Numerical studies to evaluate crack propagation behaviour of prestressed concrete railway sleepers

•Nonlinear FE model of sleepers has been presented.•Full-scale experiments have been conducted for validation.•Crack propagations are monitored and presented.•It is the first time that crack propagations are predicted.•Prestress forces play a significant role on the crack propagation. The prestressed concrete sleeper is a primary type of sleeper for railway systems around the world. Compared with wooden and composite sleepers, concrete sleepers are of good elasticity and sufficient longitudinal and lateral resistance to ensure the stability of the track. As the railway system is developing to a heavier load and higher speed system, the cracking of concrete sleepers under dynamic load and long-term service is becoming more and more critical. It is essential to evaluate the crack behaviour of prestressed concrete sleepers. In this paper, three-dimensional FEM models have been established using Abaqus based on the brittle cracking model. After the validation by experimental results, the numerical research is performed to evaluate the crack propagation behaviours of prestressed concrete sleepers with different concrete compressive strength, different prestressing force magnitudes, and different loading rates. The results reveal that the cracking resistance of a concrete sleeper turns enhanced by improving the compressive strength of concrete and the initial prestressing force of tendons. It is also observed that the cracking becomes more progressive as the loading rate increases.