TB/T 3080-2014 English PDF (TBT3080-2014)

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TB/T 3080-2014: Concrete turnout sleeper for ballasted track
TB/T 3080-2014
TB
RAILWAY INDUSTRY STANDARD OF
THE PEOPLE’S REPUBLIC OF CHINA
ICS 45.080
S 11
Replacing TB/T 3080-2003
Concrete turnout sleeper for ballasted track
有砟轨道混凝土岔枕
ISSUED ON: DECEMBER 25, 2014
IMPLEMENTED ON: MAY 01, 2015
Issued by: Ministry of Railway of PRC
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative references ... 4
3 Technical requirements ... 4
4 Inspection method ... 10
5 Inspection rules ... 11
6 Sign and storage and transportation ... 13
Appendix A (Normative) Measuring method for camber of turnout sleepers ... 14
Concrete turnout sleeper for ballasted track
1 Scope
This standard specifies the technical requirements, inspection methods, inspection rules,
signs, storage and transportation of prestressed concrete turnout sleepers for ballasted
tracks.
This standard applies to prestressed concrete turnout sleepers for ballasted tracks
(hereinafter referred to as turnout sleepers).
2 Normative references
The following documents are essential to the application of this document. For the dated
documents, only the versions with the dates indicated are applicable to this document;
for the undated documents, only the latest version (including all the amendments) is
applicable to this standard.
GB 1499.1 Steel for the reinforcement of concrete - Part 1: Hot rolled plain bars
GB/T 5223 Steel wires for the pre-stressing of concrete
TB 10424 Standard for constructional quality acceptance of railway concrete
engineering
TB 10425 Standard for check and accept of railway concrete strength
TB/T 1878 Fatigue test method for prestressed concrete sleepers
TB/T 1879 Static load crack resistance test method for prestressed concrete sleepers
TB/T 3275 Railway concrete
TB/T 3300 Prestressed concrete sleeper for ballasted track of high-speed railway
YB/T 5294 Low carbon steel wire for general uses
3 Technical requirements
3.1 General requirements
3.1.1 Turnout sleepers shall be manufactured, according to the design drawings
approved by the prescribed procedures and this standard.
3.1.2 Turnout sleepers shall be produced in a factory; the factory shall have the
necessary tooling equipment and mature production technology.
3.2 Materials
3.2.1 Aggregate shall have a re-inspection report for entering the factory. The other raw
materials and embedded parts shall have the manufacturer's delivery certificate and re-
inspection report.
3.2.2 The cement shall be Portland cement or ordinary Portland cement. The strength
grade of cement shall not be lower than 42.5; early-strength cement shall not be used;
the alkali content shall not exceed 0.60%; the sulfur trioxide content shall not exceed
3.0%; the specific surface area shall be 300 m2/kg ~ 350 m2/kg. Other technical
requirements shall comply with the provisions of TB/T 3275.
3.2.3 Coarse aggregates shall be continuously graded crushed gravels of 5 mm ~ 20
mm; crushed pebbles shall not be used. Other technical requirements shall comply with
the provisions of TB/T 3275.
The fine aggregate is natural medium-coarse river sand. The mud content shall not be
greater than 1.5% by mass. Other technical requirements shall meet the requirements
of TB/T 3275.
Aggregates, which have alkali-carbonate reactivity or alkali-silicic acid reactivity by a
mortar bar expansion (rapid method), greater than or equal to 0.20%, shall not be used.
Before the turnout sleeper is put into production, the source of the aggregate is changed,
OR the aggregate has been used for one year, the alkali activity of the aggregate shall
be tested and evaluated by an inspection organization, which has corresponding
qualifications, according to the method specified in TB/T 3275.
3.2.4 The mixing water shall comply with the relevant provisions of TB/T 3275.
3.2.5 The water reducing agent shall comply with the relevant provisions of TB/T 3275.
3.2.6 Mineral admixtures shall comply with the relevant provisions of TB/T 3275.
3.2.7 Steel materials for turnout sleepers shall meet the following requirements:
a) The prestressed steel wire shall comply with the provisions of GB/T 5223;
b) When low-carbon steel hot-rolled smooth round steel bar is used for the stirrup,
its performance shall meet the requirements of GB 1499.1; when low-carbon
cold-drawn steel wire is used, its performance shall meet the requirements of
YB/T 5294 and the steel used shall not be lower than Q235;
c) Low-carbon cold-drawn steel wire is used for the spiral reinforcement; its
performance shall meet the requirements of YB/T 5294.
3.2.8 The embedded parts in the turnout sleeper shall meet the relevant technical
requirements.
3.2.9 Unless otherwise specified, the storage and use of cement, mineral admixtures,
coarse aggregate, fine aggregate, water reducer shall comply with the provisions of
TB/T 3275. The storage and use of steel shall comply with the provisions of TB 10424.
3.3 Manufacturing
3.3.1 The prestressed steel wire shall be stretched by automatic tensioning equipment;
the tensioning equipment shall be inspected and calibrated regularly. Tensile force shall
comply with the design requirements. When the design does not specify the deviation
of the initial tension force, the deviation shall not be greater than 1.5% of the design
value.
Prestressed steel wires shall be uniformly stressed, when cutting, grouping, stretching
prestressed steel bars. When the long-line pedestal method is used for production, a
single partial tensioning process shall be adopted; the absolute deviation of the prestress
between the same sleeper's prestressed steel wires shall not be greater than 5%. When
the flowline machine set method is used for production, the cutting deviation of steel
wire shall be not more than 1.5/10000 of the steel wire length; meanwhile, the
maximum difference of the cutting length of the same group of steel wire shall be not
more than 2 mm.
The tensioning of the prestressed steel wire shall be carried out in accordance with the
procedure of: 0 → Initial tension force → Hold the load for 1 min → Increase
tension to initial tension → Lock nut.
3.3.2 The concrete mix ratio shall be determined by factory tests. The amount of
concrete cementitious material shall not exceed 500 km/m3.
Concrete mixing shall use a forced mixer. The mixing time and material measurement
error shall meet the requirements of TB/T 3275.
The temperature of the steel mold shall be 5 °C ~ 35 °C. The temperature of the concrete
entering the mold shall be 5 °C ~ 30 °C.
The forming operation of the turnout sleeper shall be carried out on the forming
equipment; the concrete shall be ensured to be dense.
3.3.3 When natural curing is used for the turnout sleeper, it shall be carried out
immediately after vibration molding; meanwhile the concrete shall be covered with
direct moisture-retaining materials. The difference -- between the concrete temperature
of the sleeper core and the surface concrete temperature of the turnout sleeper -- shall
not be greater than 15 °C; the ambient temperature for starting curing shall be 5 °C ~
the surface, which is caused by shrinkage or stress.
3.4.10 The installation holes of switchover equipment shall meet the design
requirements; the anti-rust and anti-blocking measures shall be taken.
4 Inspection method
4.1 In addition to the visual inspection of the surface appearance, the external
dimensions and appearance quality of the turnout sleeper shall be tested, using general