Doctor of Philosophy / Civil Engineering / Robert J. Peterman / A study was conducted to determine the effect of different concrete properties and prestressing steel indentation types on development length and flexural capacity of pretensioned members. Wires and strands commonly used in the manufacturing of prestressed concrete railroad ties worldwide were selected for the study. Thirteen different 5.32-mm-diameter prestressing wire types and six different strands (four, seven-wire strands and two, three-wire strands) were used to cast prisms with a square cross section. The ratio of concrete to prestressed steel in the test prism’s cross section was representable of typical concrete railroad ties. Thus, geometrical and mechanical properties of test prisms were representative of actual ties in the railroad industry. To understand the effect of concrete-release strengths and slumps on development length, all parameters were kept constant in the prisms except concrete-release strength and slump. To manufacture prisms with different release strengths, all four wires/strands were pulled and detensioned gradually when the concrete compressive strength reached 3500 (24.13 MPa), 4500 (31.03 MPa), and 6000 (41.37 MPa) psi. To determine the effect of different slumps on development length, prisms with different slumps of 3 in. (7.6 cm), 6 in. (15.2 cm), and 9 in. (22.9 cm) were manufactured and all other parameters were kept constant in prisms. All prisms were tested in three-point bending at different spans to obtain estimations of development length based on type of reinforcement, concrete-release strength, and concrete slump. Lastly, a design equation was developed based on experimental data for prediction of development length. In the last phase of load tests, cyclic-loading tests were conducted on the prisms manufactured with wires to evaluate the bond performance of wires with different indentation types under cyclic loading. A total of 210 load tests, including 14 cyclic tests, were conducted. The monotonic-load tests revealed a large difference in the development length of pretensioned concrete members manufactured with different wire/strand types and different concrete-release strengths. Also, the cyclic-load tests revealed a significant difference in bond performance of different wire types under cyclic loading compared to monotonic loading.

The pressure distribution at the ballast-tie interface of railroad track plays a key role in overall track support. Failure of the ballast or tie can result from excessive loads that were not designed for, requiring increased maintenance and reducing railroad operating efficiency. Understanding the forces acting on the ballast and tie are required to design higher performance and longer lasting track. To further this understanding, the use of Matrix Based Tactile Surface Sensors (MBTSS) is employed to measure the actual pressure distribution at the ballast-tie interface, characterized by individual ballast particle contact points and non-uniform pressures. The research explores this application of MBTSS including the development of sensor protection and calibration procedures. Results from laboratory ballast box testing conducted at the Transportation Technology Center, Inc. (TTCI) are presented. Conservative estimates of peak pressure under a typical wheel load on new ballast averaged 1450 psi and on fouled ballast averaged 680 psi. Contact areas varied across the range of ballast gradations and are shown to increase under increased applied load. A parameter to describe the "roughness" of the ballast-tie pressure distribution is offered. Results from in-track testing performed at TTCI, including pressure distributions along ten test ties, are also presented.

Doctor of Philosophy / Civil Engineering / Kyle Riding / Air voids are purposefully entrained in concrete to provide freeze-thaw durability of prestressed concrete railroad ties. Durability assurance requires consistent provision of an air void system comprised of small, well-distributed bubbles in sufficient quantity for durability and a quality control method for testing tie freeze-thaw durability. Manufacturing processes at three concrete manufacturing plants were investigated in order to determine the effects of process variability on resulting concrete air void system variability. Variation in the concrete air void system and other rheological properties occurred as results of the manufacturing process and vibration. Freezing and thawing durability testing of prestressed concrete ties is currently performed by applying ASTM C666 on 3 x 4 x 11 to 16 in. specimens cut from the shoulders of concrete ties. However, excising these specimens from prestressed concrete could lead to stress changes in the sample and cracking, potentially causing false interpretations of results. Therefore, testing was undertaken to understand the effects of prestressing and sample extraction on freeze-thaw durability measured by ASTM C666. In order to assess the effects of sampling and testing procedures on freeze-thaw quality control testing results of prestressed concrete railroad ties, full ties, half ties, and 3 x 4 x 11 in. excised samples were tested. Freeze-thaw testing included determination of the optimal method to measure freeze-thaw deterioration in large sections, the effects of saw-cutting, and the presence of reinforcement. Results indicated that the Ultrasonic Pulse Velocity accurately represented deterioration in large sections. The presence of reinforcement in excised samples led to faster deterioration compared to cast ASTM C666 samples, while saw-cutting without reinforcement did not significantly affect freeze-thaw durability.

Doctor of Philosophy / Department of Industrial & Manufacturing Systems Engineering / Chih-Hang John Wu / Quality is a result of product design and production control. Product design must maximize the ability to function across variations in production and environment. Production control must monitor and maintain the key design characteristics necessary for the intended function. Failure to do so results in premature part failure and increased costs. This has occurred in the production of modern cross ties. By designing quality into the product and production process, performance is maximized. This research presents a methodology for incorporating quality into the product design and production process. For product design, a relationship between product performance and design parameters is established by modeling techniques. These models provide a means to redesign the product to maximize performance and to understand the sensitivity of the design to fluctuation in production and environment. These models also establish the key design parameters that are critical for sustaining quality. For production, a method of monitoring the key design parameters is presented that provides an affordable means of automated inspection. Automated inspection removes operator error from the inspection process and allows for greater sampling rates to be achieved. The methodology presented allows for a potential of 100% inspection to be achieved with minimal impact to production costs. The research is applied to the analysis and quality control of pre-stressing steel reinforcement for concrete cross-ties. This application provides an opportunity to test and verify the research findings on a real world problem. Novel automated 3D spatial analysis algorithms are presented. This research furthers the state of the art of performing Geometrical Dimensioning and Tolerancing (GD&T). A cost effective method of non-contact surface profiling was developed with high resolution and high density surface profiles. The combined research findings present a methodology of achieving quality by design.