1. Measuring Concrete Crosstie Rail Seat Pressure Distribution with Matrix Based Tactile Surface Sensors Christopher T. Rapp, Marcus S. Dersch, J. Riley Edwards International Concrete Crosstie and Fastening System Symposium Urbana, Illinois 7 June 2012

2. Measuring Rail Seat Pressure Distribution with MBTSS Slide 2 Outline Pulsating Load Testing Machine (PLTM) Current Objectives of MBTSS Sensor Layout and Data Representation Experimentation at UIUC –Rail Pad Modulus Test Conclusions from Testing Future Work with MBTSS

3. Measuring Rail Seat Pressure Distribution with MBTSS Slide 3 Pulsating Load Testing Machine (PLTM) Housed at Advanced Transportation and Research Engineering Laboratory (ATREL) Owned by Amsted RPS Used for Full Scale Concrete Tie and Fastening System Testing Following AREMA Test 6 – Wear and Abrasion recommended practice Three 35,000 lb. actuators: two vertical and one horizontal –Ability to simulate various Lateral/Vertical (L/V) ratios by varying loads

4. Measuring Rail Seat Pressure Distribution with MBTSS Slide 4 Pulsating Load Testing Machine (PLTM) Vertical Actuators Lateral Actuator Loading Head Access Point Rail Vertical Actuators

5. Measuring Rail Seat Pressure Distribution with MBTSS Slide 5 Current Objectives of Experimentation with MBTSS Measure magnitude and distribution of pressure at the rail seat Gain better understanding of how load from wheel/rail contact is transferred to rail seat Compare pressure distribution to rail seats in various loading scenarios Compare pressure distribution of various fastening systems Identify regions of high pressures and quantify peak values

6. Measuring Rail Seat Pressure Distribution with MBTSS Slide 6 Rail Concrete Crosstie Sensor Installation Layout Mylar(0.007”) Teflon(0.006”) Sensor(0.004”) Teflon(0.006”) Mylar(0.007”) Concrete Crosstie Cast-in Shoulders MBTSS Setup Field Gauge MBTSS Rail Seat Pad/Abrasion Plate

7. Measuring Rail Seat Pressure Distribution with MBTSS Slide 7 Visual Representation of Data Data visually displayed as color 2D or 3D images Calculate force and pressure at each sensing point Set standard color scale to apply to all data for better comparison Sample MBTSS output FIELD GAUGE

8. Measuring Rail Seat Pressure Distribution with MBTSS Slide 8 FIELD GAUGE 0.22 in. Area = 0.0484 in 2 ~21 per 1 in 2

9. Measuring Rail Seat Pressure Distribution with MBTSS Slide 9 Experimentation at UIUC Lab experimentation to measure effect of L/V ratio on pressure distribution in the rail seat varying rail pad modulus Attempt to simulate field loading conditions in the lab

10. Measuring Rail Seat Pressure Distribution with MBTSS Slide 10 Rail Pad Test Objective: bound the experiment by using low and high modulus pads Two rail pad types with same dimensions and geometry –Santoprene™ (Lower Modulus) –Medium-Density Polyethylene (MDPE – Higher Modulus) Concrete rail seat and fastening system held constant Identical loading conditions –32.5 kip vertical load, lateral load varies based on respective L/V ratio

11. Measuring Rail Seat Pressure Distribution with MBTSS Slide 11 Rail Pad Test Results MDPE Santoprene™ Contact Area (in 2 ) 20.119.319.119.018.617.8 % of Rail Seat 595756 5552 Peak Pressure (psi) 3,2133,4693,5463,7213,8384,096 Contact Area (in 2 ) 28.827.927.325.824.021.3 % of Rail Seat 858280767163 Peak Pressure (psi) 2,1392,5732,8002,9253,1623,400 L/V Ratio0.250.440.480.520.560.60 FIELD GAUGE

12. Measuring Rail Seat Pressure Distribution with MBTSS Slide 12 Average Pressure Distribution for Santoprene™ Rail Pad

13. Measuring Rail Seat Pressure Distribution with MBTSS Slide 13 Average Pressure Distribution for MDPE Rail Pad

14. Measuring Rail Seat Pressure Distribution with MBTSS Slide 14 Conclusions from Testing L/V Ratio –A lower L/V ratio distributes the pressure over a larger contact area –A higher L/V ratio causes a concentration of pressure on the field side of the rail seat, resulting in higher peak pressures Pad Modulus –Lower modulus rail pads distribute rail seat loads over a larger contact area, reducing peak pressure values and mitigating highly concentrated loads at this interface –Higher modulus rail pads distribute rail seat loads in more highly concentrated areas, possibly leading to localized crushing of the concrete surface

15. Measuring Rail Seat Pressure Distribution with MBTSS Slide 15 Future Work with MBTSS Field testing at TTC in Pueblo, CO to understand pressure distribution varying: –Degree of curvature –Fastening system design –Train speeds Perform field testing at Monticello Railway Museum in Monticello, IL on section of concrete crosstie track Instrument high and low rail seats of a crosstie to compare varying track geometries Further investigate rail pad assemblies, moduli, and geometries Continue testing various fastening systems

16. Measuring Rail Seat Pressure Distribution with MBTSS Slide 16 Acknowledgements Funding for this research has been provided by the Federal Railway Administration (FRA) Industry Partnership and support has been provided by –Union Pacific (UP) Railroad –BNSF Railway –National Railway Passenger Corporation (Amtrak) –Amsted RPS / Amsted Rail, Inc. –GIC Ingeniería y Construcción –Hanson Professional Services, Inc. –CXT Concrete Ties, Inc., LB Foster Company Marc Killion and Timothy Prunkard – UIUC Professor Jerry Rose and graduate students – University of Kentucky AAR/TTC – Dave Davis, for assisting in field tests FRA Tie and Fastener BAA Industry Partners:

17. Measuring Rail Seat Pressure Distribution with MBTSS Slide 17 Questions / Comments Christopher T. Rapp Graduate Research Assistant Rail Transportation and Engineering Center – RailTEC University of Illinois at Urbana-Champaign e-mail: ctrapp3@illinois.edu

18. Measuring Rail Seat Pressure Distribution with MBTSS Slide 18 Clip Test Results Clip B Clip A Contact Area (in 2 ) 28.426.623.616.6 % of Rail Seat 84787049 Peak Pressure (psi) 2,1882,3272,8723,809 Contact Area (in 2 ) 27.624.521.017.2 % of Rail Seat 81726251 Peak Pressure (psi) 2,7443,0673,3854,083 L/V Ratio0.250.440.520.60 FIELD GAUGE

19. Measuring Rail Seat Pressure Distribution with MBTSS Slide 19 Average Pressure Distribution for Clip A

20. Measuring Rail Seat Pressure Distribution with MBTSS Slide 20 Average Pressure Distribution for Clip B