One of the most common failure modes of concrete crossties in North America is the degradation of the concrete surface at the crosstie rail seat, also known as rail seat deterioration (RSD). Loss of material beneath the rail can lead to wide gauge, rail cant deficiency, and an increased risk of rail rollover. Previous research conducted at the University of Illinois at Urbana-Champaign (UIUC) has identified five primary failure mechanisms: abrasion, crushing, freeze-thaw damage, hydro-abrasive erosion, and hydraulic pressure cracking. The magnitude and distribution of load applied to the rail seat affects four of these five mechanisms; therefore, it is important to understand the characteristics of the rail seat load distribution to effectively address RSD. As part of a larger study funded by the Federal Railroad Administration (FRA) aimed at improving concrete crossties and fastening systems, researchers at UIUC are attempting to characterize the loading environment at the rail seat using matrix-based tactile surface sensors (MBTSS). This instrumentation technology has been implemented in both laboratory and field experimentation, and has provided valuable insight into the distribution of a single load over consecutive crossties. A review of past research into RSD characteristics and failure mechanisms has been conducted to integrate data from field experimentation with existing knowledge, to further explore the role of the rail seat load distribution on RSD. The knowledge gained from this experimentation will be integrated with associated research conducted at UIUC to form the framework for a mechanistic design approach for concrete crossties and fastening systems.

One of the more critical failure modes of concrete crossties in North America is the degradation of the concrete surface at the crosstie rail seat, also known as rail seat deterioration (RSD). Loss of material beneath the rail can lead to wide gage, cant deficiency, reduced clamping force of the fastening system, and an increased risk of rail rollover. Previous research conducted at the University of Illinois at Urbana–Champaign (UIUC) identified five primary failure mechanisms associated with RSD: abrasion, crushing, freeze–thaw damage, hydroabrasive erosion, and hydraulic pressure cracking. Because the magnitude and distribution of load applied to the rail seat affects four of these five failure mechanisms, effectively addressing RSD requires an understanding of the factors affecting rail seat load distribution. As part of a larger study aimed at improving concrete crossties and fastening systems, UIUC researchers are attempting to characterize the loading environment at the rail seat by using matrix-based tactile surface sensors (MBTSS). This instrumentation technology has been implemented in both laboratory and field environments and has provided valuable insight into the distribution of a single load over consecutive crossties. This paper focuses on the analysis of data gathered from MBTSS experiments designed to explore the effect of manufactured RSD on the load distribution and pressure magnitude at the rail seat. The knowledge gained from these experiments will be integrated with associated research conducted at UIUC to form the framework for a mechanistic design approach for concrete crossties and fastening systems.

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As higher demands are placed on North American railroad infrastructure by heavy haul traffic, it is increasingly important to understand the factors affecting the magnitude and distribution of load imparted to concrete crosstie rail seats. The rail seat load distribution is critical to the analysis of failure mechanisms associated with rail seat deterioration (RSD), the degradation of the concrete surface at the crosstie rail seat. RSD can lead to wide gauge, cant deficiency, and an increased risk of rail rollover, and is therefore of primary concern to Class I Freight Railroads in North America. Researchers at the University of Illinois at Urbana-Champaign (UIUC) have successfully characterized the loading environment at the rail seat using matrix-based tactile surface sensors (MBTSS). Previous research has proven the feasibility of using MBTSS in both laboratory and field applications, and recent field experimentation has yielded several hypotheses concerning the effect of fastening system wear on the rail seat load distribution. This paper will focus on the analysis of data gathered from laboratory experimentation with MBTSS to evaluate these hypotheses, and will propose a metric for crosstie and fastening system design which considers the uniformity of the load distribution. The knowledge gained from this experimentation will be integrated with associated research conducted at UIUC to form the framework for a mechanistic design approach for concrete crossties and fastening systems.