AU2007216629A1 - An insert for use with a cast railway sleeper - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant: Rinker Australia Pty Ltd Invention Title: AN INSERT FOR USE WITH A CAST RAILWAY SLEEPER The following statement is a full description of this invention, including the best method for performing it known to us: 2 AN INSERT FOR USE WITH A CAST RAILWAY SLEEPER FIELD OF THE INVENTION The present invention relates to an insert, for a cast railway sleeper, which is for use in a rail fastening O \system, and also to a sleeper incorporating such an

NO

,insert.

BACKGROUND

It is known to attach rail track to a sleeper using rail fasteners. Typically, the rail fasteners are positively attached to the sleeper. In addition, the rail fastener has a clip, or like sprung component, that applies a load to the lower flange of the rail to hold the rail against the sleeper.

The manner in which rail fasteners are attached to sleepers is at least partly dependent on the type of material of the sleeper. For example, screw spikes are most commonly used with timber sleepers to attach rail fasteners to sleepers. Concrete sleepers have cast iron shoulders that are cast into the sleeper and protrude 40mm proud of the top of the sleeper. The protruding section of the shoulder has a linkage for attachment of a spring clip which anchors the foot of the rail to the protruding section of the cast in shoulder.

Timber sleepers deteriorate over time and it is often desirable to replace individual sleepers without replacing the entire track. This is commonly done by removing the damaged or aged sleeper, scouring the ballast and sliding N:\Melbourne\Cases\Patent\61000-61999\P61767.AU.1\Specis\P61767.AU. 1 Specification 2007-9-4.doc 4/09/07 3 a replacement sleeper into place beneath the rail. To reduce the amount of scouring required and hence reduce e( Sthe amount of disturbance to the ballast, it is desirable Sthat the ballast be scoured by the minimum amount.

O SUMMARY OF THE INVENTION

\O

IND

According to a first aspect of the present invention, there is provided an insert adapted to be cast into a railway sleeper body, the insert comprising: a plate having an aperture through which an engaging portion of a rail fastener can be passed; a fixing means for fixing the insert in the sleeper body; and a cavity defining structure that forms a cavity adjacent to the plate and that is accessed through the aperture when the insert is cast in the sleeper body, the cavity for receiving the engaging portion of a rail fastener, wherein the insert has a lip that is internal to the cavity on at least one side of the aperture, such that in use, the engaging portion bears against the lip to enable the rail fastener to fasten rail track to the railway sleeper.

Preferably, the plate has two apertures through which an engaging portion of a rail fastener can be passed, and two associated cavity defining structures each forming a cavity adjacent to the plate and having an internal lip on at least one side of the respective aperture, the cavity for receiving an engaging portion of a rail fastener.

N:\Melbourne\Cases\Patent\61000-61999\P61767.AU.1\Specis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 4- Preferably, the lip in each cavity is located on the side of the aperture that is closest to the other aperture.

In one embodiment, lips are located on opposite sides of the, or each, aperture.

In one embodiment, the fixing means is in the form of a plurality of legs that extend from the under surface of the plate. An end portion of each leg may be provided with a screw thread that is received in a respective threaded hole in the plate. In addition, each leg can be secured against rotation within the respective hole.

Preferably, the legs are L-shaped.

In another embodiment, the fixing means is in the form of one or more fins that extend from the, or each, cavity defining structure in a direction that is generally parallel to the plate.

Each cavity defining structure can be provided with two fins.

In embodiments in which the insert has at least two apertures, each fin can be arranged to extend in a direction parallel to an elongate direction of the plate.

In one embodiment, the insert is a unitary casting.

Accordingly, the insert can be formed by simultaneously casting the plate with the apertures, and the cavity defining structures with the fins.

N:\Melborne\Cases\Patent\61000-61999\P61767AU1\Specis\P61767AU.1 Specitication 2007-9-4.doC 4/09/07 5 In another embodiment, the, or each, cavity defining structure is in the form of a cup that is fixed to the plate.

In another embodiment, the fixing means is an anchor.

Alternatively, the fixing means can be a plurality of like anchors. In such an embodiment, the anchors may be contiguous with the plate.

The fixing means can be in the form of the material extending from the plate. In such an embodiment the end portions of each fixing means may have folded portions.

Furthermore, the end portions of each anchor may be provided with one or more splits and two or more folded sections.

In one embodiment, each cavity defining structure is in the form of a cup that is fixed to the plate. In an alternative embodiment, the cavity defining structure is in the form of a cup that is separate from the plate.

In one embodiment, the lip that is internal to the, or each, cavity completely surrounds the aperture, such that the engaging portion of the rail fastener can bear against the lip in any relative orientation of the insert and the fastener.

According to a second aspect of the present invention, there is provided a sleeper for supporting rail track, the sleeper comprising: a sleeper body of cast material; and at least one insert according to the first aspect, the insert being cast in the sleeper body such that the, N:\Melbourne\CaseS\Patent\61000-61999\P61767.AU.l\pecis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 6 or each, aperture opens onto an upper surface of the sleeper.

The plate can be flush with the upper surface of the body. Accordingly, the upper surface of the sleeper has a lower profile, when compared with a sleeper that has inserts that protrude above the upper surface of the body.

The sleeper may be provided with one insert for each rail track to be supported, each insert having two apertures and two associated cavity defining structures.

According to a third aspect of the present invention, there is provided a method for fastening rail track to a cast railway sleeper, the method comprising: placing rail track on an upper surface of a sleeper according to the second aspect, such that the rail track is in proximity to the, or each, aperture of the at least one insert; inserting a fastener into each aperture of the at least one insert, by hooking a toe of the fastener through the aperture and into the cavity and bearing the toe beneath the lip; and securing the fastener to the rail track.

BRIEF DESCRIPTION OF THE DRAWINGS In order that the invention may be more easily understood, embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: N:\Melborne\Cases\Patent\6100O-61999\P61767AU1\SpeCi\P61767.AU.1 Specification 2007-9-4doc 4/09/07 7 Figure 1 is a top view of an insert in accordance with a first embodiment of the present invention; Figure 2 is a cross sectional elevation of the insert as viewed along the line A-A of figure 1; Figure 3 is a first perspective view of an insert in accordance with a second embodiment of the present invention; Figure 4 is a second perspective view of the insert of figure 3; Figure 5 is a cross sectional view of a sleeper in accordance with a third embodiment of the present invention, and which incorporates the insert of figure 1; Figure 6 is an enlarged view of detail A in figure Figure 7 is a side elevation of a rail fastener that can be used with an insert in accordance with embodiments of the present invention; Figure 8 is a first perspective view of an insert in accordance with a fourth embodiment of the present invention; Figure 9 is a second perspective view of the insert of figure 8; Figure 10 is a side elevation view of a sleeper in accordance with a fifth embodiment of the present invention; N:\Melbourne\Cases\Patent\61000-61999\P61767.AU.l\Specis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 8 Figure 11 is a plan view of the sleeper of figure Figure 12 is a plan view of an insert in accordance with a sixth embodiment of the present invention; Figure 13 is a side elevation view of the insert of figure 12; Figure 14 is a plan view of an insert in accordance with a seventh embodiment of the present invention; Figure 15 is a side elevation view of the insert of figure 14; Figure 16 is partial view of a sleeper in accordance with an embodiment of the present invention; and Figure 17 is a partial view of the sleeper of figure 16, with a portion of rail track and two rail fasteners.

DETAILED DESCRIPTION Figures 1 and 2 show an insert 10 according to a first embodiment that is adapted to be cast into a sleeper body (not shown in figures 1 and 2) of a railway sleeper for use in supporting rail track (also not shown in figures 1 and The insert 10 has a plate 12 that is provided with an aperture 14. The insert 10 has a cavity defining structure, which defines a cavity C on one side of the plate 12. In this embodiment, the cavity defining structure is in the form of a cup 16. During casting of N:\Melbourne\Caes\Patent\61000-61999\P61767.AU.1\Specis\P61767.AU 1 Specification 2007-9-4.doc 4/09/07 9 the sleeper, the cavity defining structure prevents the material from entering the cavity C.

The cavity C is accessed through the aperture 14.

When the insert 10 is used in a rail fastening system, the cavity C receives the engaging portion of a rail fastener, which can be, for example, the toe of a rail fastener.

Rail fasteners of the type suitable for use with embodiments of the present invention are colloquially known as "hook in" rail fasteners due to the manner in which the rail fastener is connected to the sleeper.

The insert 10 has a lip 17 that is internal to the cavity C. The lip 17 includes a portion of the under surface U of the plate 12, and in this embodiment surrounds the aperture 14. The toe of the rail fastener can bear against the lip 17, as will be described in further detail in connection with figures 5 and 6.

The insert 10 is also provided with fixing means for fixing the insert in the body of the sleeper. In this embodiment, the fixing means is in the form of a pair of anchors 18, 20. Each anchor 18, 20 extends from the plate 12 in the same direction as the cup 16. The anchors 18, 20, when cast in the sleeper body fix into the hardened material, such that the insert 10 is anchored (in other words, fixed) generally within the sleeper body, and in particular when a force is applied in a direction generally perpendicular to the plate 12.

In the embodiments illustrated in figures 1 and 2 the anchors 18, 20 are in the form of a strip of material that is contiguous with the plate 12. An end portion of anchor N:\Melbourne\Cases\Patent\61000-61999\P6176?.AU l\Specis\P61767.AU.l Specification 2007-9-4.doc 4/09/07 10 18 has a split 22a and two folds 24a. An end portion of anchor 20 has two splits 22b and three folds 24b.

Accordingly, the end portions of the anchors 18, 20 are forked. This may be formed by shearing the material of the end portion of the anchors 18, Figures 3 and 4 show an insert 110 according to a second embodiment that is adapted to be cast into a sleeper body (not shown in figures 3 and 4) of a railway sleeper for use in supporting a rail track (also not shown in figures 3 and The insert 110 has a plate 112 that is provided with an aperture 114. The insert 110 has a cavity defining structure, which defines a cavity C on one side of the plate 112. In this embodiment, the cavity defining structure is in the form of a cup 116. During casting of the cast sleeper, the cavity defining structure prevents material from entering the cavity C.

The cavity C is accessed through the aperture 114 When the insert 110 is used in a rail fastening system, the cavity C receives the engaging portion of a fastener, which can be, for example, toe of a rail fastener. The insert 110 has a lip 117 that is internal to the cavity C.

The lip includes a portion of the under surface U of the plate 112, and in this embodiment surrounds the aperture 114. The toe of the rail fastener can bear against the lip 117, as will be described in further detail in connection with figures 5 and 6.

The insert 110 is also provided with fixing means, which, in this embodiment, is also in the form of a pair of anchors 118, 120 that extend from the plate 112 in the same direction as the cup 116. The anchors 118, 120, when N:\Melbourne\Cases\Patent\61000-61999\P61767,AU.l\Specis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 11 cast into the sleeper body, anchor the insert 110 in the hardened material, such that the insert 110 is restrained generally within the sleeper, and in particular when a force is applied in a direction generally perpendicular to the plate 112.

In the embodiments illustrated in figures 3 and 4 the anchors 118, 120 are in the form of a strip of material that is contiguous with the plate 112. An end portion of anchor 118 has a split 122a and two folds 124a. An end portion of anchor 120 has one split 122b and two folds 124b. Accordingly, the end portions of the anchors 118, 120 are forked. This may be formed by shearing the material of the end portion of the anchors 118, 120.

Figures 5 and 6 show in cross section a sleeper 26, which has a sleeper body of cast material, in accordance with a third embodiment of the present invention. Figures and 6 also show a section of rail track 28 in end view.

Two inserts 10 according to the first embodiment are cast into the body of the sleeper 26 for each piece of rail track 28 to be supported by the sleeper 26. The upper surface of the plate 12 is approximately flush with the upper surface of the sleeper 26 that surrounds the insert 10. Once the material of the sleeper 26 has hardened, the anchors 18, 20 are fixed in the sleeper body to restrain the inserts 10 against forces that are applied to the insert 10 in a direction that is generally perpendicular to the plate 12. Such forces act to pull the insert 10 out of the body of the sleeper 26.

N \Melbourne\CaseoPatent\61000-61999\P61767AU.1\Specis\P61?67AU.1 Specification 2007-9-4.doc 4/09/07 12 Once the rail track 28 is in position on the sleeper 26, a rail fastener 30 is installed in each insert Figure 7 shows a fastener, or rail fastener 30, that has an engaging portion, in the form of a toe 32; a body 34; and a neck portion 36 that extends between the toe 32 and the body 34. The toe 32 has a first shoulder 38 on one side of the neck portion 36, and a second shoulder 40 on the opposing side of the neck portion 36.

The toe 32 of the rail fastener 30 is inserted through the aperture 14, such that the toe 32 is located within the cavity C. As the first and second shoulders 38, 40 are wider than the aperture 14, the first shoulder 38 is first inserted through the aperture 14 and into the cavity C. Subsequently, the second shoulder 40 is inserted through the aperture 14 and into the cavity.

Accordingly, both the first and second shoulders 38, 40 of the toe 32 are located beneath the plate 12. Both shoulders 38, 40 can bear against the lip 17. Thus, the toe 32 effectively hooks into the cavity C. One type of rail fastener 30 that may be used with the insert 10 is the Track-Lok® fastener produced by OneSteel Ltd. A track fastening clip (not shown) is used to hold the rail track 28 in position against the sleeper 26.

As described above, the toe 32 is positioned beneath the plate 12 by a hooking action. Accordingly, there is no subsequent relative rotation of the rail fastener with respect to the insert 10 to secure the rail fastener 30 to the insert 10 once the toe 32 has passed through the aperture 14. Rail fasteners that are inserted by such a hooking action are known. The Track-Lok® fastener N:\Melbourne\Cases\Patent\61000-61999\P61767AU.I\Specis\P61767AU.1 Specification 2007-9-4.doc 4/09/07 13 produced by OneSteel Ltd is an example of a rail fastener that is colloquially known as a "hook in" rail fastener.

Figures 8 and 9 show an insert 210 in accordance with a fourth embodiment that is adapted to be cast into a sleeper body (not shown in figures 8 and 9) of a railway sleeper for use in supporting rail track (also not shown in figures 8 and The insert 210 has an elongate plate 212 that is provided with two apertures 214. The insert 210 has two cavity defining structures 216, which define two separate cavities C on one side of the plate 212.

Each cavity C is accessed through the respective aperture 214.

When the insert 210 is used in a rail fastening system, each cavity C receives the engaging portion of a fastener. The plate 212 has lips 217 that are internal to each cavity C. The insert 210 is also provided with fixing means, which in this embodiment is in the form of four generally L-shaped legs 218. Each leg 218 extends from the plate 212 in the same direction as the cavities C. The legs 218 are oriented such that the transverse portion of each leg 218 extends parallel to the elongate direction of the plate 212. The attachment of the legs 218 to the plate 212 is described in further detail in connection with figures 12 and 13.

When the insert 210 is cast in a sleeper body, the insert 210 is arranged such that the elongate direction of the plate 212 is generally parallel with the elongate direction of the sleeper. The two apertures 214 are spaced apart such that rail track can be positioned on the portion of the plate 212 between the two apertures 214.

N:\Melbourne\Cases\Patent\61000-61999\P61767.AU1\Specls\P61767 AU1 Specification 2007-9-4.doc 4/09/07 14 Two fasteners can be used to fasten the rail track to the insert 210, and thus to the sleeper, as described previously in reference to figures 5 and 6.

Figures 10 and 11 show in cross section a sleeper 326 in accordance with a fifth embodiment of the present invention. Figure 10 also shows two parallel sections of rail track 328 in end view and two rail fasteners 330.

Two inserts 310 are cast into the sleeper body 327 of the sleeper 326. The insert 310 is of similar structure to the insert 210 shown in figures 8 and 9, but differs in the orientation of the transverse portion of the legs 318.

The insert 310 has an elongate plate 312 that is provided with two apertures 314. The insert 310 has two cavity defining structures 316, which define two separate cavities C on one side of the plate 312. Each cavity C is accessed through a respective aperture 314.

When the insert 310 is used in a rail fastening system, each cavity C receives the engaging portion of a fastener. The plate 312 has lips 317 that are internal to each cavity C. In this embodiment, the lip 317 internal to each cavity C is located on the side of the respective aperture 314 that is closest to the other aperture 314.

The insert 310 is also provided with fixing means, which, in this embodiment, is in the form of four generally L-shaped legs 318. Each leg 318 extends from the plate 312 in the same direction as the cavities C.

The legs 318 are oriented such that the transverse portion of each leg 318 extends parallel to the elongate direction of the sleeper 326.

N:\Melbourne\CaeS\Patent\61000-61999\P61767.AU \Specis\P61767.AU Specification 2007-9-4.doc 4/09/07 15 Pre-stressed wires 342 are cast into the sleeper body 325 and extend longitudinally through the sleeper body.

The shape and orientation of the legs 318 allow the insert 310 to be cast into the sleeper body 325 without interfering with the wires 342.

Figures 12 and 13 show an insert 410 in accordance with a sixth embodiment. The insert 410 is similar to the insert 210 shown in figures 8 and 9, in that it has an elongate plate 412, which is provided with two apertures 414. Each aperture 414 has an associated cavity defining structure 416 that each form a cavity C adjacent to the plate 412. Each cavity C is accessed through the respective aperture 414.

To fasten rail track to sleeper in which the insert 410 is cast, each cavity C receives the engaging portion of a rail fastener. The insert 410 has lips 417a, 417b that are internal to each cavity C. In this embodiment, the lips 417a are located on the side of the aperture 414 that is closest to the other aperture 414. The lips 417b are located on opposite sides of the respective aperture 414 to the lips 417a. The toe of the rail fastener bears against the lips 417a to enable the rail fastener to fasten rail track to the railway sleeper. For some hookin rail fasteners, the toe of the rail fastener can also bear against lips 417b.

The insert 410 is also provided with fixing means, which in this embodiment is in the form of three generally L-shaped legs 418. Each leg 418 extends from the plate 412 in the same direction as the cavities C. The legs 418 N:\Melbourne\Caees\Patent\61000-61999\P61767.AU.l\Specis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 16 are oriented such that the transverse portion of each leg 418 extends parallel to the elongate direction of the plate 412.

The top portion of each leg 418 is provided with an external screw thread. Each leg 418 is screwed into a corresponding internally threaded hole in the plate 412.

When the legs 418 are in the desired orientation and position, the legs 418 are tack welded to the plate 412 to prevent the legs 418 being unscrewed. In alternatively, the legs may be plug welded to the plate.

As shown in figure 12, the legs 418 are oriented such that the transverse portions are parallel with the elongate direction of the plate 412.

Figures 14 and 15 show an insert 510 in accordance with a seventh embodiment. The insert 510 has an elongate plate 512 that is provided with two apertures 514. Each aperture 414 has an associated cavity defining structure 516 that each form a cavity C adjacent to the plate 512.

Each cavity C is accessed through the respective aperture 514.

To fasten rail track to sleeper in which the insert 510 is cast, each cavity C receives the engaging portion of a rail fastener. The insert 510 has lips 517a, 517b that are internal to each cavity C. In this embodiment, the lips 517a are located on the side of the aperture 514 that is closest to the other aperture 514. The lips 517b are located on opposite sides of the respective aperture 514 to the lips 517a. The toe of the rail fastener bears against the lips 517a to enable the rail fastener to N:\Melbourne\Cases\Patent\61000-61999\P61767.AU.\Specis\P61767.AU.1 Specification 2007-9-4 doc 4/09/07 I I 17 fasten rail track to the railway sleeper. For some hookin rail fasteners, the toe of the rail fastener can also bear against lips 517b.

The insert 510 is also provided with fixing means, which, in this embodiment, is in the form of fins 518.

The fins 518 extend from the cavity defining structures 516 in direction that is generally parallel to the plate.

The insert 510 can be formed by simultaneously casting the plate 512 with the apertures 514, and the cavity defining structures 516 with the fins 518. In this way, the plate 512, cavity defining structures 516 and fins 518 are in the form of a unitary casting.

Figure 16 shows a partial view of a sleeper 626 having a body of cast material in accordance with an embodiment of the present invention. The sleeper 626 has an insert 610 cast into the sleeper body. The insert 610 may be any one of the inserts 210, 310, 410, 510 previously described. The upper surface of the plate 612 of the insert 610 is flush with the upper surface of the body of the sleeper 626.

As described above, inserts in accordance with embodiments of the present invention can be used with the Track-Lok® rail fasteners. The inserts may also be used with Pandrol® brand rail fasteners.

Pandrol® "e clip" rail fasteners have a body to which a spring-biased fastening clip is connected. The "e clip" clamps the foot of the rail track between the fastening N:\Melbourne\Cases\Patent\61000-61999\P61767.AU.1\Specis\P61767 AU.1 Specification 2007-9-4.doc 4/09/07 18 clip and the sleeper. These Pandrol® fasteners have an engaging portion, in the form of a toe, and a neck portion Sthat extends between the toe and the body. The toe has a Ssingle shoulder on one side of the neck portion.

To attach the Pandrol® fastener to an insert of the present invention, the toe of the fastener is inserted

NO

through an aperture of the insert, such that the toe is located within the cavity C. The fastener is then hooked S 10 into the cavity C such that the body of the fastener is adjacent the upper surface of the plate and the shoulder is located beneath the lip of the insert. The shoulder can bear against the lip.

Figure 17 shows the sleeper 626 of figure 16 with a section of rail track 628. The foot of the rail track 628 rests on the upper surfaces of the plate 612 and the sleeper 626. As shown in figure 17, two rail fasteners 630, which in this embodiment are Pandrol® "e-clip" rail fasteners, are to be connected to the insert 610 as previously described. For clarity, the spring-biased clips have been removed. However, it will be appreciated that the rail fasteners will clamp the rail track 628 to the sleeper 626.

Sleepers in accordance with embodiments of the present invention have the advantage of a low profile that facilitates easy replacement when an old sleeper is to be removed. Due to the low profile of the sleeper, the amount of ballast to be scoured is minimized, which reduces the amount of disturbance to the ballast.

In addition, the sleeper has the advantages of a cast sleeper, which include a prolonged service life.

N:\Melborne\Caaes\Patent\61000-61999\P61767AU1\Specis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 19 It will be appreciated that, in some embodiments of the insert, a rail fastener can be attached in any relative orientation of the rail fastener with respect to the insert.

A sleeper in accordance with an embodiment of the present invention, such as the sleepers 26, 626 can be slid into place beneath the rail tracks. Accordingly, when replacing a single sleeper the amount of ballast required to be scoured from beneath the rail to replace the sleeper is less. In contrast, prior to this, a concrete sleeper requires that more ballast be scoured from beneath the rail to allow the cast in shoulders protruding from the body of the sleeper to clear the foot of the rail.

As described above, once the sleeper is in position beneath the rail track(s), the rail fasteners can be attached to the sleeper and the rail track.

In the embodiment shown in figures 1 and 2, the aperture 14 is elliptical in plan view. In the embodiment shown in figures 3 and 4, the aperture is circular in plan view. However, it is to be appreciated that in alternative embodiments the aperture may be any convenient shape, provided only that the plate surrounding the aperture can support the loads applied to the insert by the toe of the rail fastener. Furthermore, it will be appreciated that the shape of the aperture is at least partially influenced by the shape of the rail fastener intended to be used with the insert.

N:\Melbourne\Cases\Patent\61000-61999\P61767.AU .I\Specis\P61767AU1 Specification 2007-9-4.doc 4/09/07 20 The fixing means can be of any suitable shape or configuration, and may be attached to the cavity defining Sstructure rather than the plate directly. However, it is tt to be appreciated that each of the fixing means should engage material within the sleeper body such that, when a force is applied by a rail fastener to the insert, the \0 insert is restrained in the sleeper. The insert may be provided with a single anchor only. The anchor (or anchors) may be in the form of a shaft with transversely protruding engaging elements. The anchor(s) may be connected or otherwise attached to the cavity defining structure.

The cavity defining structure may be of any desirable shape or configuration. For example, the cavity defining structure may be square, frusto-conical, and/or multifaceted. Furthermore, in some embodiments the cup is not fixedly connected to the plate and the anchors. For example, the insert may be a two-piece component, in which the cavity defining structure is separate to the plate and anchors. In such a case, the cavity defining structure could be inserted into the mould for a sleeper prior to casting either separately or together with the plate and anchors.

It is to be appreciated that the body of the sleeper may be of any suitable material for casting. In some embodiments the sleeper may be concrete. However, alternatively, the sleeper may be made of plastics material, or a geopolymer.

N:\Melbourne\Cases\Patent\61000-61999\P61767.AU.l\Specis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 21 It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the scope of the invention.

In the claims of this application and in the description of the invention, except where the context requires otherwise due to express language or necessary implication, the words "comprise" or variations such as "comprises" or "comprising" are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

N\Melbourne\Cases\Patent\61000-61999\P61767.AU1\Specis\P6176.AU.1 Specification 2007-9-4.doc 4/09/07

Claims (19)

1. An insert adapted to be cast into a railway sleeper body, the insert comprising: a plate having an aperture through which an engaging portion of a rail fastener can be passed; a fixing means for fixing the insert in the sleeper body; and a cavity defining structure that forms a cavity adjacent to the plate and that is accessed through the aperture when the insert is cast in the sleeper body, the cavity for receiving the engaging portion of a rail fastener, wherein the insert has a lip that is internal to the cavity on at least one side of the aperture, such that in use, the engaging portion bears against the lip to enable the rail fastener to fasten rail track to the railway sleeper.

2. An insert as claimed in claim 1, wherein the plate has two apertures through which an engaging portion of a rail fastener can be passed, and two associated cavity defining structures each forming a cavity adjacent to the plate and having an internal lip on at least one side of the respective aperture, the cavity for receiving an engaging portion of a rail fastener.

3. An insert as claimed in claim 2, wherein the lip in each cavity is located on the side of the aperture that is closest to the other aperture. N \Melborne\Caes\Patent\6100-61999\P61767Au.l\Speci\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 23

4. An insert as claimed in any one of claims 1 to 3, wherein lips are located on opposite sides of the, or each, aperture.

5. An insert as claimed in any one of claims 1 to 4, wherein the fixing means is in the form of a plurality of legs that extend from an under surface of the plate.

6. An insert as claimed in claim 5, wherein an end portion of each leg has a screw thread that is received in a respective threaded hole in the plate.

7. An insert as claimed in claim 6, wherein each leg is secured against rotation within the respective hole.

8. An insert as claimed in any one of claims 5 to 7, wherein the legs are L-shaped.

9. An insert as claimed in any one of claims 1 to 4, wherein the fixing means is in the form of one or more fins that extend from the, or each, cavity defining structure in a direction that is generally parallel to the plate.

10. An insert as claimed in claim 9, wherein the, or each, cavity defining structure is provided with two fins.

11. An insert as claimed in either claim 9 or 10, wherein the insert is a unitary casting.

12. An insert as claimed in any of claims 1 to wherein the, or each, cavity defining structure is in the form of a cup that is fixed to the plate. N:\Melbourne\Ca3se\Patent\61000-61999\P61767 AU.1\Specis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 24

13. A sleeper for supporting rail track, the sleeper comprising: a sleeper body of cast material; and at least one insert according to any one of claims 1 to 12, the insert being cast in the sleeper body such that the, or each, aperture opens onto an upper surface of the sleeper.

14. A sleeper according to claim 13, wherein the plate of the, or each, insert is flush with an upper surface of the sleeper body.

A sleeper according to either claim 13 or 14, wherein the sleeper is provided with one insert for each section rail track to be supported, each insert having two apertures and two associated cavity defining structures.

16. A method for fastening rail track to a railway sleeper, the method comprising: placing rail track on an upper surface of a sleeper according to any one of claims 13 to 15, such that the rail track is in proximity to the, or each, aperture of the at least one insert; inserting a fastener into each aperture of the at least one insert, by hooking a toe of the fastener through the aperture and into the cavity and bearing the toe beneath the lip; and securing the fastener to the rail track.

17. An insert adapted to be cast into a railway sleeper body, the insert substantially as hereinbefore described with reference to the accompanying drawings. N:\Melbourne\Cases\Patent\61000-61999\P61767.AU.l\Specis\P61767.AU.1 Specification 2007-9-4.doc 4/09/07 25

18. A sleeper for supporting rail track substantially as hereinbefore described with reference to the accompanying drawings.

19. A method for fastening rail track to a railway sleeper substantially as hereinbefore described with reference to the accompanying drawings. N:\Melbourfle\Cafe\Pateft\610-6999\P6767AU1\Specis\P61767.AU.1 Specification 2007-9-4.doC 4/09/0~7