Numerical Evaluation of Interlayer Gaps on Dynamic Response of Precast Concrete Slab Track Systems with Maintenance Thresholds

This study presents a comprehensive numerical investigation into the dynamic response of railway precast concrete slab track (PST) systems subjected to various interlayer gap conditions. Key parameters including gap width, depth, and location were examined, along with the geometric configuration of the grouting layer, comparing current (as-is) and earlier (as-was) models. A conservative modeling approach was adopted, assuming fully unbonded interfaces and delamination gap depths extending to the shear key, with dynamic loading applied. Results showed that the maximum principal stress in both the slab and grouting layer increased with larger gap widths but stabilize beyond specific thresholds. In the as-is model, stress levels remained below reference flexural tensile strength, indicating a low risk of cracking. However, the as-was model exhibited grouting layer stresses exceeding the allowable limit at the gap widths near 4 mm and approaching critical levels even at 1.5 mm. Stress responses also varied depending on whether gaps were located at the slab–grouting layer or grouting layer–hydraulic stabilized basecourse (HSB) interfaces. Based on the examinations, allowable interlayer gap width criteria were proposed to support maintenance decisions. The study provides a rational framework for monitoring and managing interlayer gaps, enhancing resistance to early fatigue cracking and structural integrity of PST systems under dynamic railway loads.