Sleeper production

Carousel systems

Track sleepers with identical outlines are produced as bulk goods in rigid moulds on carousel systems. Due to the low variety of elements it would make sense to use a (semi) automatic system with a high repeat accuracy, which reduces staff requirement.

Due to the short elongation, wedge anchors are out of questions because of the wedge seating loss and the associated loss of stressing force. Threaded anchors ensure a transmission of the stressing force to the mould without wedge seating loss. Paul screw jacks screw themselves onto the stressing bolts, rest against the mould, stress the spindle to the stressing force set and tighten the anchor nut. Then the machine unscrews from the spindle. The stressing technology ranges from merely manual to semiautomatic and to fully automatic systems with automatic anchor nut control. If requested, this can be logged by the system control. This equipment is available both for prestressed (late-demoulded) and post-tensioned (immediately demoulded) sleepers.

Detensioning wrenches, depending on their design, mostly unscrew several anchor nuts in a synchronized manner on both sides of the mould for a uniform application of the stressing force to the sleeper, which reduces cracking. Both manual and fully automatic machines are available for this purpose, too.

For the production of sleepers with button heading anchorage we supply manual and fully automatic button heading systems in order to provide complete prestressing steels with button heads.

We should be glad to provide advice on the following subjects

  • Sleeper stressing (prestressing/post-tensioning)
  • Stressing force control
  • Transfer of stressing force in prestressed sleepers
  • Efficient button heading
  • Optimization and upgrading of your sleeper production

Long-line system

Turnout sleepers as well as track sleepers are produced on long casting beds. The turnout sleeper which is uniform in cross section is particularly suited for this method; it is produced in a string and sawn to length as required. If the lengths per bed covering are known, mould end plates are used as well between the sleepers.

Due to its outline and dynamics, the track sleeper is posing special challenges to the manufacturers as regards detensioning. But this type of sleepers can also be profitably produced on long casting beds and convinces by a simple plant technology as against production in the carousel system.

For stressing track sleepers and turnout sleepers on the long-line system we supply

Casting bed equipment:

  • Planning and in-depth advisory service for standard equipment and for special solutions
  • Complete casting bed equipment (abutment anchor posts, transverse anchor plates, detensioning equipment, vertically adjustable supports, guards/safety devices, detensioning cylinders with support sleeves)
  • Single-wire/strand stressing or multi-stressing
  • Synchronized stroke display for detensioning equipment
  • Anchor grips and couplers for strand and wire, threaded anchors or button head anchors

Basic machinery equipment:

  • Easy to operate stressing jacks, optionally with automatic elongation measurement and logging (TENSAcontrol)
  • Appropriate hydraulic pump units with jack lifting units, pneumatic tires and multiple connections
  • Small and manoeuvrable hydraulic units for constricted space conditions
  • Wire pushing machines and automatic wire pushing systems with hydraulic or mechanical steel cutters as well as strand uncoiling reels and wire cages
  • Detensioning units for smooth force transmission for highest sleeper quality
  • Force measuring units for stressing jack calibration and for stressing force control at the casting bed
  • Cleaning lines for anchor grips
  • Coiling drums and prestressing steel distributors
  • Automatic and manual button heading equipment for prestressing wire
  • Accessories and spare parts are available in the long term

We should be glad to provide advice on the following subjects

  • Optimal process sequences
  • Possible methods for your plant
  • Technical system contexts of prestressing technology
  • Reasonable combination of manual and automatic stations
  • Farsightedness: Gradual further development towards the automation of your plant