1.sleeper Design 60 KG

ATTACHMENT TO LETTER NO. SLT/NKC/CTP1&2/TECH/SLPR/2014/481 Dated 21.05.
2014
WDFC PHASE-1
COMBINED PACKAGE
CTP-1 AND CTP-2
DESIGN CALCULATIONS FOR 25T AXLE LOAD

PSC SLEEPER
DRG NO. RT 7008 (FOR 60 KG RAIL)

DESIGN CALCULATIONS FOR 25T AXLE LOAD PSC SLEEPER (Drg No. RT 7008)
CONTENTS
S. No Description Page No
1.0 DATA AND DESIGN PARAMETERS 2-6
2.0 CROSS SECTION AND BASE PLAN OF SLEEPER 7-9
3.0 RAIL SEAT LOAD CALCULATION 10
BALLAST PRESSURE DISTRIBUTION IN LOSS OF
4.0 11
CONTACT CONDITION
MOMENT AT CENTER AND RAIL SEAT OF SLEEPER IN
5.0 11-12
LOSS OF CONTACT CONDITION.
BALLAST PRESSURE DISTRIBUTION IN FULL CONTACT
6.0 13
CONDITION
6.1 13-14
FULL CONTACT CONDITION
7.0 STRESS CHECK AT TRANSFER 15-16
7.1 STRESS CHECK AT SERVICE 17
8.0 LOSS OF PRESTRESS 17-18
9.0 FACTOR OF SAFETY AGAINST CRACKING 19
10.0 ULTIMATE STRENGTH CALCULATION 20-24
a)Procedure 23
b)Ultimate moment capacity at rail seat 24
11.0 SUMMARY 25
PCM STRESCON OVERSEAS VENTURES LIMITED REV 00 SOJITZ - L&T CONSORTIUM Page 1
1.0 Data & Design Parameters

S.No Description Notation Unit Value Remarks Source
1 Sleeper Length L mm 2750 Drawing no RDSO/T-7008
2 Gauge Length g mm 1676 for 60 kg UIC rail 13.5 (1) (b) (i) of SBD-III
3 Axle Load W T 25 13.5 (1) (b) (iv) of SBD-III
13.5 (1) (b) (viii) of SBD-
4 Sleeper Spacing mm 600
III
5 Rail section to be catered Wg Kg/m 60 UIC 60 Kg/m 13.5 (1) (b) (vii) of SBD-III
13.5 (1) (b) (viii) of SBD-
6 Sleeper Density in main lines per Km 1660
III
7 Maximum speed of train Km/hr 100 13.5 (1) (b) (ii) of SBD-III
Dynamic factor for speed and rail-
8 γL 2.5 13.5 (2) (b) (iv) of SBD-III
wheel irregularities
9 Load Distribution factor γD 0.55 Varies between 0.55 to 0.6 13.5 (2) (b) (iii) of SBD-III
10 Centre binding co-efficient α 0.4 full contact condition 13.5 (2) (b) (v) of SBD-III
11 Ballast contact length b mm 1040
Minimum compressive strength of
12 fck Mpa 60 13.5 (2) (c) (i) of SBD-III
concrete
13 fck Mpa 40 13.5 (2) (c) (ii) of SBD-III
concrete prior to transfer of pre-stress
14 Premissible stresses in concrete
In compression 24 0.4 times fck 13.5 (2) (c) (iii) of SBD-III
In tension 2.4 .04 times fck 13.5 (2) (c) (iii) of SBD-III
Resisting Moment / Bending
15 Factor of safety at rail seat 2 13.5 (2) (b) (vi) of SBD-III
Moment
Failure moment / Bending
16 Load factor at rail seat bottom 3 13.5 (2) (b) (vii) of SBD-III
Moment
Sl
Description Notation Unit Value Remarks Source
No
upto 75% of breaking load
17 Initial prestressing 13.5 (2) (b) (ix) of SBD-III
(fpk)
30 % of initial prestress or as
18 Losses in prestress 13.5 (2) (b) (ix) of SBD-III
per actual
19 Static bending test loads
Cracking loads shall be
13.5 (2) (b) (viii) of SBD-
at centre top KN 65
III
13.5 (2) (b) (viii) of SBD-
at centr bottom KN 60
III
13.5 (2) (b) (viii) of SBD-
at rail seat KN 270
III
13.5 (2) (b) (viii) of SBD-
21 Failure load at rail seat KN 490
III
Description Notation Unit Calculation Formula Remarks
Sleeper Length L mm 2750.00

Wheel axle load W Tonne 25 Ref Page 2 above
Weight of rail WR kg 60 Ref Page 2 above
Gauge Length g mm 1676
Sleeper Density Nos 1660 / km
Sleeper spacing(c/c)(in main lines) s mm 600
Ballast contact length mm 1040
Dynamic augmentation factor for speed DAF 2.5 Ref Page 2 above
Load distribution factor γD 0.55 Ref Page 2 above
Center binding co-efficient (Full contact
α 0.40 Full contact condition Ref Page 2 above
condition)
Loss of contact condition α 0.00 Loss of contact condition
Rail s P KN 122.98 (0.5W*9.81 + (WR*9.81*.6)/1000)
Bearing width at rail seat bw mm 150
Grade of concrete fck Mpa 60
Young s modulus of concrete Ec Mpa 38729.83 5000*(fck^1/2) Is 456 pg 16
Flexural strength/split tensile strength Mpa 5.42 0.7*(fck^1/2) Is 456 pg 16
Ballast pressures (Loss of contact) p
Ballast pressure(Full contact) p'
As per IS 6006
Diameter high tensile steel strands dia mm 3
Clause 3.1.1
Number of wires mm 3
Permissible stress in concrete Mpa 0.4fck In compression Ref Page 2 above
0.04fck In tension Ref Page 2 above

Required Factor of safety at rail seat 2 Resisting bending moment/Applied bending moment Ref Page 2 above
Required Load factor at rail seat
Ref Page 2 above
bottom 3 Failure moment/Bending moment
Static bending load tests
Requirements
Cracking loads kN 65 At center top Ref Page 3 above
kN 60 At center bottom Ref Page 3 above
kN 270 At rail seat Ref Page 3 above
Failure load at rail seat kN 490 Ref Page 3 above
Young s modulus of pre-stressing As per Is 6006
Ep Mpa 195000
steel amendment No.3
Area of one strand Aᶲ mm2 21.21
Number of pre-stressing strands n 20
As per IS 6006
Breaking load Pk N 38250
Table 3
Breaking stress fpk Mpa 1803.4 P/Aᶲ
Percentage of initial pre-stressing
75%of fpk
force
Initial pre-stressing in one strand fpi Mpa 1352.55 0.75*fpk
2
Total area of strands As mm 424.20 n*Aᶲ
Initial prestressing force Pi KN 573.75 n*Aᶲ*fpi
IS 1343 Cl
Modular ratio m 5.03 Ep/Ec
No.18.3.1
Track modulus U kg/cm/cm 540.00 Annexure 1
Modulus of Elasticity of Rail E Mpa 211000.00

Moment of Inertia of rail I cm^4 2703.41 Annexure 1
Width of rail foot Rw cm 15.00
Rubber pad length Lw cm 36.00
Top width of sleeper bw cm 15.00
Area of cross section at end A1 mm2 50070.50 [(270+250.6)*50+(250.6+150)*185]*0.5
Area of cross section at rail 2
A2 mm 42941.31 [249.9+211.8)*98.24+(211.8+150)*112.01)]*0.5
seat
Area of cross section at
A8 mm2 35911 (235.1+150)*186.5*0.5
227.55mm
Area of cross section at center A3 mm2 34024 (220+150)*180*0.5
2
Average cross sectional area A mm 45491.3747 (((A1+A2)/2)*L1+((A2+A3)/2*L2+(A3*L3))/0.5*L
Average base width bw mm 244.41 (((b1+b2)/2*L1)+((b2+b3)/2*L2)+((b3+b4)/2*L3)+((b4*L4)))/(0.5*L)
Average base Area Ab mm2 672131 bwL
2.0 Cross Sectional Properties and base plan of sleeper
(At Centre) (At Rail Seat)

Figure 2 - Cross-section of sleeper
Figure 1 – Cross sectional dimensions of sleeper with strands
Figure 3 - Plan of base of sleeper.
Description Notation Unit Value Formula

Area of cross section at rail A2 mm2 42941.31 [249.9+211.8)*98.24+(211.8+150)*112.01)]*0.5
seat
Area of cross section at A8 mm2 35911 (235.1+150)*186.5*0.5
227.55mm
Average cross sectional A mm2 45491.3747 ( (A1+A2)/2*L1 +(A2+A3)/2*L2 + (A3*L3))/(0.5*L)
area
Average base width bw mm 244.41 ((b1+b2)/2*L1 +(b2+b3)/2*L2 +(b3+b4)/2*L3 +(b4*L4)) / (0.5*L)
3.0 Rail Seat Load Calculations
Cracking Cracking Load at Failure

Load at Centre Load at
Description Unit Rail Seat Rail Seat
At Bottom
Bottom At Top At Bottom
Moment of resistance against bending (M) kNm 27.49 18.08 17.21 50.7059
Top width of rail seat (w) cm 15.00 15.00 15.00 15.00
Depth of sleeper (d) cm 21.03 18.00 18.00 21.00
Load distribution width (V = w + d) cm 36.03 33.00 33.00 36.00
Cracking Load M*100/(14-V/8) kN 289
Cracking Load M*100/(28) kN 65 61
Failure Load M*100/(14-V/8) kN 534
Minimum cracking load as per page 3 above kN 270 65 60 490
SAFE SAFE SAFE SAFE
4 Ballast pressure distribution loss of contact condition (α = 0)
5 Loss of Contact condition (α=0)

Area (Fig 3) A4 mm2 129975.00 (270+249.9)*500*0.5
Area (Fig 3) A5 mm2 129924 (249.9+231.3)*540*0.5
Maximum Rail seat load Pmax kg 15728.00
Ballast pressure under loss of contact p Mpa 0.605 1000*P/(A4+A5)
Pressure due to axle load q Mpa 1.757 1000*P/(2*179.07*249.9)
Contact pressure between rail and sleeper qmax kg/cm^2 29.126 SAFE (29.13<40kg/cm^2)
Moment at rail seat (Tension at

kN-m 12.74 A4*p*gr4-q*(257.1+249.9)*0.5*179.07^2/2
bottom)
Distance of CG of A4 from rail seat gr4 mm 253.22 Distance of CG from centre of rail seat
Justification for gr4 = Centeroid of trapezoid (h -(h/3) *
((2a+b)/(a+b)))
Moment at Center
Distance of CG of A4 from rail center gc4 mm 1128.22 Distance of CG of A4 from centre of sleeper
Calculation of Moment for A4 at centre

M1 N-mm 88740770.45 129975*0.605158157591988*1128.23
of sleeper
M2 N-mm 47294344.54 129924*0.605158157591988*601.53
of sleeper
Calculation of Moment due to rail seat
M3 kN-mm 137620.00 15728/100*(540+185+150)
load upto centre of sleeper
M3 N-mm 137620000.00 137620*1000
Moment at Center (Tension at
kN-m -1.58 (M1+M2-M3)/1000000
Bottom)
6.0 Ballast pressure distribution under full contact condition (α = 0.4)
6.1 Full Contact condition (α=0.4)

Area A6 (Fig.3) A6 mm2 42488.95 (231.3+228.04)*185*0.5
Area A7 (Fig.3) A7 mm2 34206.00 228.04*150
Ballast pressure p’ p' Mpa 0.541 1000*P/(A4+A5+(0.4*(A6+A7))
Pressure due to axle load, q q 1.757 1000*P/(2*179.07*249.9)

Moment due to upward pressure M4 Mpa 17801.5 129975*0.541/1000*(253.23)
Pressure below the rail seat plate. kN-m 39.89 1.76*(257.1+249.9)*0.5*179.07/2/1000
CG distance of pressure below rail seat
mm 89.96
plate from rail seat
Moment due to downward pressure M5 kNm 7176.25 39.89*89.96*2
Moment at rail seat (from Fig.5)
kNm 10.625 (M4-M5)/1000
(Tension at Bottom)
Upward load from A4 kN 70.3 0.541*129975/1000
CG at A4 from centre of sleeper mm 1128.22
Moment at center cross-section M6 kN 79.31 70.3*1128.23/1000
Upward load from A5 kN 70.29 129924*0.541/1000
Moment at center cross-section M7 kN-m 42.28 70.288884*601.53/1000
Upward pressure from A6 kN-m 9.19 42488.95*0.541*0.4/1000
Upward pressure from A7 kN-m 7.40 34206*0.541*0.4/1000
Moment at cross section M9 kN 0.68 7.4021784*92.5/1000
Moment due to axle and rail load at
M10 KN-m 137.62 15728/100*(185+540+150)/1000
center
Moment at Center (from Fig.5) kNm -12.79 (M6+M7+M8+M9-M10)
Maximum moment acting at rail seatdue
MLL,r kN-m 12.74 sagging
to live load (Sagging)
Maximum moment acting at centerdue to
MLL,c kN-m -12.79 hogging
live load (Hogging)
7 Stress Check at Transfer

At rail seat
Area of cross section at rail seat A2 mm2 42941.31
Equivalent concrete area due to steel mm2 1711.60 (m-1)*n*AΦ
Area of composite section Acr mm2 44652.91 Total
CG of gross concrete area from base mm 96.51
CG of prestressing strands from base
mm 88.5
(Fig.1)
4144266.12
37541.70
96.43
CG of composite area from base Cgr mm 96.43
Eccentricity of strands at rail seat epr mm 7.93
Moment of inertia of gross section mm4 153341962.30
Moment of inertia of composite section Icr mm4 153449595.80
Bottom sectional modulus of composite
Zbr mm3 1591305.57
section
Top sectional modulus of composite
Ztr mm3 1348177.79
section
Stress at transfer of prestressing force

MPa 9.47 Pi/Acr-(Pi*epr)/Ztr
at top of rail seat

MPa 15.71 Pi/Acr-Piepr/zbr(Compression if +ve)
at bottom of rail seat
At center of sleeper
Area of cross section at centre A3 mm2 33300.00
Area of composite section Acc mm2 35011.60 Total
CG of gross area from base mm 84.32
mm 88.50
(Fig.1)
2807856.00
37541.70
85.45
CG of composite area from base Cgc mm 85.45
Eccentricity of strands at rail seat epc mm -3.05
Moment of inertia of composite section Icc mm4 88853219.41
Bottom section modulus of composite
Zbc mm3 1039827.03
section
Top section modulus of composite
Ztc mm3 939748.49
section
Stress at transfer at top of centre of

MPa 18.25 Pi/Acc-Piepc/ztc(Compression if +ve)
sleeper
Stress at transfer at bottom of centre of

MPa 14.70 Pi/Acc+Piepc/zbc(Compression if +ve)
sleeper
7. 1 Stress check at service

Loss of prestress due to elastic shortening
Presstressiong loss due to elastic
= m × stress due to prestress at its cg
shortening
Loss due to elastic shortening at rail seat MPa 65.88 m( Pi/Acr+(Pi*〖epr〗^2)/Icr)
Loss due to elastic shortening at centre of

MPa 82.81 m( Pi/Acc+(Pi*〖epc〗^2)/Icc)
sleeper
Average loss due to elastic shortening MPa 74.34

Percentage loss of prestress due to elastic
% 5.50
shortening
8.0 Loss of Pre-stress

Loss of prestress due to creep
Creep coefficient Φ 1.60 1.6
Loss due to creep MPa 118.95 (Φm) × stress due to prestress at its cg
Percentage loss of prestress due to creep % 8.79
Loss of prestress due to shrinkage

Shrinkage strain 0.0003
Loss of prestress due to shrinkage MPa 58.50 0.0003Ep
Percentage loss of prestress due to
% 4.33
shrinkage
Loss of prestress due to relaxation

Loss of prestress due to relaxation MPa 80.00 5.92 % of fpi
% 5.91
Total percentage of loss of prestress 24.53 24.54% of fpi
Effective prestressing (after all losses) fpe MPa 1020.75 (100-24.54)* fpi
Effective prestressing force Pe kN 433.00 fpe*As
Since value is less than ( Pe)/Acr-
Stress at service at top of rail seat (Pe*epr)/Ztr+(Mll,r)/Ztr
MPa 16.60
(Compression) 0.4 fck = 22 Mpa
Therefore SAFE
Since vlaue is less than ( Pe)/Acr+(Pe*epr)/Zbr-
Stress at service at bottom of rail seat (Mll,r)/Zbr
MPa 3.85
(Tension) 0.4 fck = 24 Mpa
Therefore SAFE
Since value is less than ( Pe)/Acc-(Pe*epc)/Ztc-
Stress at service at top of center of sleeper (Mll,r)/Ztc
MPa 0.17
(Compression) 0.4 fck = 24Mpa
Therefore SAFE
Since value is less than ( Pe)/(
Stress at service at bottom of center of Acc)+(Pe*epc)/Zbc+(Mll,r)/Zbc
MPa -1.20
sleeper (Compression) 0.04 fck = 2.4 Mpa
Therefore SAFE
9.0 Factor of safety against Cracking moment based on Modulus of rupture
Modulus of Rupture 5.42
At rail seat bottom, Cracking moment Mcr kN-m 27.49
9.70
2.16
27.49
At center of sleeper top, Cracking

Mcr kN-m 18.08
moment
12.37
-1.41
18.08
Factor of safety at rail seat bottom 2.16

SAFE
Factor of safety at center top 1.50 SAFE
10.0 Ultimate Strength Calculation:

The strain variation in different layers of strands at decompression and ultimate and strain variation in concrete at ultimate state is
shown in Fig.8. The corresponding forces in both pre-stressing strands and concrete are shown in Fig.9.The stress strain curve for
prestressing strands is given in Fig.10
(a) Cross-section (b) Cross-section (c) Strains in strands (d) Stains in strands and
with eccentricity at decompression concrete at ultimate
of strands state
(Fig 8)
(a) Cross section (b) Tensile force in (c) Compressive force

Strands at ultimate in concrete
(Fig. 9)
Wire (Stress Relieved), Strands and Bars (Fig. 10)
ULTIMATE MOMENT CAPACITY AT RAIL SEAT

Xu(Assumed) 94 mm
Distance Distance Distance
Area(As) Strain Strain Mur(kN-
Layer b/w n from ɛ1.i ɛp, dec, i from Stress(Mpa) Ci(kN) Ti(kN)
mm^2 ɛ2,i ɛpu,i m)
layers CG N.A(mm)
Layer 1 40 6 127.26 56.50 0.000539 0.005774 -76.25 0.002839 0.008613 1679.506 213.7339 16.3
Layer 2 35 4 84.84 21.50 0.0005 0.005774 -41.25 0.001536 0.00731 1425.3837 120.9296 4.99
Layer 3 18 2 42.42 3.50 0.00048 0.005735 -23.25 0.000866 0.0066 1287.0561 54.59692 1.27
Layer 4 18 2 42.42 -14.57 0.000375 0.00486 -5.25 0.000195 0.004665 909.57921 38.58435 0.21
Layer 5 14 2 42.42 -28.57 0.000355 0.00488 8.75 0.000326 0.004554 888.09412 37.67295 -0.33
Layer 6 11 2 42.42 -39.57 0.000339 0.004896 19.75 0.000735 0.00416 811.28154 34.41456 -0.68
Layer 7 14 2 42.42 -53.57 0.000327 0.004908 33.75 0.001257 0.003651 712.03252 30.20442 -1.02
C1 150 172.2271 6490.574 0 0 0 73.85714 0 0 40.2 260.92109 19.27089
C2 172.2271 201.8632 6697.998 0 0 0 33.57143 0 0 40.2 269.25953 9.039427
C5(compression
in Layer 5) 14 3 42.42 -28.57 799.51203 33.9153 0.296759
C6(compression
in layer 6) 11 2 42.42 -39.57 688.15169 29.191395 0.57653
C7(compression
in layer 7) 14 2 42.42 -53.57 546.42035 23.179151 0.782296
Balance
condition
(Cu=Tu) 530.2 530.2
Ultimate
moment
capacity at rail
seat 50.7059
Maximum
moment acting
at rail seat 12.74
Load factor SAFE 3.98
SUMMARY
PROPERTIES UNIT RAIL SEAT CENTRE

TOP BOTTOM TOP BOTTOM
Sleeper length mm 2750
Gauge length mm 1676
Axle load tonne 15.72
Concrete grade Mpa 60
Diameter of strands mm 6 mm (3x3 ply)
No. of strands Nos 20
Initial Pre-stress force kN 573.75
Initial Pre-Stress Mpa 1352.55
Base Area mm^2 672131
Ballast Pressure kg/cm^2 6.05
Loss in Pre-Stress Percentage 24.53
Ht of C.G of Pre-stress mm 88.5 88.5
Ht of C.G of composite section mm 96.43 85.45
Eccentricity mm 7.93 -3.05
Area of Scetion mm^2 42941.31 33000
Section Modulus mm^3 1348177.79 1591303.57 939748.5 1039827.03
B.M Imposed kN- m 12.74 12.79
Final Stress Mpa 16.6 3.85 0.17 -1.2
Permissible Stress Mpa 22 22 22 2.2
Resisting Moment kN-m 27.49 18.08
Ultimate Moment kN-m 50.7 34.77
Required Cracking load kN 270 65 60
Failure load kN 534.35
Failur load required kN 490
Factor of Safety 2.16 1.5
Load factor 3.98
Load factor required 3
WDFC PHASE-1
COMBINED PACKAGE
CTP-1 AND CTP-2

PSC SLEEPER
DRG NO. RT 7008 (FOR 68 KG RAIL)

CONTENTS
S. No Description Page No
1.0 DATA AND DESIGN PARAMETERS 2-6
2.0 CROSS SECTION AND BASE PLAN OF SLEEPER 7-9
3.0 RAIL SEAT LOAD CALCULATION 10
BALLAST PRESSURE DISTRIBUTION IN LOSS OF
4.0 11
CONTACT CONDITION
5.0 11-12
LOSS OF CONTACT CONDITION.
BALLAST PRESSURE DISTRIBUTION IN FULL CONTACT
6.0 13
CONDITION
6.1 13-14
FULL CONTACT CONDITION
7.0 STRESS CHECK AT TRANSFER 15-16
7.1 STRESS CHECK AT SERVICE 17
8.0 LOSS OF PRESTRESS 17-18
9.0 FACTOR OF SAFETY AGAINST CRACKING 19
10.0 ULTIMATE STRENGTH CALCULATION 20-24
a)Procedure 23
b)Ultimate moment capacity at rail seat 24
11.0 SUMMARY 25
1.0 Data & Design Parameters

S.No Description Notation Unit Value Remarks Source
1 Sleeper Length L mm 2750 Drawing no RDSO/T-7008
2 Gauge Length g mm 1676 for 68 kg/m (136RE14) 13.5 (1) (b) (i) of SBD-III
3 Axle Load W T 25 13.5 (1) (b) (iv) of SBD-III
13.5 (1) (b) (viii) of SBD-
4 Sleeper Spacing mm 600
III
5 Rail section to be catered Wg Kg/m 68 136RE14 13.5 (1) (b) (vii) of SBD-III
13.5 (1) (b) (viii) of SBD-
6 Sleeper Density in main lines per Km 1660
III
7 Maximum speed of train Km/hr 100 13.5 (1) (b) (ii) of SBD-III
Dynamic factor for speed and rail-
8 γL 2.5 13.5 (2) (b) (iv) of SBD-III
wheel irregularities
9 Load Distribution factor γD 0.55 Varies between 0.55 to 0.6 13.5 (2) (b) (iii) of SBD-III
10 Centre binding co-efficient α 0.4 full contact condition 13.5 (2) (b) (v) of SBD-III
11 Ballast contact length b mm 1040
12 fck Mpa 60 13.5 (2) (c) (i) of SBD-III
concrete
13 fck Mpa 40 13.5 (2) (c) (ii) of SBD-III
concrete prior to transfer of pre-stress
14 Premissible stresses in concrete
In compression 22 0.4 times fck 13.5 (2) (c) (iii) of SBD-III
In tension 2.2 .04 times fck 13.5 (2) (c) (iii) of SBD-III
Resisting Moment / Bending
15 Factor of safety at rail seat 2 13.5 (2) (b) (vi) of SBD-III
Moment
Failure moment / Bending
16 Load factor at rail seat bottom 3 13.5 (2) (b) (vii) of SBD-III
Moment
Sl
Description Notation Unit Value Remarks Source
No
upto 75% of breaking load
17 Initial prestressing 13.5 (2) (b) (ix) of SBD-III
(fpk)
30 % of initial prestress or as
18 Losses in prestress 13.5 (2) (b) (ix) of SBD-III
per actual
19 Static bending test loads
Cracking loads shall be
13.5 (2) (b) (viii) of SBD-
at centre top KN 65
III
13.5 (2) (b) (viii) of SBD-
at centr bottom KN 60
III
13.5 (2) (b) (viii) of SBD-
at rail seat KN 270
III
13.5 (2) (b) (viii) of SBD-
21 Failure load at rail seat KN 490
III
Sleeper Length L mm 2750.00

Wheel axle load W Tonne 25 Ref Page 2 above
Weight of rail WR kg 68 Ref Page 2 above
Gauge Length g mm 1676
Sleeper Density Nos 1660 / km
Sleeper spacing(c/c)(in main lines) s mm 600
Ballast contact length mm 1040
Dynamic augmentation factor for speed DAF 2.5 Ref Page 2 above
Load distribution factor γD 0.55 Ref Page 2 above
Center binding co-efficient (Full contact
α 0.40 Full contact condition Ref Page 2 above
condition)
Loss of contact condition α 0.00 Loss of contact condition
Rail s P KN 123.03 (0.5W*9.81 + (WR*9.81*.6)/1000)
Bearing width at rail seat bw mm 150
Grade of concrete fck Mpa 60
Young s modulus of concrete Ec Mpa 38729.83 5000*(fck^1/2) Is 456 pg 16
Flexural strength/split tensile strength Mpa 5.42 0.7*(fck^1/2) Is 456 pg 16
Ballast pressures (Loss of contact) p
Ballast pressure(Full contact) p'
As per IS 6006
Diameter high tensile steel strands dia mm 3
Clause 3.1.1
Number of wires mm 3
Permissible stress in concrete Mpa 0.4fck In compression Ref Page 2 above
0.04fck In tension Ref Page 2 above

Required Factor of safety at rail seat 2 Resisting bending moment/Applied bending moment Ref Page 2 above
Required Load factor at rail seat
Ref Page 2 above
bottom 3 Failure moment/Bending moment
Static bending load tests
Requirements
Cracking loads kN 65 At center top Ref Page 3 above
kN 60 At center bottom Ref Page 3 above
kN 270 At rail seat Ref Page 3 above
Failure load at rail seat kN 490 Ref Page 3 above
Young s modulus of pre-stressing As per Is 6006
Ep Mpa 195000
steel amendment No.3
Area of one strand Aᶲ mm2 21.21
Number of pre-stressing strands n 20
As per IS 6006
Breaking load Pk N 38250
Table 3
Breaking stress fpk Mpa 1803.4 P/Aᶲ
Percentage of initial pre-stressing
75%of fpk
force
Initial pre-stressing in one strand fpi Mpa 1352.55 0.75*fpk
2
Total area of strands As mm 424.20 n*Aᶲ
Initial prestressing force Pi KN 573.75 n*Aᶲ*fpi
IS 1343 Cl
Modular ratio m 5.03 Ep/Ec
No.18.3.1
Track modulus U kg/cm/cm 540.00 Annexure 1
Modulus of Elasticity of Rail E Mpa 211000.00

Moment of Inertia of rail I cm^4 3489 89% of New Rail (0.89* 3920.9)
Width of rail foot Rw cm 15.24
Rubber pad length Lw cm 36.00
Top width of sleeper bw cm 15.00
Area of cross section at rail 2
A2 mm 42941.31 [249.9+211.8)*98.24+(211.8+150)*112.01)]*0.5
seat
Area of cross section at
A8 mm2 35911 (235.1+150)*186.5*0.5
227.55mm
2
Average cross sectional area A mm 45491.3747 (((A1+A2)/2)*L1+((A2+A3)/2*L2+(A3*L3))/0.5*L
Average base width bw mm 244.41 (((b1+b2)/2*L1)+((b2+b3)/2*L2)+((b3+b4)/2*L3)+((b4*L4)))/(0.5*L)
2.0 Cross Sectional Properties and base plan of sleeper
(At Centre) (At Rail Seat)

Figure 2 - Cross-section of sleeper
Figure 1 – Cross sectional dimensions of sleeper with strands
Figure 3 - Plan of base of sleeper.
Description Notation Unit Value Formula

Area of cross section at rail A2 mm2 42941.31 [249.9+211.8)*98.24+(211.8+150)*112.01)]*0.5
seat
Area of cross section at A8 mm2 35911 (235.1+150)*186.5*0.5
227.55mm
Average cross sectional A mm2 45491.3747 ( (A1+A2)/2*L1 +(A2+A3)/2*L2 + (A3*L3))/(0.5*L)
area
Average base width bw mm 244.41 ((b1+b2)/2*L1 +(b2+b3)/2*L2 +(b3+b4)/2*L3 +(b4*L4)) / (0.5*L)
3.0 Rail Seat Load Calculations
Cracking Cracking Load at Failure

Load at Centre Load at
Description Unit Rail Seat Rail Seat
At Bottom
Bottom At Top At Bottom
Moment of resistance against bending (M) kNm 27.49 18.04 17.21 50.7059
Top width of rail seat (w) cm 15.00 15.00 15.00 15.00
Depth of sleeper (d) cm 21.03 18.00 18.00 21.00
Load distribution width (V = w + d) cm 36.03 33.00 33.00 36.00
Cracking Load M*100/(14-V/8) kN 289
Cracking Load M*100/(28) kN 64 61
Failure Load M*100/(14-V/8) kN 534
Minimum cracking load as per page 3 above kN 270 65 60 490
SAFE SAFE SAFE SAFE
4 Ballast pressure distribution loss of contact condition (α = 0)
5 Loss of Contact condition (α=0)

Area (Fig 3) A4 mm2 129975.00 (270+249.9)*500*0.5
Area (Fig 3) A5 mm2 129924 (249.9+231.3)*540*0.5
Maximum Rail seat load Pmax kg 15733.00
Ballast pressure under loss of contact p Mpa 0.605 1000*P/(A4+A5)
Pressure due to axle load q Mpa 1.758 1000*P/(2*179.07*249.9)
Contact pressure between rail and sleeper qmax kg/cm^2 29.135 SAFE (29.14<40kg/cm^2)
Moment at rail seat (Tension at

kN-m 12.75 A4*p*gr4-q*(257.1+249.9)*0.5*179.07^2/2
bottom)
Distance of CG of A4 from rail seat gr4 mm 253.22 Distance of CG from centre of rail seat
Justification for gr4 = Centeroid of trapezoid (h -(h/3) *
((2a+b)/(a+b)))
Moment at Center

M1 N-mm 88768981.53 129975*0.605350540017468*1128.23
of sleeper
M2 N-mm 47309379.62 129924*0. 605350540017468*601.53
of sleeper
M3 kN-mm 137663.75 15733/100*(540+185+150)
M3 N-mm 137663750.00 137663.75*1000
Moment at Center (Tension at
kN-m -1.59 (M1+M2-M3)/1000000
Bottom)
6.0 Ballast pressure distribution under full contact condition (α = 0.4)
6.1 Full Contact condition (α=0.4)

Area A6 (Fig.3) A6 mm2 42488.95 (231.3+228.04)*185*0.5
Area A7 (Fig.3) A7 mm2 34206.00 228.04*150
Ballast pressure p’ p' Mpa 0.541 1000*P/(A4+A5+(0.4*(A6+A7))
Pressure due to axle load, q q 1.758 1000*P/(2*179.07*249.9)

Moment due to upward pressure M4 Mpa 17801.5 129975*0.541/1000*(253.23)
Pressure below the rail seat plate. kN-m 39.90 1.758*(257.1+249.9)*0.5*179.07/2/1000
CG distance of pressure below rail seat
mm 89.96
plate from rail seat
Moment due to downward pressure M5 kNm 7178.53 39.90*89.96*2
Moment at rail seat (from Fig.5)
kNm 10.623 (M4-M5)/1000
(Tension at Bottom)
Upward load from A4 kN 70.3 0.541*129975/1000
Upward load from A5 kN 70.29 129924*0.541/1000
Moment at center cross-section M7 kN-m 42.28 70.288884*601.53/1000
Upward pressure from A6 kN-m 9.19 42488.95*0.541*0.4/1000
Upward pressure from A7 kN-m 7.40 34206*0.541*0.4/1000
Moment at cross section M9 kN 0.68 7.4021784*92.5/1000
Moment due to axle and rail load at
M10 KN-m 137.66 15733/100*(185+540+150)/1000
center
Moment at Center (from Fig.5) kNm -12.83 (M6+M7+M8+M9-M10)
Maximum moment acting at rail seatdue
MLL,r kN-m 12.75 Sagging
to live load (Sagging)
Maximum moment acting at centerdue to
MLL,c kN-m -12.83 Hogging
live load (Hogging)
7 Stress Check at Transfer

At rail seat
Area of cross section at rail seat A2 mm2 42941.31
Area of composite section Acr mm2 44652.91 Total
CG of gross concrete area from base mm 96.51
mm 88.5
(Fig.1)
4144266.12
37541.70
96.43
CG of composite area from base Cgr mm 96.43
Eccentricity of strands at rail seat epr mm 7.93
Moment of inertia of composite section Icr mm4 153449595.80
Bottom sectional modulus of composite
Zbr mm3 1591305.57
section
Top sectional modulus of composite
Ztr mm3 1348177.79
section

MPa 9.47 Pi/Acr-(Pi*epr)/Ztr
at top of rail seat

MPa 15.71 Pi/Acr-Piepr/zbr(Compression if +ve)
at bottom of rail seat
At center of sleeper
Area of cross section at centre A3 mm2 33300.00
Area of composite section Acc mm2 35011.60 Total
CG of gross area from base mm 84.32
mm 88.50
(Fig.1)
2807856.00
37541.70
85.45
CG of composite area from base Cgc mm 85.45
Eccentricity of strands at rail seat epc mm -3.05
Moment of inertia of composite section Icc mm4 88853219.41
Bottom section modulus of composite
Zbc mm3 1039827.03
section
Top section modulus of composite
Ztc mm3 939748.49
section
Stress at transfer at top of centre of

MPa 18.25 Pi/Acc-Piepc/ztc(Compression if +ve)
sleeper
Stress at transfer at bottom of centre of

MPa 14.70 Pi/Acc+Piepc/zbc(Compression if +ve)
sleeper
7. 1 Stress check at service

Loss of prestress due to elastic shortening
Presstressiong loss due to elastic
= m × stress due to prestress at its cg
shortening
Loss due to elastic shortening at rail seat MPa 65.88 m( Pi/Acr+(Pi*〖epr〗^2)/Icr)
Loss due to elastic shortening at centre of

MPa 82.81 m( Pi/Acc+(Pi*〖epc〗^2)/Icc)
sleeper
Average loss due to elastic shortening MPa 74.34

Percentage loss of prestress due to elastic
% 5.50
shortening
8.0 Loss of Pre-stress

Loss of prestress due to creep
Creep coefficient Φ 1.60 1.6
Loss due to creep MPa 118.95 (Φm) × stress due to prestress at its cg
Percentage loss of prestress due to creep % 8.79
Loss of prestress due to shrinkage

Shrinkage strain 0.0003
Loss of prestress due to shrinkage MPa 58.50 0.0003Ep
Percentage loss of prestress due to
% 4.33
shrinkage
Loss of prestress due to relaxation

Loss of prestress due to relaxation MPa 80.00 5.92 % of fpi
% 5.91
Total percentage of loss of prestress 24.53 24.54% of fpi
Effective prestressing (after all losses) fpe MPa 1020.75 (100-24.54)* fpi
Effective prestressing force Pe kN 433.00 fpe*As
Since value is less than ( Pe)/Acr-
Stress at service at top of rail seat (Pe*epr)/Ztr+(Mll,r)/Ztr
MPa 16.61
(Compression) 0.4 fck = 22 Mpa
Therefore SAFE
Since vlaue is less than ( Pe)/Acr+(Pe*epr)/Zbr-
Stress at service at bottom of rail seat (Mll,r)/Zbr
MPa 3.84
(Tension) 0.4 fck = 24 Mpa
Therefore SAFE
Since value is less than ( Pe)/Acc-(Pe*epc)/Ztc-
Stress at service at top of center of sleeper (Mll,r)/Ztc
MPa 0.12
(Compression) 0.4 fck = 24Mpa
Therefore SAFE
Since value is less than ( Pe)/(
Stress at service at bottom of center of Acc)+(Pe*epc)/Zbc+(Mll,r)/Zbc
MPa -1.24
sleeper (Compression) 0.04 fck = 2.4 Mpa
Therefore SAFE
9.0 Factor of safety against Cracking moment based on Modulus of rupture
Modulus of Rupture 5.42
At rail seat bottom, Cracking moment Mcr kN-m 27.49
9.70
2.16
27.49
At center of sleeper top, Cracking

Mcr kN-m 18.04
moment
12.37
-1.41
18.04
Factor of safety at rail seat bottom 2.16

SAFE
Factor of safety at center top 1.50 SAFE
10.0 Ultimate Strength Calculation:

The strain variation in different layers of strands at decompression and ultimate and strain variation in concrete at ultimate state is
shown in Fig.8. The corresponding forces in both pre-stressing strands and concrete are shown in Fig.9.The stress strain curve for
prestressing strands is given in Fig.10
(a) Cross-section (b) Cross-section (c) Strains in strands (d) Stains in strands and
with eccentricity at decompression concrete at ultimate
of strands state
(Fig 8)
(a) Cross section (b) Tensile force in (c) Compressive force

Strands at ultimate in concrete
(Fig. 9)
Wire (Stress Relieved), Strands and Bars (Fig. 10)
ULTIMATE MOMENT CAPACITY AT RAIL SEAT

Xu(Assumed) 94 mm
Distance Distance Distance
Area(As) Strain Strain Mur(kN-
Layer b/w n from ɛ1.i ɛp, dec, i from Stress(Mpa) Ci(kN) Ti(kN)
mm^2 ɛ2,i ɛpu,i m)
layers CG N.A(mm)
Layer 1 40 6 127.26 56.50 0.000539 0.005774 -76.25 0.002839 0.008613 1679.506 213.7339 16.3
Layer 2 35 4 84.84 21.50 0.0005 0.005774 -41.25 0.001536 0.00731 1425.3837 120.9296 4.99
Layer 3 18 2 42.42 3.50 0.00048 0.005735 -23.25 0.000866 0.0066 1287.0561 54.59692 1.27
Layer 4 18 2 42.42 -14.57 0.000375 0.00486 -5.25 0.000195 0.004665 909.57921 38.58435 0.21
Layer 5 14 2 42.42 -28.57 0.000355 0.00488 8.75 0.000326 0.004554 888.09412 37.67295 -0.33
Layer 6 11 2 42.42 -39.57 0.000339 0.004896 19.75 0.000735 0.00416 811.28154 34.41456 -0.68
Layer 7 14 2 42.42 -53.57 0.000327 0.004908 33.75 0.001257 0.003651 712.03252 30.20442 -1.02
C1 150 172.2271 6490.574 0 0 0 73.85714 0 0 40.2 260.92109 19.27089
C2 172.2271 201.8632 6697.998 0 0 0 33.57143 0 0 40.2 269.25953 9.039427
C5(compression
in Layer 5) 14 3 42.42 -28.57 799.51203 33.9153 0.296759
C6(compression
in layer 6) 11 2 42.42 -39.57 688.15169 29.191395 0.57653
C7(compression
in layer 7) 14 2 42.42 -53.57 546.42035 23.179151 0.782296
Balance
condition
(Cu=Tu) 530.2 530.2
Ultimate
moment
capacity at rail
seat 50.7059
Maximum
moment acting
at rail seat 12.74
Load factor SAFE 3.98
SUMMARY
PROPERTIES UNIT RAIL SEAT CENTRE

TOP BOTTOM TOP BOTTOM
Sleeper length mm 2750
Gauge length mm 1676
Axle load tonne 15.72
Concrete grade Mpa 60
Diameter of strands mm 6 mm (3x3 ply)
No. of strands Nos 20
Initial Pre-stress force kN 573.75
Initial Pre-Stress Mpa 1352.55
Base Area mm^2 672131
Ballast Pressure kg/cm^2 6.05
Loss in Pre-Stress Percentage 24.53
Ht of C.G of Pre-stress mm 88.5 88.5
Ht of C.G of composite section mm 96.43 85.45
Eccentricity mm 7.93 -3.05
Area of Scetion mm^2 42941.31 33000
Section Modulus mm^3 1348177.79 1591303.57 939748.5 1039827.03
B.M Imposed kN- m 12.75 12.83
Final Stress Mpa 16.61 3.84 0.12 -1.24
Permissible Stress Mpa 22 22 22 2.2
Resisting Moment kN-m 27.49 18.04
Ultimate Moment kN-m 50.7 34.77
Required Cracking load kN 270 65 60
Failure load kN 534.35
Failur load required kN 490
Factor of Safety 2.16 1.5
Load factor 3.98
Load factor required 3
ANNEXURE 01
No.CT/DG/Research Dt:16-10-2006
The Chief Track Engineer:
1. Central Railway, CST, Mumbai – 400 001.

2. Eastern Railway, Fairlie Place, Calcutta – 700 001.
3. East Central Railway, Hajipur – 844 101.
4. East Coast Railway, Chandrasekharpur, Bhubaneshwar – 751 016.
5. Northern Railway, Baroda House, New Delhi – 110 001.
6. North Central Railway, Allahabad - 211 001.
7. N.E.Railway, Gorakhpur - 273 001.
8. N.F.Railway, Maligaon, Guwahati – 781 011.
9. North Western Railway, Jaipur – 302 001.
10. Southern Railway, Park Town, Chennai – 600 003.
11. S.C.Railway, Rail Nilayam, Secunderabad – 500 371.
12. S.E.Railway, Garden Reach, Calcutta – 700 043.
13. South East Central Railway, Bilaspur 495 004
14. South Western Railway, Hubali– 580 023.
15. Western Railway, Churchgate, Mumbai – 400 020
16. West Central Railway, Jabalpur – 482 001.
Sub: Rail stress calculation methodology.

Ref: (i) Item no.1074 (SNo.9) of 76th TSC on Track
Stress Calculation.
(ii) Item no.1078 (SNo.9) of 76th TSC on review
of rail stress calculation methodology.
(iii) Railway Board’s orders on recommendations of 76th TSC vide
letter no.2005/CE-II/TSC/2 dt:13-9-2006.
The issue was discussed vide item no.957 in 73rd TSC, Item no.1031/25 in 74th
TSC and Item No.1057/12 in 75th TSC. Following the discussions on the item in 75th
TSC held at Mumbai in December, 2004, TSC had recommended that the sectional
properties of rails at different wear percentage of rails should be issued by RDSO early.
These recommendations were approved by Railway Board.
Pursuant to these recommendations and Railway Board’s order thereon, RDSO had
worked out the sectional properties of 52Kg and 60Kg rails at different percentages of wear
and circulated the same to Zonal Railways vide RDSO’s letter of even no.dt:20-10-2005.
Certain errors in the sectional properties worked out have been noticed and accordingly
revised sectional properties are enclosed herewith as Annexure-1.
Further, Railway Board have approved adoption of the values of track modulus
for PRC sleepers recommended by TSC after discussion on Item no.1078. The subject of
track stress calculation was also discussed in 76th TSC vide Item No.1074 (S.No.9).
Railway Board have desired that the rail stress calculation methodology should be
circulated by RDSO to Zonal Railways.
In view of above, the methodology for computation of track stresses comprising

of explanatory notes regarding computation of stresses in various components of track
(Annexure 2), “Stress” software for calculation of stresses (copy being sent by e-mail)
and sample calculation of rail stresses (Annexure 3) is being sent herewith for your
information and necessary action.
(Anirudh Jain)
DA: As above Executive Director/Track
For Director General/Track
Copy for information to:
1 Executive Director CE (P), Railway Board, Rail Bhawan, New Delhi-110 001.
2 Director, IRICEN, Pune.
Rail Rail Wear Moment Section modulus of Polar Factor * Lateral Lateral Distance
section (%) of of Inertia worn Rail moment section section between
area about xx- of inertia modulus for modulus for centre of twist
compres Tension
axis head foot and point of
sion
action of
lateral force
Area I'xx Zcworn Ztworn Ip (cm 4) EI1h1r/CZ1 EI1h1r/CZ2 3

Z3(cm )
3
Z4 (cm ) hf(cm)
cm 2 (cm )
4 3
(cm )
3
(cm )
66.15 10 1792.14 202.13 266.15 2090.84 0.0270 0.0259 146.80 43.86 10.28
66.15 9 1823.43 207.64 267.43 2128.56 0.0285 0.0257 138.65 44.81 10.34
52 kg 66.15 8 1855.84 213.37 268.87 2167.40 0.0297 0.0256 132.16 45.75 10.41
66.15 7 1889.40 219.34 270.45 2207.39 0.0308 0.0255 126.91 46.69 10.48
66.15 6 1924.12 225.55 272.18 2248.54 0.0318 0.0254 122.61 47.64 10.55
76.86 10 2501.54 248.98 349.72 2918.17 0.0193 0.0213 218.00 55.55 11.43
76.86 9 2549.68 256.26 351.66 2975.93 0.0211 0.0212 198.32 56.83 11.49
60 kg 76.86 8 2599.35 263.81 353.80 3035.23 0.0227 0.0211 183.83 58.12 11.55
76.86 7 2650.59 271.65 356.13 3096.10 0.0241 0.0211 172.80 59.40 11.61
76.86 6 2703.41 279.79 358.65 3158.55 0.0253 0.0210 164.19 60.68 11.67
* E= Young's Modulus of Elasticity

I1=Moment of inertia for head
I2=Moment of inertia for foot
h1=Distance of centroid of head postion from centre of twist
h2=Distance of centroid of foot postion from centre of twist
r =Factor
Z1=section modulus for head
Z2=section modulus for foot
C=Torsional Rigidity
Rail Area cm2 Wear (%) H.width(m Radius Loss of Beff (mm) Depth of Iw Ixx (cm4) Yt (cm) AwX^2 I'xx % Stipulated
section m) (mm) area A1 wear (cm4) (cm4) (cm4) Reduction load (t)
(cm2) (mm) in Ixx(cm4) Proposed
values
60t 65t
75R 47.37 4.2 61.91 11 1.98954 50.91 3.907955 0.02532 1055.56 6.629 41.39124 973.1852 7.8039 65 (90UTS) 55.31766 59.92747
47.37 4 61.91 11 1.8948 50.91 3.721862 0.021873 1055.56 6.629 41.51105 976.883 7.45358 55.52785 60.15517
47.37 3 61.91 11 1.4211 50.91 2.791397 0.009228 1055.56 6.629 42.1127 995.7044 5.670506 60(72UTS) 56.5977 61.31417
47.37 2 61.91 11 0.9474 50.91 1.860931 0.002734 1055.56 6.629 42.71869 1015.086 3.834402 57.69936 62.50764
47.37 1 61.91 11 0.4737 50.91 0.930466 0.000342 1055.56 6.629 43.329 1035.035 1.944493 58.8333 63.73608
90R 56.95 5 68.68 12.7 2.8475 55.98 5.086638 0.061397 1600 7.493 52.39832 1450.734 9.3291 77.07026
56.95 4 68.68 12.7 2.278 55.98 4.06931 0.031435 1600 7.493 53.13731 1478.922 7.56739 85(90UTS) 78.56772
56.95 3 68.68 12.7 1.7085 55.98 3.051983 0.013262 1600 7.493 53.88148 1507.93 5.754361 80.10879
56.95 2 68.68 12.7 1.139 55.98 2.034655 0.003929 1600 7.493 54.63083 1537.772 3.889278 81.69411
56.95 1 68.68 12.7 0.5695 55.98 1.017328 0.000491 1600 7.493 55.38535 1568.458 1.971403 83.32431
EXPLANATORY NOTES TO CALCULATION OF TRACK STRESSES
1. Track stresses are worked out on the basis of elastic theory which is based on the
assumption that the several components of track are one complete unit and the rails are
continuously supported on sleepers which are considered to be elastic. The ballast and
formation are also considered elastic.
2. Track Modulus:
For calculation of track stresses, the following track moduli values recommended by 53rd
and 76th Track Standards Committee vide item no.716 and Item No.1078 respectively and
approved by Railway Board are to be followed:
Gauge Sleeper Type Sleeper Initial Initial Track Elastic Track

Density Load Modulus Modulus
BG Other than PRC All 4t 75Kg/cm/cm 300 Kg/cm/cm
PRC 1540 4t 125/kg/cm/cm 425/kg/cm/cm

PRC 1660 4t 135/kg/cm/cm 540/kg/cm/cm
MG All All 3t 50 Kg/cm/cm 250 Kg/cm/cm
3. Rail section properties:
For working out rail stresses, the properties like moment of inertia and section modulus
of rails are being assumed 10% lesser than the properties for new rails. The wear is
assumed to be 5%.
4 Speed/impact factor:
For BG vehicles, the graphs plotted in RDSO’s report C-100 are being followed for
different vehicles. In case of M.G. vehicles, similar graphs plotted in Report C-92 are
being used. These graph are enclosed here with for ready reference. Where the
measured values of dynamic augment are not available , the dynamic augment values for
similar vehicles are to be adopted.
5 The Bending Stresses in rails:
These are calculated using double modulus method based on the method given in
Technical Paper 323. The maximum lateral flange force per axle is as per Prud’ Homme
Limit. In case actual measured figures are available for the stock under consideration, the
same are being assumed in calculating stresses. An eccentricity of 15mm for vertical
load is adopted for calculations.
Following permissible values for rail stresses are being adopted at present for rails
with minimum UTS of 72Kg/mm2 and 90Kg/mm2 .
i) Bending longitudinal rail stresses due to vertical wheel load including eccentricity
effect- 23.5Kg/mm2.
ii) Combined bending longitudinal rail stresses including the effect of lateral flange
forces:
For 72 UTS rail:
1 For jointed track 30 Kg/mm2
2 For track with short-welded panels 24.25 Kg/mm2
3 For long-welded rail panels 19.25 Kg/mm2
For 90 UTS rail:
1 For jointed track 36.0 Kg/mm2
2 For track with short-welded panels 30.25 Kg/mm2
3 For long-welded rail panels 25.25 Kg/mm2
6. Fishplate Stresses:
For calculating fishplate stresses, the bending moment is to be worked out adopting the
dynamic wheel load, by double modulus method, using the bending moment formula
given in the Track stresses Research Report by M/s Gelson & Blackwood (given below).
The stresses developed are to be worked out by dividing the B.M. by minimum section
modulus value for the pair of fishplates. The dynamic stress range, for fatigue
consideration should be taken as 1.33 times the calculated fishplate bending stress and
should not exceed 25 Kg/mm2. The maximum stress in fishplates is calculated by adding
the stress due to initial bolt tension, to the value of fishplate bending stress. This value is
taken as 10Kg/mm2. The maximum stress in fish plates should not exceed 30 Kg/mm2 .
The formula for calculating bending moment is as below:
Mo = Ip {W-2 Mo – (W- Mo) P }

2
LI 2 3EI + P
Where Mo = B.M. in the pair of fish plates.
=4 U to be worked out for Ui and Ue separately

4EI
U = Track modulus kg/cm/cm

L = Effective length of fishplate cm
= Influence factor from the master diagram (for distance of joint sleeper
centre from rail end)
= Additional bearing area ratio
P = U x S, ‘S’ being intermediate sleeper spacing in cm
2W = Dynamic wheel load in kgs
Ip = M.I. of pair of fishplates (cm4)
I = M.I. of rail (cm4)
E = Young’s modulus of rail steel (Kg/cm2)
7. Bolt Hole Stresses:

The principal stresses at fish bolt holes are calculated by the formula given below. A
stress concentration factor of 3 is applied.
Thus p = 3 {f1 + f2 + (f1-f2)2 +q2 }

2 2
Where f1 = Direct stress in rail web due to bolt tension of 3 tonnes

f2 = Stress in rail web due to vertical bending moment caused by dynamic load
q = Shear stress due to shear force in rail
The stress range is worked out with maximum and minimum values of principal stresses
obtained with above formula. This range should not exceed 27Kg/mm2.
Notes: For calculation of bolt hole stresses a tables showing the factors for different rail sections
has been enclosed.
8. Formation Pressure:
For working out maximum intensity of pressure on formation following formula as per
Technical Paper No.245, is used using elastic track modulus value only;
Elastic method
Pmax = 2PS 4 U
DL 64 EI
Pmax = Maximum formation pressure in Kg/cm2

P = Dynamic wheel load in kgs.
S = Sleeper spacing in cm
D = Depth of ballast in cm.
L = Effective length of sleeper per rail seat in cm 76 cm for BG, 63cm for
MG.
U = Track Modulus kg/cm/cm
E = Modulus of elasticity of rail steel in kg/cm2.
I = M.I. of rail in cm4.
The permissible limits of formation pressure are as below:-
1. For locomotives 3.5 kg/cm2
2. For other stock namely

Wagons, coaches only 3.0 kg/cm2
8. Rail wheel contact shear stress:
The contact shear stress developed at a depth of 5-7mm below top table in the head of the
rail is calculated by the following formula:
Tmax = 4.13 Q
R
Tmax = Contact shear stress in Kg/mm2
Q = wheel pressure in kg (static wheel load + 1 tonne to account for

constant on-loading on the curves)
R = wheel radius in mm ( Worn wheel radius)
The permissible value for this stress is taken as 30% of UTS of rail steel, i.e. 21.6 kg/mm2
for 72UTS rails. If these stresses are exceeded shear fatigue failures leading to kidney
shaped fatigue cracks in rail head may develop.
9. Joint Loading:
Due to the effect of unsuspended masses and speeds the joints are subjected to severe over-
loads given by the formula:
F= Fo + 0.1188 V W
Where F = Dynamic overload at joint in tonnes

Fo = Static wheel load including sprung and unsprung masses in tones
V = Velocity in km/h
W = Unsprung mass per wheel in tonnes.
The following permissible values are being adopted:
B.G.- Locomotives ….. 27 tonnes

EMU stock ….. 23 tonnes
Wagons & coaches ….. 19 tonnes
M.G- Locomotives ….. 17 tonnes

EMU stock ….. 14 tonnes
Wagons & coaches ..... 11 tonnes
CALCULATIONS FOR RAIL STRESSES DUE TO BOXN WAGON AT 75KMPH
ON 52KG, M+7(1540nos/km), 250MM TRACK
(WITH DOUBLE TRACK MODULUS METHOD)
Initial track modulus (µi) = 125Kg/cm/cm

(for first 4 tonnes live wheel load)
Elastic track modulus (µe) = 425 Kg/cm/cm

(for rest of live wheel load)
Assumed that I & Z of 5 % worn rail are reduced by 10 %
Ixx (worn) = 1942. 2cm4

Zc (worn) = 241.65 cm 3
Zt (worn) = 256.95cm 3
X1 = The distance from the load to the point of contra flexure of the rail in cm.
= 42.33 * 4 Ixx (worn)

µ
X1i for initial load of 4t = 42.33 * 4 1442.2

125
= 84.04 cm
X1e for rest of the load = 42.33 * 4 1442.2

425
= 61.89 cm
Impact factor at 75Km/h = 53 % taken from graph plotted in RDSO report no. C-100.
Axle Load = 21.82 tonnes
Wheel Load = 10.91 tonnes
Dynamic wheel load = 10.91 * 1.53 = 16.69t
B.M Co-efficient from master diagram
With Xli = 84.04cm With X1e = 61.89cm

For 200cm (-) .19 for 200.0cm (-) .10
For 452.4cm (-) 0 for 452.4cm 0
For 652.4 cm 0 for 652.4 cm 0
Effects of adjacent wheels
4 * (-).19 = - .76t 12.69 * (-) .10 = -1.2692t

for elastic loading
For initial load of 4 tonnes (balance of dynamic wheel load)
Rail stresses due to vertical bending
Tlv considering initial load of 4 tonnes.
1 2 3 4
200.0 452.4 200.0
Effect of Wheel no.1 4 -.76 - -

Effect of Wheel no.2 -.76 4 - -
Effect of Wheel no.3 - -. 4 -.76
Effect of Wheel no.4 - - -.76 4
Virtual wheel load 3.24 3.24 3.24 3.24
Effect of leading wheel to be taken if the distance between adjacent axle is more than
6 times Xli
In the present case 6 * Xli = 6 * 84.04 = 504.24 cm

No wheel except wheel nos. 1 and 4 is having effect of leading axle
Adding 10 % for the effect of leading wheel
Tl v = 3.24 + .324 = 3.564 tonnes.
Tlv considering remaining load.

1 2 3 4
200.0 452.4 200.0
Effect of Wheel no.1 12.69 -1.269 - -

Effect of Wheel no.2 -1.269 12.6.9 - -
Effect of Wheel no.3 - - 12.69 -1.269
Effect of Wheel no.4 - - -1.269 12.69
Virtual wheel load 11.421 11.421 11.421 11.421
6 * X1e = 6 * 61.89 = 371.34 cm
Hence, wheel 2 & 3 will also have leading wheel effect
Tlv for wheel nos. 1 & 4 = 11.421+1.1421= 12.5631 tonnes

Tlv for wheel nos. 2 & 3 = 11.421+1.1421= 12.5631 tonnes
For max. Value of Tlv, ,the Tlvs due to initial and elastic loading will be added.
Tlv due to initial loading 3.564 3.24 3.564 3.24
Tlv due to elastic loading 12.5631 12.5631 12.5631 12.5631
Total Tlv 16.1271 15.8031 15.8031 16.1271
Max. Tlv = 16.1271 tonnes.
B.M. in rail = .318 * 84.04 * 3.564 + .318 * 61.89 * 12.5631
= 95.246 + 247.254
= 342.50 t.cm
Stress in head (comp) = 342.5 = 1.417 t /cm2

241.65
= 14.17 Kg/mm2
Stress in foot (tensile) = 342.5 = 1.332 t /cm2

256.95
= 13.32 Kg/mm2
b) Stresses due to eccentricity of vertical load
Eccentricity (e) = 1.5cm (assumed)

Torque = 2Mt = TLv * e
Mt = 16.1271 * 1.5 = 12.095325 t.cm

2
Note: E*I1* h1*r = .0351

C*Z1
E*I1* h1*r = .0247
C*Z2
(i) Stress in head = Mt* E*I1* h1*r
C*Z1
= 12.095325 * .0351 = .427 t/cm2

= 4.27 Kg/mm2
ii) Stress in foot = Mt* E*I1* h1*r

C*Z2
= 12.095325 * 0.2470 = ..298 t/cm2
= 2.98 Kg/mm2
c) Stress due to twisting by flange force
Maxm. Flange force/axle = .85 ( 1 + 21.82)

3
= 7.032t
flange force / wheel = 3.516 t
2 Mt = 3.516 * hf
Mt = 3.516 * 10.958
2 = 19.264164 t.cm
(i) Stress in head = Mt* E*I1* h1*r

C*Z1
= .676 t/cm2 = 6.76kg/mm2
(ii) Stress in foot = Mt* E*I1* h1*r

C*Z2
= .485 t/cm2 = 4.85 kg/mm2
d) Stresses due to lateral deflection under flange force
Flange force / wheel = 3.516 t
Sleeper spring = 68 cm
BM = 3.516 * 68 = 59.772.cm
4
Lateral Modulus Z3 = 59.772

108.253 = .552 = 5.52 Kg/mm2
Lateral Modulus Z4 = 59.7725

53.324 =11.20 Kg/mm2
Combined stresses:
(a + c + d-b) for head =
14.17+ 6.76+ 5.52 - 4.27 = 22.18Kg/mm2
(a + b +d –c) for foot =13.33 + 2.98 + 11.20 – 4.85 = 22.66 Kg/mm2

WDFC PHASE-1
COMBINED PACKAGE
CTP-1 AND CTP-2

PSC SLEEPER
DRG NO. RT 7009

+1.5
1934 -0.
X INCLINATION OF RAIL SEAT SHALL

NOMINAL GAUGE (1673)
NOT EXCEED 1 IN 19 .75 NOR BE LESS
THAN 1 IN 20.25 (MEASUREMENTS TO BE
+4.5
TAKEN AS INDICATED IN PLAN BELOW) 250.6 -3.0 211.8 +4.5
-3.0
ELASTIC RAIL CLIP LINER GROOVED RUBBER SOLE PLATE 150 150
Y I IN 20
150
1 IN 20 INSERT
1 IN 20 150 150
LEVEL LEVEL
112.01
180
210.25 +4.5
185
-3.0
+4.5
235 +4.5
235 -3.0
-3.0
210.25
.
+4.5
180 +4.5
180 -3.0
-3.0
.
98.24
50
50
+4.5 +4.5
270 -3.0 220 +4.5 249.9 -3.0
X Y -3.0
882.5 1375
2750 ±3 END ELEVATION SECTION ON YY SECTION ON XX
HALF SECTIONAL ELEVATION 20 Nos. 3 x 3 DIA: H. T. S. STRANDS 150
10
10
10 10
105
120 61
18 18 14 11 14
+4.5
270 -3.0.
+1.0
+4.5
130 -0.5
+3.0
130 +1.0
250 -3.0
154 -1.5
+4.5
+3.0
-0.5
220 -3.0
.
.
154 -1.5
90
270 +4.5
.
115
-3.0
°
60
97
37 60 37
35
CL OF 20 Nos. 3 x 3 DIA: H. T. S. STRANDS
HALF SECTIONAL PLAN
26 26 44 26 26
40
GAUGING POINTS FOR MEASURING INCLINATION
AND WIND AT RAIL SEATS. WIND AT RAIL SEATS
MEASURED ON GAUGING POINTS AS SHOWN HERE
QUANTITY SCHEDULE FOR SLEEPER SHALL NOT EXCEED 1.2 mm ON A WIDTH OF 120 mm.
CENTRE OF CAST-IN INSERT
TO BE WITHIN1.5 mm OF CL
ENLARGED VIEW OF DISPOSITION
D JDS/T-IV KAMLESH JHA
OF TOP OF SLEEPER.
VOLUME APPROX. APPROX.
A.N.GUPTA
DESCRIPTION DRG N ..O MATERIAL SPECIFICATION

No. PER
SLEEPER
PER WEIGHT TOTAL
EACH WEIGHT
OF H. T. S. STRANDS.
SLEEPER CONVEX OR CONCAVE CAMBER
IN Kg. IN Kg. VALUES FOR STATIC BEND TEST IN ANY DIRECTION ON RAIL SEAT 1934
SHALL NOT EXCEED 0.8 mm.
SLEEPER RDSO/T-7008 CONCRETE IRS/T-39 1 108900 cm3 267 267
CRACKING LOAD ( KN ) FAILURE LOAD 170.4 .
TRC: COMPUTER PA DDST
20 NOS.
IS: 6006 - 0.4565 9.13 AT RAILSEAT ( KN )
REINFORCEMENT RDSO/-7008 H.T.S. 3ply3 mm CENTRE TOP CENTRE BOTTOM RAILSEAT
STRAND
P
65 60 270 490
INSERTS RDSO/T-6901 SGCI IRS/T-46 4
BY
31.1
QUANTITY SCHEDULE FOR RAILSEAT ASSEMBLY QUANTITY SCHEDULE FOR RAILSEAT ASSEMBLY 1 IN 20
FOR 1673 mm GAUGE, 60 Kg.(UIC) FOR 1676 mm GAUGE, 60 Kg.(UIC)

CHD: R.L.WAGHMARE
No. PER No. PER

DRG: K.J.SINGH
DESCRIPTION DRG N MATERIAL SPECIFICATION SLEEPER DESCRIPTION DRG N MATERIAL SPECIFICATION SLEEPER
GROOVED RUBBER COMPOSITE GROOVED RUBBER COMPOSITE

SOLE PLATES
RDSO/-7010
RUBBER
RDSO/ M&C/ RP- 2000/2007 2 SOLE PLATES
RDSO/-7010
RUBBER
RDSO/ M&C/ RP- 2000/2007 2
DETAIL OF FIXING INSERT AT RAIL SEAT
RDSO/T-8222 GLASS FILLED 2
GLASS FILLED LINERS IRS/T-44
LINERS RDSO/-6937 IRS/T-44 4 RDSO/T-8223 NYLON-66 2
NYLON-66
ELASTIC RAIL ELASTIC RAIL
RDSO/T-5919 - IRS/T-31 4 RDSO/T-5919 - IRS/T-31 4
CLIP MARK-V CLIP MARK-V
THIS DRAWING IS THE PROPERTY OF
RESEARCH DESIGNS AND STANDARDS ORGANISATION
ALT-1
(MINISTRY OF RAILWAYS)
CAL:
CH:
LUCKNOW - 226011, INDIA

AND SHALL NOT BE USED, COPIED, REPRODUCED IN
PART OR WHOLE, WITHOUT PRIOR CONSENT IN WRITING.
9. FOR ACHIEVING 1676 mm GAUGE ON THIS SLEEPER WITH 60 Kg.(UIC) RAIL TO DRG. No.RDSO/T-7008 LINERS TO DRG: No. RDSO/T-8222 & 8223 ARE TO BE USED. R. D. S. O.
FOR 1673 mm GAUGE USE LINER TO DRG. NO.RDSO/ T- 6937
C.R.No.
PAGE SNo.3205np.-21-22 PAGES
8. PART SHOWN IN QUANTITY SCHEDULE SHALL BE TO LATEST SPECIFICATION & DRAWING.

PRESTRESSED CONCRETE
7. THE LATEST VERSION OF DRAWING TO BE CONFIRMED FROM RDSO BEFORE TENDERING.
6. FOR USE OF 60 Kg RAIL ON THIS SLEEPER TO DRG. No. RDSO/T-7008, REFER ASSEMBLY DRG. No. RDSO/T-7009.
MILLIMETRES SLEEPER FOR 25t AXLE LOAD FOR
CT/SRC/3/2
5. MARKINGS ON SLEEPERS SHALL BE TO DRG. NO. RDSO/T-2466. 10 0 10 20 30 40

4. EACH STRAND SHALL BE TENSIONED WITH AN INITIAL FORCE OF 29 KN.
ALT-1
20 0 20 40 60 80 1. QUANTITY SCHEDULE FOR RAIL SEAT XX.12.11
B. G. ON 136 RE RAILS.
3. CONCRETE SHALL CONFORM TO IRS/T- 45. IRS/ T- 39 , OF GRADE M-60.
ASSEMBLY FOR 1676 mm. GAUGE &
2. ALL CORNERS SHALL BE ROUNDED OFF TO A RADIUS OF 5 mm UNLESS OTHERWISE SPECIFIED. STAN D ---------------------
(T)
..
50 0 50 100 150 200 1673mm GAUGE & NOTE No. 9 ADDED CANC LD
ADVANCE
.. ---------------------
1. ALL DIMENSIONS ARE IN MILLIMETRES. IRS / T-39 26 - 02 - 2009
AND NOTE NO.3 ALTERED. REV D ---------------------
FILE
NOTE SPECIFICATION SCALE ALT: DESCRIPTION DATE RDSO/T-7008

1.sleeper Design 60 KG

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ATTACHMENT TO LETTER NO. SLT/NKC/CTP1&2/TECH/SLPR/2014/481 Dated 21.05.

DESIGN CALCULATIONS FOR 25T AXLE LOAD

DRG NO. RT 7008 (FOR 60 KG RAIL)

1.0 Data & Design Parameters

Description Notation Unit Calculation Formula Remarks

Sleeper Length L mm 2750.00

Description Notation Unit Calculation Formula Remarks

Description Notation Unit Calculation Formula Remarks

Average base width bw mm 244.41 (((b1+b2)/2*L1)+((b2+b3)/2*L2)+((b3+b4)/2*L3)+((b4*L4)))/(0.5*L)

Average base Area Ab mm2 672131 bwL

2.0 Cross Sectional Properties and base plan of sleeper

(At Centre) (At Rail Seat)

Figure 3 - Plan of base of sleeper.

Description Notation Unit Value Formula

3.0 Rail Seat Load Calculations

Cracking Cracking Load at Failure

4 Ballast pressure distribution loss of contact condition (α = 0)

5 Loss of Contact condition (α=0)

Moment at rail seat (Tension at

Calculation of Moment for A4 at centre

6.0 Ballast pressure distribution under full contact condition (α = 0.4)

6.1 Full Contact condition (α=0.4)

Ballast pressure p’ p' Mpa 0.541 1000*P/(A4+A5+(0.4*(A6+A7))

Pressure due to axle load, q q 1.757 1000*P/(2*179.07*249.9)

7 Stress Check at Transfer

Stress at transfer of prestressing force

Stress at transfer of prestressing force

Stress at transfer at top of centre of

Stress at transfer at bottom of centre of

7. 1 Stress check at service

Loss due to elastic shortening at rail seat MPa 65.88 m( Pi/Acr+(Pi*〖epr〗^2)/Icr)

Loss due to elastic shortening at centre of

Average loss due to elastic shortening MPa 74.34

8.0 Loss of Pre-stress

Loss of prestress due to shrinkage

Loss of prestress due to relaxation

9.0 Factor of safety against Cracking moment based on Modulus of rupture

Modulus of Rupture 5.42

At rail seat bottom, Cracking moment Mcr kN-m 27.49

At center of sleeper top, Cracking

Factor of safety at rail seat bottom 2.16

10.0 Ultimate Strength Calculation:

(a) Cross section (b) Tensile force in (c) Compressive force

Wire (Stress Relieved), Strands and Bars (Fig. 10)

ULTIMATE MOMENT CAPACITY AT RAIL SEAT

PROPERTIES UNIT RAIL SEAT CENTRE

DESIGN CALCULATIONS FOR 25T AXLE LOAD

DRG NO. RT 7008 (FOR 68 KG RAIL)

1.0 Data & Design Parameters

Description Notation Unit Calculation Formula Remarks

Sleeper Length L mm 2750.00

Description Notation Unit Calculation Formula Remarks

Description Notation Unit Calculation Formula Remarks

Average base width bw mm 244.41 (((b1+b2)/2*L1)+((b2+b3)/2*L2)+((b3+b4)/2*L3)+((b4*L4)))/(0.5*L)

Average base Area Ab mm2 672131 bwL

2.0 Cross Sectional Properties and base plan of sleeper

(At Centre) (At Rail Seat)

Figure 3 - Plan of base of sleeper.

Description Notation Unit Value Formula

3.0 Rail Seat Load Calculations

Cracking Cracking Load at Failure

4 Ballast pressure distribution loss of contact condition (α = 0)

Average base width bw mm 244.41 (((b1+b2)/2L1)+((b2+b3)/2L2)+((b3+b4)/2L3)+((b4L4)))/(0.5*L)

Ballast pressure p’ p' Mpa 0.541 1000P/(A4+A5+(0.4(A6+A7))

Pressure due to axle load, q q 1.757 1000P/(2179.07*249.9)

Average base width bw mm 244.41 (((b1+b2)/2L1)+((b2+b3)/2L2)+((b3+b4)/2L3)+((b4L4)))/(0.5*L)

Ballast pressure p’ p' Mpa 0.541 1000P/(A4+A5+(0.4(A6+A7))

Pressure due to axle load, q q 1.758 1000P/(2179.07*249.9)