R-Solutions Spike Hole Plugging Compound Static and Dynamic Load Tests

Transcription

1 Materials Testing Canada Inc. R-Solutions Spike Hole Plugging Compound Static and Dynamic Load Tests Presented to: 100 South Santa Fe Dr. Denver, Colorado Attn: Walter Vizcaino, Date Issued 03 March 2005 Report Number Version Number 1 Number of pages (text, including cover) 5 Number of Appendices 3 Number of Appendix Pages (including cover) A1:4/A2:2/A3:4 Bodycote Materials Testing Canada Inc. 121 Boul. Hymus, Pointe Claire, Qc H9R 1E6 This report may not be reproduced except in its entirety without permission from Bodycote Materials Testing Canada Inc. Report refers only to items tested as indicated.

2 Introduction In accordance with the request from R-Solutions and Bodycote OS # , Bodycote Materials Testing Canada Inc., Rail/Mechanical Dept., has completed a static and dynamic test program on a spike hole treated wood tie. The test program combines the Bodycote standard test procedure for spike hole filler plus a rail roller over test criteria supplied by the BNSF Railway. Tests were conducted at the Bodycote Materials Testing Inc., Rail Products test facility in Pointe Claire, Québec, Canada. Test Preparation Two new wood ties (oak or maple) were prepared by R-Solutions according to the requirements of the BNSF test criteria. The full BNSF test program can be found in Appendix 2. The dynamic tests were performed on an MTS dynamic load frame with 110 kip maximum capacity. LVDT transducer were used to monitor the tie plates. The tie was prepared according to the BNSF test. The spike holes were cut to a specified slot pattern (see Appendix 2). The purpose of the slotted holes was to allow a direct load from the spike to the spike hole filler material itself during the test without direct support from the wood. That way the spike hole filler materials resistance to lateral loading as well as spike pull out could be monitored throughout the test. The holes at one end were filled dry after cutting. The holes at the opposite end were wet with 10ml of water before filling with compound. Both ties were prepared in this manner before shipping to Bodycote. The first tie was set up for the dynamic test and an R-Solutions representative witnessed the start-up of the test. Test Procedures Dynamic Test A cyclic load was applied simultaneously to both rail heads using a dynamic loading pattern as follows: Inclined Load Severe Service Fatigue Test Load per rail, Lateral = 16,900 lbs. max. 260 lbs. min. Vertical = 32,500 lbs. max. 500 lbs. min. Load Ratio L/V = 0.52 constant Test angle = 27.5 per arm A cyclic load was applied to the gauge corners of each rail and components were monitored. The target was 1,000,000 cycles Page 2 of 5 03 March 2005

3 Deflection measurements were taken on the gauge side of each tie plate using an LVDT transducer connected to a brush recorder to monitor plate lateral movement throughout the test. Lateral movement in this test is an indication of spike filler material failure under load. Roller-Over Test The second tie was used for the rollover test. The rollover test was performed according to the BNSF requirements (See Appendix 2). The tie plate used for the rollover test was equipped with an anti-rollover shoe fitted to the gauge side of the plate. This shoe was bolted through one of the line spike holes, leaving the second hole free for spiking. Load was applied 5/8 below the running surface on the side of the rail head. The test was terminated when the rail rolled over (pulling away from the tie plate and unable to sustain load.) Spike Insertion Extraction Test Spike insertion / extraction values were recorded were possible to add information to the test. There were due to the requirements of the BNSF protocol, there were not enough unused filled holes to perform the full Bodycote spike hole procedure. Test Results Dynamic Test The dynamic test ran uninterrupted for 742,150 cycles. At that point the tie plate on end A (dry end) cracked under the field side rail edge. After discussions with R-Solutions, the tie plate was replaced, spiking into the original holes without refilling with compound. Plate deflection on end A (dry end) at startup was 0.015, increasing slightly to by 742,150 cycles, when the plate broke. Similarly, end B (wet end) started at deflection and reached deflection by 742,150 cycles. After replacing the tie plate on end A, the tests was restarted and successfully completed the 1,000,000 cycles required. The tie plate on end A partially cracked at 970,800 cycles. was allowed to run out to the million cycles without replacement. The deflection on end A did not change significantly after re-spiking over the remaining cycles (0.020 at 970,800 cycles). Deflections on end B increased to at 1,000,000 cycles. These numbers indicate that the re-spiked tie plate did not experience a significant change in deflection despite having the spikes pulled and then re-spiked. The average pullout force on the end A spikes was 3763 lbs. after 742,150 cycles. Average pullout of end A after 1,000,000 cycles was 2970 lbs. Average pullout on end B (wet) after 1,000,000 cycles was 3120 lbs Page 3 of 5 03 March 2005

4 Roll-Over Test Two tests were conducted for this phase of the test program. Results are listed below: Dry holes: Wet holes: 21,520 lbs. force at roll-over. 15,410 lbs. force at roll-over. The rollover test could not be conducted on the dynamic tested tie since BNSF preferred the use of an anti-rollover shoe on the gauge side of the rail during the rollover test. This equipment was not provided for the dynamic test. Tables 1. Before Dynamic Test Initial Insertion Forces (Dynamic test) D=Dry W=Wet F=Field Side G=Gauge Side Location Load, lbs Location Load, lbs DG WG DG WG DF WF DF WF Broken Plate Replacement Load to Extract Load to Re-Inset Location Load, lbs Location Load, lbs. DG DG DG DG DF DF DF DF Extraction after Dynamic Cycling. Load to Extract Load to Extract Location Load, lbs Location Load, lbs DG WG DG WG DF WF DF WF Page 4 of 5 03 March 2005

5 Conclusions Dynamic deflection of the tie plate (lateral movement under cyclic load) was the same for both wet and dry holes. The difference between wet and dry spike pullout forces after 1,000,000 cycles was 5%. The difference between the dry hole pullout forces on the cracked plate at 742,150 cycles and the re-spiked holes at 1,000,000 cycles was 26.7% The difference in rollover values between wet and dry was 40% (based on one sample per test only) * * * This report refers only to the specific samples, instrumentation or other information used and referred to in said report, and is limited by the tests and/or analyses performed Page 5 of 5 03 March 2005

6 APPENDIX 1: Test Photographs Appendix 1, Page 1 of 4 03 March 2005

7 Figure 1 General test set-up, dynamic. Figure 2 Close-up of rail seat showing transducer positions(arrows) Appendix 1, Page 2 of 4 03 March 2005

8 Figure 3 Spike hole filler pattern (typical). Figure 4 Cracked plate (field side rail edge) Appendix 1, Page 3 of 4 03 March 2005

9 Figure 5- Setup for Rollover test. Figure 6- Typical rollover results Appendix 1, Page 4 of 4 03 March 2005

10 Appendix II BNSF Test Requirement Appendix 2, Page 1 of 2 03 March 2005

11 BNSF Tie Plugging Compound Test Procedure (This document is intended to outline procedures preferred by BNSF when testing tie plugging compounds and is to be approved by BNSF before use.) Dynamic Tie Test Two ties are set up in this manner (ID Tie 1 and Tie 2). A straight tie with no twist is required for the test. Slots are cut for each spike using a 3/4 x 1.25 x 4.5 hole pattern spaced to standard North American track gauge spacing on each of the ties. The spiking pattern is as shown in the graphic above; two line spikes staggered, two anchor spikes staggered. One end of the tie is set up by shooting the plugging material into dry slots to the above configuration. The opposite end of the tie is set up by first pouring 10ml of water into the slot before shooting with plugging compound Run the dynamic load test on Tie1 to 1 million cycles. Measure rail head and tie plate lateral movement throughout the test. After 1 million cycles, perform the rail rollover test (see below). Rollover Test Following the dynamic test, the individual ends are prepared for lateral load rollover testing as follows: Cut the tie to fit the lateral rollover test jig. Insert the tie section so that the load head is positioned to apply a load ~5/8 below the rail head running surface. Set a transducer on the side of the rail head, 5/8 below the running surface. Apply a load to the rail head until rail rollover occurs, recording deflection and load on the data acquisition system. Perform this test on both wet and dry ends of the tie. Prepare curves from data. In addition to the rollover on the dynamic test tie (Tie 1), perform the same test on each end of the untested tie (Tie 2) Appendix 2, Page 2 of 2 03 March 2005

12 Appendix 3 Extra Test Work Appendix 3, Page 1 of 4 03 March 2005

13 In addition to the work outlined in the foregoing report, R-Solutions requested the additional testing: roll-over test on virgin wood. insertion/extraction tests on the dynamic tested holes. Results Rollover in virgin wood = 30,000 lbs +. Note: Test was stopped at 30,000 lbs before rollover occurred due to a concern over breaking the test rail. Insertion/Extraction The following graph illustrates the results of the 10 cycle spike insertion/extraction test after 1 million cycles dynamic loading. Comparison of Wet and Dry Hole Spike Insert/Extract after 1 Milllion Dynamic Load Cycles Load, lbs Insert/Extract cycles DG1-Ins DG1-Ext WG1-Ins WG1-Ext DG2-Ins DG2-Ext WG2-Ins WG2-Ext DF1-Ins DF1-Ext WF1-Ins WF1-Ext Appendix 3, Page 2 of 4 03 March 2005

14 Insertion Extraction after 1,000,000 cycles per hole. C Dry: DG1 Wet: WG1 Cycle # Insert Extract Cycle# Insert Extract C Dry: DG2 Wet: WG2 Cycle # Insert Extract Cycle# Insert Extract Dry: DF1 Wet: WF1 Cycle # Insert Extract Cycle# Insert Extract

15 Comparison of Wet and Dry Hole Spike Insert/Extract after 1 Milllion Dynamic Load Cycles Load, lbs Insert/Extract cycles DG1-Ins DG1-Ext WG1-Ins WG1-Ext DG2-Ins DG2-Ext WG2-Ins WG2-Ext DF1-Ins DF1-Ext WF1-Ins WF1-Ext