Evaluation of mechanical and performance characteristics of a new composite railway sleeper made from recycled plastics, mineral fillers and industrial wastes

Significant increase in load, speed and passing traffic of railways, has stimulated the demand of making track components with more durable, better damping and higher service life materials. Because of environmental benefits, using recycled plastics and waste materials are of more interest, but insufficient understanding of their performance when used as railway track components has caused them not to be applied completely. To fill this gap, this research is focused on evaluation of the mechanical and performance characteristics of a new plastic composite sleeper (NPCS) made from recycled high-density polyethylene (RHDPE) combined with filler materials. The load bearing capacity, energy absorption, electrical resistance and service life characteristics of the NPCS is investigated thorough extensive experimental work. Experimental works are conducted on sixteen mixtures and composite specimens designed and produced from different type and various content of fillers. Results showed that the incorporation of fillers in the plastic sleepers improves its load bearing capacity, electrical resistance, and service life of the sleepers. The results also indicated that NPCS has less energy absorption capabilities compared with sleepers fully made from plastics, but its absorption capacity is still much higher than conventical wooden and concrete sleepers. Based on the results of this study using NPCS improves the mechanical properties of the track as well as its manufacturing costs. The NPCS is a suitable solution in parts of track where large impacts from wheel is experienced or in points where the reduction of stiffness is intended.