INFRASET Pre-Stressed Concrete Sleepers for Main Lines and Sidings
INFRASET, a business unit of AVENG (Africa), has been a leading manufacturer of railway sleepers since 1958. INFRASET produces a wide range of pre-stressed concrete sleepers for main lines and sidings, ranging from 18.5t to 30t axle loads. Specialised products include sleepers for turnouts, tunnels, stacker reclaimers and level-crossing slabs.
INFRASET has licence agreements with Abetong Teknik (Sweden), Walter Bau (Germany) and Sonneville International Corporation (US), and has the technical capacity to design and manufacture equipment to establish sleeper factories internationally. Infraset has been involved in the setting up of sleeper factories in countries such as Malawi, Australia, Brazil, Indonesia, Sri Lanka, Namibia, Zambia, Botswana, Zimbabwe and Argentina.
Concrete sleepers, the preferred choice both locally and internationally, have been used in South Africa for more than 50 years. With close ties to Abetong Teknik, INFRASET has been at the forefront of sleeper development.
Concrete sleepers maintain their geometry regardless of the conditions in which they are placed – ensuring constant rail gauge and rail seat inclinations. Their weight, end-face design and large soffit area ensure maximum ballast contact, reduced ballast pressure and excellent track stability.
High strength pre-stressed concrete
The use of prestressed 60MPa concrete ensures that sleepers are able to withstand variable loading conditions. Moreover, small cracks which can appear through accidental damage close automatically, preventing the degradation of the reinforcing steel and any damage to the integrity of the sleepers.
SABS-accredited quality control
All INFRASET concrete sleeper-producing factories are SABS ISO accredited.
Concrete sleepers are produced to strict production procedures, which ensure a quality product capable of many years’ service.
All raw materials are sampled and tested according to sampling plans and procedures, and cement supplies are accompanied with detailed test reports from the supplier.
Pre-tensioning of the wire reinforcement, concrete consistency and workability, the positioning of cast-in components and reinforcement are all closely controlled during the manufacturing process. Close attention to and monitoring of the heat curing process ensures adequate concrete strength for pre-stress transfer.
Rail seat and sleeper equipment testing
The critical concrete railway sleeper dimensions are checked according to a sampling plan. The critical dimensions checked include rail-seat cant, rail-seat relative twist, cast-in component height, rail-seat flatness, overall distance between outer shoulders and rail seats, and wire reinforcement positions.
One sleeper out of every 600 produced is randomly selected and then tested to ultimate loading. The crack load must be greater than the design crack load for the batch to be accepted. One sleeper from each production line is also tested daily to ensure that the minimum design criteria are met. These tests are carried out for rail-seat positive moments as well as for centre negative and positive moments.
All equipment used to measure or test is checked or calibrated at given periods in compliance with the measuring and testing equipment register. These checks and calibrations are traceable to an accredited calibration agency.
The high-strength-to-weight ratio of prestressed concrete electrification masts sets them apart from poles made of other materials. Fully prestressed masts are produced using 60MPa concrete.
The rectangular taper of INFRASET’s concrete masts and an I-section design results in an aesthetically pleasing light grey pole. Concrete masts are corrosion resistant and enjoy an internationally proven reputation for maintenance-free performance.
Pre-stressed concrete masts are manufactured with guaranteed design strengths which comply with client specifications.
Products and Services
A number of 880 prestressed concrete poles, manufactured by INFRASET Infrastructure Products, have been installed in place of steel masts for the support of overhead electrical equipment OHTE at Transnet's Bayhead marshalling yard in Durban. The steel masts had been in service for 35yr and were fRead more
INFRASET Building Products, which forms part of the Aveng Group, has thrown its hat into the ring and built a multi-million rand state-of-the-art concrete roof tile plant at its Rossway factory in Midrand. The plant, which will initially serve the Gauteng roofing market, began manufactuRead more
INFRASET Infrastructure Products has supplied over 500 fully prestressed concrete poles to support electronic surveillance and monitoring equipment for a freeway management system which is being implemented on most of Gauteng's major routes by the national roads agency sSANRAL. The survRead more
Some 250 street-lighting poles, specifically designed and manufactured by INFRASET Infrastructure Products to inhibit cable theft, have been installed in Knights, Germiston, for the Ekurhuleni municipality. Prior to the sinking of the new poles, Knights had experienced several incidentsRead more
Prestressed concrete poles, manufactured by INFRASET Infrastructure Products, have been successfully deployed for medium and low voltage reticulation at most of City Power's electrification projects in City of Johannesburg including, the Alexandra metering project and the Pennyville housing projeRead more
Prestressed concrete poles, manufactured by INFRASET Infrastructure Projects, are being installed to carry three-phase cabling for the electrification of over 5,100 informal settlement houses at Winnie Mandela Park in Tembisa. The electrical reticulation of Winnie Mandela Park is beingRead more
During a three-month period, which ran from mid-June to mid-September this year, INFRASET Railway Products supplied 48,000 precast concrete sleepers to Transnet Freight Rail (TFR). Weighing a cumulative 12,400t, the sleepers were used in a routine maintenance programme on the 860km Saldanha / SisRead more
A second-generation transition beam has been designed and developed by Transnet Freight Rail (TFR) and INFRASET Railway Products. Transition beams smooth out the difference in resilience between normal ballast-mounted rail track and the concrete-mounted track found in tunnels. The new bRead more
Prestressed concrete masts have been specified by Transnet for a capacity upgrade at Saldanha / Sishen iron ore rail link. Manufactured and delivered by Concrete Manufacturers Association (CMA) member INFRASET Infrastructure Products, the masts will carry a supplementary feeder line, which will bRead more