A Comprehensive Review on High-Performance Concrete with Crumb Rubber for Enhancing the Structural Efficiency and Durability of Pre-Stressed Railway Sleepers

Abstract

The increasing demand for durable, sustainable, and impact-resistant railway infrastructure has accelerated the exploration of alternative materials for prestressed concrete sleepers. High-Performance Concrete (HPC), characterised by superior strength, refined microstructure, and enhanced durability, offers significant advantages over conventional concrete; however, its inherent brittleness under high-impact and cyclic loading remains a challenge. Incorporating crumb rubber (CR), derived from waste vehicle tyres, into HPC presents a promising solution by combining mechanical resilience with environmental sustainability. This review critically examines the mechanical behaviour, durability characteristics, structural performance, and finite element modelling (FEM) insights of CR-HPC sleepers, drawing upon recent experimental and analytical studies. Results consistently demonstrate that moderate CR inclusion enhances ductility, impact resistance, crack-bridging capacity, and fatigue life while maintaining compressive strength within acceptable limits for sleeper applications. CR-HPC also contributes significantly to sustainability by reducing landfill waste, lowering the environmental footprint, and extending sleeper service life. Despite these advantages, research gaps exist in long-term field performance, ITZ behaviour under prestressing, large-scale fatigue testing, and advanced numerical modelling. The paper concludes with future directions for optimising CR-HPC mix design, adopting AI-based prediction tools, and developing standardised design guidelines for next-generation resilient railway sleepers.