This study explores the use of infrared thermography (IRT) technology for the non-destructive evaluation of ballast fouling in railway tracks, focusing on the influence of parent rock types and fouling materials. Utilizing thermal imaging, the research investigates how variations in ballast conditions affect surface temperature, which serves as an indicator of structural integrity and health. The experimental setup involved ballast samples derived from three different rock types—basalt, limestone, and andesite—fouled with commonly encountered materials like sand and clay at varying percentages. Results demonstrate that fouling level and type significantly influence the thermal signatures captured by IRT passive camera. Notably, ballast derived from darker rocks exhibited higher temperatures, indicating greater emissivity, while fouled ballast showed distinct temperature patterns compared to clean samples, emphasizing the potential of thermal imaging in detecting and quantifying fouling in ballast layers. This research underscores the viability of IRT passive camera in the routine maintenance and monitoring of railway infrastructure, providing a foundation for further development of integrated diagnostic tools for railway management systems.

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Ballast layer defects are the primary cause for rapid track geometry degradation. Detecting these defects in real-time during track inspections is urgently needed to ensure safe train operations. To achieve this, an indicator, the track degradation rate (TDR) was proposed. This rate is calculated using track geometry inspection data to locate and predict railway-line sections with ballast layer defects. The TDR is determined by the monthly standard deviation of the rail longitudinal level, which is one aspect of track geometry. The Ballast Layer Health Classification (BLHC) is designed by assessing the two successive TDRs before and after track geometry maintenance actions. The BLHC is used to categorize the conditions of the ballast layer, including normal periodic deterioration, abrupt deterioration, effective maintenance, rising deterioration, and severe deterioration. Both the TDR and BLHC were validated through field assessments of ballast layer conditions, where the two indicators were found to be effective in revealing defects. The results indicate that the TDR is sensitive to ballast layer defects, while the BLHC can quickly identify the location of these defects. Consequently, the BLHC can provide real-time guidance for ballast layer maintenance.

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Vehicle-mounted ground-penetrating radar (GPR) has been used to non-destructively inspect and evaluate railway subgrade conditions. However, existing GPR data processing and interpretation methods mostly rely on time-consuming manual interpretation, and limited studies have applied machine learning methods. GPR data are complex, high-dimensional, and redundant, in particular with non-negligible noises, for which traditional machine learning methods are not effective when applied to GPR data processing and interpretation. To solve this problem, deep learning is more suitable to process large amounts of training data, as well as to perform better data interpretation. In this study, we proposed a novel deep learning method to process GPR data, the CRNN network, which combines convolutional neural networks (CNN) and recurrent neural networks (RNN). The CNN processes raw GPR waveform data from signal channels, and the RNN processes features from multiple channels. The results show that the CRNN network achieves a higher precision at 83.4%, with a recall of 77.3%. Compared to the traditional machine learning method, the CRNN is 5.2 times faster and has a smaller size of 2.6 MB (traditional machine learning method: 104.0 MB). Our research output has demonstrated that the developed deep learning method improves the efficiency and accuracy of railway subgrade condition evaluation.

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Railway ballast performance is dictated by a complex mix of mechanical properties. These effect its performance at the particle level for example in terms of particle degradation, but also at the track system level in terms of settlement and stability. Therefore this paper seeks to develop new understandings of ballast behaviour and identify opportunities for future research directions. First, ballast particle size and size distribution curves are discussed, considering opportunities to improve breakage, settlement and drainage characteristics. Next, particle geometry is discussed, with a focus on form, angularity and surface texture. This is followed by a discussion on the degradation mechanisms of ballast particles and the effect of fouling on permeability. Next, techniques to assess and improve ballast bulk density are discussed, such as ground penetration radar and dynamic track stabilisation. Testing methods for studying ballast are also reviewed, first considering both smaller-scale tests such as direct shear tests and the Los Angeles abrasion test. Then larger-scale laboratory testing is discussed, including large-diameter dynamic triaxial testing and the use of full-scale laboratory tracks. Finally, conclusions are drawn and suggestions for future research directions are given.

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In practice, the assessment and treatment of rail corrugation are quantitatively based on the corrugation depth. Wheel–rail vertical forces (WRVF), as a direct reflection of wheel–rail interaction, can give expression to the corrugation depth and thus serve as a key parameter for assessing the corrugation. In this paper, we propose an evaluation method for rail corrugation based on the WRVF. First, a 3D wheel–rail dynamic finite element (FE) model was developed with typical parameters of CRTS II slab track and CRH3 vehicle for high-speed railways in China. The accuracy of the model was then validated with the measured WRVF data in the field. Second, using the validated model, the time–frequency domain distribution of WRVF (vehicle speed: 300 km/h) was obtained with consideration of the corrugation wavelength in the range of 40–180 mm. The non-linear least squares method and rational equation were used to fit the function between the large value of WRVF and the corrugation depth value under the conditions of different corrugation wavelengths. Next, effects of the Pinned–Pinned resonance frequency and vibration mode on the fitted parameters were analysed, by which an indicator for corrugation treatment (grinding) was proposed. Finally, the indicator was applied in the monitoring of rail corrugation for high-speed railway lines in the field. The results show that the misjudgement rate of rail grinding decisions (using the proposed indicator) is low with the accuracy at 92.5%. The proposed method can provide a basis for the rail corrugation evaluation and grinding decisions-making.

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The Sichuan−Tibet railway is built under some difficult situations, including limited ballast bed profile, frequent earthquakes and large diurnal temperature variation. These difficulties cause insufficient lateral resistance of ballasted track, which is an urgent problem for the stability and resilience of the continuously welded rail (CWR). Aiming to improve and quantify the stability and resilience of CWR, the lateral resistance of frictional sleepers (designed as that normal sleeper with arrowhead shape groove) is evaluated with the single sleeper push test (SSPT). By performing SSPT, the increment of lateral resistance of ballast bed with frictional sleepers is measured. Shapes of sleeper grooves are properly designed and optimized (three groove shapes with the same size and volume but different arrowhead directions). Whether frictional sleeper applied to ballast bed (reduced ballast shoulder width) will provide enough lateral resistance for the ballast bed at Sichuan−Tibet railway line. Results show that frictional sleepers can increase the lateral resistance by minimum 7% and maximum 21%. Arrowhead directions significantly influence the lateral resistance, which is increased by 7% (same pushing direction) and 24% (opposite pushing direction), compared to normal sleepers. Therefore, strict attention should be paid to the laying direction when laying in curved sections of ballasted track. After reducing the ballast shoulder width from 50 cm to 30 cm, using the frictional sleeper (single arrowhead direction pushed in reversed direction) can still provide enough lateral resistance, which is the same value as a mono-block Type Ⅲ sleeper with 50 cm shoulder width.

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Ground penetrating radar (GPR) is a popular technology for inspecting railway ballast layer, mainly on the ballast fouling level. However, different GPR antennas with different frequencies are suitable for different inspection emphasis and diverse railway lines (weather and sub-structure). In addition, the full-scale track model (with subgrade) for experimental tests was not seen in earlier studies. For further application of GPR in China, the GPR inspections (with 400 MHz, 900 MHz and 2 GHz antennas) were performed on a 30 m long full-scale track and three railway lines (different weather and sub-structure). Results show that ballast layer inspection should be performed mainly with the 2 GHz antenna and supplemented by the 400 MHz and 900 MHz antennas. The weather has great influence on the results of GPR inspection. This study is helpful for supplementing the guidance of ballast layer inspection with GPR.

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Ground penetrating radar (GPR) has been applied for ballast layer inspection for two decades, mainly for the analysis of ballast layer fouling levels. However, some issues that affect the inspection quality remain unsolved, such as issues involving the GPR equipment quality (antenna) and the correlation between the GPR indicator and fouling index. With the aim of solving these two issues, in this paper, we investigated the difference between the results of two different antennas, the GPR data processing technique, indicators for the fouling level (by GPR signal processing) and the correlation between the indicators and fouling index (obtained by sieving). The results show that the antenna quality determines the inspection quality. The indicators can reflect the ballast layer fouling level, and they correlate the best with the fouling index (obtained by the percentage of particles passing through a 5 mm sieve size). This study is helpful for the future modification of railway ballast maintenance standards.

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Crumb rubber (CR) has been proposed to apply in the ballast or sub-ballast layer for ballast degradation mitigation and vibration (noise) reduction. The CR can change the ballast layer stiffness, which can affect the train-track-subgrade dynamic performance and cause travel comfort and safety issues. Towards this, this study aims at confirming 1) how much the CR application can affect the dynamic performance of train and ballast layer; 2) to what extent the CR-ballast layer can distribute the train loadings to reduce subgrade surface stress. To achieve this aim, a whole train-track-subgrade system model was built by coupling multibody dynamics (MD), discrete element method (DEM) and finite difference method (FDM). The MD was used to build the train, including one vehicle body, two bogies and four wheelsets. The DEM was used to build the ballasted track, including rail, sleepers and ballast layer. The FDM was used to build the subgrade. Using the coupled model, the dynamic performance of train and track were studied, including the vehicle body acceleration, wheel-rail force, rail dynamical bending moment, sleeper acceleration, sleeper displacement and ballast acceleration. In addition, the energy dissipation of the ballast bed was also presented. For the subgrade, the subgrade surface acceleration and surface stress were measured and analysed. In the model, different CR size and percentage were considered. Results show that using the CR in ballast layer can increase the accelerations of sleeper, rail and train. But it can decrease the ballast degradation, subgrade surface acceleration and subgrade surface stress. CR helps consume train loading energy, reducing the energy that has to be consumed by ballast friction. Small size CR (8–22.4 mm) has greater influence on dynamic performance of the whole train-track-subgrade system than big size CR (9.5–63 mm). In summary, 10% percentage of CR-ballast mixture is recommended, and for CR size it is difficult to give a recommendation. Small size CR increase ballast acceleration more than big size CR, but small size CR are better at improving sleeper displacement, subgrade stress and ballast bed stress.

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In the past 20 years, many studies have been performed on ballast layer inspection and condition evaluation with ground penetrating radar (GPR). GPR is a non-destructive means that can reflect the ballast layer condition (fouling, moisture) by analysing the received signal variation. Even though GPR detection/inspection for ballast layers has become mature, some challenges still need to be stressed and solved, e.g., GPR indicator (for reflecting fouling level) development, quantitative evaluation for ballast fouling levels under diverse field conditions, rapid GPR inspection, and combining analysis of GPR results with other data (e.g., track stiffness, rail acceleration, etc.). Therefore, this paper summarised earlier studies on GPR application for ballast layer condition evaluation. How the GPR was used in the earlier studies was classified and discussed. In addition, how to correlate GPR results with ballast fouling level was also examined. Based on the summary, future developments can be seen, which is helpful for supplementing standards of ballast layer evaluation and maintenance. @en

The use of recycled materials is a new tendency in the field of railway engineering. Steel slag aggregates (SSA) are one of the recycled materials derived from the steel industry. The application of SSA in ballasted railway tracks requires mechanical examination. In the present paper, the shear behavior of the ballast layer constructed by SSA and basalt aggregates was considered to assess the use of SSA as a substitution for basalt. In this regard, a series of large-direct shear tests were performed on basalt and SSA under various normal stresses. Based on the results, basalt aggregates have higher shear resistance than SSA for all normal stress. However, steel slag has sufficient shear strength as well as particle abrasion resistance. Overall, it was proven that the SSA has suitable stability against shear forces that could be applied on railway ballast.

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The properties of railway ballast material are affected by the local geologies and climatic environments from which the parent rock is sourced. These factors can make it challenging to select the most appropriate material for railway applications. To address this issue, this paper first reviews the means of ballast selection in complex environments across the world. The selection criteria for ballast materials are compared and test methods for ballast quality quantification are summarised. Next, ballast parent rock types and the implications of mining approaches are discussed, before analysing ballast morphology with respect to ballast size and shape. Then ballast petrography is reviewed with a focus on the effect of mineral composition on performance. Finally, some promising future ballast technologies are discussed with a focus on environmental performance. These include recycled ballast, asphaltic materials, steel slag and ballast gluing. The review shows that regarding ballast selection means and criteria, the number and type of quantitative indicators varies greatly between countries. In particular there are divergences in test methods and quantitative indicators for ballast quality considering material types and local geologies. Suggested future research directions are proposed, such as the effect of tamping and dynamic track stabilisation on ballast properties.@en

Ballast layer condition should be more regularly and accurately inspected to ensure safe train operation; however, traditional inspection methods cannot sufficiently fulfil this task. This paper presents a method of ground penetrating radar (GPR) application to reflect ballast layer fouling levels under diverse field conditions (annual gross passing load, cleaning and renewal year, fouling composition and transportation type). The results show that the GPR-based inspection method can assess the ballast layer fouling level with a 1–7% difference from the traditional sieving results. Fouling composition (especially metal materials) has a great effect on the GPR signals, thus affecting the inspection accuracy of ballast layer fouling level. Developing diverse GPR-based fouling indicators (by distinguishing different GPR signal features) can improve the GPR inspection applicability to the diverse field conditions.

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Railway ballast is normally made of crushed rocks with grading (particle size distributions). Ballast is inevitably suffering from more rapid degradation. Because ballast keeps undergoing and dissipating most of the train loadings, furthermore, the train speed and freight weight are increasing, causing more intensive loadings to ballast. To prolong ballast service time and reduce ballast maintenance cost, more studies need to be performed on the ballast degradation reduction, ballast inspection, and ballast assessment. Therefore, earlier distinguished studies on these three aspects are introduced, summarized and discussed in this chapter, toward the final goal of providing research gaps, engineering guidance, and maintenance advice.

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Under the high requirement of ballast materials and the frequent maintenance of high-speed and heavy-haul railway, the maintenance cost and material consumption become an important problem. Several methods are used to increase the stability and service life of railway structure, also using recycled materials in ballast bed construction can be a way for railway sustainable development. Thus, an idea of using furnace slag as the sub-ballast was put forward in this research. To qualify the performance of furnace slag, a series of tests were carried out, including single particle crushing test, direct shear test, box stiffness test, and the crushed stone which is the traditional sub-ballast material was used as a comparison. In addition, the test and numerical simulation on box stiffness were carried. Results show that furnace slag has less possible to breakage and abrasion, its shear resistance is 16.46%–19.48% higher, and 20.44%–26.04% decrease in shear dilatancy. However, the stiffness for single particle shows not much difference, the box stiffness test and simulation indicated that furnace slag has a higher capacity and better elasticity. Based on that, this research provides the feasibility of using furnace slag as the sub-ballast, and it works as an environment-friendly way in railway construction.@en

Research purposes: The longitudinal resistance of track bed reflects the ability of track bed to limit the longitudinal displacement of track and directly affects the stability of track. In order to further study the longitudinal resistance characteristics of ballast track panel, this paper established a full-scale model, carried out a series of tests to get the longitudinal resistance and displacement curve of the track, to explore the influence of the number of sleepers, sleeper crib fullness and sleeper spacing on the longitudinal resistance, and summarized and proposed measures to enhance the longitudinal resistance.

Research conclusions:(1) With the increase of the number of sleepers, the longitudinal resistance increases, but the average longitudinal resistance to each sleeper decreases. (2) The ballast crib fullness has a great influence on the longitudinal resistance of the track panel. When the crib ballast change from zero to full, the longitudinal resistance increases by 83.2%. (3) The sleeper spacing has a significant effect on the longitudinal resistance. When the sleeper spacing decreases from 600 mm to 500 mm, the longitudinal resistance increases by 12.27%. (4) The research results can be applied to the design, construction and maintenance of ballasted tracks, which can be used as a reference for improving the stability of ballast bed.@en

In the present paper the mechanical behavior of two types of Kunststof Lankhorst Product (KLP) sleeper, namely low-density polyethylene sleeper (LDPE-16) and high-density polyethylene sleeper (HDPE-25) with 16 mm and 25 mm steel bars diameter, are studied. To this end, the static, dynamic, and longtime static three points bending moment tests are performed. The HDPE-25 and LDPE-16 with six strain gauges are mounted on the steel bars to assess their mechanical responses. Moreover, a Finite Element Method (FEM) model is developed to perform sensitivity analysis on 16 mm HDPE (HDPE-16) and 25 mm LDPE (LDPE-25) based on different steel bar diameters. The results showed that the LDPE-16 steel bar yielded under a load of 30 kN for 4 hours, while HDPE-25 showed significant resistance. Numerical results showed that HDPE-25 is overdesigned and can be replaced by LDPE-25, which is lighter in weight and lower in price. The natural frequencies of HDPE-25 were almost 16%, 19%, 16%, and 33% higher than the three first bending frequencies and first torsion frequency of LDPE-25, respectively. These findings prove the better performance of LDPE-25 in the case of preventing resonance. In addition, the exural modulus of HDPE-25 was almost 42%, 45%, and 65% higher than that of HDPE-16, LDPE-25, and LDPE-16, respectively.

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To enhance the stability of continuous welded rail (CWR) tracks, frictional sleepers have been developed. The frictional sleepers are new types of sleepers with grooves on the bottom, and different bottom grooves improve lateral resistances at different magnitudes. In this study, single sleeper push test (SSPT) and its model with discrete element method (DEM) were carried out to confirm how much arrowhead groove frictional (AGF) sleeper increases the lateral resistance of ballasted track. The SSPTs were performed to confirm the lateral resistance results, and also to validate and calibrate the DEM models. With the validated models, the groove factors influencing the lateral resistances were studied, including groove sizes (depth, width), arrowhead groove direction and groove numbers. The reason of lateral resistance improvement was studied at mesoscopic level, including the ballast-sleeper contact numbers and contact force chains. Results show that applying the AGF sleeper is able to improve lateral resistance by 7–24%, and it can provide enough lateral resistance after reducing ballast shoulder width from 500 mm to 300 mm. The AGF sleeper can improve the sleeper-ballast interaction by increasing sleeper-ballast contact number. The study is helpful for frictional sleeper design, further improving track stability.

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Ballast rheology is a phenomenon that describes movements of ballast particles due to the discrete nature, which eventually leads to the ballast bed fluid deformation after a long-time service. In most cases, ballast rheology is the main reason of track irregularity that leads to some track defects, e.g., hanging sleeper and mud spots. Therefore, it is significant to confirm the ballast rheology mechanism, which not only benefits for alleviating track defects, prolonging track service and providing safe transportation, but also provides an innovated means for accurately calibrating the discrete element method (DEM) models. Towards this aim, the Particle Image Velocimetry (PIV) is utilised to study ballast rheology through measuring ballast particle displacements in the single sleeper push test (SSPT). The ballast rheology results are compared with those from the DEM SSPT model, through which the DEM model is calibrated. Results show that the PIV is an effective technical means for ballast rheology study and DEM model calibration. This study is helpful for the researchers to build more precise DEM models, further providing theoretical methodology for ballast track construction and innovations.

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