FFU Synthetic Sleeper I Railway Technology

Pulsatory fatigue test in
ballast bed following
DIN EN 13230-3
Sleeper screw extraction test
FFU synthetic sleeper
after impact test
After two impact tests conducted on
the same section of the sleeper, the
FFU synthetic sleeper merely showed
the impression of a wheel flange. The
FFU sleeper retained its stability even
after this derailment simulation and
thus guarantees the retention of the
track gauge. The electrical resistance
tests conducted on FFU resulted in a
value of R33 = 71.9 kΩ. The requirement
of R33 ≥ 5 kΩ was maintained
with certainty, confirming the high
electrical insulation of FFU synthetic
sleepers. During static testing in the
centre of an FFU sleeper, a force of
240 kN was deflected without any
damage to the sleeper.
By comparison, a wooden sleeper
failed by breaking at only 80 kN.
The deflection of the FFU sleeper was
continuously recorded here by four
gauges. The fatigue test was carried
out under exceptionally critical test
conditions in the middle of the
sleeper and only showed a slight
change of 0.4mm after 2.5 million
load cycles. There were no
perceptible signs of fatigue.
When carrying out the static compressive
test, a load of 300 kN was
applied to the FFU sleeper through
the rail and rail fastening. In this test
a plastic deformation of only 0.8 mm
was measured.
To analyse behaviour at low
temperatures, FFU sleepers were put
into storage at -20°C. The ensuing
test showed that, even at extremely
low temperatures, the fibres of
FFU synthetic wood remain free of
brittleness.
The fatigue test under the sleeper
bed was performed in the most
unfavourable conditions such as poor
track geometry, uneven distribution of
loads through the rails, stiff rail seat
section and a high dynamic
allowance for an axle load of 250 kN.
Without exception, no damage of any
kind was observable on the FFU
sleepers, even after two million
load cycles.
8