United States Department of Transportation
i
Rail Integrity and Initial Performance Testing at the Mega Sites [Research Results]
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2019-04-01
[PDF-715.48 KB]
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Abstract:The Federal Railroad Administration (FRA) with the Association of American Railroads (AAR) co-sponsored rail integrity and performance testing as part of the joint Heavy-Axle-Load (HAL) Revenue Service Program. Transportation Technology Center, Inc. (TTCI) investigated the performance of improved rail alloys, curve lubrication practices, and grinding practices in revenue service at the eastern and western mega sites located near Bluefield, WV, and Ogallala, NE, respectively. The testing and evaluation began in 2005 and concluded in 2017. This report serves as the final update for those tests. The test zone at the western mega site was comprised of one 1-degree curve and two 2-degree curves. These curves supported 200–250 million gross tons (MGT) of traffic annually under operating speeds ranging between 40 and 50 mph over near-flat grades. The track structure is comprised of concrete ties with elastic fasteners. The test zone at the eastern mega site was comprised of two 6.8-degree curves and two 10-degree curves. These curves supported an estimated 55 MGT of traffic annually, under operating speeds ranging between 15 and 25 mph over grades as steep as 1.4 percent. The track structure was comprised of timber ties with cut spikes. The results obtained from testing at the mega sites include the following: (1) Over the testing period, more than 2,200 MGT was accumulated at the western mega site and more than 500 MGT at the eastern mega site; (2) No internal rail defects were reported to TTCI over the period of testing; and (3) Only intermittent rolling contact fatigue (RCF) growth was detected after approximately 1,000 MGT. There was also a statistically significant reduction in the rate of wear for both high and low rails in one of the 2-degree curves at the western mega site, following the implementation of top-of-rail (TOR) friction modifier.
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