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Conenor Composite Railway Crossties

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Composite Railway Crossties
Status & Developments
Markku Vilkki, Conenor Ltd
Composite Railway Crossties
(known also as ”Sleepers”)
 O V E R T H E PA S T 2 0 Y E A R S
COMPOSITE SLEEPERS MADE FROM
R EC YC L E D P L A S T I C S H AV E B EC O M E
C O M M O N S TA N D A R D P R O D U C T S
 S E V E R A L M A N U FA C T U R E R S A L L
OVER THE WORLD INTHE
U S A , R U S S I A , C A N A D A , J A PA N , U K ,
G E R M A N Y, I N D I A , TA I W A N , A F R I C A ,
THAILAND, NETHERLANDS AND
AUSTRALIA
 C O M P O S I T E R A I L W AY S L E E P E R S
ARE REPLACING EXISTING CONCRETE,
S T E E L A N D , P A R T I C U L A R LY, T I M B E R
O N E S I N B OT H M A I N L I N E A N D H EAV Y
HAUL RAIL NETWORKS
references from one US manufacturer Axion
Benefits of Composite Sleepers
 ENGINEERING
- M E E T A N D E X C E E D N AT I O N A L S TA N D A R D S

MORE DURABLE
- R E S I S TA N T T O R O T, F U N G U S , I N S E C T S , A N D M O I S T U R E

E A S Y - T O - I N S TA L L
- I N S TA L L S U S I N G T R A D I T I O N A L W O O D - T I E E Q U I P M E N T

E N V I R O N M E N TA L LY S A F E R & C L E A N E R
- I N E R T M AT E R I A L A N D C O N TA I N S N O T O X I C M AT E R I A L S
 G R E E N S U S TA I N A B L E P R O D U C T
- M A D E F R O M 1 0 0 % R E C YC L E D M AT E R I A L A N D A R E 1 0 0 %
R E C YC L A B L E AT T H E E N D O F T H E I R L O N G L I F E
 PROVEN LONGER LASTING
- R E S I S T P L AT E W E A R , H O L D S P I K E S , A N D M A I N TA I N
G A U G E A C C U M U L AT I N G W E L L A X L E L O A D S
 LOW E R L IF E C YC L E CO STS
Manufacturers of
Composite Sleepers
 H T T P : / / W W W. A X I O N S I . C O M /
 H T T P : / / W W W. AT L A S T I E S . C O M / I N D E X . P H P

H T T P : / / W W W. B O I S C O M M E R C I A L W O O D . C O M / C AT C O N T E N T. A S P ? C
AT 2 I D = 2 4
 HTTP://INTEGRICO.COM/PRODUCTS/INTEGRITIES/
 H T T P : / / W W W.T I E T E K . N E T/ P R O D U C T. A S P
 H T T P : / / W W W. S I C U T. C O . U K /

H T T P : / / W W W. I C S S E R V I C E S . C O M . A U / W K G / P D F S / C A R B O N L O C M A
NUALGENERAL5.PDF
 H T T P : / / T V E M A . C O M / C ATA L O G / S U P P O R T - S Y S T E M S . H T M L
Manufacturing Process of
Composite Sleepers
MANUGACTURING OF COMPOSITE
SLEEPERS IN THREE STEPS;
1.
PROCESSING PROPER PLASTIC WASTE
2. PRODUCTION OF COMPOSITE
MATERIAL FORMULATION
WITH OR WITHOUT REINFORCEMENTS
3. PRODUCTION OF SLEEPERS
- by intrusion method
- by extrusion method
Manufacturing Process of
Composite Sleepers
VIDEO IN YOUTUBE FROM INTEGRICO
HTTPS://WWW.YOUTUBE.COM/WATCH?V=8T
ZNUV-0WLS
Different Types of
Composite Sleepers

TYPE-1 SLEEPERS WITH SHORT OR NO FIBRE REINFORCEMENTS
S L E E P E R S T H AT C O N S I S T O F R E C YC L E D P L A S T I C ( P L A S T I C B A G S , S C R A P P E D
VEHICLE TYRES, PLASTIC COFFEE CUPS, MILK JUGS, LAUNDRY DETERGENT
BOT T LES ETC. ) O R BI T UMEN W I T H FI LLERS (SA N D, G RAVEL , RECYCLED G LA SS O R
SHORT GLASS FIBRES < 20 MM)

TYPE-2 SLEEPERS WITH LONG FIBRE REINFORCEMENT IN THE
LONGITUDINAL DIREC TION
TYPE-2 SLEEPERS ARE SLEEPER TECHNOLOGIES REINFORCED WITH LONG
CONTINUOUS GLASS FIBREREINFORCEMENT IN THE LONGITUDINAL DIRECTION
AND NO OR VERY SHORT RANDOM FIBRE IN THE TRANSVERSEDIRECTION

TYPE-3 SLEEPERS WITH FIBRE REINFORCEMENT IN LONGITUDINAL AND
TRANSVERSE DIRECTIONS
T YPE - 3 SLEEPERS HAVE LO NG REI NFO RCEMENT FI BRES I N BOT H LO NG I T UDI NA L
A N D T R A N S V E R S E D I R E C T I O N S A N D C O N S E Q U E N T LY B O T H T H E F L E X U R A L A N D
S H E A R B E H AV I O U R A R E D O M I N AT E D B Y F I B R E S .
Different Types of
Composite Sleepers
Source: Composite Railway Sleepers – Recent developments, challenges and future prospects / Article in Composite Structures · August 2015
Comparing Advantages and
Disadvantages of Composite
Type1 and Type2 Sleepers
Source: Composite Railway Sleepers – Recent developments, challenges and future prospects / Article in Composite Structures · August 2015
Summary of Composite
Type1 Sleepers
 The most common composite sleeper material, Type-1 sleepers
offer a range of benefits including ease of drill and cut, good
durability, consumption of waste materials, reasonable price, and
tough.
 However, it suffers from low strength and stiffness, limited design
flexibility, temperature and creep sensitivity, and low resistance to
fire.
 The notable sleepers in this category are TieTek (USA), Axion
(USA), IntegriCo (USA), I-Plas (UK), Tufflex (S-Africa), Natural rubber
(Thailand), Kunststof Lankhorst Product KLP (Netherlands), Mixed
Plastic Waste MPW (Germany) and Woodcore (USA).
Source: Composite Railway Sleepers – Recent developments, challenges and future prospects / Article in Composite Structures · August 2015
How to Improve Strength of
Composite Type1 Sleepers
 Because of the short length of the fillers, they do not have
a major reinforcing effect and the failure behavior of these
sleepers is mainly polymer driven.
 Due to the lack of any long reinforcement fibres these
sleepers are flexible and expand and contract significantly
with temperature.
However, as stronger Type 2 and Type 3 composite sleepers become
very expensive up to 10x more compared to wood sleepers, there is
an incentive to develop further the low cost Type 1 sleepers to
become stronger and more durable !
Comparing the Performance of
Composite Sleepers to AREMA
(USA) Specification Requirements
Source: Composite Railway Sleepers – Recent developments, challenges and future prospects / Article in Composite Structures · August 2015
MOR- and MOE-values of
Composite Type1 Sleepers
 Modulus of Rupture (flexural strength) and Modulus of Elasticity
(stiffness) values for composite materials are defined in 3-point
bending test in laboratory conditions
 The minimum values stated in AREMA (USA) specification (MOR
@13.8 MPa and MOE @1.2 GPa) represent those levels typical for
polyethylene (PE) polymer – and this is logical because Type 1
composite sleepers are made mainly from this waste material
When producing the composite material formulation one may combine
other stronger waste materials in the PE-waste polymer for improving
the mechanical performance of Type 1 sleepers into much higher level
without increasing costs !!
Choice of Materials for Type1
Composite Sleepers
MOR- and MOE-values of
Conenor Developed FRP-Waste
Reinforced HDPE-Waste Plastic
MOR-values up to 36 MPa !
MOE-values up to 3 GPa !
Mechanical properties of ”FRC”material from waste exceed AREMA
requirements by 2,5 times and
outperform those existing Type 1
composite sleepers in the market
Ideal for stronger Type 1
Composite Sleepers !
FRP-Waste Reinforced Material
is an Invention by Conenor Ltd
Patent Application EP 3 159 127 A2
 Simple and Low Cost Thermo-Mechanical Process
 Using Commodity Existing Equipment
 No Processing Waste
 Applicable Stronger Material for Plastic
Processing (injection, extrusion, intrusion)
 Technology Available on License Basis
 see http://www.conenor.com/recyclingthermoset-frpwaste/
Conenor Ltd – a Private
Development Company
in Waste Composites
 SME founded 1995
 Inventor of unique CONEX®-Extrusion Technology
 Participation in EU-Commission funded R&D-projects;
- http://www.ircow.eu/
- https://osirysproject.eu/
- http://www.hiserproject.eu/
- http://cordis.europa.eu/project/rcn/210181_en.html
-
 Outsourced client R&D-projects from waste composites
for major corporations (including among others);
- UPM; see http://www.conenor.com/client-projects-trials/
- StoraEnso
- Kuusakoski / Metsähallitus
-
www.conenor.com
 Composite extrusion facilities for R&D, sampling and
pilot production at Orimattila Town in South-Finland
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