Design methodology for heavy-haul railway track foundations under 40-tonne axle loads

Tengfei Wang, Zhongcheng Yan, Taifeng Li, Liyang Wang and Qiang Luo

International Journal of Rail Transportation, 2025, vol. 13, issue 6, 1098-1113

Abstract: Heavy haul railway, recognized for high capacity and efficiency, is gaining traction worldwide. However, heavier axle loads can accelerate track and foundation deterioration without robust structural design. This study proposes a practical design methodology for heavy-haul track foundations under 40-tonne axle loads. Short axle spacing was considered in analyzing train load distribution, revealing significant stress superposition on the subgrade. Based on general strength, deformation, and long-term stability, a standardized multi-axle load pattern (4Z1800/2400) is introduced to capture these effects. The recommended design ensures cumulative deformation remains within the subgrade “working zone” by integrating induced stress levels and fill materials, surpassing single-factor approaches. Long-term stability, indicated by cumulative deformation approaching slow convergence, serves as the control requirement. Proposed design solutions include: 1) roadbed thickness of 3.5 m, with subgrade reaction modulus (K30) ≥110 MPa/m below the roadbed; 2) lower roadbed of 2.3 m, K30 ≥130 MPa/m, with thickness adjustments as needed; 3) upper roadbed of 0.7 m using high-quality graded gravel. These measures effectively control deformation, thus ensuring the performance and longevity of heavy-haul track foundations under extreme axle loads. The outcomes support global heavy-haul development.

Date: 2025
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DOI: 10.1080/23248378.2025.2453928

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International Journal of Rail Transportation is currently edited by Wanming Zhai and Kelvin C. P. Wang

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