1、| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | BRITISH STANDARD BS 500:2000 ICS 45.080 NO
2、 COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW Steel sleepersThis British Standard, having been prepared under the direction of the Engineering Sector Committee, was published under the authority of the Standards Committee and comes into effect on 15 November 2000 BSI 11-2000 F
3、irst published November 1956 Second edition November 2000 The following BSI references relate to the work on this standard: Committee reference RAE/2 Draft for comment 97/710769 DC ISBN 0 580 33178 4 BS 500:2000 Amendments issued since publication Amd. No. Date Comments Committees responsible for th
4、is British Standard The preparation of this British Standard was entrusted to Technical Committee RAE/2, Railway track components, upon which the following bodies were represented: British Precast Concrete Federation Confederation of British Forgers London Underground Ltd. Prestressed Concrete Assoc
5、iation Railtrack Railway Industry Association Society of Chemical Industry Timber Trade Federation UK Steel AssociationBS 500:2000 BSI 11-2000 i Contents Page Committees responsible Inside front cover Foreword ii 1 Scope 1 2 Normative references 1 3 Information and requirements to be agreed and to b
6、e documented 1 3.1 General 1 3.2 Information to be supplied by the purchaser 1 3.3 Information to be supplied by the manufacturer when tendering to supply 2 4 Sleeper dimension 2 5 Type approval tests 2 5.1 Cyclic loading resistance 2 5.2 Lateral resistance 2 5.3 Electrical resistance 2 6 Marking 2
7、Annex A (informative) Advice on achieving and verifying product consistency 3 Annex B (informative) Estimation of the maximum rail seat reactions and lateral forces 4 Annex C (normative) Cyclic loading test procedure 5 Annex D (normative) Method of determining sleeper lateral resistance 10 Annex E (
8、normative) Method of measuring electrical resistance 11 Annex F (normative) Specification for ballast 12 Bibliography 13 Figure C.1 Cyclic loading test arrangement 8 Figure C.2 Detail of thrust arm 9 Figure D.1 Ballast box dimensions 10 Figure E.1 Electrical resistance test arrangement 12 Table F.1
9、Ballast sizes 12ii BSI 11-2000 BS 500:2000 Foreword This British Standard has been prepared by Technical Committee RAE/2. It supersedes BS 500:1956, which is withdrawn. The standard differs radically from previous editions in that it is performance based and is intended to provide the supplier with
10、the maximum flexibility in design and manufacture compatible with achieving a consistent and satisfactory service performance. Extracts from Railtrack Line Specification RT/CE/S/021, Steel Sleepers, are used with permission. Assessed capability. Users of this British Standard are advised to consider
11、 the desirability of quality system assessment and registration against BS EN ISO 9001 or BS EN ISO 9002 by an accredited third-party certification body (see annex A). A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsibl
12、e for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 13 and a back cover. The BSI copyright notice displayed in this doc
13、ument indicates when the document was last issued.BS 500:2000 BSI 11-2000 1 1 Scope This British Standard specifies performance requirements for steel sleepers for railway track. It includes definitive requirements relating to the ability of the sleeper to retain track geometry, sleeper durability,
14、electrical resistance, and the control of the production process so that the consistency of the sleepers performance is assured. 2 Normative references The following normative documents contain provisions which, through reference in this text, constitute provisions of this British Standard. For date
15、d references, subsequent amendments to, or revisions of, any of these publications do not apply. For undated references, the latest edition of the publication referred to applies. BS 812-103.1, Testing aggregates Part 103: Method for determination of particle size distribution Section 103.1: Sieve t
16、ests. BS 812-105.1:1989, Testing aggregates Part 105: Methods for determination of particle shape Section 105.1: Flakiness index. BS 812-105.2:1990, Testing aggregates Part 105: Methods for determination of particle shape Section 105.2: Elongation index of coarse aggregate. BS 6072:1981, Method for
17、magnetic particle flow detection. BS EN 27888:1993, Water quality Method for the determination of electrical conductivity. BS EN ISO 7500-1:1999, Metallic materials Verification of static uniaxial testing machines Part 1: Tension/compression testing machines Verification and calibration of the force
18、-measuring system. 3 Information and requirements to be agreed and to be documented 3.1 General For compliance with the standard, both the definitive requirements specified throughout the standard and the following documented items shall be satisfied. 3.2 Information to be supplied by the purchaser
19、3.2.1 Fastening system specified by purchaser If the purchaser specifies the fastening system to be used, the following information shall be supplied and fully documented: a) the rail fastening system to be used (including the rail pad and any insulators) and whether its components are to be supplie
20、d with the sleeper; b) the nominal track gauge; c) the rail profile to be used; d) the nominal rail inclination; e) the maximum static and dynamic rail seat reactions and the maximum lateral force to be supported (see annex B); f) any specific requirements to ensure that installation of the sleepers
21、 and track maintenance can be undertaken effectively using the procedures available to the purchaser; g) any specific requirements for the packaging and protection of sleepers in transit; h) whether an electrical resistance test is required and the minimum resistance to be achieved. 3.2.2 Fastening
22、system not specified by purchaser If the purchaser does not specify the fastening system to be used, the following information shall be supplied and fully documented: a) whether the fastening system is to be supplied with the sleeper as an assembled unit; b) the nominal track gauge and the acceptabl
23、e variation; c) the rail profile to be used; d) the nominal rail inclination and its acceptable variation; e) the maximum static and dynamic rail seat reaction, and the maximum lateral force to be supported (see annex B); f) any specific requirements to ensure that installation of the sleepers and t
24、rack maintenance can be undertaken effectively using the procedures available to the purchaser; g) any specific requirements for the packaging and protection of sleepers in transit; h) whether an electrical resistance test is required and the minimum resistance to be achieved.2 BSI 11-2000 BS 500:20
25、00 3.3 Information to be supplied by the manufacturer when tendering to supply The following information shall be supplied by the manufacturer and fully documented: a) a dimensioned and toleranced drawing of the sleeper that is to be supplied; b) the sleeper mass; c) a statement of how the manufactu
26、rer will ensure that all sleepers meet the requirements of this specification. Sufficient detail, including the grade of steel, shall be provided to enable the purchaser or a third party to verify that the manufacturer is adhering to the stated method; NOTE Advice on achieving a consistent and verif
27、iable performance is given in annex A. d) the results of the cyclic loading tests specified in 5.1; e) the results of the sleeper lateral resistance measurements specified in 5.2; f) if electrical isolation of the rail from the sleeper is required, the results of the electrical resistance test speci
28、fied in 5.3; g) the method by which any specific requirements of the purchaser in relation to installation of the sleepers in track and the subsequent maintenance of the track have been met 3.2.1f); h) where the purchaser has no specific packaging or protection arrangements, the method of packaging
29、which will be used, including stack size; i) if the purchaser has specified the fastening system, the maximum and minimum track gauge and rail inclination possible. 4 Sleeper dimension The soffit width shall be such that the ballast pressure under a force equal to the maximum static rail seat reacti
30、on shall not exceed 0.5 MN/m 2 , assuming this load to be uniformly distributed over a length of 0.8 m, unless otherwise specified by the purchaser (see B.5.1). To ensure that this can be achieved, the sleeper soffit shall be continuous for at least 450 mm on either side of the rail seat centre line
31、 except for small apertures necessary for fastening attachment. 5 Type approval tests 5.1 Cyclic loading resistance The cyclic loading resistance determined in accordance with annex C shall be not less than 2.4 times the dynamic rail seat reaction see 3.2.1e). This test shall be repeated when there
32、is any change in the sleeper design or manufacturing process which might affect fatigue performance. NOTE The results of the tests required by annex C are reported in terms of the total vertical load, i.e. twice the rail seat reaction. An additional factor of 1.2 has been applied to allow for the po
33、tential loss of section in service through corrosion. 5.2 Lateral resistance The lateral resistance of the sleeper in a ballast box containing uncompacted ballast shall be not less than 4.5 kN when tested in accordance with annex D. 5.3 Electrical resistance If the rail is to be electrically insulat
34、ed from the sleeper, the resistance of the assembly shall be tested in accordance with annex E. 6 Marking Sleepers shall be durably marked with the following information: a) the identification mark of the manufacturer; b) the last two figures of the year of manufacture; c) the sleeper type. The mark
35、ing shall be clearly visible with the sleeper installed in track.BS 500:2000 BSI 11-2000 3 Annex A (informative) Advice on achieving and verifying product consistency A.1 General Subclause 3.3c) requires the manufacturer to submit to the purchaser a statement of the means to ensure that the performa
36、nce requirements of this specification are consistently achieved. It is recommended that the primary route to product performance and consistency is control of materials and of the production process. Areas where particular attention should be paid are given in A.2 to A.5 below. Verification by test
37、, for example the measurement of critical dimensions, is always necessary but the frequency of such testing may be relaxed as confidence in the control of the production process grows. Repetition of the tests undertaken prior to tender to demonstrate the products performance is only necessary if the
38、 design, materials or the production process is changed from that used to produce the sleepers tested to provide the data reported in accordance with clause 3. A.2 Quality assurance In order that adherence to the procedures used to ensure consistency can be verified, it is necessary that they can be
39、 documented. This is best achieved through the implementation of a formal quality system. It is recommended that: the sleeper designer should operate an independently approved and audited quality system conforming to the requirements of BS EN ISO 9001; the sleeper manufacturer should operate an inde
40、pendently approved and audited quality system conforming to the requirements of BS EN ISO 9002; all testing should be undertaken by a test house operating an independently approved and audited system procedure conforming to the requirements of BS EN ISO 9002 or BS 7501; and that the adoption of thes
41、e standards forms part of the submission. A.3 Materials and processing The statement should define the steel grade to be used and the steps that the supplier will take to verify the steel conforms to the specification. EXAMPLE “Sleepers shall be manufactured from steel conforming to EN 10025-72, gra
42、de Fe360B OPT BS: chemical composition and tensile properties shall be determined once per cast”. The production process should also be defined. EXAMPLE “Sleepers shall be hot-rolled to shape with a finishing temperature of. . Spade ends will be cold formed”. A.4 Attachment of rail fastenings The fa
43、tigue strength of the sleeper will usually be crucially dependent on the method of attachment of the rail fastenings. Where a welded attachment is used, the welding process and procedure should be stated and the nature and frequency of post welding quality checks, for example magnetic particle inspe
44、ction or verification of the throat thickness. The consumables to be used should be defined. If the fastenings or their housings are to be attached by holes, the method of producing the holes (drilling, punching, etc.) should be stated; also whether de-burring will be undertaken and the checks to be
45、 made and their frequency to confirm the absence of cracks or tears in finished sleepers. A.5 Geometry The statement should include a demonstration (for example, drawings showing the effect of combining components at the limits of their permitted tolerance) that the requirements for gauge and rail i
46、nclination of clause 3.2.2b) and d) are met by the design, assuming nominal dimensions for the rail. The statement should also describe the gauges or other means that will be used to verify that the key dimensions are within the required tolerances. Of particular importance are the rail seat inclina
47、tion and the position of the rail fastening locating points. The frequency with which key dimensions will be verified should be stated.4 BSI 11-2000 BS 500:2000 Annex B (informative) Estimation of the maximum rail seat reactions and lateral forces B.1 General Where no information is available on the
48、 rail seat reactions to be expected at track irregularities, the following method of estimation is recommended. B.2 Symbols For the purposes of this annex the following symbols apply. d is the track gauge in millimetres (mm) +50 (mm); E is the Youngs modulus for the rail in meganewtons per square me
49、tre (MN/m 2 ); h 1 is the maximum cant deficiency for the vehicle concerned in millimetres (mm); h* is the height of vehicle centre of gravity above rail top in millimetres (mm); I is the moment of inertia (second moment of area) of the rail (m 4 ); k is the uniformly distributed force required to cause a uniform unit track deflection in meganewtons per metre, per metre of track (MN/m/m); K t2 is the wheel force required to cause unit deflection of the track in meganewtons per metre (MN/m); M is the unsprung mass of vehicle, per wheel in
