Influence of Ballast and Sub-Ballast Thickness on Structural Behavior of Heavy-Haul Railway Platform Determined by Using Finite Element Modeling

Abstract

This study investigates the influence of ballast and sub-ballast thicknesses on the structural behavior of a heavy-haul railway platform by using finite element modeling with SysTrain software (v. 1.84) A parametric analysis was conducted to assess how variations in layer thickness affect key performance parameters, including total deflection, bending moments in the rails, and vertical stresses within the railway track. The results indicate that reducing ballast thickness increases deflection and vertical stresses, while excessive thickness elevates system stiffness, reducing its ability to dissipate stresses. This condition can intensify the transmission of dynamic loads to track components, accelerating rail and sleeper wear and requiring more frequent corrective interventions, thereby increasing maintenance costs. Deflections remained within the 6.35 mm limit established by AREMA, except for one case (6.85 mm), where an excessive ballast thickness (160 cm) combined with low material stiffness resulted in non-compliance. Vertical stresses in the substructure ranged from 106.9 kPa to 155.9 kPa, staying within admissible limits. Additionally, the study highlights the significant role of material properties, particularly the resilient modulus, in the overall track performance. The findings enhance the understanding of how ballast and sub-ballast geometry affect railway structural behavior, demonstrating how numerical modeling with SysTrain can support decision-making in track design and maintenance strategies.

Keywords

• heavy haul railway
• structural performance
• finite element method
• SysTrain software