SECTION 5

SLEEPERS

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VOLUME 1 JULY 2012 SECTION 5 - SLEEPERS PAGE 5.1

5.0 INTRODUCTION

Sleepers perform the functions of holding the rails to correct gauge and distributing to the ballast the loads imposed on the rails by traffic.

Sleepers are very important components of the track structure and they also represent a considerable proportion of the cost of the track. It is therefore most important to use sleepers correctly and to obtain the maximum life from them.

5.1 TIMBER SLEEPERS

Timber sleepers used in cane railways are cut from Eastern Queensland hardwoods. A section covering the supply of timber sleepers for cane railways can be found in Volume 2, Section 1 of this guide. This section contains guidelines for the dimensions, tolerances, allowable defects and acceptable timber species for sleepers.

5.2 STORAGE AND STACKING OF TIMBER SLEEPERS

New sleepers are usually delivered by the sleeper cutters to the mill yard where they should be uniformly stacked with the heart face downwards so that they can be readily counted and inspected. An air space should be provided to allow the sleepers to season properly and prevent decay. It is better to make small stacks with all sleepers parallel because this saves handling and allows stacks to be moved readily in case of fire. Stacks should be kept clear of grass and undergrowth as a precaution against fire damage. If stacks are likely to remain for some time, they should be placed clear of the ground on old rail bearers to reduce the danger of termite attack.

5.3 MASS OF TIMBER SLEEPERS

The average mass of a 1500 mm x 200 mm x 100 mm timber sleeper is 32 kilograms.

5.4 LIFE OF TIMBER SLEEPERS

Until about 1975 timber sleepers in cane railways had an average life of eight to ten years. However the introduction of stone ballast and better drainage since then has extended the life of good quality timber sleepers to about 16 years.

VOLUME 1 JULY 2012 SECTION 5 - SLEEPERS PAGE 5.2

The life of a sleeper is affected by many factors, the main ones being:

species of timber, quality of the timber in the sleeper, climate, derailment damage, density of traffic, location of sleeper (in curved or tangent track), and preservation treatment used.

5.5 DEFECTIVE SLEEPERS

Sleepers are classed as 'defective' and therefore unsuitable to remain in the track when they can no longer safely carry the loads imposed by rolling stock or are unable to be securely spiked. It is difficult to accurately define when a sleeper is 'defective' and much depends on the experience and judgement of the person making the inspection. In general, the reasons for sleepers becoming 'defective' fall within the following six categories:

1. Perished or decayed. 2. Spike kill or overbored. 3. Split. 4. Rail cut (not usual on cane railways). 5. White ants or other termite attacks. 6. Miscellaneous - includes damage by derailments, bushfires, etc.

It is not necessary to provide for full replacement of 'defective' sleepers and generally a small percentage of defective sleepers could be allowed to remain in the track. The important point to observe is that defective or weak sleepers are well dispersed and the track is kept strong with sufficient sound timbers. New sleepers should be spread throughout a section of track so that the best use is made of the available new timber to maintain the strength of the track at a uniform standard.

More latitude can be allowed in the condition of the sleeper on straight track than on curved track. While some 'defective' sleepers can be permitted in straight track, it is most important that all joint sleepers and all sleepers on curves should be sound. On straight track, defective sleepers should have sound sleepers on either side. Sleepers can be considered 'sound' when they have sufficient strength to withstand the vertical and lateral train forces and provide a good spike hold.

If any section of track contains more than ten per cent defective sleepers consideration should be given to face relaying rather than spot re-sleepering.

VOLUME 1 JULY 2012 SECTION 5 - SLEEPERS PAGE 5.3

5.6 INSPECTION AND CONDEMNATION OF TIMBER SLEEPERS

In arriving at a decision as to whether a sleeper should be 'condemned', the person making the inspection should take into account the volume and mass of traffic carried, train speeds, whether the sleeper is on a straight or a curve, the condition of the formation, species of timber, size and condition of the sleeper, and the condition of the adjoining sleepers. Other relevant matters such as white ant attack and damage from derailments should be given due consideration.

5.6.1 Sleeper Inspection

The inspection of timber sleepers for defects due to traffic and time should include the following:

Visual examination

The general condition of the sleeper should be noted and allowance made for such defects as splits, checks, shrinkage, cracks, rot or other form of decay which would effectively reduce the size, strength and durability of the sleeper. Further detailed information relating to these defects is given in Volume 2, Section 1.

The end of the sleeper should be cleared of ballast to see if termite attack or other defects exist.

Dogspikes testing

The condition of the spiking should be tested by striking spike heads with a light hammer blow. If spikes are loose, fresh holes should be bored to see if the timber is good enough to respike. This should be done if the sleeper is otherwise sufficiently sound. The maximum number of borings a sleeper may have on one side of the rail is three. On no account should spikes which are 'standing up' be simply driven down as this is only waste of time and effort because the spike will quickly return to the 'standing up' position. Levering the end of the sleeper

Sleepers which have badly cut rail seats or which otherwise appear weak should be further tested by levering the end with a pick. If the sleeper cracks or breaks at the rail seat, it must be 'condemned'.

VOLUME 1 JULY 2012 SECTION 5 - SLEEPERS PAGE 5.4

5.7 MARKING OF CONDEMNED SLEEPERS

Sleepers to be removed from track should be marked by any of the following means:

1. 'Nicking' the end of the sleeper with an axe. 2. Painting marks on sleeper or rail. 3. Marking with lumber crayon or other similar means on sleeper or rail.

5.8 GANG NAIL PLATES

Gang nail plates on the ends of timber sleepers are sometimes used to prevent end splits and similar defects either occurring or when present in new sleepers increasing in size.

5.9 CONCRETE SLEEPERS

Concrete sleepers used in cane railways are prestressed, that is, the concrete is in compression resulting from tension in the steel tendon wires. The rails are held to gauge by being attached to the concrete sleeper by clips. Prestressed concrete sleepers for 610 mm gauge are supplied in two lengths, these being 1200 mm and 1370 mm. The 1370 mm sleeper is mainly used for mainline upgrading or construction, programmes where train speeds and traffic densities are higher. Although the shorter 1200 mm long sleeper is still used by some mills for new track construction, 1370 mm long concrete sleepers are now the preferred option for many mills. Where 1370 mm sleepers are used the shorter 1200 mm sleeper used for siding and loop construction, branch line rehabilitation and spot replacement work on mainlines where these sleepers are already in place. The CF2 spike is generally used for this work. Pandrol e 1200 and e 1400 elastic fastening systems (Figure 2.5.2.1) can be fitted to 1200 mm and 1370 mm long sleepers. Pandrol CF2 fastenings are also used by some mills. These CF2 fastenings do not provide any significant toe load. For this reason many mills only use them for sidings and loop construction work. Concrete sleepers can be supplied with cast in shoulders or holes to suite all rail foot sizes for both e series clips and CF2 fastenings.

Concrete sleepers can be purchased from five manufacturers. Tables 5.9.1 to 5.9.7 set out the principal features for sleepers produced by each manufacturer. Although the sleepers are produced for a nominal 610 mm gauge, most 60 lb section rails have foot widths of 102 or 108 mm which means several rail types fit the same sleeper. However differences in head widths frequently result in track gauge wider than nominal. Where possible these increased in gauge have been identified in the actual gauge column of the tables but these figures should be confirmed by the manufacturer before purchase.

Figure 5.9.1 shows the principal dimensions and configuration of each sleeper type.

VOLUME MAY 2007 JULY 2012 SECTION 5 - TRACK MATERIALS PAGE 5.5 PAGE 5.5

Table 5.9.1 Austrak sleepers for Pandrol clips

Gauge Seat width Overall dimension

Width Mass No/ Maker Code Type Nom Actual Pandrol Clip no. mm in Length Top Bottom Depth kg Pallet Rail Type lb/yd

Austrak S102 A 610 610 e1207/e1403 104 4.09 1370 120 200 125 74 24 60NSW 60B

S102 A 610 614 e1207/e1403 104 4.09 1370 120 200 125 74 24 58WAR

S108 A 610 610 e1207/e1403 110 4.33 1370 120 200 125 74 24 60AS 60BHP AS60A AS60B

S108 A 610 615 e1207/e1403 104 4.09 1370 120 200 125 74 24 61(QR)

S108 A 610 618 e1207/e1403 104 4.09 1370 120 200 125 74 24 61SAR

C102 A 610 616 e1207/e1403 104 4.09 1370 120 200 125 74 24 60NSW 60B

C102 A 610 620 e1207/e1403 104 4.09 1370 120 200 125 74 24 58 WAR

C108 A 610 616 e1207/e1403 110 4.33 1370 120 200 125 74 24 60AS 60BHP AS60A AS60B

C108 A 610 621 e1207/e1403 110 4.33 1370 120 200 125 74 24 61(QR)

C108 A 610 624 e1207/e1403 110 4.33 1370 120 200 125 74 24 61SAR

PS83 A 610 613 e1207/e1403 85 3.35 1220 140 200 95 50 30 41¼, 42

PS88 A 610 e1207/e1403 90 3.54 1220 140 200 95 50 30

PS95 A 610 610 e1207/e1403 95 3.74 1220 140 200 95 50 30 45BHP 46¼ WAR

PS102 A 610 610 e1207/e1403 104 4.09 1220 140 200 95 50 30 60NSW 60B

PS102 A 610 614 e1207/e1403 104 4.09 1220 140 200 95 50 30 58WAR

PS108 A 610 610 e1207/e1403 110 4.33 1220 140 200 95 50 30 60AS 60BHP AS60A AS60B

PS108 A 610 615 e1207/e1403 110 4.33 1220 140 200 95 50 30 61(QR?)

PS108 A 610 618 e1207/e1403 110 4.33 1220 140 200 95 50 30 61SAR

PS127 A 610 e1207/e1403 129 5.08 1220 140 200 95 50 30

CT102 A 610 e1401 116 4.57 1220 140 200 95 50 30

CT108 A 610 e1401 122 4.80 1220 140 200 95 50 30

VOLUME MAY 2007 JULY 2012 SECTION 5 - TRACK MATERIALS PAGE 5.6 PAGE 5.6

Gauge Seat width Overall dimension

Width Pandrol Mass No/ Maker Code Type Nom Actual Clip no. mm in Length Top Bottom Depth kg Pallet Rail Type lb/yd

Austrak 60NSW 60B - Insulated IS102 A 610 610 e1401 116 4.57 1370 120 200 125 74 24 Sleepers

60AS 60BHP AS60A AS60B - IS108 A 610 610 e1401 122 4.80 1370 120 200 125 74 24 Insulated Sleepers

60NSW 60B - Insulated IC102 A 610 616 e1401 116 4.57 1370 120 200 125 74 24 Sleepers

60AS 60BHP AS60A AS60B - IC108 A 610 616 e1401 122 4.80 1370 120 200 125 74 24 Insulated Sleepers

Prefix Identification

PS Pandrol shoulder CT Circuited track - Pandrol shoulder S Pandrol shoulder - straight gauge C Pandrol shoulder - curve gauge IS Insulated track - straight gauge IC Insulated track - curve gauge

VOLUME MAY 2007 JULY 2012 SECTION 5 - TRACK MATERIALS PAGE 5.7 PAGE 5.7

Table 5.9.2 Austrak (Mackay) concrete sleepers for CF2 fastenings.

Gauge Seat width Overall Dimensions (mm) Nom No. width nominal actual No. of Mass per Maker Code Type (mm) (mm) Clip type holes (mm) (in) length top bottom depth (kg) pallet Rail type (lb/yd)

Austrak 83-102 610 612 CF2 6 83 3.25 1220 140 200 95 50 30 41¼, 42 .CF2 622 CF2 6 102 4.0 1220 140 200 95 50 30 58 WAR

618 CF2 6 102 4.0 1220 140 200 95 50 30 60 NSW

83-108 610 612 CF2 6 83 3.25 1220 140 200 95 50 30 41¼, 42 .CF2 610 CF2 6 86 3.375 1220 140 200 95 50 30

618 CF2 6 108 4.25 1220 140 200 95 50 30 60 AS

623 CF2 6 108 4.25 1220 140 200 95 50 30 61 (QR)

626 CF2 6 108 4.25 1220 140 200 95 50 30 61 SAR

83-102 1067 1069 CF2 6 83 3.25 1800 180 200 125 102 18 41¼, 42

1079 CF2 6 102 4.0 1800 180 200 125 102 18 58 WAR

1075 CF2 6 102 4.0 1800 180 200 125 102 18 60 NSW

83-108 1067 1069 CF2 6 83 3.25 1800 180 200 125 102 18 41¼, 42

1067 CF2 6 86 3.375 1800 180 200 125 102 18

1075 CF2 6 108 4.25 1800 180 200 125 102 18 60 AS

1080 CF2 6 108 4.25 1800 180 200 125 102 18 61 (QR)

1083 CF2 6 108 4.25 1800 180 200 125 102 18 61 SAR

CF 95 - 1067 1069 CF2 4 83 3.25 41¼, 42 4H 1069 CF2 4 95 3.75 45 R

VOLUME MAY 2007 JULY 2012 SECTION 5 - TRACK MATERIALS PAGE 5.8 PAGE 5.8

Table 5.9.3 Amatek Rocla concrete sleepers for Pandrol clips.

Gauge Overall Dimensions (mm)

nomin Seat width Nom al actual Pandrol clip width Mass No. per Maker Code Type (mm) (mm) type mm length top bottom depth (kg) pallet Rail type (lb/yd)

Amatek 1370/102/54/B58 BTR 610 610 e1207/e1403 Rocla (Mackay) e1207/e1403 102 1350 120 200 125 67 24 60 lb/yd BA or CR Rail 29/32 HD 4" Foot

1370/108/56/B61 “ 610 e1207/e1403 108 1350 120 200 125 67 24 61 lb/yd S.A. Rail 2 3/16" HD 4 1/4 Ft

1370/108/63/B60 “ 610 e1207/e1403 108 1350 120 200 125 67 24 AS60A (60 lb/yd) 2½ HD 4 ¼ Ft

1070/108/63/B61 “ e1207/e1403 108 1350 120 200 125 67 24 AS60B 63 lb/yd) 2½ HD 4 ¼ Ft

1370/129/54H/IN Pandrol 610 e1401 129 1350 120 200 125 67 24 58 lb/yd W.A. Rail Insulated

1370/129/56H/IN “ 610 e1401 129 1350 120 200 125 67 24 61 lb/yd S.A. Rail 23/16" HD 4¼" Foot

1370/129/58H/IN “ 610 e1401 129 1350 120 200 125 67 24 61 lb/yd 25/16" HD 4¼" Foot

e1401

1370/CI/INS/60 BTR C.I. “ e1401 112 1350 120 200 125 67 24 AS60AS (60 lb/yd) Shldr. Insulated

1370/CI/INS/60A “ “ e1401 128 1350 120 200 125 67 24 AS ‘A’ (60 lb/yd)

1370/CI/INS/61 “ “ e1401 118 1350 120 200 125 67 24 (61 lb/yd) 25/16" HD 4¼" Foot

VOLUME MAY 2007 JULY 2012 SECTION 5 - TRACK MATERIALS PAGE 5.9 PAGE 5.9

Table 5.9.4 Amatek Rocla (Mackay) concrete sleepers for CF2 fastenings.

Gauge Overall Dimensions (mm)

No. of width Nom nominal actual Clip cast Mass No. per Maker Code Type (mm) (mm) type holes length top bottom depth (kg) pallet Rail type (lb/yd)

Amatek 1200/610/25-60 C 610 610 CF2 6 1200 140 200 100 47 24 suits 25-60 lb/yd rails Rocla (Mackay) 1200/610/58 C 610 610 CF2 4 1200 140 200 100 47 24 suits 58 lb/yd WAR rails

1200/610/58/45 C 610 610 CF2 6 1200 140 200 100 47 24 suits 58 lb WAR, 45 lb BHP, 46 lb rails

1200/610/60 C 610 610 CF2 4 1200 140 200 100 47 24 suits 60 lb AS rail

1200/610/60/42 C 610 610 CF2 6 1200 140 200 100 47 24 60AS, 42

1200/610/60/45 C 610 610 CF2 6 1200 140 200 100 47 24 60AS, 45BHP, 46

1200/610/BCSR C 610 610 CF2 6 1200 140 200 100 47 24 60BHP 60NSW, 42

1200/610/63 C 610 610 CF2 4 1200 140 200 100 47 24 AS60B (63 lb/yd) 2½ HD 4 ¼ Ft

1200/610/45 C 610 610 CF2 4 1200 140 200 100 47 24 45

1200/610/60/45 C 610 610 CF2 4 1200 140 200 100 47 24 46¼

VOLUME MAY 2007 JULY 2012 SECTION 5 - TRACK MATERIALS PAGE 5.10 PAGE 5.10

Table 5.9.5 Isis Mill concrete sleepers for Pandrol fastenings.

Gauge Seat width Overall Dimensions (mm)

width Nom Maker’s nominal actual Pandrol Mass No. per Maker Code Type (mm) (mm) Clip No. (mm) (inches) length top bottom depth (kg) pallet Rail type (lb/yd)

Isis Mill V B 610 610 e1209 82.5 3.25 1350 120 195 125 63 25 41¼, 42

I B 610 610 e1209 92.1 3.625 1350 120 195 125 63 25 45

B B 610 610 e1209 101.6 4.00 1350 120 195 125 63 25 58WAR 60B

C B 610 610 e1209 104.8 4.125 1350 120 195 125 63 25 60AS

O B 610 610 e1209 111.1 4.375 1350 120 195 125 63 25 60

T B 610 610 e1209 127 5.00 1350 120 195 125 63 25 80

U B 610 610 e1209 139.7 5.50 1350 120 195 125 63 25 90

VOLUME MAY 2007 JULY 2012 SECTION 5 - TRACK MATERIALS PAGE 5.11 PAGE 5.11

Table 5.9.6 Tully Mill concrete sleepers.

Gauge Seat width Overall Dimensions (mm)

No. of width Nom nominal actual Clip cast Mass No. per Maker Code Type (mm) (mm) Type (mm) (in) holes length top bottom depth (kg) Bundle Rail type (lb/yd)

Tully Mill 6045* C 610 610 CF2 95 3¾ 6 1220 120 180 96 47 40 45

5 C 612 CF2 110 4 /16 6 1220 120 180 96 47 40 60

4260 C 610 610 CF2 83 3¼ 6 1220 120 180 96 47 40 41¼ 42

C 610 CF2 108 4¼ 6 1220 120 180 96 47 40 60 AS

C 610 610 CF2 108 4¼ 4 1220 120 180 96 47 40 60 AS

C 610 610 CF2 102 4 4 1220 120 180 96 47 40 60 B

C 610 612 CF2 108 4¼ 4 1220 120 180 96 47 40 60 WAR, 60 SAR

*Production discontinued

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Table 5.9.7 Milltrack NQ (Proserpine) concrete sleepers for Pandrol fastenings.

Gauge Seat width Overall Dimensions (mm)

width Nom Maker’s nominal actual Pandrol Mass No. per No. Maker Code Type (mm) (mm) Clip No. mm ins length top bottom depth (kg) pallet Rail type (lb/yd)

1 Milltrack N.Q. B 610 610 e1209 110 4.33 1350 120 195 125 62 25 AS60 (Proserpine) 2 B 610 610 e1209 102 4.01 1350 120 195 125 62 25 AS60

3 B 610 610 e1209 95 3.74 1350 120 195 125 62 25 45WAR

4 B 610 610 e1209 85 3.35 1350 120 195 125 62 25 42

5 B 610 610 e1209 170 6.69 1350 120 195 125 62 25 AS60

6 B 610 610 e1209 170 6.69 1350 120 195 125 62 25 AS60

7 B 610 610 e1209 150 5.90 1350 120 195 125 62 25 60SAR

8 B 610 610 e1209 150 5.90 1350 120 195 125 62 25 60SAR

Notes: No. 5 sleepers have 2 x 170 mm wide seats for parallel mechanical joints in AS60 rail. Clip locates on top of fish plate. No. 6 sleepers for 60AS rail have 1 x 110 mm and 1 x 170 mm wide seats for use in curves. Joint on 1 rail. No. 7 Sleepers have 2 x 150 mm wide seats for use at joints (60SAR rail). No. 8 Sleepers have 1 x 110 mm and 1 x 150 mm wide seat (60SAR rail).

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