A novel concept of polymer railway sleeper is proposed in this study that has the potential to meet static performance requirements within the cost of hardwood timber. The existing challenges of composite sleepers, such as low performance or high cost, can be overcome using this innovative concept. Such a proclamation is proven through limit state design criteria and a series of experimentations. Results show that polyurethane foam as an infill material can provide sufficient strength and stiffness properties to the sleeper, but the inadequate screw holding capacity could be a problem. This limitation, however, can be overcome using a particulate filled resin system. The findings of this study will help the railway industry to develop a timber replacement sleeper.
Keywords: GFRP; composite sleeper; structural performance; sustainable development; timber replacement sleeper.