RIVAS Railway Induced Vibration Abatement Solutions

80 Pages·2014·7.67 MB·English

by  Mads Bergendorff

RIVAS
SCP0-GA-2010-265754

RIVAS
Railway Induced Vibration Abatement Solutions
Collaborative project

RESULTS OF LABORATORY TESTS FOR BALLASTED TRACK MITIGATION
MEASURES
CEDEX TRACK BOX TESTS

Deliverable D3.7 (PART A)

Submission date: 07/06/2013

Project Coordinator:
Bernd Asmussen
International Union of Railways (UIC)
[email protected]

RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page I of IV 07/06/2013
RIVAS
SCP0-GA-2010-265754

RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page II of IV 07/06/2013
RIVAS
SCP0-GA-2010-265754

Title Results of laboratory tests for ballasted track mitigation measures
mCEeDasEuXre tsraCcEkD bEoXx CteCsEtsD EX

Domain WP3,Task 3.2

Date 07/06/2013

Author/Authors V. Cuéllar, J. Estaire, F.Navarro, M.A. Andreu, M.Rodríguez, A. Andrés
AWn.d Rreüsc kWer.,R Eü.c kBeorn, gEin.Bi,o An.g Piniei ringer, R. Garburg, F. Baldrick

E. Knothe, S. Schwieger, L. Auersch, H. Flöttmann
CEDECEDEX
Partner CEDEX
Document Code RIVAS_CEDEX_ WP3_D3_7_ V01
Version 2
Status 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) x
CO Confidential, only for members of the consortium (including the Commission Services)

Document history
Revision Date Description
1 03/06/2013 First Draft
2 07/06/2013 Final Version

RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page III of IV 07/06/2013
RIVAS
SCP0-GA-2010-265754

RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page IV of IV 07/06/2013
RIVAS
SCP0-GA-2010-265754

TABLE OF CONTENTS

TABLE OF CONTENTS ............................................................................................................. 1
EXECUTIVE SUMMARY ............................................................................................................ 3
1 INTRODUCTION .................................................................................................................. 5
2 CEDEX TRACK BOX ........................................................................................................... 7
2.1 Description ................................................................................................................... 7
2.2 Capacity to simulate the track effects of vertical loads moving horizontally ................... 9
2.3 Sensor system ............................................................................................................ 11
2.3.1 Introduction ..................................................................................................... 11
2.3.2 External System .............................................................................................. 12
2.3.3 Internal System ............................................................................................... 20
2.4 Acquisition and measuring systems ............................................................................ 26
3 PHYSICAL MODEL PROPERTIES .................................................................................... 27
4 LOADING TIME HISTORIES .............................................................................................. 33
4.1 Introduction ................................................................................................................. 33
4.2 Quasi-static loads ....................................................................................................... 33
4.3 Dynamic loads ............................................................................................................ 33
5 TRACK SYSTEMS AND BALLAST STATES TESTED ....................................................... 45
5.1 Introduction ................................................................................................................. 45
5.2 Spanish track components .......................................................................................... 46
5.3 German track components .......................................................................................... 51
6 TESTS PERFORMED ........................................................................................................ 55
6.1 Introduction ................................................................................................................. 55
6.2 Receptance test .......................................................................................................... 55
6.2.1 High frequency tests ........................................................................................ 56
6.2.2 Low frequency tests ........................................................................................ 60
6.3 Static tests .................................................................................................................. 61
6.4 Quasi-static tests ........................................................................................................ 62
6.4.1 Long lasting test .............................................................................................. 62
6.4.2 Short lasting tests ............................................................................................ 63
6.5 Dynamic short lasting insertion loss tests ................................................................... 64
7 RESULTS OBTAINED ........................................................................................................ 67
7.1 Introduction ................................................................................................................. 67
RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 1 of 241 07/06/2013
RIVAS
SCP0-GA-2010-265754

7.2 Track receptance tests ............................................................................................... 67
7.3 Static tests .................................................................................................................. 80
7.4 Quasi static long lasting test ....................................................................................... 88
7.5 Track systems insertion loss ....................................................................................... 97
REFERENCES ....................................................................................................................... 111

APPENDIX 1: CEDEX RAIL PAD TESTS…………………………………………………………..113

APPENDIX 2: TRACK RECEPTANCE CURVES………………………………………………....119

APPENDIX 3: INSERTION LOSS GRAPHS…………………………………………………........181

RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 2 of 241 07/06/2013
RIVAS
SCP0-GA-2010-265754

EXECUTIVE SUMMARY

Task 3.2 of work package 3 (WP3) in the EU FP7 project RIVAS focusses on vibration
mitigation measures for ballasted track by optimizing rail fastening system, sleeper and
sleeper/substructure interaction. Also promotes innovative solutions by combining computer
simulation, laboratory tests and field tests.

Concerning the optimisation of the sleeper and the sleeper/substructure interaction, a prototype
sleeper provided with hard rail pads and a soft under-sleeper pad has been manufactured and
delivered by RAILONE to CEDEX to be tested in its big dimension track box under realistic
conditions (i.e. realistic traffic scenarios with different speeds). The new sleeper is a mono-bloc
concrete pre-stressed B90.2 model having a mass of 610 kg and approximately the same
dimensions that standard mono-bloc sleepers.

The objective of this deliverable 3.7 (Part A) has been the presentation in a comprehensive way
of the results obtained in the tests run for the RIVAS project in CEDEX track box.

Among the different types of test performed, those carried out to shed light on the vertical
vibration insertion loss capacity of the new type of sleepers compared with standard sleepers
have received special attention.

To carry out the insertion loss tests, 13 units of the B90.2 sleeper type have been installed in
the central zone of the track box replacing the same number of standard sleepers that having
been also tested under the same testing and ballast conditions have been considered as a
reference for comparative purposes.

Accordingly, constant high amplitude quasi-static load time histories, with frequencies according
to the geometric distribution of axles and bogies in EU trains travelling at 300 km/h and 120
km/h, have been generated in the track box using a set of computer controlled 250 kN and 50
Hz servo-hydraulic cylinders. The combination of a couple of such cylinders, one on each rail,
with two 20 kN and 300 Hz piezoelectric shakers, has also enabled the setting up in the track
box of the variable low amplitude dynamic load time history generated by the passage of an EU
freight vehicle travelling at 120 km/h over the vertical irregularities of a given track.

For each one of those quasi-static and dynamic vertical vibration sources, velocity and
acceleration insertion losses have been determined in the track superstructure elements (rail,
sleeper, ballast) and substructure components (subballast, form layer, upper and lower
embankment) in short lasting tests. Additional data provided by two 1Hz geophones deployed at
the foundation of the track box have been also used.

To characterize the track and ballast conditions under which the insertion loss tests were
performed, other track receptance and static loading tests have been carried out in the central
zone of the track box. They have also provided data enabling the comparison of the insertion
loss results obtained in the track box with those provided by EIFFAGE rig tests, and other in situ
data collected in experimental sites having the same track systems.

Also, one long lasting quasi-static test has been run with the new sleepers so that the results
obtained can be compared with those provided by a previous test of the same type, run in
CEDEX track box outside of the RIVAS project, with standard sleepers. In those tests, an
accelerated loading process was implemented simulating the passage over 7 consecutive
RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 3 of 241 07/06/2013
RIVAS
SCP0-GA-2010-265754

sleepers of 2 M freight vehicle axle loads at a travelling speed of 120 km/h. For both sleeper
configurations, the amplitudes of: rail deflections, rail pad and ballast compressions, velocities
and accelerations of the different track superstructure and substructure elements, generated
along such a loading process have been recorded. The evolution with the number of axle load
applications of the ballast irreversible compressions obtained in the test (ballast fatigue curve)
has been also obtained.

In chapter 2 of the present report, the CEDEX track box and its capacity to simulate the track
effects of vertical loads moving horizontally are described. The sensor systems used in the tests
and the data acquisition and measuring systems employed are also described in that chapter.

In chapter 3, the properties and dimensions of the physical model used to run the tests are
presented. That model represents, at 1:1 scale, a cross section of the Madrid-Barcelona high
speed line with an embankment 2.5 m high. The static track stiffness measured in the model
with standard sleepers ranged between 100 and 150 kN/mm.

In chapter 4, the quasi-static and dynamic load time histories previously cited are defined and
the process adopted to derive the PSD function for the dynamic forces is fully explained.
Besides, the track vertical irregularity PSD function selected has been compared with those
suggested by ORE.

In chapter 5, the track systems and ballast states analysed, to assess the insertion losses
induced in the different track superstructure and substructure elements by the new sleepers
compared with the standard sleepers, are introduced. Reference is made in that chapter to
Appendix 1 in the document, where the results obtained in the compression tests made in
CEDEX with the two types of rail pad used in the track box tests have been collected. Also a
reference is made to part B of deliverable 3.7 where the results of the tests made by BAM to
characterise the mechanical behaviour and properties of the new sleepers and under-sleeper
pads are reported

In chapter 6, the types of test performed are described and the testing routine adopted for each
one of them is identified.

In chapter 7, the results obtained in the different tests performed for the RIVAS project are
presented. A series of tables have been produced summarizing the comparative study of the
track receptance functions made in Appendix 2, where the receptance curves obtained with
different procedures are gathered. Also a family of tables compiling the velocity and
acceleration one-third octave band insertion loss values, provided in Appendix 3 for different
vibration sources, are given. The results provided by the static tests and the long lasting quasi-
static test have been condensed in tables and figures.

Although many of the figures and tables given in chapter 7, comparing the results obtained in
the different tests performed, may be considered as conclusive, no formal conclusions have
been included in this report. After those results have been properly discussed, on the light of the
information provided in other RIVAS documents, and compared with the data obtained in other
rig and in situ tests, conclusions suitable to be inserted in RIVAS final reports will be drawn.

RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 4 of 241 07/06/2013
RIVAS
SCP0-GA-2010-265754

1 INTRODUCTION

In the framework of the EC FP7 project Railway Induced Vibration Abatement Solutions
(RIVAS) work package 3 (WP3) deals with track vibrations at source and the mitigation
measures at the track itself. Within that work package, Task 3.2 focusses on vibration mitigation
measures for ballasted track by optimizing rail fastening system, sleeper and
sleeper/substructure interaction.

Concerning the optimisation of the sleeper and the sleeper/substructure interaction, 13 units of
a prototype sleeper with hard rail pads and soft under-sleeper pads have been manufactured
and delivered by RAILONE to CEDEX to be tested under realistic conditions (i.e. realistic traffic
scenarios with different speeds) in its big dimension track box.

The main objective of the short lasting insertion loss tests performed in the track box has been
to shed light, under well defined track substructure conditions and a good testing control
system, on the vertical vibration insertion loss capacity of the new sleepers as compared with
the standard sleepers.

To that aim, constant high amplitude quasi-static load time histories, with frequencies according
to the geometric distribution of axles and bogies in EU trains travelling at 300 km/h and 120
km/h, have been generated in the track box using a set of computer controlled 250 kN and 50
Hz servo-hydraulic cylinders.

For the generation of a variable low amplitude high frequency dynamic load time history,
simulating the passage of an EU freight vehicle travelling at 120 km/h over the track vertical
irregularities of a given track, a couple of servo-hydraulic cylinders, one on each rail, has been
used in conjunction with two 20 kN and 300 Hz piezoelectric shakers.

Besides the short lasting insertion loss tests run with the two types of vibration source
mentioned above, other receptance and static loading tests have been carried out to
characterize the track systems and ballast states used. Also a long lasting quasi-static test with
2M freight vehicle axle loads has been performed.

In chapter 2, the CEDEX track box and its capacity to simulate the track effects of vertical loads
moving horizontally are described. The sensor systems used in the tests and the data
acquisition and measuring systems employed are also described in that chapter. In chapter 3,
the properties and dimensions of the physical model used to run the tests are presented. In
chapter 4, the quasi-static and dynamic load time histories previously cited are defined and the
process adopted to derive the PSD function of the dynamic forces is fully explained. In chapter
5, the track systems and ballast states analysed are described and reference is made to
Appendix 1 where the results of the compression tests made in CEDEX with the two types of rail
pad used are collected. In chapter 6, the types of test performed are described and the testing
routine adopted for each one of them is identified. Finally, in chapter 7 the results obtained in
the different tests performed for the RIVAS project are presented. A series of tables have been
produced summarizing the comparative study of the track receptance functions obtained with
different procedures (Appendix 2) and the velocity and acceleration insertion losses achieved in
the track elements with different vibration sources (Appendix 3). The results provided by the
static tests and the long lasting quasi-static test have been also condensed in tables and
figures.

RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 5 of 241 07/06/2013
RIVAS
SCP0-GA-2010-265754

RIVAS_CEDEX_WP3_D3_7_PART_A_FINAL Page 6 of 241 07/06/2013