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TRACKWORK SYSTEMS

SLEEPERS

Sleeper geometry, rail-seat positions, fastening interfaces and reinforcement requirements can be developed around the approved track layout and applicable customer specifications.

TRACKWORK SYSTEMS

HOLDING THE TRACK TO ITS GEOMETRY

CAL Group manufactures prestressed concrete sleepers for mainline, turnout and specialised trackwork applications. Production capability extends from 3-metre sleepers to long trackwork sleepers measuring up to 13 metres.
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PRESTRESSED CONCRETE SLEEPERS

FROM STANDARD LENGTHS TO COMPLETE TRACKWORK LAYOUTS

Prestressed concrete sleepers provide the structural support, gauge control and load distribution required across railway track systems. CAL Group can manufacture sleepers from 3 to 13 metres in length for mainline, turnout and specialised track configurations.

CONTROLLED GEOMETRY

EACH SLEEPER HAS A DEFINED POSITION AND FUNCTION

Turnout design begins with an understanding of how the route will be used, what loads it will carry and how it must fit within the available railway layout.

LENGTH AND GEOMETRY

Sleeper length, section and geometry are developed around the loads, rail positions and space available within the track arrangement.

RAIL-SEAT POSITION

Rail seats are positioned to maintain the required gauge, alignment and route geometry across the complete layout.

FASTENING INTERFACES

Insert locations and rail-seat details are coordinated with the applicable fastening system and rail section.

LOADING REQUIREMENTS

Prestressing, reinforcement and concrete requirements are established around the applicable structural and service conditions.

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IDENTIFICATION AND SEQUENCING

Turnout and specialised sleepers can be identified and sequenced to support their correct position within the final track layout.

CUSTOMER REQUIREMENTS

Sleepers can be manufactured against approved drawings, specifications and defined inspection requirements.

CONNECTED INTERFACES

DEVELOPED FOR THE FASTENING SYSTEM AROUND THEM

The sleeper and fastening system must work as one controlled interface. Rail-seat geometry, insert positions, electrical insulation requirements and fastening locations are therefore incorporated into the sleeper design and manufacturing information.
RAIL-SEAT CONTROL
Rail-seat position and inclination are maintained according to the applicable track and rail requirements.
INSERT POSITIONING
Embedded components are located and secured around controlled dimensional requirements.
SYSTEM COMPATIBILITY
Sleeper interfaces can be coordinated with the fastening arrangement specified for the project.
DIMENSIONAL VERIFICATION
Critical dimensions and insert locations are inspected before the sleeper is released.

PRODUCTION ASSURANCE

CONTROLLED FROM INPUT MATERIALS TO FINISHED DIMENSIONS

MATERIAL CONTROL

Concrete inputs, reinforcement and prestressing materials are checked against the applicable requirements.

PRESTRESSING CONTROL

Prestressing operations are performed through defined production procedures and recorded parameters.

CONCRETE PERFORMANCE

Applicable concrete properties are verified against the specified acceptance requirements.

DIMENSIONAL INSPECTION

Sleeper length, section, rail-seat geometry, insert positions and other critical dimensions are checked before release.

TRACEABILITY

Production and inspection information remains linked to the identified sleeper or production batch.

FROM 3-METRE SLEEPERS TO COMPLETE TURNOUT LAYOUTS.

Discuss sleeper lengths, rail-seat positions, fastening interfaces and track-layout requirements with our team.
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