SLN0315 and SLN0613 after freeze thaw test RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 24 of 89 10/06/2013
5.3.3 Shear strength Table 5-9: Shear strength test conditions Conditions: Specimen dry test object, for each material 3 concrete cubes with USP on two sides, 200 * 200 * 200 mm³ only SLN0613 and SLN0315 Temperature Load application (23 ± 3) C The two USP sides of the specimen were glued onto steel plates and the steel plates were fixed vertically in the testing machine, load applied in the middle of the concrete cube with a 30-mm-wide loading blade parallel to the bonded surface Loading rate /t = 0.01 N/mm²/min Test rig see Table 8-8 Results All specimens had the breakdown within the USP material, see Figure 8-27 to Figure 8-29. The stress-deformation curves are documented in Figure 5-12 and Figure 5-13. The values of the shear strength are documented in Table 8-20. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 25 of 89 10/06/2013
0.60 0.50 0.40 B31 B32 0.30 B33 0.20 0.10 0.00 0 5 10 15 20 25 displacement [mm] SLN0613 Datei: SLN0613_AbSch.TDM VII.2 Ingenieurbau Layout: AbSch_SLN0615.TDR Figure 5-12: Shear strength, SLN0613 0.60 0.50 0.40 C31 C32 0.30 C33 0.20 0.10 0.00 0 5 10 15 20 25 displacement [mm] SLN0315 Datei: SLN0315_AbSch_korr.TDM VII.2 Ingenieurbau Layout: AbSch_SLN0315.TDR Figure 5-13: shear strength, SLN0315 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 26 of 89 10/06/2013
5.3.4 Freeze-thaw resistance One type of USP was foreseen for the freeze-thaw resistance test. The USP type SLN 0613 was chosen for the test, since this type has been preselected as potential useful soft USP type for main line according to the simulation [7]. T 30 C RT u 2h 24h time -20 C 11h Test-cycle 50x 1h + 11h + 1h + 11h = 24h Figure 5-14: Test routine freeze-thaw test Table 5-10: Freeze-thaw resistance - Test conditions Conditions: Specimen Test medium Temperature Preparation Load application Loading rate Temperature application Temperature rate Before and after the test dry test object before conditioning, 1 concrete block with USP, 300 * 300 * 100 mm³ distilled water (23 ± 3) C, (-20 ± 3) C, (30 ± 3) C USP of the concrete block 24 h in distilled water on the German-NSP first 2 hours in water bath pulsed load with u = 0,05 N/mm² and o = 0,15 N/mm² 30 strokes per hour 50 freeze-thaw cycles -20 C to 30 C, 1 day for each cycle -20 C to 30 C in 1 hour determine the low-frequency bedding modulus at 10 Hz RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 27 of 89 10/06/2013
bedding modulus RIVAS Results The curve of the low-frequency bedding modulus before and after the freeze-thaw-test is shown in Figure 5-15 and the values are given in Table 8-21. The bedding modulus after the test is in the maximum 3% higher than before the test. The curve of the pull-off strength before and after the freeze-thaw-test is shown in Figure 5-11 and the values are given in Table 8-19. The arithmetic average of the maximum stress is about 8% lower than before the freeze thaw resistance test and the standard variance is 21% higher. The visual inspection after the freeze-thaw cycles didn t show any damage. 0,07 Freeze-thaw resistance, low frequency bedding modulus SLN0613 0,06 0,05 0,04 0,03 before the test after the test 0,02 0,01 0,00 0 10 20 30 40 frequency [Hz] Figure 5-15: Freeze-thaw resistance, SLN0613, low-frequency bedding modulus, before and after the test RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 28 of 89 10/06/2013
6. EXAMINATION OF THE SLEEPERS B90.2 BALLASTED TRACK The test procedure was carried out according to DIN EN 13230-2 Railway applications Track Concrete sleepers and bearers Part 2: Prestessed monoblock sleeper, English version of [3]. The test program includes four different tests: The static and dynamic test for positive moment at the rail seat section, the static test at the centre section for negative moment and the fatigue test for positive moment at the rail seat section. All tests carried out are summarized in Table 8-24. The loadings according to DBS 918 143 [6] as provided by RAIL.ONE GmbH are summarized in Table 8-25. Photos of all tested sleepers are given in Figure 8-39 to Figure 8-44. 6.1 MATERIAL AND SPECIMEN The tested sleepers were of the type B90.2 as shown in Figure 8-31 and Figure 8-32. In total 16 + 4 sleepers, 16 for the tests and 4 in reserve, were delivered by RAIL.ONE GmbH. The material of the sleepers is concrete C50/60 with an aggregate of iron ore. Therefore one sleeper has got a weight of 600 kg, without fastening. In comparison, a standard sleeper B90 has a weight of 333 kg. The main dimensions of one sleeper are: Length 2600 mm, Width 320 mm. 6.2 STATIC TEST RAIL SEAT The static test on the rail seat section with positive load was carried out with 6 sleepers and additionally with 4 sleepers. The test set-up is shown in Figure 8-34 and Figure 8-35. The test routine is shown in Figure 6-1. For the test conditions see Table 6-1. There were two test sequences. In the first sequence the sleepers were dry during the tests and in the second one wet. Four sleepers were additionally tested because in the first sequence 2/3 of the sleepers failed the tests. In tests afterwards the sleepers had been put under water for a minimum of two days prior the testing according to the technical supply specitication of the DB-AG. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 29 of 89 10/06/2013
10 kn 10 kn RIVAS force FrB Fr0,05 Frr Fro max. 120 kn/min time 10s < t < 5min detecting of the crack max. 5min Figure 6-1: Test routine, rail seat section, static test Table 6-1: Static test rail seat (+) test conditions Conditions: dry test object (sleeper 1 to sleeper 6) wet test object (sleeper 21 to sleeper 24) according to the DB-AG technical supply specification [6] Specimen 6 prestressed monobloc sleepers, B90.2 Temperature and frequency Load application Loading rate Type of load Procedure preparation Procedure test (23 ± 3) C The load was applied perpendicular to the base of the sleeper in middle of the rail seat section. The sleeper opposite shall be unsupported F max /time = 2 kn/s quasi static Choice of the sleeper no cracks and spalling in the test area, because the crack detection will be difficult Marking of the evaluation area, 15 mm parallel to the bottom of the sleeper Position the piston on the sleeper, set point 20 kn Raise the force until Fro=176kN, loading rate 2kN/s Search for the first crack under load increase the force in steps of 10kN up to the first crack Further increase of the force, steps of 10kN up to 356 kn RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 30 of 89 10/06/2013
force [kn] RIVAS Unloading of the sleeper and search for cracks Repeat the loading and unloading up to a crack with a width of 0.05mm at the bottom of the sleeper Further increase of the force up to the break of the sleeper Crack detection Cracks are searched at the side of the sleeper in an area 15 mm from the bottom and under the sleeper between the support Detection equipment includes crack loupe, mirror, acetone (only initial crack inspection prior testing) The results for the static test at the rail seat section are shown in Table 8-26 and Figure 6-2. For the dry sleeper two of six sleepers passed the first pass/fail criteria with Fr r > Fr 0, the others had got the first crack at Fr r = Fr 0. All sleepers passed the second and third criteria. For the wet sleeper all four sleepers passed the first, second and third criteria. Only the testing of wet sleepers is in accordance with DB specification [6] and thus governing, testing on dry sleepers is on the conservative side, when criteria are met. Pass/fail criteria: 1. Fr r > Fr 0 with Fr 0 = 176 kn 2. Fr 0,05 > k 1s * Fr 0 = 264 kn with k 1s = 1,5 3. Fr B > k 2s * Fr 0 = 369,6 kn with k 2s = 2,1 sleeper tests B90.2 static, rail seat 700 600 500 400 300 200 Fr0 Frr F r0.05 FrB 100 testcondition dry testcondition wet 0 1 2 3 4 5 6 21 22 23 24 number of the sleeper Figure 6-2: Static test, rail seat, B90.2 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 31 of 89 10/06/2013
5 kn RIVAS 6.3 STATIC TEST CENTRE The static test at the centre section with negative load was carried out with three sleepers. The test set-up is shown in Figure 8-36 and Figure 8-37. The test routine is shown in Figure 6-3. For the test conditions see Table 6-2. force FcBn Fcrn Fcon max. 120 kn/min 10s < t < 5min time Figure 6-3: Test routine, centre section, negative bending moment, static test Table 6-2: Static test centre (-) test conditions Conditions: dry test object Specimen 3 prestressed monobloc sleepers, B90.2 Temperature and frequency Load application Loading rate Type of load Procedure preparation (23 ± 3) C The load was applied perpendicular to the base of the sleeper in middle of the centre section. The sleeper lies upside down in the test rig. F max /time = 2 kn/s quasi static Choice of the sleeper no cracks and spalling in the test area, because the crack detection will be difficult Marking of the evaluation area, 15 mm parallel to the base (top in fact) of the sleeper RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 32 of 89 10/06/2013
Procedure test Position the piston on the sleeper, set point 2 kn Raise the force until Fc 0n = 48 kn, Loading rate 2kN/s Search for cracks under load Further increase of the force, steps of 5kN up to F crn Repeat further increase of the force, steps of 5kN up to the break of the sleeper Crack detection Cracks are searched at the side of the sleeper in an area 15 mm from the bottom (top in fact) and under the sleeper between the support Detection equipment includes crack loupe, mirror, acetone (only initial crack inspection prior testing) The results for the static tests in the centre section are shown in Table 8-29. All three sleepers passed the pass/fail criterion. Only the testing of wet sleepers is in accordance with DB specification [6] and thus governing, testing on dry sleepers is on the conservative side, when criteria are met. Pass/fail criterion: Fc rn > Fc 0n = 48 kn 6.4 DYNAMIC TEST RAIL SEAT The dynamic test at the rail seat section with positive load was carried out with six sleepers. The test set-up was the same as for the static test rail seat section. The test routine is shown in Figure 6-4. For the test conditions see Table 6-3. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 33 of 89 10/06/2013
force 176 * 1,7 kn = 299,2 kn 176 x 1,3 kn = 228,8 kn 20 kn 176 kn = Fro 50 kn 5.000 load cycles 2Hz< f <5Hz max. 5 min time Figure 6-4: Test routine, rail seat section, dynamic test Table 6-3: Dynamic test rail seat (+) test conditions Conditions: dry test object Specimen 6 prestressed monobloc sleepers, B90.2 Temperature and frequency Load application (23 ± 3) C The load was applied perpendicular to the base of the sleeper in the middle of the rail seat section of the sleeper. Load levels see Table 8-27: Load steps B90.2, dynamic test rail seat (+) Type of load Procedure preparation Procedure test Harmonic excitation at f = 5 Hz Choice of the sleeper no spalling in the test area, because the crack detection will be difficult Marking of the evaluation area, 15 mm parallel to the bottom of the sleeper Position the piston on the sleeper, set point 20 kn Raise the force until Fr middle = 113 kn, Loading rate 2kN/s Search for cracks under load RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 34 of 89 10/06/2013
Start the harmonic excitation Further increase of the force, steps for Fr middle 10kN up to Fr 0 = 319,2 kn, 10 kn over the 2 nd pass/fail criteria Search for cracks after every load step Crack detection Cracks are searched at the side of the sleeper in an area 15 mm from the bottom and under the sleeper between the support Detection equipment includes crack loupe, mirror, acetone (only initial crack inspection prior testing) The results for the dynamic test at the rail seat section are shown in Table 8-28. All six sleepers passed the pass/fail criteria. Pass/fail criteria: 1. Fr 0,05 > k 1d * Fr 0 = 228,8 kn with k 1d = 1,3 2. Fr B > k 2d * Fr 0 = 299,2 kn with k 2d = 1,7 6.5 FATIGUE TEST The fatigue test at the rail seat section with positive load was carried out with one sleeper. The test set-up is shown in Figure 8-38. The test routine is shown in Figure 6-5. For the test conditions see Table 6-4. force Load rate 2 kn/s 2 mill cycles, f = 5 Hz time Figure 6-5: Test routine, rail seat section, fatigue test (source [3]) RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 35 of 89 10/06/2013
Table 6-4: Fatigue test 2 Mio LC (+) test conditions Conditions: dry test object Specimen 1 prestressed monobloc sleepers, B90.2 Temperature and frequency Load application Loading rate (23 ± 3) C The load was applied perpendicular to the base of the sleeper in middle of the rail seat section. The overhanging sleeper opposite shall be unsupported F max /time = 2 kn/s to the set point and after the harmonic excitation up to Fr B Load levels F ru = 50 kn, F r0 = 176 kn Type of load Procedure preparation Procedure test harmonic excitation f = 3 Hz, 2 mill load cycles Choice of the sleeper no spalling in the test area, because the crack detection will be difficult Marking of the evaluation area, 15 mm parallel to the bottom of the sleeper Position the piston on the sleeper, set point 20 kn Raise the force until Fr r like in the static test rail seat section start the harmonic excitation, 2 mill load cycles Raise the force until Fr 0 and then until Fr B Crack detection Cracks are searched at the side of the sleeper in an area 15 mm from the bottom and under the sleeper between the support Detection equipment includes crack loupe, mirror, acetone (only initial crack inspection prior testing) The results for the fatigue test in the rail seat section are given in Table 8-30. The sleeper passed all three pass/fail criteria. Pass/fail criteria after the 2 mill load cycles: 1. Crack width is < 0,1 mm when loaded at Fr 0 2. Crack width is < 0,05 mm when unloaded 3. Fr B > k 3 * Fr 0 = 299,2 kn; k 3 = k 2d = 1,7 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 36 of 89 10/06/2013
7. CONCLUSION A possible mitigation measure at track has been found and intensely tested, a heavy sleeper and soft under sleeper pads. The expected benefit of the heavy sleeper and soft sleeper pads can be concluded from the results of the parametric study in [7] and the measured characteristics of the track elements in the present report. The under sleeper pads yield a reduction of the high-frequency dynamic loads. Therefore, the high-frequency bedding modulus is of interest. The performance at the track depends on the stiffness per sleeper which is calculated from the high-frequency bedding modulus multiplied by the sleeper base area. The three different under sleeper pads have the following values: Table 7-1: Overview Results USP parametric study and laboratory tests Type SLN1010 SLN0613 SLN0315 Dynamic bedding modulus (10 9 N/m 3 )* 0.332 0.146 0.082 Stiffness per standard sleeper (10 9 N/m) 0.236 0.104 0.058 Resonance frequency standard sleeper (Hz)** 64 50 35 Resonance frequency heavy sleeper (Hz)** 57*** 42*** 28*** * The dynamic bedding modulus is the mean value of the frequencies 40, 80 and 160 Hz (see Table 8-16). ** The resonance frequencies are taken from the parametric study [7]. *** The frequencies with three asterisk are taken from the simulation results of the isolated wide sleeper track as a first approximation since it has almost the same weight than the tested B90.2 sleeper type. The reduction of the dynamic train loads starts at a frequency which is 1.4 times the resonance frequency. The lowest resonance frequency yields the best mitigation of ground vibrations. The heavier sleeper always yields a better reduction than the standard sleeper, and the softer under sleeper pads yield better reduction than the stiffer under sleeper pads. So, it can be concluded that efficient mitigation measures for train induced ground vibration have been found. The soft under sleeper pads can be combined with the heavy or normal sleepers, and the new heavy sleeper can be used with the tested or other soft under sleeper pads. The results of the laboratory tests help to adjust the mitigation measures to the specific site conditions. RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 37 of 89 10/06/2013
8. ANNEX 8.1 REFERENCES [1] DIN 45673-6:2010-08 (E) Mechanical vibration - Resilient elements used in railway tracks - Part 6: Laboratory test procedures for under-sleeper pads of concrete sleepers ; DIN Institute; Beuth Verlag; August 2010 [2] DIN 45673-7:2010-08 (E) Mechanical vibration - Resilient elements used in railway tracks - Part 7: Laboratory test procedures for resilient elements of floating slab track systems ; DIN Institute; Beuth Verlag; August 2010 [3] DIN EN 13230-2:2009-10 (E) Railway applications Track Concrete sleepers and bearers Part 2: Prestressed monoblock sleepers ; DIN Institute Beuth Verlag; October 2009 [4] Draft CEN/TC 256: Railway applications Track Concrete sleepers and bearers concrete sleepers and bearers with under sleeper pads, 2012-02 [5] Railway Induced Vibration Abatement Solutions, Description of Work. Collaborative project for theme SST.2010.1.1-3. Attenuation of ground-borne vibration affecting residents near railway lines in the seventh framework programme, European Commission, 2010-11 [6] DBS 918 143: Concrete sleepers and bearers for ballast superstructure and slab track, Technical supply specification of DB-AG; January 2012 [7] Auersch L: Mitigation measures for ballasted tracks - sleepers, sleeper pads and substructure - Results from the finite-element boundary element method. Report for RIVAS Deliverable D3.2, BAM, Berlin, January 2012 8.2 ABBREVIATIONS 8.2.1 Terms and definitions Bonding layer The bonding layer is a grid to connect concrete and USP. It can be manufactured of felt or geogrid RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 38 of 89 10/06/2013
Elastomer Felt Tear chip NSP GBP gauge block Material of the USP Protective layer for the elastomer of the USP, one side or both sides test area for the bonding test German ballast plate, in German: Normschotterplatte geometric ballast plate ceramic slices with a defined thickness to validate the displacement sensors 8.2.2 Symbols Examination of the USP USP NSP GBP A C12 Cdyn(f) Cstat Cstat 0 under sleeper pad German ballast plate geometric ballast plate area secant modulus dynamic bedding modulus static bedding modulus at-rest value of the static bedding modulus stress s1, s2 displacement f test frequency RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 39 of 89 10/06/2013
Examination of the sleepers k1s k2s Mdr Fr0 Frr Fr0,05 FrB Mdcn Fc0n Fcrn FcBn Static coefficient to be used for calculation of Fr0,05 test load Dynamic coefficient to be used for calculation of Fr0,5 or FrB test load Positive design bending moment at rail seat, in knm Positive initial reference test load for the rail seat section in kn for all tests: Fr0 = 176 kn Positive test load which produces first crack formation at the bottom of the rail seat section The first crack is a crack with a length of 15 mm from the bottom of the sleeper, detected at lateral surface Load where the crack gets a width of 0.05 mm in the unloaded state Maximum test load for which a crack width of 0,05 mm at the bottom of rail seat section Maximum positive test load at the rail seat section which cannot be increased in kn, Breaking of the sleeper Negative design bending moment at centre section, in knm Negative initial reference test load at the centre section of the sleeper in kn Negative test load which produces first crack formation at the centre of the sleeper in kn Maximum negative test load at the centre section which cannot be increased in kn RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 40 of 89 10/06/2013
8.3 TABLES EXAMINATION OF THE USP Table 8-1: Specimens, arrival, SLN 1010 Type Sample Weight L X B H = concrete H = USP* test [g] [mm] [mm] [mm] SLN 1010G A-01 22947,0 300x300 103 12 bedding modulus SLN 1010G A-02 22997,5 300x300 103 12 bedding modulus SLN 1010G A-03 23060,5 300x300 105 12 bedding modulus SLN 1010G A-04 22728,0 300x300 103 12 SLN 1010G A-05 23267,0 300x300 103 12 SLN 1010G A-06 22913,5 300x300 105 12 SLN 1010G A-07 23418,0 300x300 105 12 SLN 1010G A-08 23013,5 300x300 105 12 SLN 1010G A-09 23131,5 300x300 105 12 SLN 1010G A-10 22964,0 300x300 103 12 SLN 1010G A-11 22793,0 300x300 103 12 bond strength average 23021,2 SLN1010 P01 P-01 565,5 300 x 300 only USP 10,0 high-frequency bedding modulus SLN1010 P02 P-02 554,6 300 x 300 only USP 10,0 high-frequency bedding modulus SLN1010 P03 P-03 555,7 300 x 300 only USP 10,0 high-frequency bedding modulus * Height H includes 2 mm ballast contact felt Vh 7243_Rivas_schwellenbesohlung\Tabellen\Probeneingang\[Probeneingang_pieringer_bis_MAERZ13.xlsx]SLN-en RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 41 of 89 10/06/2013
Table 8-2: Specimens, arrival, SLN 0613 Type Sample Weight L X B H = concrete H = USP test [g] [mm] [mm] [mm] SLN 0613 B-01 22501,5 300x300 102 15 bedding modulus SLN 0613 B-02 22199,5 300x300 100 15 bedding modulus SLN 0613 B-03 21826,5 300x300 102 15 bedding modulus SLN 0613 B-04 22400,0 300x300 100 15 SLN 0613 B-05 22114,0 300x300 102 15 bond strength SLN 0613 B-06 21998,5 300x300 100 15 SLN 0613 B-07 21734,5 300x300 100 15 SLN 0613 B-08 22078,5 300x300 102 15 freeze-thaw resistance, bond strength SLN 0613 B-09 22448,5 300x300 100 15 SLN 0613 B-10 22448,5 300x300 103 15 SLN 0613 B-11 22056,0 300x300 100 15 SLN 0613 B-12 22466,5 300x300 102 15 average 22189,4 SLN 0613 B-21 42600,0 300x300 195 15 fatigue test SLN 0613 B-31 20015,0 200x200 200 2x15 shear test SLN 0613 B-32 20041,0 200x200 200 2x15 shear test SLN 0613 B-33 20052,5 200x200 200 2x15 shear test average 20036,2 SLN0613 P01 P-01 484,3 300 x 300 only USP 13 high-frequency bedding modulus * Height H includes 2 mm ballast contact felt Vh 7243_Rivas_schwellenbesohlung\Tabellen\Probeneingang\[Probeneingang_pieringer_bis_MAERZ13.xlsx]SLN-en RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 42 of 89 10/06/2013
Table 8-3: Specimens, arrival, SLN 0315 Type Sample Weight L X B H = concrete H = USP test [g] [mm] [mm] [mm] SLN 0315 C-01 21855,0 300x300 100 17 bedding modulus SLN 0315 C-02 21692,0 300x300 100 17 bedding modulus SLN 0315 C-03 21969,0 300x300 100 17 bedding modulus SLN 0315 C-04 21744,5 300x300 100 17 SLN 0315 C-05 21695,0 300x300 100 16 SLN 0315 C-06 22281,0 300x300 100 15 SLN 0315 C-07 21563,0 300x300 98 17 SLN 0315 C-08 21607,0 300x300 100 16 SLN 0315 C-09 22054,0 300x300 100 15 bond strength SLN 0315 C-10 22110,0 300x300 100 15 bond strength SLN 0315 C-11 22107,0 300x300 100 16 average 21879,8 SLN0315 P01 P-01 435,5 300 x 300 only USP 15 high-frequency bedding modulus SLN0315 P02 P-02 435,9 300 x 300 only USP 15 high-frequency bedding modulus SLN0315 P03 P-03 432,8 300 x 300 only USP 15 high-frequency bedding modulus * Height H includes 2 mm ballast contact felt Vh 7243_Rivas_schwellenbesohlung\Tabellen\Probeneingang\[Probeneingang_pieringer_bis_MAERZ13.xlsx]SLN-en RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 43 of 89 10/06/2013
8.3.1 Measuring System Table 8-4: Measuring system static and at-rest value of the static bedding modulus, lowfrequency bedding modulus Test rig static and at-rest value of the static bedding modulus and low-frequency bedding modulus Designation KPM - testing machine for small components 100 kn Type: servo-hydraulic tensile-compression testing machine Producer: Carl Schenck AG, Darmstadt Piston stroke: s max = 125 mm Force measurement Designation Load cell PM 100 Rn; suitable for testing machines class 1 Producer: Carl Schenck AG, Darmstadt Maximum static force F max = 100 kn Maximum dynamic force F dyn = 80 kn Calibration periodically, test certificate MPA Displacement measurement (external), because the piston stroke is not sufficient Designation inductive displacement sensors WA 10 HBM Quantity 2 Measuring range: 0 10 mm Output signal: 80 mv/v Linearity error: ±0.2 % Temperature range: -20 to +80 C Validation made by gauge blocks Climatic chamber Temperature range: 40 C to + 180 C Dimensions inside: height 1000 mm, width 1200 mm, depth 700 mm Electronic control and measuring technique type Instron series 8400 control computer measurement amplifier separate, every single channel can be recorded digitally Maximum measuring frequency per channel: 5 khz RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 44 of 89 10/06/2013
Table 8-5: Measuring system high-frequency bedding modulus Test rig High-frequency bedding modulus of elastomer pads Designation Type: Producer: Piston stroke: Force measurement servo-hydraulic tensile-compression testing machine with 7 kn cylinder BAM/ Instron Systems s max = ±50 mm Designation Load cell PM 07 Rn; suitable for testing machines class 1 Producer: Maximum static force Maximum dynamic force Calibration Instron F max = ±7 kn F dyn = 6 kn periodically, test certificate MPA Displacement measurement (external), because the piston stroke is not sufficient Designation Quantity 3 Measuring range: Output signal: inductive displacement sensors WA05 0 2 mm 80 mv/v Linearity error: ±0.2 % Temperature range: Validation Electronic control and measuring technique -20 to +80 C made by gauge blocks type Instron series 8800 control Maximum measuring frequency per channel: computer 5 khz RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 45 of 89 10/06/2013
Table 8-6: Measuring system fatigue test Test rig fatigue test Designation ballast test rig with 400kN cylinder (ballast trough) Type: fatigue test of elastomer pads in ballast Producer: BAM/ Instron Systems, test area Piston stroke: s max = ±200 mm Force measurement Designation Load cell PM 400 Rn; suitable for testing machines class 1 Producer: Carl Schenck AG, Darmstadt Maximum static force F max = 400 kn Maximum dynamic force F dyn = 320 kn Calibration Displacement measurement (external), because the piston stroke is not sufficient Designation laser displacement sensors Type Micro-Epsilon optoncdt 1401 Quantity 4 Measuring range: 0 50 mm Output signal: 12.5 mm/v Linearity error: ±0.2 % Temperature range: Validation made by gauge blocks Electronic control and measuring technique electronic control system type Instron series 8500 control computer analogous signals sampled by 16 bit A-D converter measuring system Cronos, IMC Maximum measuring frequency per channel: 100 khz RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 46 of 89 10/06/2013
Table 8-7: Measuring system bond strength by pull-off Test rig bond strength by pull-off Designation RK Toni 25 kn Type: Producer: MFL/ Toni-Technik Piston stroke: s max = 125 mm Force measurement Designation Load cell suitable for testing machines class 1 Producer: Maximum static force F max = 25 kn Maximum dynamic force F dyn = 25 kn Calibration periodically, test certificate MPA Displacement measurement (internal), piston stroke Measuring range: 0 250 mm Output signal: Linearity error: ±0.2 % Validation Electronic control and measuring technique type MTS Serie TestStar control computer Maximum measuring frequency per channel: 5 khz RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 47 of 89 10/06/2013
Table 8-8: Measuring system shear test Test rig shear test Designation test rig with 400 kn cylinder Type: Producer: BAM/ Instron Systems, test area Piston stroke: s max = 200 mm Force measurement Designation Load cell PM 400 Rn; suitable for testing machines class 1 Producer: Carl Schenck AG, Darmstadt Maximum static force F max = 400 kn Maximum dynamic force F dyn = 320 kn Calibration periodically, test certificate MPA Displacement measurement (external), because the piston stroke is not sufficient Designation rope displacement sensors ASM 1410 Quantity 2 Measuring range: 0 50 mm Output signal: 5 mm/v Linearity error: ±0.2 % Validation by incremental linear encoder system Heidenhain Electronic control and measuring technique electronic control system type Instron series 8500 control computer analogous signals sampled by 16 bit A-D converter measuring system Cronos, IMC Maximum measuring frequency per channel: 100 khz RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 48 of 89 10/06/2013
8.3.2 Results USP Table 8-9: SLN1010 static and at-rest value of the static bedding modulus - DIN 45673-6; 23 C, 0 C, -20 C SLN1010 static bedding modulus - DIN 45673-6; 23 C; NSP sample C01 C02 C03 average C stat medium ballast compaction 0,0991 0,0935 0,0945 0,0957 C stat high ballast compaction 0,1322 0,1258 0,1264 0,1281 C stat0 medium ballast compaction 0,0825 0,0787 0,0792 0,0801 C stat0 high ballast compaction 0,1121 0,1076 0,1080 0,1092 SLN1010 static bedding modulus - DIN 45673-6; 0 C; NSP sample C01 C02 C03 average C stat medium ballast compaction 0,0964 0,0920 0,0969 0,0951 C stat high ballast compaction 0,1298 0,1240 0,1298 0,1279 C stat0 medium ballast compaction 0,0816 0,0782 0,0820 0,0806 C stat0 high ballast compaction 0,1123 0,1079 0,1122 0,1108 SLN1010 static bedding modulus - DIN 45673-6; -20 C; NSP sample C01 C02 C03 average C stat medium ballast compaction 0,0931 0,1084 0,1035 0,1017 C stat high ballast compaction 0,1262 0,1409 0,1383 0,1351 C stat0 medium ballast compaction 0,0788 0,0838 0,0874 0,0833 C stat0 high ballast compaction 0,1090 0,1147 0,1197 0,1145 \Vh7243_Rivas_schwellenbesohlung\Messdaten\T6_Ergebnisse_Excel\[1_Bericht_SLN-Getzner_Bettungsmodul-alle_B.xlsx]A_StatBett RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 49 of 89 10/06/2013
Table 8-10: SLN0613 static and at-rest value of the static bedding modulus - DIN 45673-6; 23 C, 0 C, -20 C SLN0613 static bedding modulus - DIN 45673-6; 23 C; NSP sample B01 B02 B03 average C stat medium ballast compaction 0,0468 0,0475 0,0441 0,0461 C stat high ballast compaction 0,0568 0,0576 0,0532 0,0559 C stat0 medium ballast compaction 0,0399 0,0405 0,0381 0,0395 C stat0 high ballast compaction 0,0493 0,0500 0,0468 0,0487 SLN0613 static bedding modulus - DIN 45673-6; 0 C; NSP sample B01 B02 B03 average C stat medium ballast compaction 0,0476 0,0473 0,0473 0,0474 C stat high ballast compaction 0,0576 0,0577 0,0575 0,0576 C stat0 medium ballast compaction 0,0405 0,0409 0,0401 0,0405 C stat0 high ballast compaction 0,0504 0,0510 0,0502 0,0505 SLN0613 static bedding modulus - DIN 45673-6; -20 C; NSP sample B01 B02 B03 average C stat medium ballast compaction 0,0520 0,0494 0,0495 0,0503 C stat high ballast compaction 0,0626 0,0597 0,0600 0,0608 C stat0 medium ballast compaction 0,0420 0,0403 0,0407 0,0410 C stat0 high ballast compaction 0,0522 0,0502 0,0508 0,0511 \Vh7243_Rivas_schwellenbesohlung\Messdaten\T6_Ergebnisse_Excel\[1_Bericht_SLN-Getzner_Bettungsmodul-alle_B.xlsx]A_StatBett RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 50 of 89 10/06/2013
Table 8-11: SLN0315 static and at-rest value of the static bedding modulus - DIN 45673-6 (4.1); 23 C, 0 C, -20 C SLN0315 static bedding modulus - DIN 45673-6; 23 C; NSP sample C01 C02 C03 average C stat medium ballast compaction 0,0293 0,0292 0,0297 0,0294 C stat high ballast compaction 0,0374 0,0374 0,0379 0,0376 C stat0 medium ballast compaction 0,0251 0,0251 0,0254 0,0252 C stat0 high ballast compaction 0,0331 0,0331 0,0335 0,0332 SLN0315 static bedding modulus - DIN 45673-6; 0 C; NSP sample C01 C02 C03 average C stat medium ballast compaction 0,0306 0,0306 0,0308 0,0307 C stat high ballast compaction 0,0387 0,0386 0,0388 0,0387 C stat0 medium ballast compaction 0,0247 0,0252 0,0253 0,0251 C stat0 high ballast compaction 0,0329 0,0333 0,0334 0,0332 SLN0315 static bedding modulus - DIN 45673-6; -20 C; NSP sample C01 C02 C03 average C stat medium ballast compaction 0,0352 0,0332 0,0332 0,0339 C stat high ballast compaction 0,0436 0,0423 0,0418 0,0426 C stat0 medium ballast compaction 0,0267 0,0256 0,0259 0,0261 C stat0 high ballast compaction 0,0354 0,0346 0,0346 0,0349 \Vh7243_Rivas_schwellenbesohlung\Messdaten\T6_Ergebnisse_Excel\[1_Bericht_SLN-Getzner_Bettungsmodul-alle_B.xlsx]A_StatBett RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 51 of 89 10/06/2013
Table 8-12: static and at-rest value of the static bedding modulus different loading plates SLN1010 static bedding modulus - DIN 45673-6, different profiled plates C EU-GBP German-NSP variance EU-GBP / German-NSP C stat medium ballast compaction 0,0894 0,0992-10 % C stat high ballast compaction 0,1212 0,1322-8 % C stat0 medium ballast 0,0746 0,0825-10 % compaction C stat0 high ballast compaction 0,1030 0,1121-8 % SLN0613 static bedding modulus - DIN 45673-6, different profiled plates C EU-GBP German-NSP variance EU-GBP / German-NSP C stat medium ballast compaction 0,0515 0,0468 10 % C stat high ballast compaction 0,0646 0,0568 14 % C stat0 medium ballast 0,0425 0,0399 7 % compaction C stat0 high ballast compaction 0,0546 0,0493 11 % SLN0315 static bedding modulus - DIN 45673-6, different profiled plates C EU-GBP German-NSP variance EU-GBP / German-NSP C stat medium ballast compaction 0,0346 0,0293 18 % C stat high ballast compaction 0,0415 0,0374 11 % C stat0 medium ballast 0,0265 0,0251 6 % compaction C stat0 high ballast compaction 0,0338 0,0331 2 % \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Messdaten\StatEUdeu\[StatEUdeu.xls]Tabelle1 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 52 of 89 10/06/2013
Table 8-13: low-frequency bedding modulus - DIN 45673-6 (4.2); 23 C SLN1010 low-frequency bedding modulus - DIN 45673-6 (4.2); 23 C; NSP frequency [Hz] A01 A02 A03 average 5 0,1236 0,1176 0,1174 0,1195 10 0,1280 0,1212 0,1220 0,1237 20 0,1316 0,1249 0,1252 0,1272 30 0,1350 0,1294 0,1282 0,1309 SLN0613 low-frequency bedding modulus - DIN 45673-6 (4.2); 23 C; NSP frequency [Hz] B01 B02 B03 average 5 0,0572 0,0582 0,0528 0,0561 10 0,0593 0,0600 0,0546 0,0580 20 0,0612 0,0620 0,0568 0,0600 30 0,0628 0,0636 0,0581 0,0615 SLN0315 low-frequency bedding modulus - DIN 45673-6 (4.2); 23 C; NSP frequency [Hz] C01 C02 C03 average 5 0,0369 0,0357 0,0371 0,0366 10 0,0380 0,0370 0,0382 0,0377 20 0,0395 0,0386 0,0401 0,0394 30 0,0410 0,0402 0,0422 0,0411 \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Messdaten\Körperschall\Körperschall_Excel\[1_Bericht_Oct24Oct25Körperschall.xls]DatenBericht Table 8-14: low-frequency bedding modulus - DIN 45673-6 (4.2) SLN1010 low-frequency bedding modulus - DIN 45673-6 (4.2); NSP, sample A3 Temperatur -20 C 0 C 23 C C dyn1 (10Hz) 0,1649 0,1236 0,1220 SLN0613 low-frequency bedding modulus - DIN 45673-6 (4.2); NSP, sample B01 Temperature -20 C 0 C 23 C C dyn1 (10Hz) 0,1068 0,0635 0,0593 SLN0315 low-frequency bedding modulus - DIN 45673-6 (4.2); NSP, sample C01 Temperature -20 C 0 C 23 C C dyn1 (10Hz) 0,0824 0,0413 0,0380 \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Messdaten\Körperschall\Körperschall_Excel\[1_Bericht_Oct24Oct25Körperschall.xls]DatenBericht RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 53 of 89 10/06/2013
Table 8-15: Low-frequency dynamic stiffening ratio on NSP SLN1010 Low-frequency dynamic stiffening ratio DIN 45673-6 (4.3), NSP C dyn1 (10 Hz) C stat k dyn1 (10 Hz) SLN1010 medium ballast compaction 0,1237 0,0957 1,29 SLN1010 high ballast compaction 0,1237 0,1281 0,97 SLN0613 Low-frequency dynamic stiffening ratio DIN 45673-6 (4.3), NSP C dyn1 (10 Hz) C stat k dyn1 (10 Hz) SLN0613 medium ballast compaction 0,0580 0,0461 1,26 SLN0613 high ballast compaction 0,0580 0,0559 1,04 SLN0315 Low-frequency dynamic stiffening ratio DIN 45673-6 (4.3), NSP C dyn1 (10 Hz) C stat k dyn1 (10 Hz) SLN0315 medium ballast compaction 0,0377 0,0294 1,28 SLN0315 high ballast compaction 0,0377 0,0376 1,00 \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Messdaten\T6_Ergebnisse_Excel\[SLN_Dyn_Vers_T6.xls]Tabelle1 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 54 of 89 10/06/2013
Table 8-16: high-frequency bedding modulus (under preload) - DIN 45673-6 (4.4) on NSP SLN0315 high-frequency bedding modulus - DIN 45673-6 (4.4); 23 C; NSP; 7,0 mm/s frequency [Hz] P01 P02 P03 average 10 0,0718 0,0733 0,0731 0,0727 20 0,0757 0,0772 0,0764 0,0764 40 0,0796 0,0806 0,0802 0,0801 average 80 0,0817 0,0844 0,0826 0,0829 0,0822 160 0,0825 0,0818 0,0862 0,0835 SLN0613 high-frequency bedding modulus - DIN 45673-6 (4.4); 23 C; NSP; 7,0 mm/s frequency [Hz] P01 P02 P03 average 10 0,1230 0,1260 0,1245 20 0,1324 0,1337 0,1331 40 0,1397 0,1418 0,1408 average 80 0,1452 0,1480 0,1466 0,1462 160 0,1480 0,1546 0,1513 SLN1010 high-frequency bedding modulus - DIN 45673-6 (4.4); 23 C; NSP; 7,0 mm/s frequency [Hz] P01 P02 P03 average 10 0,2653 0,2773 0,2651 0,2692 20 0,2929 0,3067 0,2926 0,2974 40 0,3089 0,3288 0,3116 0,3164 average 80 0,3232 0,3489 0,3323 0,3348 0,3319 160 0,3342 0,3656 0,3333 0,3444 \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Messdaten\Körperschall\Körperschall_Excel\[1_Bericht_Oct24Oct25Körperschall.xls]DatenBericht RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 55 of 89 10/06/2013
Table 8-17: Higher-frequency dynamic stiffening ratio on NSP SLN1010 High-frequency dynamic stiffening ratio DIN 45673-6 (4.3); NSP Cdyn2(80 Hz) Cstat kdyn2(80 Hz) SLN1010 medium ballast compaction 0,3348 0,0957 3,50 SLN1010 high ballast compaction 0,3348 0,1281 2,61 SLN0613 High-frequency dynamic stiffening ratio DIN 45673-6 (4.3); NSP Cdyn2(80 Hz) Cstat kdyn2(80 Hz) SLN0613 medium ballast compaction 0,1466 0,0461 3,18 SLN0613 high ballast compaction 0,1466 0,0559 2,62 SLN0315 High-frequency dynamic stiffening ratio DIN 45673-6 (4.3); NSP Cdyn2(80 Hz) Cstat kdyn2(80 Hz) SLN0315 medium ballast compaction 0,0829 0,0294 2,82 SLN0315 high ballast compaction 0,0829 0,0376 2,20 \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Messdaten\T6_Ergebnisse_Excel\[SLN_Dyn_Versteifung_T6.xls]Tabelle1 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 56 of 89 10/06/2013
Table 8-18: Mechanical fatigue strength - Minute of the damage - DIN 45673-6 (5.2) Minute of the damages 5 Mio 09.11.2012 specimen: SLN 0613 B - 21 Nr. depth [mm] size or length [mm] comment 1 6 45 on the right side of [1] 2 3 25 three damages in the area of [2] 3 3 40 * 50 big area 4 5 20 5 9 45 perforated USP up to the concrete! 6 2,5 40-50 7 6 45 slender 8 11 40 broken off on the border (b) damage under [8] 5mm depth) 9 11 30 edge broken off up to the concrete 10 6 50 on the right side of [10] \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Bilder\Schotterstand\2012_11_08_ 5M Lastwechsel\[Schadenaufnahmen.xlsx]Bericht-en Minute of the damages 8 Mio 04.12.2012 specimen: SLN 0613 B - 21 Nr. depth [mm] size or length [mm] comment 1 7,5 50 pressure area 2 6 20 cut 3 3 45 cut 4 6 20 pressure area 5 8 60 pressure area 6 5 30 pressure area 7 6 15 pressure area 8 5 20 pressure area 9 5 60 pressure area 10 6 40 pressure area 11 5 45 pressure area 12 3,5 30 pressure area 13 12 20 pressure area 14 7 45 pressure area 15 4 20 pressure area 16 6,5 35 pressure area 17 6 40 pressure area 18 5 60 pressure area 19 3 50 pressure area 20 3 40 pressure area \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Tabellen\Schotter_dauerversuch\[Schadenaufnahme01.xlsx]Bericht-en RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 57 of 89 10/06/2013
Table 8-19: bond strength by pull of - DIN 45673-6 (5.3) Pull-off strength SLN 1010 A 11, DIN 45673-6 Sample Load Stress Displacement Position - [N] [N/mm2] [mm] - 01 1595,3 0,812 4,50 bonding layer 02 1433,0 0,730 3,98 bonding layer 03 1225,5 0,624 3,71 bonding layer 04 1403,4 0,715 3,62 bonding layer 05 1285,8 0,655 3,28 bonding layer Pull-off strength SLN 0613 B 05, DIN 45673-6 Sample Load Stress Displacement Position - [N] [N/mm2] [mm] - 01 841,1 0,428 8,60 bonding layer 02 788,8 0,402 8,27 bonding layer 03 760,2 0,387 7,28 bonding layer 04 649,2 0,331 7,74 bonding layer 05 891,4 0,454 9,07 bonding layer arithmetic average 0,400 standard deviation 0,042 Pull-off strength SLN 315 C 09, DIN 45673-6 Sample Load Stress Displacement Position - [N] [N/mm2] [mm] - 01 758,4 0,386 10,18 bonding layer 02 747,5 0,381 9,97 bonding layer 03 845,0 0,430 12,94 Elastomer + bonding layer 04 939,2 0,478 14,85 Elastomer 05 854,5 0,435 12,65 Elastomer Pull-off strength SLN 0613 B 08, DIN 45673-6, after freeze thaw test Sample Load Stress Displacement Position - [N] [N/mm 2 ] [mm] - 01 848,3 0,432 9,42 bonding layer 02 825,1 0,420 7,48 bonding layer 03 680,9 0,347 8,41 Elastomer + bonding layer 04 609,5 0,310 5,37 bonding layer 05 633,6 0,323 5,72 bonding layer arithmetic average 0,366 standard deviation 0,050 Vh 7243_Rivas_schwellenbesohlung\Messdaten\Abreißfestigkeit\Tabellen\[Abreißverhalten_Alle_Einfach_Tabellen.xlsx]Tabelle1 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 58 of 89 10/06/2013
Table 8-20: shear strength - DIN 45673-6 (5.4) Shear strength SLN0613 DIN 45673-6 (5.4) specimen stress [N/mm²] B31 0,558 B32 0,567 B33 0,563 specimen Shear strength SLN0315 DIN 45673-6 (5.4) stress [N/mm²] C31 0,407 C32 0,459 C33 0,457 Comment: SLN1010 was not requested (no specimen were delivered and no tests were carried out) \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Messdaten\AbSch\[Tabelle_Abscherfestigkeit_korr.xlsx]Tabelle1 Table 8-21: Freeze-thaw resistance - DIN 45673-6 (5.5) SLN0613 freeze-thaw resistance - DIN 45673-6 (5.5); 23 C; NSP low-frequency bedding modulus frequency before the test after the test variance [Hz] Hz 5 0,0520 0,0524 1% 10 0,0537 0,0546 2% 20 0,0556 0,0566 2% 30 0,0570 0,0587 3% \\scl1\service31\720serv\02_vorhaben\vh 7243_Rivas_schwellenbesohlung\Messdaten\FrostTau\FrostTau-Tabellen\[SLN0613_B05_FrostTau.xls]SLN0613_B05_FrostTau RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 59 of 89 10/06/2013
8.4 FIGURES - EXAMINATION OF THE USP 8.4.1 Specimen SLN 1010 5 cm Figure 8-1: Under-sleeper pad SLN1010 SLN 0315 Figure 8-2: Under-sleeper pad SLN0315 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 60 of 89 10/06/2013
8.4.2 Test rig Figure 8-3: Test rig for small components (KPM), static and low-frequency bedding modulus Concrete block with USP German ballast plate Figure 8-4: Test rig for small components (KPM), static and low-frequency bedding modulus, detail RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 61 of 89 10/06/2013
Figure 8-5: Test rig for high-frequency bedding modulus (structure-borne noise) Spring for preload Under sleeper pad German ballast plate Figure 8-6: Test rig for high-frequency bedding modulus (structure-borne noise), detail RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 62 of 89 10/06/2013
Figure 8-7: Test rig fatigue test for USP in ballast trough Ballast trough USP Figure 8-8: Test rig fatigue test for USP in ballast trough, detail RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 63 of 89 10/06/2013
Figure 8-9: Test rig bond strength Figure 8-10: Test rig bond strength, detail RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 64 of 89 10/06/2013
Figure 8-11: Test rig shear test Concrete cube 200 * 200 * 200 mm USP Figure 8-12: Test rig shear test, detail RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 65 of 89 10/06/2013
8.4.3 Evaluation static bedding modulus 0.25 7.00 0.20 0.15 0.10 displacement [mm] 6.00 5.00 4.00 3.00 0.05 2.00 1.00 0.00 0 500 1000 1500 2000 2500 time [s] 0.00 0 500 1000 1500 2000 2500 time [s] SLN315 sample C01 SLN315 sample C01 7.2 Ingenieurbau File: SLN0314_C01_demo.TDM Layout: SLN0314_C01_demo_quad.TDR 7.2 Ingenieurbau File: SLN0314_C01_demo.TDM Layout: SLN0314_C01_demo_quad.TDR Figure 8-13: SLN0315 static bedding modulus, stress and displacement during the test 0.25 SLN0315_C01_statBett_T6 0.20 SLN0315_C02_statBett_T6 Stress [N/mm²] 0.15 0.10 SLN0315_C03_statBett_T6 high ballast compression 0.05 mid ballast compression 0.00 0 2 4 6 8 displacement [mm] SLN0315 File: SLN0315_C_statBett_T6.TDM 7.2 Ingenieurbau Layout: SLN0315_C01_report.TDR Figure 8-14: SLN0315 static bedding modulus RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 66 of 89 10/06/2013
0.25 7.00 0.20 0.15 0.10 displacement [mm] 6.00 5.00 4.00 3.00 0.05 2.00 1.00 0.00 0 500 1000 1500 2000 2500 time [s] 0.00 0 500 1000 1500 2000 2500 time [s] SLN0613 SLN0613 7.2 Ingenieurbau File: SLN0613_B_statBett_T6.TDM Layout: SLN0613_report.TDR 7.2 Ingenieurbau File: SLN0613_B_statBett_T6.TDM Layout: SLN0613_report.TDR Figure 8-15: SLN0613 static bedding modulus, stress and displacement during the test 0.25 SLN0613_B01_statBett_T6 0.20 SLN0613_B02_statBett_T6 Stress [N/mm²] 0.15 0.10 SLN0613_B03_statBett_T6 high ballast compression 0.05 mid ballast compression 0.00 0 1 2 3 4 5 6 displacement [mm] SLN0613 7.2 Ingenieurbau Layout: SLN0613_report.TDR File: SLN0613_B_statBett_T6.TDM Figure 8-16: SLN0613 static bedding modulus RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 67 of 89 10/06/2013
0.25 4.00 0.20 0.15 0.10 displacement [mm] 3.00 2.00 0.05 1.00 0.00 0 500 1000 1500 2000 2500 time [s] 0.00 0 500 1000 1500 2000 2500 time [s] SLN1010 SLN1010 7.2 Ingenieurbau File: SLN1010_A_statBett_T6.TDM Layout: SLN1010_report.TDR 7.2 Ingenieurbau File: SLN1010_A_statBett_T6.TDM Layout: SLN1010_report.TDR Figure 8-17: SLN1010 static bedding modulus, stress and displacement during the test 0.25 SLN1010_A01_statBett_T6 0.20 SLN1010_A02_statBett_T6 Stress [N/mm²] 0.15 0.10 SLN1010_A03_statBett_T6 high ballast compression 0.05 mid ballast compression 0.00 0 1 2 3 4 displacement [mm] SLN1010 7.2 Ingenieurbau Layout: SLN1010_report.TDR File: SLN1010_A_statBett_T6.TDM Figure 8-18: SLN1010 static bedding modulus RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 68 of 89 10/06/2013
0.25 0.20 SLN1010_A01_statBett_EU 0.15 SLN1010_A01_statBett_T6 high ballast compression 0.10 0.05 mid ballast compression 0.00 0 0.5 1 1.5 2 2.5 3 3.5 4 displacement [mm] Stat. bet. EU/DE File: StatEUdeu.TDM 7.2 Ingenieurbau Layout: SLN1010_vergleich_EU_DE.TDR Figure 8-19: Static bedding modulus comparison German-NSP and GBP SLN1010 A01 0.25 0.20 SLN613_B01_statBett_EU 0.15 SLN0613_B01_statBett_T6 high ballast compression 0.10 0.05 mid ballast compression 0.00 0 1 2 3 4 5 6 7 8 displacement [mm] Stat. bet. EU/DE File: StatEUdeu.TDM 7.2 Ingenieurbau Layout: SLN0613_vergleich_EU_DE.TDR Figure 8-20: Static bedding modulus comparison German-NSP and GBP SLN0613 B01 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 69 of 89 10/06/2013
0.25 0.20 SLN0315_C01_statBett_EU 0.15 SLN0315_C01_statBett_T6 high ballast compression 0.10 0.05 mid ballast compression 0.00 0 1 2 3 4 5 6 7 8 displacement [mm] Stat. bet. EU/DE File: StatEUdeu.TDM 7.2 Ingenieurbau Layout: SLN0315_vergleich_EU_DE.TDR Figure 8-21: Static bedding modulus comparison German-NSP and GBP SLN0315 C01 RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 70 of 89 10/06/2013
Figure 8-22: Fatigue test specimen after 5 mio load cycles Figure 8-23: Fatigue test, overview pressure marks, after 5 mio (l) and 8 mio (r) load cycles RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 71 of 89 10/06/2013
a) after 5 mio load cycles Relative dimensions b) after 8 mio load cycles Figure 8-24: Pressure marks (relative) on the fleece after 5 Mio (a) and 8 Mio (b) load cycles, measuring system ATOS RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 72 of 89 10/06/2013
Figure 8-25: Bond strength, prepared specimen Figure 8-26: Bond strength, SLN1010-A11-1 (left), SLN0613-B05 (right) RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 73 of 89 10/06/2013
Figure 8-27: Shear strength, SLN0613 B-33, SLN0315 C-32, during the test Figure 8-28: Shear strength, SLN0613 B-31, SLN0315 C-33, after the test Figure 8-29: Shear strength, SLN0315 C-32, after the test RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 74 of 89 10/06/2013
8.5 DATA SHEETS USP FIRM GETZNER WERKSTOFFE GMBH Figure 8-30: Product data sheet, SLN 0315, source Getzner Werkstoffe GmbH RIVAS_BAM_ WP3_D3_7_PartB_final.docx Page 75 of 89 10/06/2013