Engineering Standard Track

ESC 240 BALLAST

Version 2.2 Issued August 2011

Owner:

Chief Engineer Track Andrew Wilson Technical Specialist Wheel/Rail Authorised by: Malcolm Kerr Chief Engineer Track

Approved by:

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document users sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp

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Engineering Standard Engineering Standard

RailCorp Engineering Standard Track Ballast

ESC 240

Document control
Revision 2.2 2.1 2 1 Date of Approval August, 2011 December, 2009 October, 2007 October, 2006 Summary of change Changes detailed in Summary table below Format change only Revision of ramp requirements for change of formation level below turnouts First issue as a RailCorp document. Includes content from TS 3101, TS 3402, RTS.3430, CTN 04/09.

Summary of changes from previous version

Section Document Control 4.2.8 Control changes New section - Moderating track stiffness. Addition of guidelines for use of ballast mat on rigid support. Summary of change

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Contents
1 2 Purpose, Scope and Application ............................................................................................................ 4 References ................................................................................................................................................ 4 2.1 2.2 2.3 2.4 3 3.1 3.2 4 4.1 4.2 5 5.1 5.2 5.3 5.4 6 6.1 6.2 6.3 7 Australian and International Standards ......................................................................................... 4 RailCorp Documents ..................................................................................................................... 4 Other References .......................................................................................................................... 4 Definitions ...................................................................................................................................... 4 Track configuration ........................................................................................................................ 4 Ballast design criteria .................................................................................................................... 4 Ballast material and grading .......................................................................................................... 5 Ballast profile ................................................................................................................................. 5 Ballast material and grading ........................................................................................................ 10 Crib and shoulder height ............................................................................................................. 10 Ballast shoulder width.................................................................................................................. 10 Ballast depth ................................................................................................................................ 11 Contamination ............................................................................................................................. 11 Strength/stiffness......................................................................................................................... 11 Profile........................................................................................................................................... 11

Design & Performance Criteria ............................................................................................................... 4

Approved configurations......................................................................................................................... 5

Acceptance Standards........................................................................................................................... 10

Damage Limits ........................................................................................................................................ 11

Repair standards .................................................................................................................................... 11

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Purpose, Scope and Application

This Standard establishes functional and design requirements, approved configurations, acceptance standards, damage limits and repair standards for rail ballast. It is applicable to all RailCorp main line and siding tracks and shall be applied to the design of new trackwork, track renewal, reconditioning and ballast cleaning.

2
2.1

References
Australian and International Standards
AS 2758.7-1996: Aggregates and rock for engineering purposes Part 7: Railway Ballast

2.2

RailCorp Documents
ESC 200 - Track System ESC 310 - Underbridges SPC 241 - Ballast Specification

2.3

Other References
Nil

2.4

Definitions
Ballast : Ballast is a free draining coarse aggregate or metallurgical slag used to support railway tracks. The designation of an aggregate which gives an indication of the largest size particle present.

Nominal Size :

3
3.1

Design & Performance Criteria

Track configuration
The configuration of track elements, including ballast, is specified in ESC 200 Track System.

3.2

Ballast design criteria

The ballast material design and track cross-sectional ballast profile in this standard have been developed in consideration of the following criteria: Loading Service loads including effects of track alignment, maintenance standards, and traffic task.

Materials Ballast consolidation requirements.

Interfaces with other rail infrastructure Sleeper material, type and spacing. Electrical properties in track circuited areas.

Support Requirements
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Required track modulus. Track support conditions and deflection criteria. Track formation material and condition.
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Performance requirements The need to interlock sufficiently to provide resistance against excessive vertical, lateral (buckling of the track) and longitudinal movement of sleepers and bearers. The need to reduce excessive loading and failure of the track formation. The need to provide adequate drainage of the track structure to the cess and allow fines to migrate out. The need to be durable enough to resist crushing when subjected to the nominal loadings

4
4.1

Approved configurations
Ballast material and grading
Ballast grading shall be either "Standard" or "Fine" in accordance with the existing or proposed track structure class detailed in RailCorp standard ESC 200 and as detailed in Table 1. For existing applications, detailed in ESC 200, all ballast shall meet the material and grading requirements of RailCorp Specification SPC 241. Alternative gradings (either as specified in AS 2758.7, or specifically designed) to meet special requirements (eg special gradings necessary in conjunction with reduced ballast depth) must be approved by the Chief Engineer Track. Ballast Grade Standard Sieve size (mm) 60 (graded ballast) 100 85 100 50 70 20 35 10 20 2 10 05 02 Table 1 - Ballast grading Fine 50 (graded aggregate) 100 70 100 40 60 20 30 10 20 5 - 10 Nominal size (mm)

% passing by mass 63.0 53.0 37.5 26.5 19.0 13.2 9.50 4.75 2.36

4.2

Ballast profile
A typical track cross-section illustrating ballast profile is shown in

Figure 1.

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Ballast Shoulder Width Sleeper Ballast Shoulder Height Slope 1 Ballast

Formation

Ballast Depth

Figure 1 - Typical track cross-section and ballast profile

4.2.1

Shoulder Height
Ballast shoulder height (the distance from sleeper soffit to the under side of the rail) is determined by the sleeper design. The ballast shall be profiled to the top of the end of the sleepers. Depending on the sleeper design, the rail seat area may be higher than the centre and ends.

4.2.2

Crib Height
The ballast shall be profiled to the top of the centre of the sleepers.

4.2.3

Shoulder Slope
For freestanding ballast, the slope of the ballast shoulder is assumed to be 1:1.5 (height:width)

4.2.4

Shoulder Width
The minimum shoulder distance is determined by the track stability requirements of rail length. The requirements for current applications are detailed in Table 1. Design Ballast shoulder width (mm) Minimum Main line CWR and LWR Siding CWR and LWR Loose Rail 400 300 700 700 400 700 Maximum

Operating Class

Table 2 - Ballast Shoulder widths Ballast Shoulder width is measured from the extreme end of the sleeper, not the visible end when the track is fully ballasted. Design ballast shoulder width is one factor that contributes to overall track lateral stability. Additional ballast shoulder width above the minimum and a ballast windrow up to rail height outside the sleeper may be necessary in areas of poor track lateral stability to provide adequate resistance to track buckling on sharp curves where design radius is outside normal limits.

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Rail Level

Location of ballast windrow

Gauge Face

Figure 2 - Location of ballast windrow

4.2.5

Ballast depth
Ballast depth is the distance from the underside of the sleeper to the top of the finished formation. On superelevated track, the depth of ballast is measured from under the low rail. Ballast depth shall be either "High" or "Medium" or "Low" in accordance with the existing or proposed track structure class detailed in RailCorp standard ESC 200 and as detailed in Table 3 and Table 4. Design Ballast depth(mm) Minimum High Medium Low H M L L(150) L(100) L(Nom) 350 300 250 150 100 Nominal Maximum 500 500 500 500 500 500

Category

Table 3 - Ballast depth categories New Operating Class Sleeper type Main line Passenger Main Line Medium duty concrete Heavy duty concrete Mixed Passenger Freight Main Line Light Line Medium duty concrete Heavy duty concrete NA H L Timber L Ballast depth
(Note 3)

Existing Sleeper type Ballast depth

(Note 1, 2)

Timber Timber Heavy duty concrete

M L H

Heavy Freight Option Heavy duty concrete Sidings General Yard(1) Passenger operations/ or maintenance
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Medium duty concrete Medium duty concrete

L L

Timber Timber

L(150) L(150)

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New Operating Class Sleeper type Passenger Siding Engineering Maintenance Siding Timber Timber Ballast depth
(Note 3)

Existing Sleeper type Timber Ballast depth

(Note 1, 2)

L(100)

L(100) L(Nom)

L(Nom) Timber Table 4 - Ballast height

Note 1:

2: 3:

Full ballast depth in existing track includes ballast that is not free draining Free draining ballast may include ballast with fines such as sand, brake dust and other fine material that does not restrict water flow. Existing track may not necessarily achieve the target ballast depth. Use of the design ballast depths with poor subgrades may still cause the subgrade to be over stressed. Detailed investigation and analysis of the whole track structure including the substructure condition may be necessary in these problem situations. It can equally be demonstrated that in areas with very good subgrades (natural or designed) it is possible to provide adequate support to the track structure with lower ballast depths than those specified in Table 4. The design ballast depth is based on the formation design model detailed in Section 4.2.6.

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Through turnouts the minimum ballast depth under turnout bearers is to be maintained by lowering the formation level as required. The change in level of the formation is to be ramped off as follows: Turnout installation or replacement where adjacent track is also being installed or reconstructed where major track reconstruction is not being undertaken Maximum grade (relative to the track grade) 1 in 200 1 in 20

4.2.6

Formation Basic design model

The basic design model for ballast depth is based on the following formation strength. Top of formation - CBR >8 Capping layer of 150mm thickness - CBR >50

H=500 to 1000mm

Capping 150mm CBR>50, Compaction 100% Standard

Base of excavation

H=500 if insitu material CBR=3 to 8 H=1000 if insitu material CBR=1 to 3

Structural Fill Compacted to 100% Standard Compaction

CBR>8

Figure 3 Track Formation - Basic Design Model

4.2.7

Alternative Ballast Profiles

The following alternative ballast profile designs may be adopted: 1. Ballast shoulder width may be reduced to a minimum of 75mm provided that: 2. 3. lateral restraint, such as a retaining wall, is provided. The additional lateral restraint shall be at least equivalent to the restraint provided by the missing shoulder ballast. arrangements are made for drainage of water from the formation.

Ballast shoulder width may be increased (eg for walkways or examination areas) provided that alternative arrangements are made for drainage of water from the formation. Ballast depth may be reduced provided that measures are included to provide strength and durability at least equivalent to the approved design measures are included to provide stiffness no less than the approved design (eg use of special vibration isolation fastenings or a ballast mat).

4.2.8

Moderating track stiffness

The ballast profiles detailed above are suitable for standard track on earth foundations. For track on rigid foundations such as ballast top bridges consideration shall be given to moderating the track stiffness. Guidelines for use of ballast mat on rigid structures are provided in Table 5. Special measures are required for transitioning between areas of different stiffness such as bridge ends (see ESC 310). The design of the ballast mat should also consider the bridge design requirements such as waterproofing (see ESC 310).

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Track Category
(Note 1)

Sleeper Type
Heavy duty concrete

Min Ballast Depth (exc. mat)

> 300 and < 600 mm 250 -300 mm < 250 mm but > 200 mm (Note 2)

Recommended Ballast Mat Stiffness Range

Ballast mat (cstat = 0.15 N/mm3) Ballast mat (cstat = 0.10 N/mm3) Ballast mat (cstat = 0.10 N/mm3) Ballast mat (cstat = 0.15 N/mm3) Ballast mat (cstat = 0.10 N/mm3) Ballast mat (cstat = 0.10 N/mm3) Ballast mat (cstat = 0.15 N/mm3) Ballast mat (cstat = 0.10 N/mm3) Ballast mat (cstat = 0.10 N/mm3)

High (H)

Medium (M)

Heavy or Medium duty concrete Medium duty concrete

> 250 and < 600 mm 200 -250 mm < 200 mm but > 150 mm (Note 2)

Low (L)

> 200 and < 600 mm 150 -200 mm < 150 mm but > 100 mm (Note 2)

Table 5 - Guideline for Ballast Mat Usage on Stiff Structures (Bridge/Tunnel)

Note 1 2

Operating Class: Main Line refer to Table 4 for definition of Track Category should consider case by case

Acceptance Standards
All work involving the laying of ballast as part of new track installation or track renewal shall meet the following acceptance requirements:

5.1

Ballast material and grading

Supplied (new) ballast shall meet an approved design (SPC 241 or equivalent approved by the Chief Engineer Track).

5.2

Crib and shoulder height

The ballast shall be profiled to the top of the centre and end of the sleepers.

5.3

Ballast shoulder width

Ballast shoulder width (mm) Operating Class Acceptance Minimum Main line CWR and LWR Siding CWR and LWR Loose Rail 390 290 700 700 390 700 Maximum

Table 6 - Ballast shoulder width acceptance limits

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5.4

Ballast depth
Ballast depth(mm) Category Acceptance Minimum High Medium Low H M L L(150) L(100) L(Nom) 325 275 225 125 100 NA Maximum NA NA NA NA NA NA Minimum Free Draining 200 75 75 75 NA NA

Table 7 - Ballast Depth acceptance limits

6
6.1

Damage Limits
Contamination
Ballast shall be considered to have failed to meet functional requirements when the Fouling Index >40. The Fouling Index (FI) = P(4) + P(200) Where P(4) = Percentage passing 4.75 mm (No 4) sieve

P(200) = Percentage passing 0.075 mm (No 200) sieve.

6.2

Strength/stiffness
To be determined

6.3

Profile
To be determined

Repair standards
Recycled ballast must be cleaned to remove fines and contaminants, AND must meet an approved design (SPC 241 or equivalent approved by the Chief Engineer Track), OR must have reinforcement designed to provide strength and durability at least equivalent to the approved design, OR must ONLY be used below the depth specified for free draining ballast.

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