Concrete | Concrete Sleeper Factory | SGB Group | Projects

The factory will consist of ten production lines. Five of those lines will be capable of producing PR607 the other five lines will be producing Pandrol Fast clips.

Our partners Rail Moulds & System Ltd (RM&S) will be responsible in supplying the:

RM&S specialize in the Supply of concrete sleeper moulds for long line and short line production and the technology to cast sleepers based on the long line system.

The company has vast experience in the supply of these moulds and specializes in the supply of ling line production systems. The company uses the latest mould design and manufacturing methods to supply moulds to cast sleepers with rail fasteners such as Pandrol Fast clip and E clip and Vossloh fixings.

SKAKO Ltd of Denmark will be responsible in supplying a batching plant with two mixers with a capacity of 40 cm³ as well as the concrete transportation system which contains two the following:

SKAKO makes concrete equipment and production solutions that reduce the cost of producing high-quality concrete for ready-mix and precast applications

Their solutions - concrete batching plants, silo systems, mixers, control systems, and proportioning equipment - are engineered to make a difference. So that no matter what concrete production requirement. They will supply the best single source of robust and high-performance plant and equipment solutions.

Moulds specification

The sleeper mould is precision fabricated from M.S. Plate and rolled sections all welded to BS 1856. The rail seat is recessed to take the Pandrol shoulder insert which is held in the correct position by a plastic pad and built-in retaining pin. On the either side of the mould, running channels are provided for the vibrator system. The mould is mounted on the wheels to run on rails in the production floor. The split end plates are precision cut from M.S. plate and are complete with set of end plates, clips and springs.

Strand Running Machine

The machine comprises a fabricated R.H.S. support base with chequer plate operator deck area. The frame is fitted with 4 cast steel wheels suitable for running on 35 lb/yd flat bottom section rails.

A slide latch location unit is mounted onto the base and 8 floor mounting angle brackets are provided, these are supplied loose for setting by customer when unit is aligned with strand running track.

The traction unit may be positioned in either a horizontal or vertical mode to suit wire line height. The unit comprises a 'globe pneumatic' radial piston air motor, fitted with an integral 6.04/1 gearbox and brake. This motor drives directly a grooved wheel and via a 1:1 chain drive a second grooved wheel, both wheels are fitted to shafts housed in bearings of ample proportions. The traction wheels are 200 mm in diameter. and engineered to rotate at speed up to 248 RPM providing a Strand through-put speed of approx.155 meters/min.

The chain drive is fitted with a jockey tensioned wheel.

The strand will be held in contact with the two traction wheels by means of two smaller diameter pressure wheels these are also fitted to shafts which are supported in bearings. Pressure will be applied by a hand-wheel and screw acting through two crank arms, to allow for wear of the wheel faces a number of "Bellville" washers are used to ensure pressure is always applied.

The whole assembly is designed for ease of maintenance and replacement of wearable details.

Cutting Machine

a) Traveling speed:
FORWARD and BACKWARD infinitely variable by means of hand lever abt. 0-20 n/min
Cutting blade: - Diameter 24" 609,6 mm
Cutting Speed:- FORWARD and BACKWARD infinitely
Variable by potentiometer abt. 0 - 1C n/min
The machine is fitted with rotating drums for both electric cable and water hose.
The cutting blade travels in both directions.

There is a positive locating system for the cutting blade which is a pair of hydraulic rams which enter the gaps provided between the moulds and holds the machine in position during the cutting process.

b) Small disc cutter is electric powered with 350 mm blade hand operated portable with "dead can" switch, guards etc.

Jackheads

The jackhead is a fabricated steel structure fitted into the end blocks of the prestressing bed. One type is designated the "live end" jackhead and has fitted to it 2 No.300T hydraulic Jacks with a moving crosshead and the other type is designated the "dead end" jackhead which has a fixed crosshead.

a) The dead end crosshead is fabricated from heavy mild steel plate ultrasonically tested to BS 4336. 4 plates are set horizontally to take the main thrust and 2 plates are set vertically to take the eccentric couple from the anchor plate. Suspended from this assembly are machined MS guide plates to receive the individual sleeper anchor plates. The heavy suspension plates are arranged through a pin joint to ensure that the main thrust is in line on the crosshead.

b) The live end crosshead is fabricated from heavy mild steel plate ultrasonically tested to BS 4336. These plates are mounted in line and pinned by means of a clevis end to the jackhead upright and are supported on a trolley assembly at each end. This mounting is capable of adjustment to ensure alignment. The individual sleeper anchor plates are suspended from a fabricated steel plate tied back to the crosshead with 18 No. high tensile steel tension road to the trolley assembly.

c) The live end uprights are fabricated from heavy mild steel plate ultrasonically tested to BS 4336. They are symmetrically arranged either side of the crosshead centre line and the 300T jack centre lines. The jack body is fixed to the upright by clevis ends and a pin assembly. The assembly is such that it can be removed to make other products and thus pivots about a centre heavy reaction plate with a kicker plate set low down in the end block to the prestressing bed.

d) The dead end uprights are similar to the live end except that as they do not contain any hydraulic jacks the upright width is reduced to allow 1 m clearance between adjacent uprights for better access to the production line. The crosshead is bolted and welded to the upright for stability and to absorb the out of balance from the anchor plate suspension system.

e) The hydraulic jacks are double acting 300 ton capacity with a 900 mm stroke at a working pressure of 6000 p.s.i. They are formed from forged mild steel, honed and hand chromium plated in the bores. The rams are threaded for the locking nut with a heavy duty square thread and fitted with oil seals and wear rings.

f) The hydraulic system for operating the rams comprises a 3 HP electric motor driven mono radial pumping unit complete with oil reservoir, filler, filter unit, oil level indicator, isolating valve, relief valve and solenoid operated control valve.

The hydraulic pipe work is to BSS 1387, solid drawn, descaled and annealed. The valves are of the 'gate' type and of mild steel tested to 1.5 times working pressure. The hydraulic gauges are of the Bourdon tube type with dials calibrated to read the ram force direct.

Each jack has a pressure gauge in the supply line. The control valves and pressure gauges are mounted on a control panel and marked for identification.

Lifting Tackle

Contains the following:-
1 Set steel chain slings with centre ring and hooks 3 meter long for SWL of 5 tons.
2 Sets steel wire rope slings 6 m long with loops each end for SWL 5 tons.
4 Sets steel wire rope slings 3 m long with loops each end for SVL 2 tons.
4 Standard shackles for SWL of 5 tons.
4 Standard shackles for SWL of 2 tons.

All to relevant British Standards specification for lifting tackle.

Concrete Distribution

Self dumping slave hopper with capacity of 1 c.m of concrete Electric actuator clam shell doors, Suspended from 2 No. 2 wheels trolleys having hardened steel wheels and side rollers traveling on overhead rail track 116 meters long on a continuous runway linking the Batching Plant. Driven by a rubber tyred electric mono tractor unit, 2 speed operation with maximum speed of 100 m/min.

The Spreader unit is a double bridge structure carried on two fabricated end carriages, each fitted with two flanged steel runner wheels on steel axles, located in jig bored holes. One wheel in each end carriage driven simultaneously through twin drive arrangement comprising squirrel cage dual speed geared motor unit fitted with electro magnetic brakes, on the top of this unit runs a I.C.M. receiving hopper fitted with bottom discharge clam shell doors operated by electric actuator. This hopper carried on fabricated crab unit driven simultaneously through twin drive arrangement comprising squirrel cage duel speed geared motor units fitted with electro magnetic brakes. Under slung is a I.C.M. pouring hopper with clam shell bottom doors both operated by hydraulics for fine adjustment when pouring. The hopper is suspended from fabricated under slung carrier carried on runner wheels. Control of all motions of the spreader unit is from multi button console at drivers position.

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