The modest appearance of a concrete sleeper does not readily show the enormous static and dynamic loads that these track components must withstand. Additional loads result from the great number of load cycles of train axles that pass overhead, often associated with irregular conditions of use: e.g., by non-exact train wheel running surfaces, as well as poor track bed conditions. At any rate, operational safety must be assured. This is possible by the planning reserves designed into the components, as well as the extraordinarily great safety redundancy of the railway track.
For the planner, this signifies sleeper design that fully satisfies requirements, with required computer-aided verification, in additional to practical prototype tests in accordance with the applied standards. Long years of experience and insights from practical operations are powerful supports for our work here.
Beijing: acceptance procedure of quad-moulds for prestressed-concrete sleepers, at the plant of the manufacturer Hanghua Xing Metal Structure Factory
The steel moulds for the production of prestressed-concrete sleepers, and of other special sleepers, are extremely demanding production components. The special challenges encountered by the manufacturers of these welded components include great prestressing forces up to more than 600 kN, with simultaneous dynamic introduction of forces during the vibratory step, and observance of geometric exactness of only a few tenths of millimetres tolerance.
In the planning of a production plant for one or more sleeper designs, a great number and variety of requirements must be considered – which must be investigated and evaluated for each individual case.
The planning and construction of new production plants can represent a very extensive effort – but one which is usually highly effective for major projects or new railway networks (for example, in remote areas of a country). In addition to sleeper design, output capacity of the plant and production engineering standards, external criteria must also be considered: supply of media, transport routes, and the logistic prerequisites for future installation of the track: And: planning should allow a maximum of flexibility in location optimization or possible later transfer of production locations – all with a minimum of production interruption.
According to a specific project, completely mobile production plants can represent the most effective solution. Such solutions are indeed possible. To ensure good production quality, however, one restriction must be taken into account: the output of such a plant should not exceed approx. 100,000 sleepers per year.
Modifications to existing production plants – for example, for adaptation to new sleeper types – logically is considerably simpler, since planning would be restricted to modification of individual plant components. For all these tasks, Bachmann Consult offers the required desktop design services, as well as local location analyses and project management in the construction of new plants.
India in 2010: construction of an additional production facility with a new plant for the manufacture of prestressed-concrete sleepers in the mid-performance range, and with longline prestressing bed technology.
Our many years of mutually satisfying collaboration with selected international partners mean that we can create not only the necessary sleeper design, but can also procure the required materials and equipment that combine a maximum of quality expectations and cost-effectiveness.
Bachmann Consult supports sleeper manufacturers in the production and delivery of steel moulds and other production plant components for a range of production technologies: for small plants or high-performance facilities.
India in 2009: construction of a new plant for production of prestressed-concrete sleeper, in the mid-performance range, and with longline prestressing bed technology.
Various types of concrete reinforcing steel are used on the international sleeper market. Our prominent Chinese partner manufactures 500,000 tonnes of reinforcement annually. Their extensive product portfolio is manufactured on the basis of the respective international standards and directives.
For manufacture of special products such as bi-block sleepers for ballastless track, we use lattice-girder reinforcement steel. For products with variable dimensions, we also deliver machines for their manufacture.
Track systems planning:
Value engineering and project management
Railway track design and dimensioning
Product design and production plant planning
Procurement and erection
Damage assessment and repair
Local project management
Design and engineering services
for construction projects
Sleeper design and Production plant planning
International procurement of
Material, components, and equipment