Turnout sleeper production plant
A long-line plant for prestressed concrete turnout bearers. Every bearer in a turnout set has its own length and fastening positions, so the line casts long beams on prestressing beds and saw cuts them to the lengths of the set.
- Product
- Prestressed concrete turnout bearers
- Production method
- Long-line beds with saw cutting
- Set layout
- Length and dowel positions per bearer
- Design standard
- EN 13230-4 or as specified
- Capacity
- Defined per project, expandable
Indicative figures based on manufacturer data. Capacity and specification are confirmed in each offer.
What turnout sleepers are
Turnout sleepers, also called turnout bearers, carry the rails at switches and crossings, where a train moves from one track to another. They are produced as sets. Within a set, the length, the number of dowels and the dowel positions change from bearer to bearer. Prestressed concrete bearers are used on new lines and are replacing timber bearers on existing ones.
How a turnout sleeper line works
Bearers are cast on long steel prestressing beds. Dowels are positioned on the bed to the drawing of each bearer, reinforcement and stirrups are placed, and the wires are tensioned from a hydraulic tensioning station. A travelling casting machine fills and compacts the bed along its length. After curing, the force is released, the beams are demoulded and turned, and an automatic saw cuts them to the lengths of the set.
Why buyers choose this line
- Built for sets. Dowel and cut positions are set for each bearer, so a complete turnout set can be produced on the same bed.
- Automated stages. Tensioning, release, casting, vibration, turning, curing control and cutting are machine-driven, which keeps dimensions consistent.
- Scalable. Capacity is defined per project and can be increased by adding beds.
- Support beyond delivery. Layout, installation, operator training and spare parts can be included in the scope.
How the line works
Reinforcement preparation
Prestressing wires are cut to length and prepared with their anchorages.
Bed preparation
The bed is cleaned and oiled, and dowels are fixed to the positions of each bearer in the set.
Reinforcement placement
Wires and stirrups are placed along the bed and fixed in position.
Tensioning
The hydraulic tensioning station tensions the wires to the design force.
Casting and curing
A travelling casting machine fills and vibrates the bed. The concrete then cures under controlled conditions.
Release, turning and cutting
The force is released, the beams are demoulded and turned, and an automatic saw cuts each bearer to length. Bearers are stacked as sets.
Main machines and systems
Long-line prestressing beds
Steel beds on which the bearers are cast in a continuous line.
- Bed length
- Per manufacturer's offer
- Number of beds
- Per manufacturer's offer
Tensioning and release station
Hydraulic cylinders with a control panel tension the wires before casting and release them after curing.
- Tensioning force
- Per manufacturer's offer
Travelling casting machine
Runs along the bed with its own hopper, distributes the concrete and compacts it with vibration.
Turning system
Turns the demoulded beams so they can be inspected and moved to the saw.
Automatic sleeper cutting machine
PLC-controlled saw with touch panel that cuts the cast beams into bearers of the required lengths.
Lifting and stacking equipment
Lifting beams and crane equipment for stacking bearers as complete sets.
Specifications
Typical values from manufacturer documentation. Final figures are confirmed in the manufacturer's offer for your project.
| Product | Prestressed concrete turnout bearers |
|---|---|
| Bearer length range | Per manufacturer's offer |
| Bearer cross-section | Per manufacturer's offer |
| Bed length | Per manufacturer's offer |
| Number of beds | Defined per project |
| Tensioning force | Per manufacturer's offer |
| Cutting | Automatic saw, PLC control |
| Design standard | EN 13230-4 or as specified |
Bed layout, bearer sizes and capacity are defined for each project from the turnout drawings.
Built for these buyers
Turnout and track component producers
Companies adding concrete turnout bearers to their range.
Existing sleeper plants
Mainline sleeper producers extending into switches and crossings.
Rail infrastructure contractors
Contractors who need turnout sets produced for a network programme.
Railway administrations
Owners replacing timber turnout bearers with prestressed concrete.
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