Document Number: NIST-2651

STANDARD Date of Issue: 24/01/2012

Revision Number: 01

Use of Sleepers

1. PURPOSE
This Standard specifies requirements for the use of sleepers.

2. SCOPE
The Standard applies to all infrastructure managed by V/Line, Infrastructure under the
Regional Infrastructure Lease.

3. HISTORY
Revision 01, new standard, replaced parts of CEC 3/87, ... Welded Rail Track and FAL
Construction Standards 2630, 2631, 2632, and 2633. Revision 02, included requirements
for interspersing low profile concrete sleepers and incorporates CEC 18/87, Sleeper
Marking and part of FAL 2687, Tie Renewal.
This revision: renumbers NIPR-2651, Use of Sleepers, as a standard; clarifies the use of
low profile concrete sleepers; and has been updated.

4. DEFINITIONS
Please refer to the NIMG-2600, Infrastructure Definitions and Terminology for
abbreviations and terms used in this Standard.

5. STANDARD
5.1. INTRODUCTION
This Standard describes requirements for:
Sleeper types and materials;
Sleeper use; and
Sleeper handling and laying.
5.2. SLEEPER TYPES
Sleeper Types
Sleeper types comprise:
Track sleepers;
Bridge transoms; and
Turnout bearers
5.3. NEW SLEEPER MATERIALS
Currently Type Approved sleeper materials include
Concrete;
Timber; and
Steel.
Concrete Sleepers
Concrete sleepers are to comply with AS 1085.14 – Railway Track Material:
Prestressed Concrete Sleepers or other approved design.
For full specification details, refer NIST-2651.1 – Specification for Concrete
Sleepers and Bearers.

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Timber Sleepers
Timber sleepers for open track shall be made from the following species – grey box,
red ironbark or red gum.
Timber sleepers are to comply with:
AS 3818.1 – Timber – Heavy Structural Products – Visually Graded – General
Requirements; and
AS 3818.2 – Timber – Heavy Structural Products – Visually Graded – Railway
Track Timbers.
The minimum grade of sleepers to be used for Classes of track are:
Class 1 and 2M track – Grade 1;
Other mainlines – Grade 2, red gum which complies with Grade 2 limits may be
used; and
Sidings – Grade 3.
Broad gauge sleepers are to be 9’ *10” * 5” (2750mm * 250mm * 125mm) and
standard gauge sleepers are to be 8’6” *10” * 5” (2590mm * 250mm * 125mm).
Steel Sleepers
Steel sleepers are to comply with AS 1085.17 – Railway Track Material: Steel
Sleepers.
Bridge Transoms
Open deck bridges must be fitted with timber transoms, complying with the
Standards specified in AS 3818.2 Bridge Transoms Grade timbers. Transom sizes
vary according to the design of the bridge spans, and track gauge.
Turnout Bearers
Turnout Bearers maybe made from either timber (turnout timbers) or concrete.
Timber turnout bearers shall be AS3818.2 Special Sleeper Grade either forest red
gum, river red gum or ironbark or those authorised for track sleepers on the class of
line (refer Section 5.5).
Concrete Bearers are to comply with AS 1085.14 – Railway Track Material:
Prestressed Concrete Sleepers or other approved design.
Sizes of turnout bearers are shown on the drawings for the applicable turnout. For
selection of sleeper type, refer NIPR 2660, Use and Construction of Turnouts.
5.4. SERVICEABLE SLEEPERS
Serviceable sleepers of all types may only be used in renewal works with the
approval of the Engineer Manager Track and Civil.
Concrete Seconds
Concrete sleepers which are non-compliant with manufacturing specifications (e.g.
due to surface cracking), but which are nevertheless serviceable, may be used in
class 4 and 5 tracks, and in sidings (refer Table 1).
Concrete sleepers which have been recovered from the main line due to derailment
damage, and which still have effective prestressing, may be used in sidings (refer
Table 1). Damaged sleepers with ineffective prestressing (e.g. broken through or
with significant exposed tendons) are unserviceable.

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Timber
Serviceable timber sleepers may be classified into two grades:
Grade A; and
Grade B.
Requirements for Grade A sleepers are:
Sound surface area under the sleeper plates;
No significant splits; and
Bored not more than once.
Requirements for Grade B sleepers are:
Sound surface area under the sleeper plates;
Not excessively split;
No rot within the sleeper plate area; and
Bored not more than twice.
Steel
Serviceable steel sleepers for use on mainlines are to have no significant loss of
section due to corrosion and must provide effective retention of the fastening
system.
Steel sleepers that have been damaged (e.g. in a derailment, minor corrosion etc)
may be reused in sidings if they remain serviceable.
Steel sleepers removed from track due to major corrosion or cracking are
unserviceable.
Steel sleepers are to be fully insulated in track circuited areas.
5.5. TRACK SLEEPERS
Uses
Permitted uses of different sleeper material types in open track are shown in Table
1.

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Class 1 Class 2 Class 3 Class 4 Class 5 Sidings

Full Face TA TA TA TA*y TAy TAy

Concrete

-
rs
Regular NCA NCA NCA NCA NCA NCA

ed spe
r
te
In
Random NCA NCA NCA NCA NCA NCA
Low Profile

Full Face TA# TA TA TA TA TA

Concrete

-
rs

Regular NCA TA TA TA TA TA
ed spe
r
te
In

Random NCA TA TA TA TA TA

Full Face NCA NCA NCA TA* TA TA

Steel

-
rs

Regular NCA NCA NCA TA* TA TA

ed spe
r
te
In

Random NCA NCA NCA TA* TA TA

Full Face NCA TA TA TA TA TA

Timber

-
rs

Regular NCA TA TA TA TA TA
ed spe
r
te
In

Random NCA TA TA TA TA TA

TA - Type Approved (may have 'grandfather' type approval)

PTA - Provisionally Type Approved
NCA - Not Currently Approved
* Is Not Currently Approved for passenger Class 4 track
y
May use defective sleepers
# Timber replacement only

Table 1 – Use of Sleeper Materials – Track Sleepers

Low profile concrete sleepers are primarily for timber sleeper replacement. Low
profile concrete sleepers may not be used to replace full depth concrete sleepers.
Full depth concrete sleepers are to be used in the construction of new main lines
unless approved by the General Manager Infrastructure.
For new installation and major renewals concrete sleepers/turnout bearers shall be
installed in a face in confined areas such as station pits, bridges, tunnels, adjacent
to retaining walls, fencing etc. Timber may be used for maintenance works where
necessary due to site limitations (such as bridge load), with the approval of the
Maintenance Manager.
A confined area for sleepers is where there is less than 4.5m horizontal clearance
from centre line to obstructions on both sides of the track or where track centres are
less than 6m for centre tracks on multiple track lines at the same horizontal level.
For Turnouts/Crossovers a confined area is where the horizontal clearance to
obstructions on both sides of the track is less than the length of the longest timber
plus 2m.

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Dual Gauge/Gauge Convertible Sleepers
There are no Dual Gauge/Gauge Convertible Sleepers currently type approved for
use in Gauge Convertible Configuration. Sleepers are not to be used in the gauge
convertible configuration.
Sleepers to be placed in level crossings or other covered areas may only be used in
Dual Gauge mode in a face with the 3rd rail installed.
Dual Gauge sleepers are currently only designed to be used with 47/50kg rail due
to rail foot size. The following configurations of rails maybe used with these
sleepers on main line:
the 2 outer rails 47kg, with a 50kg standard gauge inner rail; or
all 3 rails 47kg; or
all 3 rails 50kg.
Standard Spacing
Sleeper spacings, for all sleeper types, are specified in Table 2.
Location Spacing between Sleeper Centres
All, except as shown below 685 mm
New and upgraded level crossings 500mm or 600 mm
Joints with angle type fishplates 510 mm
Glued insulated joints 510 mm
Mechanical insulated joints – plastic coated fishplate 510 mm
Joints with bar type fishplates 460 mm
Mechanical insulated joints – type 1939 460 mm

Table 2 – Sleeper Spacing

Sleepers at Joints
At joints (including mechanical insulated joints), combinations of sleepers and
fastening systems must ensure consistency of material both sides of the joint.
Sleepers are to be adjusted so joints are located centrally between sleepers.
Timber sleepers must be used with angle type fishplates.
Sleepers at Welds
Sleepers shall not be installed within 50mm of welds.
Interfaces between Sleeper Types
If concrete sleepers are installed in a face adjoining plain timber track a transition
zone is to be provided consisting of either:
10 low profile concrete sleepers in a face or:
10 300mm x 150mm timber sleepers spaced at 600mm centres with resilient
fastenings on the first 5 timber sleepers.
For requirements on fastenings refer to NIPR-2652, Use of Fastenings.
Special Sleepers
Special sleepers particularly may be required in the following situations:
Where the proximity of drainage pits to the track necessitates short sleepers;

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Where equipment is to be attached to the sleeper;
For mixed gauge track (3 rails); and
Where subsequent gauge conversion may take place (i.e. gauge convertible
sleepers).
Trimming of Sleepers
Timber sleepers maybe trimmed to suit provided that a sufficient area remains to
retain track fastenings, taking into consideration direction of grain and potential for
end splitting
Where the location of drainage pits or other obstruction requires a special size
concrete sleeper either:
special “short” sleepers are to be ordered from the manufacturer or;
a maximum of 125mm may be removed from each end of the sleeper using a
masonry cutting disc subject to the approval of the General Manager
Infrastructure.
Where sleepers are trimmed the sleeper spacing may need to be adjusted to
provide adequate distribution of weight on the ballast and or to accommodate the
obstruction.
5.6. SLEEPER RENEWAL
Spot resleepering may be performed by various track gangs to maintain the
infrastructure in adequate condition.
Major resleepering open track is generally undertaken by a Tie renewal gang
specifically setup for high production on open track.
Sleeper Marking
An assessment of sleeper condition on each line section is to be provided to the
Engineer Manager Maintenance in January each year to enable input into the
Budget cycle for the following 2 financial years where necessary, refer NIPR-2709,
Inspection and Assessment of Sleepers and Fastenings.
The following requirements are to be considered when assessing sleeper quotas
and marking of sleepers for mechanised tie renewal.
The total number of sleepers to be replaced in a section of track is to be determined
based on the existing sleeper condition, line speed, type/frequency of traffic,
operational priorities and other business needs.
The minimum quality of bearer and frequency of ties accepted will vary with the
ability of the track to cope with the tonnage per annum and speed of traffic at
specific locations, tangent, curved track etc. All sleepers should be bearers, i.e.
broken or severely crushed sleepers should be renewed within the quota where
possible particularly on Passenger Lines.
Uniformity of the frequency of tie sleepers is to be aimed at allowing for cross boring
that can be carried out and proposed renewal of nearby sleepers. Joint sleepers
should be adequate as ties. The density of tie sleepers required is heavier on
heavily trafficked lines than on branch lines and higher on curve’s than on straight
track.

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Multiple renewals are to be avoided wherever possible consistent with the other
criteria. Renewal of three in a face must be avoided more strongly than two in a
face, and four more strongly than three, etc.
Local knowledge should be applied sensibly in the marking of sleepers, such as the
need to have a better tie standard in areas where there are dips in the grade, heavy
breaking etc, may make the line more difficult to hold.
Sleepers marked out should be generally either below the accepted minimum for
bearers, i.e. failed as bearers or particularly on main lines failed as ties. Sleepers
should be renewed after they have reached this standard, not in anticipation, unless
there would be a number of well advanced aged sleepers which would otherwise be
left in a face and it is probable that they would fail together within the next few years
causing serious loss of tying.
When the tie renewal is approved sleepers shall be marked prior to the tie renewal
unless otherwise approved by the General Manager Infrastructure. Where possible
3 months prior to the cycle commencing. Sleepers are to be marked by a Track
Supervisor, or above unless otherwise approved by the General Manager
Infrastructure.
A record of marking is to be kept detailing sleeper renewals for each km section.
Where occupation crossings, bridges etc are included within the approved scope
these are to be individually identified by asset type km and sleepers required. A
copy of the marking is to be forwarded to the Engineer Manager Maintenance.
Sleeper Renewal Requirements
The new/released timbers and fastenings shall be kept outside of the maximum
rollingstock outline and materials stockpiles at least 3 meters away from track, and
clear of access roads.
Sleepers shall be stored and handled such as to avoid damage to the sleeper being
installed or other infrastructure. Care needs to be taken during old sleeper
extraction and installation to minimise disturbance to the track.
The bed for the new sleeper should be levelled or scarified to ensure a clear bed for
the sleepers such that the sleepers are not subjected to centre binding;
Where resleepering in existing track a bay for sleeper insertion shall be prepared
such that the sleeper is inserted at the nominal standard spacing or in the centre of
the two adjoining sleepers such that the spacings on either side of the inserted
sleeper differ by no more than 33% of the largest spacing and the distance to
adjoining sleepers is not less than 500mm between centres. Where the spacing
between adjoining sleepers is less than 900mm, the existing sleepers should be re-
spaced where possible and no new sleeper installed.
All sleepers installed shall be installed with their heart side down and at right angles
to the existing track. Tolerance for squaring shall be +/- 40mm;
The sleepers inserted should be spot tamped to bring the sleeper up to the rail,
eliminate centre binding and to provide support for the sleeper
Timber sleepers with no or single shouldered plates shall have double shouldered
plates installed where available.
Timber sleepers are to be fastened using an equivalent fastening system to that
existing.

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Prior to the completion of the shift on operational lines, sufficient sleepers shall be
tied for the restricted track speed. At minimum 1 in 3 shall be tied on straight track
and 1 in 2 on a curve under 2000m radius.
Any unspiked/fastened sleeper left in the track should be spiked in the following
shift, next day or before surfacing; whichever is earlier.
All timber sleepers which have anchors applied are to have the anchors removed
and four anchors reapplied hard up against the sleeper as part of the resleepering
process.
Ballast is to be boxed up prior to tamping. In summer season ballast must be boxed
up at end of shift or prior to leaving site which ever is the sooner.
Resleepering of Special/Constrained Locations
Bridges, Station Pits, Level Crossings, Occupation Crossings, Sidings, Yards
TPWS and Axle counter locations, which have access constraints, require
additional specialist resources or are not efficient with a large tie renewal gang are
undertaken on an individual needs basis and are not renewed as part general tie
renewal cycle unless specifically included within the scope of works.
Where these are due for renewal at the same time as a general tie renewal cycle a
smaller gang should be deployed to undertake these works in advance of the main
tie renewal works or at an appropriate time within the tie cycle to maximise use of
resources
Discharge from Moving Trains
Sleepers are not to be discharged from moving trains at locations where such
discharging may create a hazard or cause an accident unless confirmed as
acceptable through risk assessment. Examples include:
In narrow cuttings;
In tunnels;
At bridges;
Adjacent to retaining walls
5.7. General Requirements for Interspersal of Sleeper Types
Interspersal of sleepers in any class of track must be approved by the General
Manager Infrastructure and is subject to Type Approval for the type of sleepers
involved and the pattern to be adopted.
Gauge
Standard concrete/steel sleepers have a fixed foot gauge which is dependant on rail
size. Standard insulators are available for 41kg, 47/50kg and 53/60kg rail foot size
to achieve a nominal 1600mm head gauge when used with new rail. Special inserts
maybe available to alter foot gauge where necessary for gauge widening on curves
or tightening to account for rail wear.
Head Gauge (or Rail Gauge)
If track gauge due to rail headwear is greater than that shown in Table 3 below,
concrete or steel sleepers are not to be installed unless special gauge adjusting
insulators are used or rail transposed or replaced unless otherwise approved by the
General Manager Infrastructure.

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers

Track Class 1 Class 2 Class 3 Class 4 Class 5 &

Class Sidings
Straight 1606mm 1609mm 16011mm 1612mm 1614mm
track
Curves 1610mm 1612mm 1616mm 1622mm 1622mm

Table 3: Gauge limit for installation of concrete sleepers due to rail head wear measured in the field

5.8. INTERSPERSAL OF LOW PROFILE CONCRETE SLEEPERS

Rail Size
Low profile concrete sleepers (LPC) are generally only to be used on 47kg/90lb or
larger rail size. Use with 41kg/80lb rail must be approved by the Infrastructure
Manager. Low profile concrete sleepers are not permitted to be installed with a rail
size under 80lb.
Foot Gauge
Where LPC are being interspersed within existing timber sleepers the timber
sleepers are to be –3 +6 of the appropriate foot gauge.
Sleeper Installation Pattern
Table 4 provides the minimum approved interspersion rate for the various track
alignments and locations.
Track Type Installation Pattern
Tangent Track Random or regular pattern.
regular pattern min 1 in 4,
Curve > 800m radius
380m< Curve < 800m regular pattern min 1 in 2,
< 380m replace in a face
Curves <200m radius in a subject to use of special
face insulators for gauge widening
unless otherwise approved.
Within 6m of start/ finish Regular Pattern 1 in 2
(CBA plates) of turnouts.
On or within 6m of a in a face
bridge/level crossing
Table 4: Low Profile Sleepers Interspersion Rates

Where a regular pattern is specified, random installation is permitted for infill of

remaining timber sleepers once the initial regular pattern is established. The regular
pattern must extend through and clear of the feature for a minimum of 10 sleepers.
If the existing timber sleepers are back canting or working in a curve then either:
LPC interspersal must be at a regular pattern, of 1 in 2 or better or;
the back canting sleepers must be replaced with new timber sleepers.
High durability pads must be used.

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Mechanical Joints
When LPC sleepers are being interspersed in track containing joints a minimum of
the 1st and 2nd sleepers either side of the joint must be replaced with LPC sleepers.

LP Concrete

st
Figure 1 LPC insertion Mechanical Joint 1
nd
and 2 Sleeper replaced

Anchors
Standard anchor patterns are to be maintained, as a minimum, on track with
resilient fastenings interspersed. A low profile concrete sleeper with resilient
fastening is considered to be equivalent a dog spike sleeper with rail anchors. i.e.
rail anchors do not need to be applied to a resilient fastened sleeper.
Tamping
When low profile sleepers are being installed as part of a full tie cycle the section of
track is to be face tamped.
When LPC sleepers are installed as part of a spot replacement the LPC and 2
sleepers either side must be tamped to ensure proper support of the LPC and to
reduce the risk of centre binding as shown in figure 2

LP Concrete

Tamp

Figure 2. Tamping around a LPC Sleeper

5.9. MANAGEMENT OF OUTCOMES

Exceedences or asset conditions that deviate from the specified requirements are
to be managed in accordance with NIPR-2606, Management of Inspection

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 Document Number: NIST-2651
STANDARD Date of Issue: 24/01/2012
Revision Number: 01

Use of Sleepers
Outcomes. Long-term high risk or greater issues are to be managed in accordance
with SAPR-009, Enterprise Risk Management (EWRM) Guide.

6. RELATED DOCUMENTS
AS 1085.14 – Railway Track Material: Prestressed Concrete Sleepers
AS 1085.17 – Railway Track Material: Steel Sleepers
AS 3818.1 – Timber – Heavy Structural Products – Visually Graded – General
Requirements
AS 3818.2 – Timber – Heavy Structural Products – Visually Graded – Railway Track
Timbers
SAPR-009 – Enterprise Risk Management (EWRM) Guide
NIMG-2600 - Infrastructure Definitions and Terminology
NIPR-2606 – Management of Inspection Outcomes
NIPR-2650 – Use and Laying of Rail
NIST-2651.1 – Specification for Concrete Sleepers and Bearers
NIPR-2652 – Use of Fastenings
NIPR-2660 – Use and Construction of Turnouts
NIPR-2709 – Inspection and Assessment of Sleepers and Fastenings

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