Industry Overview
Sleepers are transverse members laid across railway tracks to support and secure rails, transfer rail loads to the ballast and subgrade, maintain track geometry, and contribute to the longitudinal and lateral stability of the permanent way. An effective sleeper should be economical, durable, moderately weighted, easy to handle and maintain, and capable of resisting shocks, vibrations, crushing and stresses generated by heavy axle loads and higher train speeds.
Prestressed concrete is concrete in which internal stresses are deliberately introduced, generally through tensioned steel, to counteract stresses developed during service. Prestressing may be carried out by pre-tensioning, where the steel is tensioned before concreting, or post-tensioning, where the prestressing steel is tensioned against hardened concrete.
Prestressed concrete sleepers are increasingly preferred by railways over timber sleepers because of timber scarcity and the technical advantages of concrete for long welded tracks, heavier axle loads and higher operating speeds. Their structural properties and elastic fastenings improve track stability and help maintain important parameters such as gauge, cross levels, twist and alignment. Among the various concrete sleeper designs, monoblock prestressed concrete sleepers constitute a major proportion of those in use.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 1000 Nos/Day |
| Land & Building (10,000 sq.mt.) | Rs. 4.03 Cr |
| Plant & Machinery | Rs. 3.80 Cr |
| Working Capital for 1 Month | Rs. 4.91 Cr |
| Total Capital Investment | Rs. 13.02 Cr |
| Rate of Return | 35% |
| Break Even Point | 50% |
Content Index
- INTRODUCTION
- CLASSIFICATIONS OF SLEEPERS
- TYPES OF PSC SLEEPER
- A. MONO BLOCK CONCRETE SLEEPERS (MBC):
- B. TWIN BLOCK CONCRETE SLEEPERS:
- IMAGES
- FIG. 1: MONO BLOCK CONCRETE SLEEPER
- FIG. 2: TWIN BLOCK CONCRETE SLEEPER
- PSC SLEEPER AND ITS FUNCTION
- FUNCTIONS
- DESIGN CONSIDERATION FOR PRESTRESSED CONCRETE SLEEPERS
- DESIGN AND MODELLING OF CONCRETE SLEEPERS
- SLEEPER SECTION:
- MATERIAL PROPERTIES:
- PRESTRESSED CONCRETE SLEEPERS
- THE DESIGN IS BASED ON:
- USES AND APPLICATION
- CAUTIONS
- B.I.S. SPECIFICATION
- RUSSIAN
- HUNGARIAN
- OTHER FOREIGN STANDARDS
- STANDARD FOR M.I. FITTINGS SPECIFICATIONS
- RAW MATERIALS
- BEND TEST
- REVERSE BEND TEST
- GAUGE CONVERSIONS
- B. HIGH STRENGTH CONCRETE MIXES FOR PRESTRESSED CONCRETESLEEPERS
- CONSTIUENTS OF CONCRETE
- MATERIALS AND THEIR EFFECTS
- CEMENT
- AGGREGATES
- COARSE AGGREGATE
- FINE AGGREGATE
- ULTRAFINES
- WATER
- ADMIXTURES
- ACCELERATORS
- RETARDERS
- WORKABILITY AGENTS
- AIR-ENTRAINING AGENTS
- WATER REPELLING AGENTS
- GAS-FORMING AGENTS
- GENERAL PRINCIPLES OF MIX DESIGNS
- DESIGN OF HIGH STRENGTH CONCRETE
- GENERAL
- TABLE - SUGGESTED RANGES OF VALUES OF WORKABILITY OF CONCRETE FOR DIFFERENT PLACING CONDITIONS
- TABLE - MINIMUM CEMENT REQUIRED IN CEMENT CONCRETE TO ENSURE DURABILITY UNDER SPECIFIED CONDITIONS OF EXPOSURE
- REQUIREMENTS FOR PLAIN AND REINFORCED CONCRETE EXPOSED
- TO SULPHATE ATTACK
- MINIMUM CEMENT CONTENT REQUIRED IN CEMENT CONCRETE TO ENSURE DURABILITY UNDER SPECIFIED CONDITIONS OF EXPOSURE
- FOR PRESTRESSED CONCRETE
- TABLE - REQUIREMENTS FOR PRESTRSSED CONCRETE EXPOSED
- TO SULPHATE ATTACK
- TABLE LIMIT FOR CHLORIDE ION IN CONCRETE PRIOR TO EXPOSURE
- IN SERVICE
- ENTROPY AND SHAKLOK METHOD
- (I) SELECTION OF STRENGTH FOR THE DESIGN OF MIX
- (II) SELECTION OF WORKABILITY
- (III) WATER - CEMENT RATIO
- (IV) AGGREGATE - CEMENT RATIO
- (V) DETERMINATION OF PROPORTION OF FINE & COARSE AGGREGATES
- EXAMPLE NO.1:
- SIEVE ANALYSIS OF 6-10 MM SIZE AGGREGATES
- SIEVE ANALYSIS OF 10-12 MM SIZE AGGREGATE
- SIEVE ANALYSIS OF 12-10 MM SIZE AGGREGATE
- WEIGHT OF CEMENT FOR ONE CUBIC OF CONCRETE = 502 KG
- CEMENT
- HIGH TENSILE STEEL
- CONCRETE
- RESEARCH & DEVELOPMENT
- MODERN DEVELOPMENTS IN THE DESIGN & CONSTRUCTION ASPECTS
- VACUUM CONCRETE
- DESIGN CONSIDERATIONS FOR PCC SLEEPERS
- DESIGN LOADS
- SALIENT FEATURES OF PCC SLEEPERS
- SLEEPER DENSITY
- EXAMPLE
- OVERVIEW OF CONCRETE SLEEPER PLANT
- PRODUCTION POSITION OF CONCRETE SLEEPER PLANTS
- THE RANGE OF MANUFACTURING IS AS FOLLOWS:
- THE CONCRETE SLEEPERS MANUFACTURED BY THESE COMPANIES ARE SUITABLE FOR:
- POLICY OF CONCRETE SLEEPER PLANT IN INDIAN RAILWAY
- GOVERNMENT OF IND MINISTRY OF RAILWAYS (RAILWAY BOARD)
- SUB: REVISED POLICY FOR CONCRETE SLEEPER PLANTS ON INDIAN RAILWAYS
- 1.1 POLICY ON SHIFTING OF SLEEPER PLANTS
- 1.2 POLICY ON SETTING UP OF NEW CONCRETE SLEEPER PLANT (CSP)
- QUALIFYING REEQUIREMENTS:
- OTHER TERMS AND CONDITIONS:
- EASTERN DEDICATED FREIGHT CORRIDOR PROJECT
- INDIAN RAILWAY GROWTH AND FUTURE PROSPECTS
- MARKET SIZE
- INVESTMENTS/ DEVELOPMENTS
- FEW RECENT INITIATIVES TAKEN UP BY THE GOVERNMENT ARE:
- PROMINENT MANUFACTURERS PROFILE OF RAILWAY SLEEPER
- LOCATIONS
- PRESENT MANUFACTURE OF PRESTRESSED CONCRETE RAILWAY SLEEPER
- PROCESS WISE EQUIPMENT DESCRIPTIONS
- AGITATIONS
- THE FREE FULL MIXER ARE OF THE FOLLOWING TYPES:-
- AUTOCLAVE CURING
- THE FORM WORK
- PRESTRESSING APPARATUS
- 1.TENSIONING APPARATUS
- TESTING OF CONCRETE MIXES
- SAMPLING & TESTING OF CONCRETE
- APPARATUS FOR TESTING
- METHODS OF MANUFACTURE AND TESTS FOR ACCEPTANCE
- PRODUCTION OF PRE-TENSIONED SLEEPERS:-
- 1.LONG-LINE METHOD
- STRESS-BENCH METHOD (4-SLEEPER MOULDS) METHOD
- INDIVIDUAL MOULD METHOD
- POST-TENSIONED SLEEPERS
- TEST FOR ACCEPTANCE OF SLEEPERS
- FOR THE PRODUCTION OF THE FIRST 10,000 SLEEPERS:
- MANUFACTURING PROCESS
- TESTING ARRANGEMENT FOR STATIC BENING STRENGTH TEST FORPRESTRESSED MONOBLOCK CONCRETE SLEEPERS FOR BG AND MG
- TABLE - 1
- TABLE - 2
- PROPERTIES OF CONCRETE:
- DETAILED PROCESS OF PRESTRESSED RAILWAY CONCRETE SLEEPERS
- PROCESS FLOW DIAGRAM
- SUPPLIERS OF RAW MATERIALS
- PORTLAND CEMENT
- STEEL WIRE (HIGH TENSILE)
- SUPPLIERS OF PLANT & MACHINERY (GLOBAL)
- SUPPLIERS OF PLANT & MACHINERY
- PROJECT ECONOMICS
- SYSTEMS
- BASIS FOR RAW MATERIAL COMPUTATIONS
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
A railway sleeper supports and secures the rails while transferring rail loads to the ballast and subgrade below. It maintains the correct rail gauge, transverse level and rail tilt and contributes to the longitudinal and lateral stability of the permanent track. Sleepers also provide an elastic medium between rails and ballast, support the required level and super elevation, and facilitate correction of track geometry during service and maintenance operations.
Prestressed concrete sleepers are railway sleepers manufactured from concrete in which internal stresses are deliberately introduced using tensioned steel. The prestressing helps the sleeper counteract stresses developed during service. The report describes both pre-tensioning and post-tensioning methods. Prestressed concrete sleepers are widely used because their structural characteristics support long welded tracks, heavier axle loads and higher speeds while helping maintain important track parameters.
Pre-tensioning tensions the prestressing steel before the concrete is cast, whereas post-tensioning tensions the prestressing steel against hardened concrete. In pre-tensioned sleeper production, the prestressing arrangement can be integrated with long-line, stress-bench or individual mould methods. The selection of a production method depends on the sleeper design, manufacturing arrangement and applicable production and testing requirements.
Concrete sleepers are preferred in many railway applications because they offer structural and operational advantages and reduce dependence on timber. The report specifically highlights timber scarcity and the suitability of concrete sleepers for long welded tracks carrying heavier axle loads and operating at greater speeds. Concrete sleepers with elastic fastenings can also provide better safeguards for gauge, cross levels, twist and alignment, thereby contributing to overall track stability and performance.
The report covers monoblock concrete sleepers and twin block concrete sleepers as principal types of PSC sleepers. It also discusses pre-tensioned and post-tensioned sleepers, together with different production methods such as the long-line method, stress-bench method using 4-sleeper moulds and individual mould method. Design, material properties, testing, manufacturing processes and applications are addressed as part of the broader technical treatment.
Key materials discussed in the report include cement, aggregates, water, admixtures and high tensile steel. The concrete section covers coarse and fine aggregates, ultrafines and several types of admixtures, including accelerators, retarders, workability agents, air-entraining agents, water-repelling agents and gas-forming agents. High tensile steel is also identified as a principal material for prestressing. The report further addresses concrete mix design, material effects and testing considerations.
The report covers detailed manufacturing processes for prestressed railway concrete sleepers, including process flow, formwork, prestressing apparatus, tensioning apparatus, concrete mixing, curing and testing. It discusses sampling and testing of concrete, apparatus for testing, methods of manufacture and tests for acceptance, as well as static bending strength testing of prestressed monoblock concrete sleepers. Production methods for pre-tensioned and post-tensioned sleepers are also included.
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