ESC 362

TRACK SLABS
Version 1.3
Issued February 2011

Owner:

Chief Engineer Civil

Approved
by:

John Stapleton
Principal Engineer Technology
& Standards

Authorised
by:

Richard Hitch
Chief Engineer Civil

Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document users sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp.

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Engineering Standard

Engineering Standard
Civil

RailCorp Engineering Standard Civil

Track Slabs

ESC 362

Document control
Version
1.3

Date
February, 2011

1.2

July, 2010

1.1

November,
2009

1.0

October, 2007

RailCorp
Issued February 2011

Summary of change
Section 5.7.1 - specify minimum thickness of rail pad when
using epoxy grouts
Correct internal section references throughout; Section 4.12
- change reference to TMC 304 to SPC 301; Section
5.7.4.2 - add guard rail insulation requirements from CTN
08/06
Change of format for front page, change history and table of
contents; minor editing and formatting throughout
First issue of this standard.

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ESC 362

Contents
1

Purpose, Scope and Application...........................................................................................4

2
2.1
2.2
2.3

References...............................................................................................................................4
Australian and International Standards.....................................................................................4
RailCorp Documents .................................................................................................................4
Other References......................................................................................................................5

Definitions and Abbreviations ...............................................................................................5

4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13

General Requirements............................................................................................................5
Use of Track Slabs....................................................................................................................5
Design Standards......................................................................................................................5
Integrated Designs ....................................................................................................................6
Approved Materials ...................................................................................................................6
Clearances ................................................................................................................................6
Safety ........................................................................................................................................6
Protection of the Environment...................................................................................................6
Heritage.....................................................................................................................................6
Services.....................................................................................................................................6
Design Procedure New or Infrequently Used Products .........................................................7
Drawing Standards....................................................................................................................7
Construction ..............................................................................................................................7
Maintenance..............................................................................................................................7

5
5.1
5.2
5.3
5.4
5.5
5.6
5.7

5.8
5.9

Design Requirements .............................................................................................................8

General......................................................................................................................................8
Design Loads ............................................................................................................................9
Infill Slabs ................................................................................................................................10
Width of Track Slab.................................................................................................................10
Allowable Movements .............................................................................................................10
Drainage..................................................................................................................................10
Track Interface ........................................................................................................................10
5.7.1
General ....................................................................................................................10
5.7.2
Slab Construction ....................................................................................................11
5.7.3
Turnouts...................................................................................................................11
5.7.4
Guard Rails..............................................................................................................11
5.7.4.1 General.....................................................................................................11
5.7.4.2 Signalling Interface...................................................................................12
Noise and Vibration.................................................................................................................13
Transition Section Trackforms ................................................................................................14

Prohibited Configurations....................................................................................................14

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Purpose, Scope and Application

This Standard details design and performance requirements for track slabs on the
RailCorp network.
It includes requirements for both rigid and floating slabs, the interface with track, the
transition between rigid and floating slabs, and the transition to other forms of track
support.
It covers track slabs where the track is fixed directly to a concrete slab.
This Standard does not address the design requirements for floating slabs supporting
ballasted track.

References

2.1

Australian and International Standards

AS 1170 - 2002 - Structural design actions
AS 1726 - 1993 - Geotechnical site investigations
AS 2159 - 1995 - Piling Design and installation
AS 3600 - 2001 - Concrete structures
AS 5100 - 2004 - Bridge design
BS 6177:1982 - Guide to selection and use of elastomeric bearings for vibration isolation
of buildings
ISO 14837-1:2005 - Mechanical vibration Ground-borne noise and vibration arising
from rail systems Part 1: General guidance

2.2

RailCorp Documents
ESC 100 - Civil Technical Maintenance Plan
ESC 200 - Track System
ESC 210 - Track Geometry and Stability
ESC 215 - Transit Space
ESC 302 - Defect Limits
ESC 310 - Underbridges
ESC 340 - Tunnels
ESC 420 - Track Drainage
SPC 234 - Resilient Fastenings
SPC 235 - Resilient Baseplates
SPC 301 - Structures Construction

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ESG 100.17 - Signal Design Principles Track Circuits

SMS-12-PR-0371 - Managing Engineering Design Control

2.3

Other References
Workcover Code of Practice - Tunnels under Construction
Environment Protection Authority NSW - Interim Guideline for the Assessment of Noise
from Rail Infrastructure Projects

Definitions and Abbreviations

The following defined terms are used in this document:
Trackform:

The type of track structure. May be ballasted or non-ballasted.

Ballasted trackform consists of ballast, ties, rail fastening
assemblies and rails.
Non-ballasted trackform consists of concrete slab(s), rail
fastening assemblies and rails.

Track Slab:

Concrete slab or slabs with directly fixed track

Rigid Track
Slab:

Track slab which is directly fixed to the ground or supporting

structure.

Floating Track
Slab:

Track slab which is isolated from the ground or supporting

structure using resilient bearings.

General Requirements

4.1

Use of Track Slabs

The use of track slabs may be necessary in the following situations:
locations with limited vertical clearance
existing tunnels where clearances to the track need to be increased to allow the
use of larger rolling stock or to increase the clearance to the overhead wiring
new tunnels where the use of non-ballasted track may enable a smaller tunnel
profile to be used, ongoing maintenance requirements to be minimised or where
the attenuation of noise and vibration is critical.

4.2

Design Standards
Designs are to comply with the requirements of the relevant Australian Standards,
specific site geotechnical parameters and the requirements of this Document.
Relevant standards and documents include:

AS 1170 - Structural design actions

AS 2159 - Piling Design and installation
AS 3600 - Concrete structures
AS 5100 - Bridge design
AS 1726 - Geotechnical site investigations
Workcover Code of Practice - Tunnels under Construction

The design life of track slabs shall be 100 years.

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4.3

ESC 362

Integrated Designs
The design of each track slab is to be integrated taking into account all associated
requirements such as drainage, track, overhead wiring, signalling infrastructure,
communications services, fire safety equipment and platforms.

4.4

Approved Materials
Approved construction material for main structural elements is concrete.
The use of polymer concrete sleepers embedded into track slabs is approved.
Fibre reinforced concrete is not to be used without the approval of the Chief Engineer
Civil.
Timber and masonry materials shall not be used.
Materials in tunnels shall generally be non-flammable and shall comply with specific
requirements for fire safety detailed in RailCorp Engineering Standard ESC 340 Tunnels.

4.5

Clearances
Horizontal and vertical clearances from slabs to structures adjacent to and over the track
are to comply with RailCorp Engineering Standard ESC 215 - Transit Space.

4.6

Safety
The design of track slabs is to take into account safety considerations for construction
and maintenance personnel, and any other parties including operations personnel who
may be required to use the structure.
Designs are to incorporate the requirements of the RailCorp Safety Management System,
particularly SMS-12-PR-0371 Managing Engineering Design Control.
Designs of track slabs in tunnels are also to comply with the requirements of Workcover
NSW Code of Practice - Tunnels under Construction.

4.7

Protection of the Environment

The design of track slabs is to take into account environmental impacts during
construction and maintenance activities, with a view to minimising any impacts.

4.8

Heritage
Heritage considerations and classifications must be observed in track slab designs. This
may have particular application in circumstances where an existing structure is being
refurbished or modified, or where a new structure is being proposed in the vicinity of
existing heritage items.

4.9

Services
Provision must be made in the design and installation of track slabs for services as
required, e.g. signalling, electrical, communications.
Services are to be positioned in accordance with the following requirements:
Transit space standard ESC 215;

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Clear of any walking areas where they might present a trip hazard;
Not to interfere with or obstruct emergency walkways;
Not to obstruct access to or reduce the capacity of refuge areas:
Not to obstruct drainage
Not to obstruct Track Control Marks.

The location of any services is also to be selected so that future access for maintenance
of the services is facilitated.

4.10

Design Procedure New or Infrequently Used Products

If any products specified in the design documentation can reasonably be deemed to be
new or infrequently used, these must be identified by the designer and referred to the
Chief Engineer, Civil for approval. The designer must be satisfied that the
manufacturer/constructor/maintainer understands any special requirements/practices
relating to the product prior to release of the design documentation.

4.11

Drawing Standards
Construction drawings are to comply with RailCorps standard procedures and formats,
and are to detail the design loadings, horizontal and vertical clearances, and any other
information that is relevant to ensuring that the new structure is constructed and
maintained in accordance with the design.

4.12

Construction
The design of track slabs is to take into account construction constraints, particularly live
road and rail operating conditions and track possession constraints.
RailCorp has a suite of technical specifications covering various aspects of civil
construction. The specifications are detailed in RailCorp Engineering Specification SPC
301 - Structures Construction and are to be incorporated in design and construction
documentation.
Construction methods include top down, bottom up or a combination of both.
Top down construction involves setting the rails in place with temporary supports and
casting the concrete slab in situ.
Bottom up involves installing a slab(s) and attaching the rails.
Track slab configurations include:

4.13

monolithic slab
base slab and top slab
sleepers embedded in a slab
base slab with kerb walls and an infill slab
concrete monoblocks embedded in concrete.

Maintenance
The design of track slabs is to take into account the ability to access key components for
inspection and maintenance purposes.
The design shall also consider provision for safe egress from maintenance plant and
vehicles onto the track slab.
Components, materials and finishes should be chosen to minimise future maintenance.

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Maintenance requirements are to be specified in all design documentation for track slabs.
Requirements are to include examination tasks and frequencies, damage limits, and
repair standards, and be supported by documentation showing the basis for these
requirements.

Design Requirements

5.1

General
Track slab design is a system design taking into account the stiffness of the:

sub-base
slab(s)
rail fastening assemblies
rail.

The sub-base is to be designed based on the results of a geotechnical investigation to

ensure it provides a continuous uniform support of the track structure. The sub-base shall
be designed to prevent the infiltration of water under the track slab and to mitigate against
the adverse effects of high water tables.
Track slab designs shall:
Include materials, components and design with proven service history. However,
this does not preclude the use of improved track technology that may become
available over time (refer to Clause 4.10 above);
Be capable of adoption throughout varying configurations of the structure, e.g. in
tunnels where configurations may vary between the running tunnel, crossover
caverns and underground stations;
Minimise the risk of derailment owing to track irregularities;
Provide uniform transmission of all rail borne forces to the trackform;
Incorporate continuous rail with no mechanical joints;
Provide appropriate electrical insulation and electrolysis mitigation measures;
Incorporate rail lubrication systems where maintenance requirements dictate;
Provide for future track maintenance, including rail replacement, in-situ rail welding
and emergency rail clamping.
In addition to the above, the design and installation of floating slabs shall ensure the
following:
The dynamic deflections must not cause the transit space to be compromised;
The dynamic behaviour of the floating slab must not act adversely with the vehicle
suspension modes, resulting in increased wear of any component or a reduction in
ride quality;
Bearing materials must minimise the increase in dynamic stiffness as the
frequency rises. Bearings must be designed and tested in accordance with the
requirements of AS5100.4-2004 - Bridge design Bearings and deck joints and BS
6177:1982 - Guide to selection and use of elastomeric bearings for vibration
isolation of buildings;
An adequate airgap is provided beneath the floating slab to avoid acoustic coupling
effects;
Resilient direct fixation of the rails is provided on top of the floating slabs;
The maintainability of the trackform is not compromised.
The trackbed vibration isolation systems must be optimised for operation with the rolling
stock that is to operate on the track. Where the proposed rolling stock is passenger only,
the systems must also be capable of withstanding occasional heavier loads, to account
for maintenance trains and other events that differ from normal operations.

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The maximum height of grout bed under the rail fixings shall be 60 mm. Packers are not
to be used.
High impact epoxy grouts/mortars or specially developed grouts are to be used under the
rails to accommodate the high dynamic effects and movement of the slab. There shall be
no metallic elements in the epoxy. Standard cementitious grouts shall not be used.
The grout bed shall provide sufficient edge distance to the bolt to avoid cracking of the
grout.
Where different trackforms are used on a particular project, the geometric tolerances
specified at the wheel/ rail interface should be the same. Different slab trackforms are to
be effectively bonded at the interface.
The design of track slabs shall provide for easy access to bearings for inspection,
maintenance and replacement. Procedures shall be specified in Technical Maintenance
Plans.
The design shall mitigate against debris getting into gaps around floating slabs. All gaps
shall be effectively sealed to prevent debris from entering gaps between structural
elements.
Non-resilient fastening assemblies are not to be used on track slabs.
Where the track slab consists of a base slab and a top slab, the top slab shall be tied to
the base slab with anchors.

5.2

Design Loads
Track slabs shall be designed to accommodate the train loadings as specified below:
Operating Class
Passenger Main Line / Light Line

200LA plus Impact

Mixed Passenger Freight Main Line

300LA plus Impact

Heavy Freight Option

350LA plus Impact

The loading is based on the railway traffic load in AS 5100 - Bridge design. The
Reference Load is 300LA. For the other loadings, all axles are to be proportioned by the
ratio of the nominated LA load divided by 300.
Operating Classes are defined in RailCorp Engineering Standard ESC 200 - Track
System.
For loadings less than 300LA, future loading requirements need to be considered. Final
approval of the design loads shall be obtained from the Chief Engineer, Civil.
The impact factor shall be in accordance with the dynamic load allowance in AS 5100
with the characteristic length based on either deck slabs or direct rail fixation.
Track slabs shall also be designed for the derailment load requirements of AS 5100.
Track slabs shall be designed for earthquake forces in accordance with AS 5100. The
earthquake design category shall be Type III i.e. essential to post-earthquake recovery.

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5.3

ESC 362

Infill Slabs
Where track slabs are constructed using top down methods in which a concrete infill
section is provided to connect the track fixings to the base slab, the concrete infill shall be
designed and detailed to ensure structural adequacy and durability to give a 100 year
design life to AS 5100.
In particular the construction joint between the infill concrete and track slab shall be
prepared by removing laitance to expose the aggregate using appropriate mechanical
equipment.
The reinforcement provided in the infill shall be designed to limit cracking due to early
thermal and shrinkage effects. Cracks shall not exceed 0.2 mm in width.
The infill slab shall be adequately tied down to the main track slab to ensure that debonding does not occur due to dynamic effects or thermal/shrinkage effects. The
maximum spacing of the bars shall be 500 mm in any direction.
The minimum thickness of the concrete infill shall be 250 mm.

5.4

Width of Track Slab

The track slab shall extend a minimum width of 500 mm beyond the fasteners on each
side of the running rails at the level of the slab under the rails. The maximum vertical drop
at the edges of the track slab shall be 150 mm, unless guard rails are provided.

5.5

Allowable Movements
The design of the track slab shall provide for allowable movements of the slab that do not
adversely affect the integrity of other infrastructure such as track and signalling.
Movements shall not result in the track geometry being outside the limits as specified in
RailCorp Engineering Standard ESC 210 - Track Geometry and Stability.
The design shall provide for construction, expansion and contraction joints as
appropriate.

5.6

Drainage
Provision must be made for adequate surface drainage by efficiently directing water into
the track drainage system. The track drainage system shall be cleanable as specified in
RailCorp Engineering Standard ESC 420 - Track Drainage.
Baseplates and fastenings must remain above water at all times.
Ponding must not occur on slabs or in the void beneath any floating slab. The drainage
design shall ensure that depth of run-off water on track slabs does not interfere with
signalling and electrical equipment.

5.7

Track Interface

5.7.1

General
The design of the track slab shall take of account of the interaction with the track
including longitudinal effects, thermal effects, concrete shrinkage and traction/braking
loads. The design shall consider the effect on both the track and the track slab, including
interaction of slab expansion and rail expansion.

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Track fastenings shall be approved resilient fastenings in accordance with RailCorp

Engineering Specifications SPC 234 - Resilient Fastenings and SPC 235 - Resilient
Baseplates.
Where epoxy grouts are used under the rail seat pad, the minimum thickness of the pad
shall be 7.5 mm.

5.7.2

Slab Construction
Where rails are to be fixed to the completed slab, the finished surface of the slab shall be
constructed to a tolerance of + 0 mm, - 5 mm from the design level.
Where top down construction is used, the construction method shall ensure track
fastenings are fully supported with no voids under the track fastenings. This is especially
important on superelevated track.

5.7.3

Turnouts
Where turnouts are planned in the track slab, full base plate fixings shall be installed to
allow installation of the turnout.
The rail must be straight railed through the turnout location without joints.

5.7.4

Guard Rails

5.7.4.1

General
Guard rails may be required to be provided along track slabs where it is determined to be
appropriate for providing protection to adjacent structures.
Concrete upstands may be provided as an alternative to standard guard rail sections.
Upstands are to be installed in the four foot, not on the outside of the track. The upstands
shall be designed for a 80 kN lateral load.
Guard rail installations are to comply with the following requirements:
Guard rail shall be new rail or recycled rail Category 1 (White rail).
Guard rail section is to be the same as the running rail or one section size less
than the running rail.
Top of guard rail is to be no higher than the adjacent running rail and no more than
50 mm below the running rail.
Each guard rail is to be plated and fastened on both sides at the same spacing as
the running rail fasteners.
Guard rails are to extend parallel for a minimum 20 metres in advance of the area
being protected on the train approach side.
Guard rails are to extend parallel for a minimum of 3 metres beyond the area being
protected on the train departure side.
A tapered nose section (vee), minimum 3.6 metres long, is to be installed on the
train approach side of the guard rail. The design of the vee shall be in accordance
with Drawing Number 785-570. The nose of the vee shall be bolted.
Where rail traffic is bi-directional, the guard rail is to extend 20 metres beyond the
area being protected on both approach and departure sides.
Where traffic is bi-directional, the tapered nose section is to be installed on both
ends of the guard rails.
Clearance between gauge face of running rail and adjacent face of guard rail is to
be 380 mm.
Block-out holes for guard rail fastenings in concrete sleepers/slab shall be grouted
with a high strength grout.

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For fixing details, dimensional set-out and componentry detail and sizes, standard guard
rail drawings are available:

5.7.4.2

785-568

Bridge guard rails Ballast top bridge Arrangement for concrete

sleepered track

785-569

Bridge guard rails Details of concrete guard rail sleepers Concrete

sleepered track

785-570

Bridge guard rails Ballast / Transom top bridge Arrangement for

timber sleepered track

785-571

Bridge guard rails Timber sleepered track Details of special plating

for tapered nose

Signalling Interface
Suitable isolation arrangements are to be made, where required, in track circuited and
electrified areas.
The tapered nose section (Vee) is to be insulated with an approved component - refer to
Figure 1. This insulation requirement applies to new installations and where
refurbishment of the guard rails is undertaken.

Figure 1
Where guard rails exceed 50 metres in length, additional insulation and bonding
arrangements may be required. Design drawings are to specify that insulation and
bonding arrangements shall be in accordance with the requirements of the Chief
Engineer Signals. See RailCorp Engineering Standard ESG 100.17 - Signal Design
Principles Track Circuits.

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5.8

ESC 362

Noise and Vibration

Track slabs shall be designed and constructed to attenuate the levels of vibration and
regenerated noise in adjoining properties and structures, to the limits specified for the
particular location or project and to comply with RailCorps environmental standards.
Where floating track slabs are used to mitigate noise and vibration effects, they shall be
of proven design with demonstrated performance in operating environments similar to the
RailCorp network.
The design shall take into account flexural vibration and noise radiation.
The design shall provide for ease of access for inspection and maintenance of all track
slab components.
Operational rail vibration arises at the wheel/rail interface and propagates via the track
support system to the tunnel structure, the ground and surrounding buildings. Occupants
of nearby buildings may detect rumble noise during the passage of trains, called
ground-borne noise. In some cases, occupants may directly perceive vibration, called
ground-borne vibration. The operation of highly sensitive medical or scientific equipment
can also be affected by vibration.
Ground-borne noise and vibration are highly complex issues. ISO 14387-1 - Mechanical
vibration Ground-borne noise and vibration arising from rail systems Part 1: General
guidance provides general guidance on prediction and design methods. Where
assessment and mitigation of ground-borne noise and vibration is required,
methodologies shall be consistent with those defined in ISO 14387-1.
The Interim Guideline for the Assessment of Noise from Rail Infrastructure Projects
published by the New South Wales Department of Environment & Climate Change
provides guidance on ground-borne noise goals.
Ground-borne noise and vibration is likely to have a significant bearing on the tunnel
alignment and/or track design. It is also important to consider operational and
maintenance issues that may influence ground-borne noise and vibration from tunnels,
including:
Track design features such as curves and crossovers, which increase the levels of
ground-borne vibration generated at source,
Ongoing maintenance of rolling stock, particularly wheels, and
Ongoing maintenance of track, particularly the rail running surface.
Source vibration levels are dependent on the dynamic interaction of the train with the
track support system. It is possible to vary the vibration spectrum generated at source by
varying the track support stiffness. Reduction in the track support stiffness results in a
reduction in source vibration and a reduction in ground-borne noise and vibration in
surrounding buildings. However, the effect of varying track support stiffness actually has
a frequency-dependent (tuning) effect. While there may be vibration reductions at most
frequencies, a reduction in track support stiffness actually results in an increase in
vibration at certain low frequencies. In other words, tuning of the track support system
results in redistribution of vibration energy from one part of the frequency spectrum to
another.
The selection and design of such track support systems for ground-borne noise and
vibration control requires careful consideration of maintenance and performance aspects.
Particular consideration shall be given to:
Modes of vibration of floating slab elements which may lead to a significant
increase in low frequency radiated noise
Transitions between track sections with differing support stiffness characteristics

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Wheel / rail interface issues such as corrugation development

Access and inspection and maintenance of resilient components.

5.9

Transition Section Trackforms

Transition section trackforms must be provided in locations where two differing trackforms
abut. The transition section must be designed to:
Provide a progressive change in track stiffness;
Provide an easily maintained trackform transition, which will not be prone to
differential settlement;
Provide accurate matching of track alignment under all load conditions, in order to
avoid stress concentrations in components or uneven ride characteristics;
Achieve the nominated levels of vibration and regenerated noise attenuation;
Minimise the number of transition sections.
Where track slabs abut ballasted track, a transition slab must be provided to achieve a
progressive change in track stiffness. The ballasted track on the transition slab shall be
designed and installed in accordance with RailCorps track engineering standards.
The minimum length of transition section trackform shall be 4.5 m.
Transition section trackforms shall be designed for the same loads as the track slab.

Prohibited Configurations
The following track slab configurations are prohibited:
Embedded rail systems.

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