Fouling and mud-pumping problems in ballasted track significantly degrade serviceability and jeopardize train operational safety. The phenomenological approaches for post hoc forensic investigation and remedies of mud pumps have relatively been well studied, but there still lacks studies on inherent mechanisms and ex ante approaches for early-age detection of mud pumps. This paper was aimed to exploring the feasibility of using particle acceleration responses to diagnose and identify early-age mud-pumping risks in real-world field applications. The innovative wireless sensors with 3D-printed shells resembling real shape of ballast particles were instrumented in the problematic railway section to monitor ballast particle movement prior to, during, and after maintenance operations, respectively. The real-time particle-scale acceleration data of ballast bed under both degraded and maintenance-restored clean conditions were recorded. The time histories, power spectra, and marginal spectra of 3D acceleration were comparatively analyzed. The results showed the 3D acceleration of ballast particles underneath rail-supporting tie plates displayed relatively clear periodicity of about 0.8 s with adjacent bogies regarded as a loading unit. The tamping operation was effective for compacting ballast bed laterally and improving the lateral interlocking of ballast particles, whereas the stabilizing operation was effective mainly in the lateral direction and for ballast particles underneath the sleepers. The mud pumps caused intensive particle-scale acceleration, and ballast particles underneath the sleepers were affected more severely than those in between adjacent sleepers. The ballast particles directly underneath tie plates exhibit dramatic acceleration variations due to maintenance operations as compared to those in other positions studied; hence, it seems promising to use particle-scale acceleration underneath tie plates as readily-implementable indicators for smart in-service track health monitoring.

The ballast bed constantly degrades under the repeated applications of impact loading exerted by passing trains in terms of the particle size, shape, breakage, fouling, etc., thus significantly jeopardizing the in-service performance and operational safety of ballasted tracks. In this study, the morphology and breakage evolution characteristics of railroad ballasts of single- and multiple-size ranges were investigated from laboratory impact-load tests. Both a concrete block and sand layer were placed to mimic the distinct under-ballast supports. The degradation trends of the typical shape and breakage indices were comparatively quantified for different combinations of ballast particle sizes and shapes, under-ballast supports, impact energies, and number of impact-load applications (N). The results show that both shape and size affect ballast particle breakage, with shape being more influential. The breakage severity of flake-like particles is about 1.5–1.66 times and 1.25–1.5 times higher than those of regular and needle-like particles, respectively. Under impact loading, large and small single-size ballasts degrade mainly by breakage and abrasion, respectively. The modified fouling index (FI) of flake-like particles within 31.5–40 mm is about 3.6 times that of regular particles within 50–63 mm. The shape indices of the ballast particles within 31.5–40 mm exhibit the most profound changes. The severities of the ballast breakage and fines generation (or modified FI) increased by 50% and 74%, respectively, due to the increase in the under-ballast support stiffness by 100 times and the drop height of 80 cm, respectively. The convexity and ballast breakage index (BBI) are promising for quantifying particle-degradation trends, and their statistical correlation found herein is potentially useful for the transition of ballast-bed-maintenance management from the current plan-based scheduling to condition-based upgrading.