GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS
(RAILWAY BOARD)

INDIAN RAILWAY

STANDARD SPECIFICATION

FOR PRE-TENSIONED PRESTRESSED CONCRETE SLEEPERS

FOR

BROAD GAUGE AND , METRE GAUGE AND NARROW GAUGE

SERIAL NO. T-39

(SIXTH REVISION – JUNE OCTOBER 2020)

RESEARCH DESIGNS AND STANDARDS ORGANISATION

LUCKNOW – 226011
 CONTENTS

Para No. Description

0. FOREWORD

1. SCOPE

2. GENERAL

3. MATERIAL

3.1 High tensile steel

3.2 Cement
3.3 Admixture
3.4 Aggregate
3.5 Water
3.6 Concrete
3.7 SGCI Insert

4. MANUFACTURE
4.1 Mould
4.2 Stretching of wire
4.3 Mixing & consolidation of concrete
4.4 De-tensioning
4.5 Curing
4.6 Supervision
4.7 Finish
4.8 Stacking
4.9 Lot

5. INSPECTION AND TESTING

5.1 General
5.2 General
5.3 Checks and Test
5.3.1 General
5.3.1.1 Visual and dimensional check
5.3.2 Casting of cubes
5.3.3 Method of testing
5.3.4 Compressive strength of cube at transfer of prestress
5.3.5 Compressive strength of cube at 15 days
5.3.6 Modulus of rupture of beam at 15 days
5.3.7 Static bending strength of sleepers
5.3.7.1 Method of testing
5.3.7.2 Acceptance test
5.3.7.3 Acceptance of lot
5.3.7.4 Retest
5.3.7.5 Testing of PSC sleeper in Zonal Railways testing
facility or at RDSO

Page 1 of 34
5.3.8 Measurement of Electrical resistance
5.4 Competency certificate

6 STAMPING AND MARKING

7 LOADING AND DISPATCH

8 GUARANTEE

Page 2 of 34
 INDIAN RAILWAY SPECIFICATION FOR
FOR PRE-TENSIONED PRESTRESSED CONCRETE SLEEPERS
(BROAD GAUGE AND METRE GAUGE)
SERIAL NO. T-39
(SIXTH REVISION – AUGUST OCTOBER 2020)

0. FOREWORD

0.1 This standard specification (First revision) was adopted by the

Indian Railways in May 1985 after the draft was finalized by the
Sub-committee of Track Standards Committee.

0.2 The last revision (Fifth Revision) was adopted by the Indian
Railways in February 2016.

0.3 The present revision (Sixth Revision) has been taken up with a
view to incorporate modifications found necessary as a result of
use of the specification both by the manufacturer and user.

0.4 The significant modifications incorporated in this revision are as

follows :-

0.4.1 All Correction slips /Corrigendum (Corrigendum no. 1 to 6)

issued till date have been incorporated.

0.4.2 Guarantee Clause has been revised to make it applicable for all
type of line sleepers plying on Indian Railways.

0.4.3 List of specifications (IS/IRS codes) needed for daily use and
referred to in this specification has been updated in Annexure-
VI.

0.4.4 Clause for acceptance of lot has been revised to make it

applicable for all type of line sleepers plying on Indian Railways.

0.4.5 Annexure-I has been revised.

0.4.6 Annexure-IIB showing gauge to measure toe gap at rail seat

with SGCI Insert to Drg. No. RT/6901 has been added.

0.4.7 Annexure-III has been revised to make it applicable for all type
of line sleepers plying on Indian Railways.

Page 3 of 34
1. SCOPE

1.0 This specification covers the manufacture and supply of pre-

tensioned pre-stressed concrete sleepers for broad gauge and
meter gauge. For production of PSC sleepers through long line
method, some of the provisions of this Specification may not be
implementable. In such cases, manufacturer shall approach
RDSO for specific dispensations, wherever required and these
dispensations will be considered by Track and Quality
Assurance Directorate of RDSO.

2. GENERAL

2.1 The manufacture of sleepers shall be to the Purchaser’s drawing

or to drawings approved by the Purchaser and the production
shall commence with the prior approval of the Inspecting
Officer. Any subsequent change in material or production
technique shall require prior approval of Inspecting Officer.

2.2 The reference to IRS specifications and drawings in this

specification relates to the latest version of these standards as
amended from time to time. The provisions of this specification
shall override the corresponding provisions of IS: Specifications.
Any special requirements given in the drawings of the sleepers
will override the relevant provisions of the specification.
Annexure-I shows the list of specifications required for
manufacturing of sleepers.

3. MATERIALS

3.1 High Tensile Steel

3.1.1 High tensile steel in the form of plain wire or strand shall
conform to IS: 1785 Part-I and IS: 6006 respectively. It shall be
procured only from BIS approved manufacturers who shall
furnish the proof of approval by BIS with the first consignment
during the currency of approval and for each fresh approval.
Each consignment of high tensile steel must be accompanied by
a test certificate showing the serial no. of coils. Each coil shall
carry a tag in accordance with the IS specifications mentioned
above. In addition to the normal tests stipulated in the IS
specifications for every consignment, results of “relaxation test”
shall also be furnished once in six months. In case of change
of source the first test certificate shall include “relaxation test”
results also.
The steel shall be used for production only after ascertaining
that it meets the provisions of relevant specifications.

3.1.2 Whenever directed by the Inspecting Officer, the manufacturer

shall get the steel in stock tested at his own cost.
Page 4 of 34
3.2 Cement

3.2.1 Cement shall be OPC 53-S conforming to IS:269-2015 (as

amended upto date). However, upper limit of SO3 and C3A
content in 53-S grade cement is revised as 3.3% & 9.0%
respectively for improvement in quality of PSC sleepers on IR.
Upper limit of initial setting time (IST) of 53-S grade cement is
specified as 120 minutes preferably but not more than 150
minutes.

3.2.2 Each consignment of cement shall be covered by a test

certificate. Each consignment shall be stocked separately,
tested in the laboratory of the plant immediately for all relevant
properties and shall be clearly identified. Cement more than 3
months old, if free from lumps, shall be tested for physical
properties by an independent government approved laboratory
or as directed by the Inspecting Officer and may be used after
his approval.

3.2.2.1 The Inspecting Officer has the right to have the cement in stock
tested at any time at the cost of manufacturer.

3.2.2.2 In case the source of supply of cement is changed, the mix

design shall be reviewed and modified, if necessary, as per
instructions given in para 3.6.3.1.

3.2.3 The cement content of the mix shall not be less than 350 kg/cu.
m. and not more than 450 kg/cu.m.

3.3 Admixture

3.3.1 Super Plasticizer conforming to IS: 9103 may be used with the
prior approval of RDSO. At this stage the revised concrete mix
design shall also be submitted to RDSO for approval. However,
following shall be observed:

3.3.2 Use of any admixture containing chloride in any form is

prohibited.

3.3.3 Generally one admixture at a time should be used.

3.3.4 The admixture should be stored as per specified conditions by

its manufacturer and its shelf life should be monitored
continuously. Regular testing of admixture shall be done
annually from NABL approved laboratory/NCCBM/IITs/NITs.

3.3.5 All containers should be correctly labeled. Reliable liquid

dispenser for liquid admixtures should be used and calibrated.

Page 5 of 34
3.3.6 The admixture containing Cl and SO3 ions shall not be used.
Admixtures containing nitrates shall also not be used.
Admixture based on thiocynate shall be prohibited.

3.4 Aggregates

3.4.1 The aggregates shall conform to IS: 383 - 2016 (third revision)
and shall, before use, be got tested through an approved testing
institute, and results submitted in accordance with Appendix ‘A’
of IS: 383 - 2016 (third revision) to the Inspecting Officer for
approval. These tests shall be got done at the manufacturer’s
cost once in a year or at the time of approval/review of mix
design or as desired by inspecting official. The aggregates shall
have maximum 30% abrasion and maximum 30% impact value
suitable for wearing surfaces when tested in accordance with
IS:2386 (Part-IV) - 1963. The flakiness index and elongation
index shall not exceed 30% when tested in accordance with IS:
2386 (Part-I) - 1963.

3.4.2 Coarse and fine aggregates shall pass sodium or magnesium

sulphate accelerated soundness test specified in IS: 2386 (part
V)-1963.

3.4.3 Aggregates shall not contain harmful material such as pyrites,

coal, lignite, mica shale or similar laminated material clay,
alkali soft fragments, sea shells and organic impurities in such
quantity as to affect the strength for reinforced concrete shall
not contain any material liable to attack steel reinforcement.
Maximum limit of deleterious material in aggregates should
conform IS: 383 - 2016 (third revision) when tested in
accordance with IS: 2386(Part-II) -1963.

3.4.4 Aggregates which are reactive with alkalies of cement are

harmful as cracking of concrete may take place. Potential
reactiveness of aggregates shall be tested as per IS:2386 (part
VII)-1963 .

3.4.5 Coarse aggregates shall be crushed stone, angular in shape and

gravel shall not be used.

3.4.6 Different sizes of aggregates shall be stacked in different storage

bins or stock piles on proper hard floor surface. The bins near
batching plant must be located under a covered shed to avoid
any chance of raw material getting wet due to rains.
Alternatively, auto sensors may be used to record the moisture
content in the aggregate along with auto mechanism for
adjusting water to be added to concrete in the weigh batcher.

3.4.7 If crushed stone sand is being used as fine aggregates then

bond strength (pull out test) of concrete shall be tested as per
IS: 2770 (Part I)-1967 during mix design approval and after
Page 6 of 34
 production of every 5000 sleepers during regular production.
Crushed stone sand being used should not be by-product of any
other manufacturing process. The pullout strength of concrete
shall not be less than 60KN.

3.5 Water
3.5.1 Water to be used in making and for curing concrete shall
conform to IS: 456. However use of sea water is prohibited.
3.5.2 If water needs any treatment before use, adequate storage of
treated water for daily requirement shall be made. Facilities for
testing treated water shall be provided in the plant. Treated
water shall be tested daily or as directed by the Inspecting
Officer.

3.5.3 The total water content per batch shall be regulated with
conform with the ratio by weight of free water to cement
required for the particular design mix as established by
preliminary tests. The total water content of a batch includes:
(a) Absorbed water in the aggregates;
(b) Free water in the aggregates; and
(c) Free water added to the mix.

3.5.3.1 The water to be mixed at the mixer shall be free water content
required per batch less the amount of free water in the
aggregates, if wet, or plus the amount of water the aggregates
will absorb, if dry. Free moisture content shall be determined at
least once a day.

3.6 Concrete

3.6.1 The concrete shall be of controlled quality with the nominal

maximum size of aggregates limited to 20mm. Where wire
spacing permits, aggregates upto 25mm may be used. The
manufacturer shall get the concrete mix design along with the
upper and lower limits of granulometric curves approved by the
Inspecting Officer.

3.6.1.1 The granulometric curves shall be plotted on semilog graph

once in a week and shall be between the approved limits.

3.6.1.2 Coarse and fine aggregates shall be batched separately.

3.6.2 The concrete shall satisfy the following design parameters:

i) Minimum release strength after 40 N/sq.mm (For Mix M-55)
steam curing 40N/sq.mm (For Mix M-60)

ii) 15 days characteristic strength 55 N/sq.mm (For Mix M-55)

after water curing 60 N/sq.mm (For Mix M-60)

Page 7 of 34
 iii) Percentage of cubes with strength Not more than
less than the characteristic strength 2.5%
as per mix design/statistical analysis

iv) Co-efficient of variation Less than 7%

3.6.3 Concrete mix shall be designed as per guidelines in IS:10262-

2019 (or latest version) and complying design parameters as per
para 3.6.2 by the sleeper plant, checked by zonal railways and
got approved from RDSO before start of the sleeper production.
RDSO will check and verify the new mix design at the sleeper
plant by testing of trial cubes as per para 3.6.4 and complying
design parameters as per para 3.6.2.

3.6.3.1 Zonal railways shall review the concrete mix design themselves
whenever the source of cement or water or admixture is
changed as per guidelines in IS: 10262: 2019 (or latest version)
provided the quantity of cement is not reduced. All new
ingredients must be got tested before hand from reputed
laboratory to ascertain whether they are suitable to be used as
per relevant standards/ specifications. The copy of test report of
all ingredients, mix design calculations, record of trial cube
testing and records of modification should be communicated to
RDSO for information and should be available with zonal
railway as well as with CSP, so that the same can be inspected
during oversight inspection by RDSO official. However, if the
source of aggregate changes, RDSO should be approached by
the zonal railways for approval of the source and also for
reviewing/revising the mix design.

Zonal Railway or RDSO will check and verify the revised mix
design at the sleeper plant by testing of trial cubes as per para
3.6.4 and complying design parameters as per para 3.6.2.

3.6.3.2 Workability of mix should be kept low i.e. compacting factor in

range of 0.75-0.80 for stress bench method. For long line
method, workability should be kept slightly higher with slump
up to 25mm if required, for proper compaction of concrete, but
not leading to segregation to constituents of concrete mix under
vibrations.

3.6.4 At the time of approval/review of mix design, 80 cubes shall be

cast, using materials proposed for regular manufacture, in 10
separate concrete batches of 8 cubes each, 4 for steam curing
and 4 for water curing.

3.6.4.1 All the 40 cubes cured according to the proposed steam curing
cycle shall attain the specified minimum release strength.

Page 8 of 34
3.6.4.2 The statistical analysis of the compressive strength values of the
40 water cured cubes shall satisfy the design parameters of
clause 3. 6.2 (ii), (iii) & (iv).

3.7 SGCI Inserts

3.7.1 SGCI inserts shall conform to IRS Specification No.T-46-1996 as

amended up-to-date and will be procured only from RDSO
approved manufacturers. Each consignment of SGCI inserts
shall be accompanied by a test certificate from inspecting
agency for inspection conducted prior to dispatch of
consignment from supplier’s premises.

3.7.2 Whenever directed by the inspecting official, the sleeper

manufacturer shall get the SGCI inserts in stock tested at his
own cost.

4. MANUFACTURE

4.1 Moulds
Moulds shall be of steel with minimum plate thickness of 10
mm in Rail seat area as well as for end plates. For other
locations minimum plate thickness is to be 6 to 8 mm. Moulds
shall be of rigid construction so as to prevent any in-service
distortions. Moulds shall not allow any appreciable leakage of
cement mortar in casting. The holes in the end plates shall be
accurately drilled for correct placement of prestressing wires.

4.2 Stretching of wires

The prestressing wire shall be stretched either individually or

collectively by an approved method. The tensioning force shall
be as shown on the sleeper drawing. The final force to be
adopted, duly considering the losses while stretching shall be
approved by the Inspecting Officer. However, the stretching
force shall in no case exceed 75% of the minimum specified UTS
of the wire. The pre-tensioning force in the wire shall be applied
by a tensioning device equipped with automatic load cut off unit
along with measuring gauge. The final force shall also be
verified by measuring the extension of the wire.

4.3 Mixing and consolidation of concrete

4.3.1 Manufacture of sleepers shall be done under a shed.

4.3.2 Batching of different ingredients shall be done by weight only.

A modern, mechanized, or automatic weigh batcher shall be
used for weighing aggregates and cement. The weigh batcher
shall have an accuracy of +/- 3% for aggregate, admixtures &
water and +/- 2% for cement.

Page 9 of 34
4.3.3 Modern high speed mixer, pan, turbine or any other suitable
type, approved by the Inspecting Officer shall be used for mixing
concrete. Concreting shall commence within 2 hours of
stressing of wires, failing which the HTS wires shall be checked
and re-tensioned, if necessary.

4.3.4 Concrete shall be thoroughly mixed and consolidated by means

of vibrators of at least 9000+4% revolutions/minute. The
vibrator should normally be fixed at the bottom of the mould, at
least at two different locations for a sleeper. Any other vibration
system should have prior approval of RDSO.

4.3.5 Freshly cast sleepers shall be protected during the first stage of
hardening from adverse weather conditions.

4.4 De-tensioning of wires

Anchoring system shall provide a device for gradual de-
tensioning of the wires. Back pulling of wires for releasing any
wedge shall be strictly prohibited. De-tensioning of wires shall
be undertaken only after the concrete has attained a
compressive strength of 40 N/sq.mm.

4.5 Curing
4.5.1 Initial curing of concrete sleeper shall be done by steam at
atmospheric pressure till the concrete attains a compressive
strength of 40 N/sq.mm. Pre-steaming period shall not be less
than the initial setting time of cement.
Total steam curing cycle duration can vary from 10 to 12 hours
depending on time taken in the steam curing stages e.g.
presteaming, temperature rising (heating), constant temperature
duration, cooling etc. Total cycle time depends on ambient
temperature.

i) Normal pre-steaming period is recommended as 2 hours or

initial setting time (IST) of cement whichever is greater.
ii) Temperature rising time is recommended as 2.0 to 2.5
hours keeping maximum rate of rise of temperature as 15°C
per hour.
iii) Maximum steam curing temperature shall be not more than
60°C keeping constant temperature in range of 55 – 60°C.
Constant temperature duration can be kept between 3.5 to
5.0 hours.
iv) Cooling of sleepers shall be gradual and cooling period is
recommended in range of 2 to 3 hours with cooling rate not
exceeding15°C per hour.

Extra one hour cooling of sleepers at ambient temperature

before demoulding is desirable/recommended, if feasible
Page 10 of 34
 keeping the total cycle time upto 12 hours to minimize
difference in external and internal (inside) temperature of
sleepers.

Mix design shall be revised, if minimum strength of 40 steam

cured cubes is less than 40 N/mm2 following the above
mentioned stipulations on steam curing cycle. The steam
curing cycle which is proposed to be adopted shall have prior
approval of the inspecting official.

4.5.2 After de-tensioning & de-moulding, the sleepers shall be cured

for a further period of not less than 14 days (as per mix design)
by submerging in water. Water used for curing should conform
to the quality prescribed for water to be used for concrete mix.

4.5.3 Each steam chamber in stress bench method or production line

in long line method shall be attached with a separate digital
thermal sensor, temperature shall be recorded continuously and
record shall be maintained.

4.6 Supervision

4.6.1 Suitably qualified persons as per Schedule of Technical

Requirement shall be engaged by the manufacturer for
supervising the following items at the works:

i) Placing and stressing of prestressing wire;

ii) Batching, mixing, placement and compaction of concrete.

Checking of the steam curing arrangement for its
adequacy.

iii) De-moulding of sleepers, water curing, stacking/ loading

etc.

iv) Inserts shall be checked by suitable jigs before use by the

manufacturer.

v) Testing of cement, cement mortar cubes, concrete cubes,

concrete beams;

vi) Calibration of testing and measuring equipment and

different gauges;

vii) Checking electrical resistance of sleepers.

Page 11 of 34
4.6.2 Supervisor so engaged shall maintain records as directed by the
Inspecting Officer and shall present them for scrutiny when
demanded.

i) A site register shall be maintained in which inspecting

officer shall record observations against which compliance
will be recorded by the supervisor.

ii) Suitable records as per Schedule of Technical

Requirement shall be maintained in such a manner that it
can be correlated at a later date to the sleeper laid in field.

4.7 Finish

4.7.1 All sleepers shall be free from surface defects such as water
retaining pockets, air holes or honey combed formations. The
underside of the sleeper coming in contact with ballast shall be
left rough but the unevenness shall not exceed 5mm. The ends
of the prestressing wires shall be cut close to the surface of the
sleeper in such a way that there is minimum damage to end
plate and the wire in no case shall project more than 3 mm from
the concrete surface. Two coats of suitable ISI mark anti
corrosive paint, approved by Inspecting Officer, shall be applied
at the ends of the sleepers in the following manner:

i) First coat of paint, sufficient thick to form impervious film of

paint covering full surface of either ends of a sleeper shall be
applied just after de-moulding from sleepers mould, and

ii) Second coat after taking out the sleepers from submerged water
curing tank in the above manner, ensuring that surface to be
painted is completely dry and clean of dirt etc.

4.7.2 No touching up or finishing by cement mortar etc. shall be

permitted on concrete sleeper, after it is de-moulded, except as
provided in clause 4.7.3.

4.7.3 Such sleepers which are not found acceptable due to surface
defects, shall be accepted up to a ceiling of 1% of the supplies
made any time during the currency of the contract provided
such sleepers are adequately treated with epoxy compounds to
the satisfaction of the Inspecting Officer. However, epoxy
treatment of rail seat area is not acceptable. These sleepers
shall be marked as shown in Drawing No.RDSO/T-2466 before
dispatch. The rectified sleepers shall be paid for at the rates
fixed by the Purchaser.

4.8 Stacking
After the sleepers have been cured in terms of clause 4.5.2 and
checked both dimensionally and visually they shall be stacked
Page 12 of 34
 at convenient place in lots. The stacking of sleepers shall be
done on leveled and consolidated ground, one over another up
to 25 layers. Each layer shall be separated by wooden/concrete
battens of 50mm x 50mm size of suitable lengths to avoid any
damage.

4.9 Lots
All sleepers cast in one shift shall form one lot.

5. INSPECTION AND TESTING

5.1 The manufacturer shall supply at his expense, all the sleepers
required for tests and retests, samples of materials, labour,
machine, tools, gauges, apparatus, forms of test reports etc.
and any other item which may be necessary or required by the
Inspecting Officer for carrying out any or all of the checks and
tests mentioned in these specifications and shall render all
reasonable assistance in conducting such checks and tests. All
measuring and testing appliances shall be got checked and
calibrated according to the schedule given in Annexure-I,
through government approved agency or as directed by the
Inspecting Officer. The calibration certificate shall be furnished
to the Inspecting Officer. The cost of all such checks and
calibrations shall be borne by the manufacturer.

The plant controlling Railway officer minimum JAG level have

liberty to recalibrate the various gauges and testing equipments
in the concrete sleeper plant or by engaging the external
government approved agency who can bring their calibration
equipments at the plant itself, whenever they consider
necessary. The necessary arrangements will be facilitated by the
manufactures and cost will be borne by the manufacturer.

5.2 Inspecting Officer and the Purchaser shall have free access at
all reasonable times to the works in which the sleepers are
manufactured. They shall be at liberty to inspect the
manufacture of sleepers at any stage and to reject any material
supplies not conforming to the terms of the specifications and to
reject sleepers not manufactured according to approved
manufacturing process. They shall be provided with necessary
assistance for inspection by the manufacturer.

5.3 Checks and tests

5.3.1 In addition to the control checks exercised on the materials and

manufacturing process specified above, the concrete and the
finished sleepers shall be subjected to regular checks and tests,
after 14 days submerged water curing, as detailed in clause
5.3.1.1.

Page 13 of 34
5.3.1.1 Visual and Dimensional Check

Every sleeper shall be visually inspected for surface finish. No

sleeper shall have surface defects except as provided in para
4.7.3.

Sleeper dimensions to be checked are listed below:

(i) Critical dimensions are toe gap, location of inserts,

distance between inserts at rail seat, distance between
outer most inserts and slope at rail seat.

(ii) General dimensions are depth of sleeper at centre, rail

seat and end of sleeper; width of sleeper at top and
bottom; length of sleeper, camber and wind at rail seat
and position of high tensile steel wires at ends.

The sketch at Annexure-II shows the dimension checking

arrangement. The dimensions, shown on the sleeper
drawing, shall be checked by means of approved gauges,
procured by the manufacturer. (Annexure II/A & II/B
shows the gauges for measuring toe gap of rail seat).

(iii) Scale of check

a) Prior to stabilization of production technique*:-

Scale of check per lot for critical dimension is 100%
(hundred percent) and for general dimensions 10%
(ten percent) of sleepers produced.

b) After stabilization of production technique* :- Scale

of check per lot for critical dimensions is 10% (ten
per cent) and for general dimension 1% (one
percent), but the dimensions between outer inserts
shall be checked 100%.

c) Notwithstanding the provisions in (a) & (b) above

the Inspecting Officer may decide to check the
dimensions at scale higher than mentioned in para
(a) & (b) above.

* Acceptance of minimum 10000 sleepers and achieving

rejection rate less than 2% consistently, whichever is
later, shall be one of the major criteria for deciding the
stabilization of the manufacturing technique. After
stabilization, the rejection rate shall be assessed after
every 30000 numbers sleeper production and if it is found
beyond 2%, then all the testing have to be done as per the
Page 14 of 34
 frequency prescribed for pre-stabilized production. The
additional cost of sleepers required for testing shall be
borne by the firm.

5.3.2 Casting of cubes

15 cm size cubes shall be cast on a vibrating table conforming

to IS:2514 (1963) from random samples spread over the entire
lot, out of concrete used for casting sleepers for testing prior to
transfer of prestress and 15 days.

5.3.3 Method of testing

The cubes shall be surface dry at the time of testing. The rate of
loading shall be about 400 KN/minute.

5.3.4 Compressive strength of concrete at transfer (release) of

prestress

These cubes shall be steam cured along with sleepers in the

same manner and tested for transfer of prestress to concrete (at
least one cube for every steam chamber/3 for each long line but
not less than a total of 3 in any case).

5.3.5 Test for 15 day compressive strength of concrete

These cubes shall not be steamed but shall be water cured for
14 days after de-moulding. Two number of samples per lot (one
sample comprises of 3 cubes) shall be taken.

The samples should be spread over the entire period of

concreting in a lot. Cubes of these samples shall be tested for 15
days compressive strength of concrete. The test result of a
sample shall be the average of the strength of three cubes.
Individual variation in cube strength in a sample should not be
more than ±15% of the average. If variation is more than ±15%,
the test results of the sample is invalid and the lot shall be
rejected.

Further, if mean of two test results of two samples is < fck and /
or minimum of the two test results of two samples is < fck – 5
N/mm2, the lot shall also be rejected. Where, fck is characteristic
strength of concrete i.e. 55 N/mm2 for M55 and 60 N/mm2 for
M60 grade of concrete.

Otherwise, the concrete is accepted for further testing of

sleeper/s as per para 5.3.7.2.2.

Page 15 of 34
5.3.6 Test for 15 day modulus of rupture of concrete

The test for 15 day modulus of rupture of concrete shall be

carried out on concrete beams of 10 x 10 x 50 cm size as
specified in IS:516 – 1959. One specimen shall be tested daily
prior to the stabilization of production technique, and once a
week thereafter. If any value falls below 5.2 N/mm2 for M55
and 5.5 N/mm2 for M60, the mix design shall be reviewed.

5.3.7 Tests for static bending strength of sleepers

5.3.7.1 Method of testing

5.3.7.1.1 The tests shall be conducted in accordance with the

arrangement shown in Annexure-III.

5.3.7.1.2 The sleepers shall be loaded gradually (30-40 KN/min) upto the
specified load, which will be retained at this level for three
minutes for observing cracks, if any. For the purpose, a crack
is defined as one which is barely visible to the naked eye and is
at least 15mm long from the tension edge of the sleeper.
However, if crack appears at a load smaller than the specified
load, that value shall be recorded.

5.3.7.1.3 In case of ‘Moment of Resistance’ (MR) test, the sleeper shall be

deemed to have passed the test if it sustains the loads specified
in Annexure-III or in relevant sleeper drawing without cracking.
While loading, load can be applied upto 5KN in excess of
specified load.

5.3.7.1.4 In case of ‘Moment of failure’ (MF) test, the sleeper shall be

deemed to have passed the test if it is able to take load beyond
the specified test load. The initial cracking loads shall also be
recorded for rail seat bottom, centre top and / or centre bottom
(as the case be) for further statistical analysis of data during MF
test.

5.3.7.1.5 Sleepers for test shall be selected randomly by the inspecting

officer.

5.3.7.2 Acceptance tests

5.3.7.2.1 Moment of failure (MF) test (for rail seat bottom)

Prior to stabilization of production technique, one sleeper for

every 250 sleepers manufactured shall be tested. After the
production technique gets stabilized the testing scale shall be
reduced to one sleeper for every 2500 sleepers produced.

Page 16 of 34
5.3.7.2.2 Moment of resistance (MR) test (Rail seat bottom, centre
top, centre bottom)

Depending on 15th day test results of samples of the lot as

mentioned in para 5.3.5, the scale of testing of sleepers for the
lot shall be as follows (as explained in Table -1):

i) Wherever mean of the two test results of two samples is ≥

fck + 3 N/mm2 or fck + 0.825 x established standard
deviation whichever is greater and minimum of the two
test results of two samples is ≥ fck - 3 N/mm2 and the lot
is not rejected as per the criteria given in para 5.3.5– one
sleeper per lot

ii) Wherever mean of two test results of two samples is < fck
+ 3 N/mm2 or fck + 0.825 x established standard
deviation whichever is greater but ≥ fck or minimum of
the of the two test results is < fck - 3 N/mm2 but ≥ fck -
5 N/mm2 or both and the lot is not rejected as per the
criteria given in para 5.3.5 – two sleeper per lot

iii) In case, mean of two test results of two samples is < fck
and /or minimum of the two test results of two samples
is < fck – 5 N/mm2, the lot shall be rejected and no
testing for moment of resistance or moment of failure will
be conducted.

Note:
a. Prior to stabilization of production technique: Sleeper to
be tested shall be subjected to rail seat bottom, centre top
and centre bottom tests.
b. After stabilization of production technique: Sleeper to be
tested shall be subjected to rail seat bottom and centre
top tests only.
Table -1: Acceptance / Rejection Criteria of Concrete and No. of
Sleepers for SBT Test per Lot

SN First condition Second Conditions to be No. of

Condition complied sleeper per
lot for test
Case If average of test If minimum of Both conditions Concrete is
1 results of two test results of are to be fulfilled accepted
samples is ≥ fck+ 3 two samples is and the lot is not and one
N/mm2 ≥ fck– 3 rejected as per the sleeper will
or N/mm2 criteria given in tested for
Page 17 of 34
 ≥ fck + 0.825 x para 5.3.5. SBT from
established the lot.
standard
deviation, N/mm2
whichever is
greater
Case If average of test If minimum of Any one of them Concrete is
2 results of two test results of or both conditions accepted
samples is < fck + two samples is are fulfilled and but two
3 N/mm2 < fck – 3 the lot is not sleepers will
or N/mm2 but rejected as per the be tested
< fck + 0.825 x ≥ fck – 5 criteria given in for SBT
established N/mm2 para 5.3.5 from the
standard lot.
deviation, N/mm2
whichever is
greater
but ≥ fck N/mm2

Case If average of test If minimum of Any one of them Lot rejected

3 results of the two test results of or both condition without any
samples is < fck two samples is are fulfilled. further
N/mm2 < fck – 5 testing on
N/mm2 sleepers of
the lot.

5.3.7.3 Acceptance of ‘lots’

5.3.7.3.1 All sleepers tested in accordance with clause 5.3.7.1 should

pass all the acceptance tests provided in clause 5.3.7.2 for the
lot to be accepted. The specified values of Load for Centre Top,
Centre bottom, Rails Seat cracking and MF test shall be as per
relevant RDSO’s drawings of various PSC sleepers.

5.3.7.3.2 If the sleeper fail in any of the tests conducted as per clause
5.3.7.2.2 (i), the lot shall be subjected to ‘retest’ as per clause
5.3.7.4.

5.3.7.4 RETEST

5.3.7.4.1 Moment of resistance (MR) test

For every sleeper failed in acceptance tests as per clause
5.3.7.2.2 (i), two more sleepers from the same lot shall be
retested as per clause 5.3.7.2.2.

However, in case of testing of two sleepers as per clause

5.3.7.2.2(ii), if any of the sleepers fail, the lot shall be rejected.

5.3.7.4.2 Moment of failure (MF) test

In case of failure of the sleeper in MF test as per clause
5.3.7.2.1, 2 more sleepers from the same lot shall be selected for
testing in MF as per clause 5.3.7.2.1 and 5.3.7.2.2 and
Page 18 of 34
 subjected to all relevant tests. However, if the sleeper has
passed MF test and failed in some other test MF test need not
be repeated on subsequent sleepers subjected to testing.

5.3.7.4.3 For acceptance of the lot, all the sleepers tested in ‘retest’ must
pass all the tests conducted. However, sleepers failing in any
static bending tests shall not be paid for.

Also final passing of the lot is a prerequisite condition for

payment for any sleeper having passed all the relevant tests
conducted on that sleepers.

Sleeper/sleepers tested for rail seat bottom failure test and

passes the test, shall be paid by the purchaser, if that particular
lot passes all the relevant retests.

NOTE:

In case where more than one test value is obtained in retests.

The lowest value obtained will be taken as strength of the lot for
deciding the result of the lot.

5.3.7.5 Testing of PSC sleeper in Zonal Railways testing facility or

at RDSO

Three/Four sleepers due for testing selected randomly at the

level of minimum JAG will be sent for Static Bend Test (SBT)
and Moment of Failure (MF) test to RDSO or at testing facilities
available with Zonal Railways such as ‘Bridge Workshops/‘Soil
Testing Lab’ or any other Lab of Open line / Construction Unit
of Zonal Railways for a frequency not less than once in a year.
Zonal Railways should choose testing agency either RDSO or
Railways who can perform the testing within 7 to 14 days
including transportation time. Out of which one sleeper selected
randomly will be tested. If sleeper fails in any of the test as per
clause 5.3.7.1, the other two sleepers shall be subjected to
retest as per clause 5.3.7.4. The testing cost including
transportation etc. for above testing will be borne by the
Railway.

If the sleeper fails in above testing:

(i) All sleepers manufactured in that batch will be rejected and re-
calibration of the all gauges and various testing equipments in
the sleeper plant is to be carried out at manufacturers cost.

(ii) Three/four sleepers from next one batch will also be got tested
for Static Bend Test (SBT) and Moment of Failure (MF) test as
above from RDSO or at testing facilities available with Zonal
Railways such as ‘Bridge Workshops/‘Soil Testing Lab’ or any
other Lab of Open line / Construction Unit of Zonal Railways. In
case of failure of sleeper in any of the test as per clause 5.3.7.1,
Page 19 of 34
 two sleepers from the same batch shall be subjected to retest as
per clause 5.3.7.4. In case failure of sleepers from next one
batch, the concerned batch shall be rejected and further
production shall be suspended. The detailed enquiry of the
concerned sleeper plant is to be ordered by PCE of Zonal
Railway. In addition, the quality audit is to be ordered by an
Officer not below the rank of JAG.

All precautions should be taken during handling &

transportation of sleepers for outside testing so that these are
not received in cracked Condition for testing. The condition of
the sleepers received before testing shall also be mentioned in
the test report.

(iii) The sleeper plant representative can be permitted to witness the

transportation of sleepers and the testing in RDSO/Railways
Lab.

5.3.8 Measurement of electrical resistance

5.3.8.1 All sleepers shall be tested as per Annexure-V for electrical

resistance for their fitness for use in track circuited area.

5.3.8.2 Competency Certificate

For inspection of concrete sleepers, officials having competency

certificate issued after due test by RDSO/Chief Track Engineer
only shall be posted.

6. STAMPING AND MARKING

6.1 All the sleepers shall have legible permanently inscribed and
painted markings on the top as per drawing No.RDSO/T-2466.

6.2 The accepted sleepers shall bear the passing marks of the
Inspecting Officer in indelible paints. Sleepers which have been

subjected to static bending strength test up to cracking and

accepted, shall in addition be marked on the top in indelible
paint with the letter ‘T’. MF tested and accepted sleepers shall
bear the marking ‘MF’ in paint with yellow bands at ends.

6.3 All sleepers fit for use in track circuited area shall bear the
mark ‘FTC’ at the center of the sleeper.

6.4 Rejected sleepers shall be stacked separately by the

manufacturer so as to avoid their mixing with the accepted
sleepers. Such rejected sleepers shall be marked in the way
specified in drawing No.RDSO/T-2466.
Page 20 of 34
 The rejected sleepers shall be permanently damaged so as to
render them un-useable and a certification that all rejected
sleepers of previous batches have been permanently damaged
will be given by manufacturer before offering next batch for
inspection. The same shall be verified and ensured by
inspecting officials/ SSE’s and AIE before issuing the IC.

6.5 All markings mentioned in para 6.1 to 6.3 shall be done with
enamel paint of ISI mark and shall be such as to last for at least
3 years under normal weather conditions. Colour and quality of
the paint used shall be got approved by the Inspecting Officer.
All such markings shall be done by the manufacturer at his
cost.

7. LOADING AND DESPATCH

7.1 Only those sleepers which have been passed, properly marked
and accepted by the Inspecting Officer shall be loaded for
despatch.

7.2 The loading of the passed sleepers in wagon shall be done by

the manufacturer at his cost as per the loading arrangement
approved by the purchaser. The sleepers shall be properly
secured to avoid movement and displacement during transit.
The manufacturer shall be responsible to replace, free of cost,
all the sleepers which are found damaged in transit on account
of defective loading.

8. GUARANTEE

8.1 The sleepers shall be guaranteed by the manufacturer for a

period of five years from the date of manufacturing / 3 years
from the date of placement in service (whichever is earlier). If
during the guarantee period, sleepers in general are found to
develop defects attributable to bad material and workmanship
as established during investigation, leading to large scale
withdrawal from service, the cost of sleepers and their
replacement shall be borne by the manufacturer. The defective
sleepers withdrawn from service can be taken over at site by the
manufacturer for their disposal. The manufacturer shall make
good the cost due within 60 days of advice of defects. The
sleeper manufacturer will also be involved during inspection /
investigation and his view will be considered by the Purchaser
before taking decision. The decision of the purchaser shall be
final and binding in this regard.

Page 21 of 34
 ANNEXURE-I

SCHEDULE FOR CALIBRATION OF VARIOUS GAUGES AND TESTING

EQUIPMENTS IN THE CONCRETE SLEEPER PLANT

S.No. Equipment Frequency

1 15 cm concrete cube testing Once in 3 months
machine (2000 KN capacity)
2 Cement mortar cube testing Once in 6 months
machine (500 KN capacity)
3 Sleeper Static Bend Test Machine Once in 3 months or after testing 250
(1000 KN capacity) sleepers, whichever is earlier.
4 Pre tensioning Jacks (500 KN Once a month or after casting 5000 sleepers
capacity for single mould bench) & for single mould and once a month or after
(1000 KN Capacity for twin mould casting 10,000 sleepers for twin mould,
bench) whichever is earlier.
5 Pre-tensioning load cell Once a month or after casting 5000 sleepers
for single mould and once a month or after
casting 10,000 sleepers for twin mould,
whichever is earlier.
6 Concrete Beam Testing Machine Once in 6 months
(100 KN capacity)
7 Aggregate weight batcher Once every week or after casting 2000 4000
sleepers, whichever is earlier.
8 Cement weighing equipment Once every week or after casting 4000
sleepers, whichever is earlier.
9 Water Meter Once every week or after casting 4000
sleepers, whichever is earlier.
10 Admixture dispenser Once every week or after casting 4000
sleepers, whichever is earlier.
11 Master gauges for checking Once in 6 months
correctness of dimension measuring
gauges
12 Dimension checking gauges Once every 15 days or after inspecting 5000
sleepers, whichever is earlier.
13 Proving rings (2000 KN, 500 KN, Once in 18 months
1000 KN and 100 KN capacity)

14 Weights & Measures By Weights & Measures Department as per

extant rules.
15 Tachometer Once a year

ANNEXURE-I (CONTD.)

Note:

1. The items referred at S.No.1 to 6 above should be calibrated by

proving rings in the sleeper plant itself.

2. The items referred at S.No.7 & 8 should be calibrated by dead

weights and item at S.No.9 & 10 by measuring cans which should
be available in the plant.

Page 22 of 34
3. The proving rings should be got calibrated from a reputed
organization like the IITs, NCCBM or NPL etc.
4. The record of calibration of all the above equipments should be
maintained in a manner that previous records can be easily
connected.

5. The calibration can be done more frequently at the discretion of the

Inspecting Official.

Page 23 of 34
Page 24 of 34
 Annexure – IIA

130
80

8mm M.S. ROD

8
DST- IV ASHWANI KUMAR

HANDLE
13
R 5R
DDST-II S.K.AWASTHI

27
INSERT DRG. No. TO
20 mmDIA: PIN BE STAMPED HERE.
75mm LONG WELD OF SUITABLE SIZE OR SCREWED
RT-
HEEL
13 12
IA: T0E
20D C

50

50
APPD: A:
Y
A: DI
5

DI 20

X
TRC: COMPUTER

20

R25

5
3
35 50 10 75
10mm THICK
PLATE.
ELEVATION SIDE ELEVATION
CH:
K.J.SINGH

130

TABLE

10
INSERT TO DIMENSIONS mm
DRG. No. x y
DRG:
CH:

RDSO/T-381 17 7

RDSO/T-4847 9.5 7
CAL: M.BOTKE

WELD OF SUITABLE SIZE RDSO/T-4848 8.2 7

AND OR SCREWED 7.75
RDSO/T-2479 17.75

75
RDSO/T-3705 21,70 7.00
CH:

RDSO/T-3087 22.40 9.50

20 20 20
R. D. S. O.
PAGE n/55 TO 57 PAGES
CT/FD/2/CI CR.No.

PLAN

±1
±1 STAN D

1. REVISED AND REDROWN

CANC LD
REV ..D
..
..
ADVANCE
25-11-92 (T)
FILE

NOTE SPECIFICATION SCALE ALT: DESCRIPTION DATE RDSO / T- 4154

Page 25 of 34
Annexure-IIB

Page 26 of 34
 ANNEXURE-III

Note:- The testing arrangement is for guidance purpose only. Testing shall be
conducted as per test loads mentioned in the relevant RDSO’s drawings
of PSC sleepers. The dimensions A & B mentioned in above testing
arrangement shall be referred from relevant RDSO’s drawing of PSC
sleepers.

1. All dimensions are in millimeters.

2. The load ‘P’ will be applied at centre line of Rail Seat through pressure
distributing M.S. Plate with 1 in 20 slope and size 145X25mm, covering
the full width of sleeper.

Page 27 of 34
3. One rail seat bottom shall be tested at a time. It shall be ensured that
the other end is not restrained in upward direction. The rate of loading
is 30-40KN per minute.

4. Cracks shall not appear up to the load mentioned in relevant drawings,

when retained for three minute.

5. A coat of lime wash shall be applied on the sleeper surface before

testing.

Page 28 of 34
Page 29 of 34
 ANNEXURE-IV (Contd.)

NOTATIONS & EXPLAINATORY NOTES:

MR: MOMENT OF RESISTANCE TEST:

 RAIL SEAT BOTTOM, CENTRE TOP & CENTRE BOTTOM (PRIOR
TO STABILISATION)
 RAIL SEAT BOTTOM & CENTRE TOP (AFTER STABILIZATION)

MF: MOMENT OF FAILURE TEST FOR RAIL SEAT BOTTOM

TEST/RETEST SLEEPER FROM THE SAME LOT

T-1 RT-2

NUMBER OF SLEEPERS TO BE TESTED

PASSES : SLEEPER PASSES RELEVANT TEST SUCCESSFULLY

FAILS : SLEEPER FAILS IN ANY OF THE RELEVANT TEST

NOTE : (1) WHEN DUE, MF TEST SHALL BE CONDUCTED

ON THE FIRST SLEEPER SELECTED FOR
TESTING UNDER MR

(2) WHENEVER MF IS DONE, PASSING THIS TEST

IS A PREREQUISITE FOR ACCEPTANCE OF
THAT LOT UNDER ‘A’ OF FLOW CHART.

(3) IF THE FIRST SLEEPER HAS PASSED MF TEST

BUT FAILED IN ANY OTHER TEST, MF TEST
NEED NOT BE REPEATED ON SUBSEQUENT
SLEEPERS SUBJECTED TO RE-TESTING.

Page 30 of 34
 ANNEXURE-V

PROCEDURE FOR CHECKING FITNESS OF CONCRETE SLEEPERS ON

TRACK CIRCUITED STRETCH (AT THE TIME OF INSPECTION IN THE
CONCRETE SLEEPER MANUFACTURER’S PREMISES

1. All the sleepers shall be tested.

2. The sleeper shall be checked for electrical resistance at 230 volts AC

supply. The circuitry to be followed will be shown in sketch at
Annexure-V (Contd.).

3. The 230 volts AC supply will be passed through a not less than 300 W
test lamp in series with the pairs of inserts being tested. For the sake
of comparison, another comparator bulb of the same wattage directly
connected to the 230 volts AC supply will be fitted along side.

4. Since the testing is being done at a higher voltage, removal of the rust
layer by grinding shall not be necessary.

5. Resistance will be checked against 2 rail seats.

6. If the test lamp emits light dimmer than the comparator lamp in the
sleeper, the sleeper shall be accepted and marked ‘FTC’ ( Fit for Track
circuit). If it emits light with the same brightness as the comparator
lamp, the sleeper will be rejected and marked ‘NFTC’ (Not fit for track
circuit). In case the test lamp does not emit light at all, it indicates that
the circuitry is defective and should be rechecked.

7. In the event of doubts regarding comparison of brightness, such

sleepers will not be marked. They will be retested with 1.5 V Avometer
and marked for fitness, if found fit with 200 ohms resistance.

8. The ’NFTC’ marked sleepers should be stacked separately. The

FTC/NFTC marking shall be done on top of sleepers in middle portion,
as shown on Drawing No.RDSO/T-2466.

9. As the testing is done at higher voltage, all precautions such as use of

gloves in the hands, insulated boots and insulated chairs for operator
and other necessary precautions shall be taken for the safety purpose.

Page 31 of 34
Page 32 of 34
 ANNEXURE-VI

LIST OF IRS & BIS CODES REFERRED TO

(Up-to-date version of Codes/Specifications with latest
amendments/correction slips shall be followed)

S.N IRS/IS No. & Year Description

o.
1 IS:269-2015 Ordinary Portland Cement- Specification (Sixth
Revision)
2 IS:1343 – 2012 Prestressed Concrete-Code of Practice (Second revision)
(Reaffirmed-2017)
3 IS:383 – 2016 Coarse and fine aggregates for concrete-specification
(third Revision)
4 IS:456-2000 Plain and reinforced concrete- code for practice (Fourth
(Reaffirmed-2016) Revision)
5 IS:516 – 1959 Method of test for strength of concrete
(Reaffirmed-2018)
6 IS:650 – 1991 Standard sand for testing of cement (Second Revision)
(Reaffirmed-2018)
7 IS:1785 Pt.I - 1983 Specification for plain hard drawn steel wire for
(Reaffirmed-2018) prestressed concrete Part.I Cold drawn stress relieved
wire (Second Revision)
8 IS: 2386 - 1963 Methods of tests for aggregate for concrete
Pt. I – VIII
(Reaffirmed-2016)
9 IS:2430 –1986 Methods for sampling of aggregate for concrete(First
(Reaffirmed-2019) Revision)
10 IS:2514 – 1963 Specification for concrete vibrating table
(Reaffirmed-2017)
11 IS:3536 - 2016 Ready mix paint, Brushing, Wood primer-Specification
(second revision)
12 IS:4031 –(Part-1)- Methods of physical tests for hydraulic cement Part -1
1996 (Reaffirmed- Determination of fineness by dry sieving (Second
2019) Revision)
13 IS:4031 (Part 2) - Part-2 Determination of fineness by specific surface by
1999 (Reaffirmed- blaine air permeability method (First Revision)
2019)
14 IS:4031 (Part 3) - Part-3 Determination of soundness (First Revision)
1988 (Reaffirmed-
2019)
15 IS:4031 (Part 4) - Part-4 Determination of consistency of standard cement
1988 (Reaffirmed- paste (First Revision)
2019)
16 IS:4031(Part 5) - Part-5 Determination of initial and final setting times
1988 (Reaffirmed- (First Revision)
2019)
17 IS:4031 (Part 6) – Part-6 Determination of compressive strength of
1988 (Reaffirmed- hydraulic cement (other than masonry cement) (First
2019) Revision)
Page 33 of 34
18 IS:4031(Part 14) - Part-14 Determination of false set
1989 (Reaffirmed-
2019)
19 IS:4032 – 1985 Methods of chemical analysis of hydraulic cement
(Reaffirmed-2019)
20 IS:6006 - 2014 Uncoated stress relieved strand for pre-stressed
(Reaffirmed-2019) concrete-Specification (Second Revision)
21 IS:9103 – 1999 Specification for concrete Admixture
(Reaffirmed-2018)
22 IS:10262 – 2019 Concrete Mix Proportioning – Guidelines (Second
Revision)
23 IS:2770 (Pt.1)-1967 Methods of testing bond in reinforced concrete
(Reaffirmed-2017) Part 1: Pull-out test
24 IRS:T-46 -1996 Specification for Spheroidal Graphite Cast Iron inserts
25 STR - 2016 Schedule of Technical Requirement for manufacture of
PSC Sleepers as applicable from time to time.

Page 34 of 34