Technical Specification Turnouts and Expansion Switches
Technical Specification Turnouts and Expansion Switches
Technical Specification Turnouts and Expansion Switches
INFRASTRUCTURE DIVISION
TRACK AND RIGHT OF WAY DEPARTMENT
Technical Specification
for
Manufacture and Supply of
Turnouts and
Expansion Switches
for Use in Israel Railways
Conventional Track Network
No. E-01-0022
June 2015
CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.4
4
5
8
8
11
13
15
16
16
SWITCH PANELS
16
CROSSING PANELS
17
ACTUATION SYSTEM, LOCKING AND DETECTION DEVICES
18
TURNOUT COMPONENTS
20
RAILS
20
GROOVED RAILS
20
CHEAK RAILS
21
PRE-HARDENED MONOBLOCK CAST AUSTENITIC MANGANESE CROSSING 21
10.5
24
10.6
28
10.7
10.8
WOOD BEARERS
10.9
10.10
FASTENING SYSTEMS
10.11
10.12
29
31
31
32
33
33
33
11.
FLASH-BUTT WELDING
34
12.
DRAWINGS
36
13.
37
14.
QUALIFICATION TESTS
37
14.1
14.2
37
37
9.1
9.2
9.3
10.
10.1
10.2
10.3
10.13
SCOPE
STANDARDS REFERENCES
RELATED ISR TECHNICAL SPECIFICATION REFERENCE
DEFINITIONS
GENERAL REQUIREMENTS
TURNOUTS DESIGN CRITERIA
IN-CURVE TURNOUTS
EXPANSION SWITCHS
TURNOUT PARTS
38
15.
QUALITY TESTS
38
15.1
15.2
15.3
38
39
40
16.
40
17.
ACCEPTANCE TESTS
41
18.
41
19.
20.
21.
42
42
45
22.
LAYING,
MAINTENANCE,
INSTRUCTION MANUALS
REPLACE
23.
24.
25.
52
54
AND
INSPECTION
46
60
65
68
69
70
72
74
76
77
ENVIRONNEMENTAL CONDITIONS
TECHNICAL ATTACHMENT A - Technical specification for manufacture
and supply of 54E1 and 60E2 Rails R260 and
R350HT Grades No. E-01-0004.T_June_2015
TECHNICAL ATTACHMENT B - Technical specification for manufacture and
supply of Glued Insulating Rail Joints for
Turnouts No. E-01-0023.T_June_2015
TECHNICAL ATTACHMENT C - Technical specification for manufacture
and supply Fastening Systems for Turnouts No.
E-01-0026.T_June_2015
TECHNICAL ATTACHMENT D - Technical specification for manufacture
and supply of Wood Bearers No. E-01321A.2.T_June_2015
TECHNICAL ATTACHMENT E - Technical specification for manufacture and
supply of Steel Hollow Bearers for ALD
(Actuation System, Locking Device and
Detection Device) integration No. E-010025.T_June_2015
78
83
96
114
120
1.
SCOPE
3
1.1
1.2
Switch Panels;
Closure Panels;
Crossing Panels;
Actuation System;
Locking Device;
Detection Device.
Rails;
Check Rails;
Crossing Component (Frog)
o Pre-Hardened Monoblock Cast Austenitic Crossing;
o Central Monoblock Crossing Nose;
Glued Insulating Rail Joints;
Concrete with USP Bearers/ Wood Bearers/ Steel Hollow Bearers
Fastening Systems;
Manual Switch Stand;
Switch Rail Roller Device;
And any other Components.
1.3
1.4
1.5
The Turnouts on Concrete Bearers and Slab Track shall be designed for a
minimum service life of 30 years.
1.6
The design of Switch Panels, Closure Panels and Crossing Panels and their
components and Sub-components for turnouts on Wood Bearers shall be
the same as for turnouts on Concrete Bearers and for turnouts for Slab
Track (exclude Fastening Systems).
1.7
1.8
Each and every Turnouts and Expansion Switches Component or Subcomponent shall be manufactured in accordance with the Turnouts and
Expansion Switches manufacturer's layout design and its quality
management plan complying to ISO 9001 and based on the relevant EN,
UIC and ISO standards conforming with this technical specification
(including related ISR technical specifications, see section 3. hereinafter).
All in reference to the technical requirements and the Quality Tests in
particularly, or by their mechanical and chemical characteristics, only in
the non-existence of ISO or EN or UIC standards.
1.9
1.10
1.11
2.
EN 13232-2
Railway applications - Track - Switches and crossings Part 2: Requirements for geometric design;
EN 13232-3
Railway applications - Track - Switches and crossings Part 3: Requirements for wheel rail interaction;
EN 13232-4
Railway applications - Track - Switches and crossings Part 4: Actuation locking and detection;
EN 13232-5
EN 13232-6
Railway applications - Track - Switches and crossings Part 6: Fixed common and obtuse crossings;
EN 13232-8
EN 13232-9
EN 13674-1
EN 13674-2
EN 13674-3
EN 14811
EN 15689
Railway applications - Track - Switches and crossing Crossing components made of cast austenitic manganese
steel;
EN 16273
EN 13481-2
EN 13481-3
EN 13481-5
EN 13481-7
EN 13146-1
EN 13146-2
EN 13146-3
EN 13146-4
EN 13146-5
EN 13146-6
EN 13146-7
EN 13146-9
EN 13145
EN 13230-4
EN 16431
EN 14587-3
prEN16730
EN 15313
EN 13715
EN 206-1
UIC 866
UIC 713
UIC 864-2
UIC 510-2
ISO 9001
3.1
3.2
3.3
4.
DEFINITIONS
turnout
Diamond
Expansion Switch
Part
Component
Sub-component
Crossing Legs
Under Concrete
Sleeper/Bearer Pad (USP) as defined in prEN16730, sections 3.9
ISR
ISR Order
ISRR
ISRTS
The Laboratory
and/or
and/or
Prfamt
fr
Landverkehrswegen,
Universitt, Mnchen
9
Bau
von
Technische
The Inspector
Component
Qualification Test
Component/
Sub-component
Quality Test
Acceptance Test
GBP
NDT
5.
GENERAL REQUIREMENTS
5.1
5.2
5.2.1
The turnout with grooved rail with rail profile 68G1 and rail grade R260
shall be designed based on ISR order.
5.3
5.4
5.5
5.6
All Concrete Bearers shall be equipped with elastic Under Bearers Pads, in
accordance with the requirement prescribed in section 10.6.
5.7
The Rails in Turnouts shall be fastened to the Bearers with elastic rail
Fastening System including with tension clamp:
SKL-W12 for Wood Bearers;
SKL-W14 or other equivalent SKL-W for Concrete Bearers;
SKL-W15 for Bogl System and/or SKL-W15 for RHEDA2000 System
and/or SKL-W14 for LVT System for Slab Track.
in accordance with ISRTS No. E-01-0026.T_June_2015 (Technical
Attachment C).
11
5.8
5.9
5.10
5.11
5.12
5.13
5.14
The drawings shall include welding point to assemble the Turnouts panels.
ISR could request to change their position without extra cost.
5.16
5.17
5.18
6.
6.1
6.2
6.3
6.4
Maximum permissible speed: in accordance with technical appendix A The Turnouts to be supplied list, hereinafter.
6.5
6.6
6.7
6.8
Switch and Stock Rails adjacent (proper closing): at least 3 [m] from the
Switch Rail toe.
13
6.9
Gap between switch rail and stock rail (GAP J1) plus Gap between locking
component and clamp component (GAP J2) (see technical appendix I
Switch and Stock Rails closing measurement principle): max 1 [mm].
6.10
Gap between locking part and the foot of stock rail (GAP J3) (see technical
appendix I Switch and Stock Rails closing measurement principle): max
1[mm];
6.11
Gap between the foot of switch rail and the slide chair (GAP J4) (see
technical appendix I Switch and Stock Rails closing measurement
principle): max 1[mm].
6.12
6.13
6.14
6.15
6.16
Speed [km/h]
Vmax 100
Maximum cant
deficiency [mm]
110
100
60
6.17
6.18
6.19
Wheel dimensions:
The Turnouts shall be designed to ensure safe and comfort wheel passage
with the following ISR wheel profiles:
14
6.20
Axle bogies
The Turnouts shall be designed to ensure safe and comfort passage for
rolling stocks, freight trains and other railbourn vehicles with 2-axle bogie
and with 3-axle bogies. The Turnout geometry design shall ensure safe and
comfort passage in reference to the speeds and safety geometric dimensions
prescribed in technical appendix C ISRR of Turnout safety geometry
criteria, hereinafter.
6.21
6.22
1,370
1,39532
1,39532
1,3803
1,3703
1,3703
1,39532
1,3703
6.24
The Turnouts designed shall ensure that each 2 close Bearers shall be with
a distance no smaller than 500 [mm].
6.25
The Turnouts designed shall ensure that all welds central axis shall be in
the middle of 2 close Bearers.
15
7.
IN-CURVE TURNOUTS
7.1
7.2
7.3
Vmax 120
Maximum cant
deficiency [mm]
110
100
60
8.
EXPANSION SWITCHES
8.1
8.2
8.3
8.4
8.5
8.6
8.7
9.
TURNOUT PARTS
9.1
SWITCH PANEL
16
9.1.1
9.1.2
9.1.3
All bolts and other fixing instruments in the Switch Panel shall be
minimum grade 5.6, exclude bolts in Glued Insulation Rail Joints which
shall be minimum grade 10.9, other specifications and requirements shall
be in accordance with UIC 864-2. Blocks and fittings shall be
manufactured to minimum steel grade R200.
9.1.4
The Switch Panel shall be designed with flexible Switch Rail in accordance
with EN13232-5 section 3.2.2.
9.1.5
The Switch Panel shall be manufactured and supplied with full depth
Switch Rails or shallow depth Switch Rails based on ISR order details.
9.1.6
The wheel transfer between switch and Stock rail shall be designed to give
the greatest support and smallest lateral jerk within the transfer region.
9.1.7
9.1.8
9.1.9
The location of the toe of the point rail shall be punch marked on the stock
rail.
9.1.10
All Switch Rails and Stock Rails shall be examined by the Turnout
manufacturer in accordance with EN 13232-5, section 6.5.
9.1.11
The Half Set of Switch could be ordered with stock rails with extra length
on each side and switch rails on the heel side of: 80 mm or 600 mm based
on ISR order details.
9.2
9.2.1
CROSSING PANELS
Crossings Panel shall be supplied with one of the following types:
or
9.2.2
Pre-Hardness Monoblock Cast Austenitic Manganese Crossing with flashbutt welded Crossing Legs
17
9.2.2.1
9.2.2.2
9.2.3
9.2.3.1
9.2.3.2
9.2.4
All bolts and other fixing instruments in the Crossing Panel to the bearers
shall have minimum grade of 5.6, other specifications and requirements in
accordance with UIC864-2. Blocks and fittings shall be manufactured to
minimum steel grade R200.
9.2.5
The Crossing Panels could be ordered with Crossing Legs with extra length
on each side of: 80 mm or 600 mm, based on ISR order details).
9.3
9.3.1
9.3.2
9.3.3
The Turnout manufacturer shall supply the Turnout with the Actuation
system rods and fastener components, the Locking Device and the
Detection Devices. The Detection Device shall be supplied based on ISR
order details.
18
9.3.4
The Turnout manufacturer shall ensure the full integration and the Turnouts
operation with the Actuation System, Locking Device, Detection Devices
and Manual Switch Stand.
9.3.5
9.3.6
9.3.7
The Locking and Detection Devices shall be insulated from both rails with
not less than 5 M / 500 V DC.
9.3.8
Each turnout shall have holes in for the installation of the Locking and
Detection Devices (the turnout shall have holes for the Detection Devices
even if the turnout is ordered without it).
9.3.9
9.3.10
9.3.11
9.3.12
Switch and Stock Rails adjacent (proper closing); (see section 6.8)
19
9.3.13
Gap between switch rail and stock rail (GAP J1) plus Gap between
locking component and clamp component (GAP J2) (see section 6.9)
Gap between locking part and the foot of stock rail (GAP J3) (see
section 6.10)
Gap between the foot of switch rail and the slide chair (GAP J4) (see
section 6.11)
9.3.13.1 The same tests prescribed in section 9.3.12 aforementioned shall be carried
out by the Turnout manufacturer on every Turnout, ordered by ISR.
9.3.13.2 The Locking and Detection Devices shall be insulated from both rails with
not less than 5 M / 500 V DC.
(**) to perform the qualification and Quality Tests the Turnout
manufacturer shall be equipped with the Actuation System motors types
prescribed aforementioned, and Manual Switch Stand.
10.
TURNOUT COMPONENTS
10.1
RAILS
10.1.1
The Rails Switch Rails; Closure Rails; Stock Rails; Crossing Legs and
rails in Glued Insulating Rail Joints, to be used in Turnouts and Expansion
Switches shall be made of steel grade R260 or R350HT, based on ISR
order details and manufactured in accordance with EN13674-1, EN13674-2
and ISRTS No. E-01-0004.T_June_2015 (Technical Attachment A).
10.1.2
10.1.2.1 The qualification tests shall be carried out in accordance to ISRTS No. E01-0004.T_June_2015 (Technical Attachment A). The Qualification Tests
report shall be submitted.
10.1.3
10.1.3.1 The Quality Test shall be carried out in accordance to ISRTS No. E-010004.T_June_2015 (Technical Attachment A). The Quality Test report
shall be submitted.
10.2
GROOVED RAILS
21
10.2.1
The Grooved Rails Switch Rails; Closure Rails; Stock Rails; Crossing
Legs and rails in Glued Insulating Rail Joints, to be used in Turnouts shall
be made of steel grade R260, profile G70, based on ISR order details and
manufactured in accordance with EN14811.
10.2.2
10.2.2.1 The Quality Test including Electric conductivity shall be carried out in
accordance to EN14811 section 8. The Quality Test report shall be
submitted.
10.3
CHECK RAILS
10.3.1
10.3.2
10.3.3
Technical drawings for each type of check rails for each Turnout and speed
shall be submitted.
10.3.4
Check rails without bolt holes shall be manufactured and supplied based on
ISR order details.
10.3.5
The bolts fasten the check rails shall be designed with applicable length for
installation of different adjustment plates with thickness up to 9 mm.
10.3.6
The bolts fasten the Check Rails shall be protected against the loosening of
bolted joints with NORD LOCK washers.
10.3.7
10.4
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
10.4.6
10.4.6.1 All casting shall be carefully cleaned of sand and all loose oxide; casting
gates, air-holes and sink-heads must be removed. The casting shall be free
of the following defects: shrinkage cavities, scabs, cold shuts, flakes,
cracks, blisters, lack of metal, porosity and inclusions.
All casting shall have clean surfaces; any irregularities, traces of joints,
casting fins, etc. shall be carefully ground off.
10.4.6.2 Running surfaces and their connecting fillets, fishing surfaces and all
surfaces which make contact on assembly, together with end, shall be
contently shaped.
10.4.7
10.4.8
10.4.9
10.4.10
Pre-Hardened Monoblock
Qualification Test
Cast
Austenitic
Manganese
Crossing
10.4.10.1 The test report for sample approval in accordance with EN 15689, section 5
of the following Turnouts types of: 1/8; 1/9; 1/12; 1/20; Double Slip;
Scissor Crossover, and for the following rail profiles: 54E1 (UIC54); 60E2,
shall be submitted.
22
Test method
chemical analyze
impact bend
pre-hardened crossing
every 2 years
Metallographic
examination
Visual inspection
Radiography
Hardness test
Hardness test
Dye penetrate testing
Test requirements
23
10.4.11.1 The following Quality Tests shall be carried out on the Pre-Hardened
Monoblock Cast Austenitic Crossing by its manufacturer during the
manufacturing process:
Test method
Test frequency
Test requirements
chemical analyze
impact bend
each melt
and heat
charge.
Metallographic
examination
each melt
and heat
charge.
Visual inspection
each casting
each monoblock
crossing before preharding
Radiography
1 in 50 castings from
the same pattern
every pre-hardened
crossing
after pre-hardening
Hardness test
Dye penetrate testing 2
10.4.11.2 The Quality Test reports shall be submitted, while the NDT tests and
results shall be signed by certified NDT operators (accordance to EN473 or
equivalent standard).
10.5
10.5.1
The Central Monoblock Crossing Nose shall be heat treated steel with:
24
10.5.3
10.5.4
10.5.4.1 All casting shall be carefully cleaned of sand and all loose oxide; casting
gates, air-holes and sink-heads must be removed. The casting shall be free
of the following defects: shrinkage cavities, scabs, cold shuts, flakes,
cracks, blisters, lack of metal, porosity and inclusions.
All casting shall have clean surfaces; any irregularities, traces of joints,
casting fins, etc. shall be carefully ground off.
10.5.4.2 Running surfaces and their connecting fillets, fishing surfaces and all
surfaces which make contact on assembly, together with end, shall be
contently shaped.
10.5.5
10.5.6
10.5.6.1 The test results for sample approval in accordance with EN 15689, section
5 of the following turnouts types of: 1/8, 1/9 with the following rail
profiles: 54E1 (UIC54); 60E2, shall be submitted.
Test method
chemical analyze
impact bend
Test requirements
Visual inspection
Radiography
Hardness test
10.5.7
26
test
procedure
in
accordance EN 15689
section 8.1.3, hardness
in accordance with
section
10.4.1
aforementioned
10.5.7.1 The following Quality Tests shall be carried out on the Central Monoblock
Crossing Nose by its manufacturer:
Test method
Test frequency
chemical analyze
impact bend
each melt
test
procedure
in
accordance EN 15689
section 7.2, mechanical
properties
in
accordance with section
10.4.1 aforementioned
Metallographic
examination
each melt
test
procedure
in
accordance EN 15689
sections 7.3 and 6.2 (to
be carried out before
the impact bend test on
the
same
piece),
microstructure
in
accordance with section
10.4.2 aforementioned
Visual inspection
each
monoblock
nose
each central
monoblock crossing
nose
27
Test requirements
indication
allowed.
Radiography
Hardness test
1 in 50 central
monoblock crossing
nose from the same
pattern
each central
monoblock crossing
nose
shall
be
test
procedure
in
accordance EN 15689
section 8.1.3, hardness
in accordance with
section
10.4.1
aforementioned
10.5.7.2 The Quality Test reports shall be submitted, while the NDT tests and
results shall be signed by certified NDT operators (accordance to EN473 or
equivalent standard).
10.6
10.6.1
10.6.2
10.6.3
10.6.4
10.6.5
28
The Quality Test shall be carried out in accordance to ISRTS No. E-010023.T_June_2015 (Technical Attachment B). The Quality Test report
shall be submitted.
10.7
10.7.1
10.7.2
10.7.3
10.7.4
10.7.5
10.7.6
10.7.7
The Concrete Bearers technical design data including static and dynamic
calculations based on the requirement specified in UIC713 and EN13230-4
prEN16730 shall be submitted and includes: design bending moments
parameters; Positioning of fastening components; Tolerances; absolute
maximum and minimum weight and all other required information in
accordance to the standards.
10.7.8
The USP Pads for Concrete Bearers under the Crossing Component shall
be with Cstat of 0.10 N/mm - 0.15 N/mm.
The USP for Concrete Bearers under the rest of the Turnout Concrete
Bearers shall be with Cstat of 0.25 N/mm - 0.35 N/mm.
10.7.9
10.7.10
10.7.11
The USP dimension shall have recess from the bearer edges of 10 mm.
10.7.12
The description of the UPS to the Concrete Bearers bonding process shall
be submitted.
29
10.7.13
10.7.13.1 The Concrete Bearers Qualification Test shall be carried out in accordance
to EN13230-4, section 5.6., and prEN16730, section 5. The test report shall
be submitted
10.7.13.2 The Qualification Tests shall be carried out by The Laboratory with
reference to track category TC3, on:
Under Concrete Bearers Pads alone and for concrete block with Under
Concrete Bearers Pads;
Concrete Bearers with Under Concrete Bearers Pads.
10.7.13.3 The following tests shall be carried out on the Under Concrete Bearers
Pads alone and on the concrete block with Under Concrete Bearers Pads:
Dimensions and masses of Under Concrete Bearers Pads in accordance
with prEN16730, sections 5.3.1 and 5.6;
Tensile strength of Under Concrete Bearers Pad as defined in
accordance with prEN16730, sections 5.3.2 and 5.6;
Static and low frequency dynamic vertical bedding modulus of Under
Concrete Bearers Pad alone with GBP, with reference to track category
TC3, in accordance with prEN16730, sections 5.3.3 and 5.6;
Fatigue test with Under Concrete Bearers Pads applied on concrete
block, with reference to track category TC3, in accordance with
prEN16730, section 5.3.6;
Capability for stacked stocking of Concrete Bearers with Under
Concrete Bearers Pad on concrete block in accordance with
prEN16730, section 5.3.8;
Resistance to fire in accordance with prEN16730, sections 5.3.9.
The test shall be carried out in accordance with DIN 53438 or
equivalent standard. The stage K2 shall be achieved at least.
Resistance to ozone in accordance with prEN16730, sections 5.3.9.
10.7.13.4 The following tests shall be carried out on the Concrete Bearers with Under
Concrete Bearers Pads:
Dimensions and masses of Concrete Bearers with Under Concrete
Bearers Pads in accordance with prEN16730, sections 5.5.1 and 5.6;
Bond strength by pull-out of Concrete Bearers with Under Concrete
Bearer Pad in accordance with prEN16730, sections 5.5.2 and 5.6.
31
10.8
WOOD BEARERS
10.8.1
10.8.2
The Wood Bearer technical data, including: drawing with dimension and
tolerances of the bearer section; dimensions and tolerances for each
individual bearer; tolerances for installing (fastening position and
geometrical dimensions); preservation process; bearer identification, shall
be submitted.
10.8.3
10.8.4
In case the wood bearers shall be planed to be fitted to the 1/30 rail
inclination the following items shall be delivered with the first order:
10.8.5
3 adzing machines;
10.9
10.9.1
10.9.2
The Steel Hollow Bearers technical data shall be submitted and include:
drawing with dimension and tolerances of the bearer; tolerances for
installing (fastening position and geometrical dimensions); bearer
identification.
10.9.3
10.9.4
10.10
FASTENING SYSTEMS
10.10.1
10.10.2
10.10.3
32
10.11.1
Turnouts for marshalling yards shall be installed with manual switch stand.
The Manual Switch Stand shall be ordered separately from the Turnout.
10.11.2
The manual switch stand shall conform the requirements of ISRTS No. E01-0028.T_June_2015 (Technical Attachment G).
10.11.3
10.12
10.12.1
Turnouts shall be manufactured and supplied with and without Switch Rail
Rollers Device based on ISR order details.
10.12.2
Only proven switch rail rollers types on track in at least two railway
companies shall be offered. Reference list shall be submitted including
supplied quantity, to whom it supplied and its operation period.
10.12.3
The Switch Rail Rollers device shall be incorporated with the bearer
baseplate.
10.12.4
The Switch Rail Rollers device design and position shall not disturb the
operation of maintenance vehicles.
10.12.5
A single switch roller device could be replaced without disassemble the rest
of the switch roller devices.
10.12.6
The switch rail rollers device to be used in the Turnouts shall be lubrication
free and maintenance free.
10.12.7
The switch rail rollers device shall be designed to fit with full depth switch
rails and shallow depth switch rail. Technical drawing and specification
shall be submitted.
10.12.8
10.12.9
10.13
10.13.1
A complete set for each type of all other Component and Sub-component
technical specification and manufacturing drawings with dimensions,
tolerances, mechanical and chemical properties, material type, coating and
heat treatment process details, method of welding (actuation system and
locking device relevant Components and Sub-components), etc. shall be
submitted.
10.13.2
List of all the Components and Sub-components, the relevant EN, UIC and
ISO standards they comply with, test method, test frequency and the
standard it manufactured in accordance shall be submitted.
11.
FLASH-BUTT WELDING
11.1
11.2
All welding shall be carried out on a flash butt welding machine using an
automatic, programmed welding sequence using an approval weld
procedure.
11.3
11.4
11.5
Each Turnout shall be supplied with quality certificate for every welding.
11.6
11.6.1
11.6.2
34
11.7.1
11.7.2
The approval tests report shall be for the following rail groups:
11.7.3
R260;
R350HT.
The approval test report shall include the following tests in accordance to
the requirements in EN14587-3, section 10.4: weld geometry and
dimensions; visual inspection; surface finish; liquid penetrate testing and
magnetic particle testing; internal soundness; bend testing; fatigue testing;
micro-examination test; macro-examination; hardness testing.
It shall include photographs of the fracture faces (one per sample) of all
broken test welds as well as macro and micro examination, and the rail
profile grid, which is shown in EN14587-3, Annex C, shall be included.
Acceptance criteria in the approval tests, in accordance with EN 14587-3.
11.7.4
The approval test report carried out by The Laboratory or RA (as defined in
EN14587-3, section 3.17) shall include the information defined in EN
14587-3, section 10.5, and shall be submitted.
11.8
Weld production
11.8.1
11.8.2
The welding program and parameters shall be as those for which approval
was guaranteed.
35
11.8.3
The production test report shall include the following tests, in accordance
to the requirements in EN14587-3, section 13: weld geometry and
dimensions; visual inspection; surface finish (roughness) in accordance to
EN14587-3, section 7; liquid penetrate testing and magnetic particle testing
(in accordance EN14587-3, section 10.4.5); internal soundness; bend
testing.
The production test report template shall be submitted for ISR approval.
11.8.4
11.8.4.1 Liquid penetrate testing shall be carried out on every flash-butt welding in
accordance with EN14587-3, section 10.4.5.
11.8.4.2 Internal soundness (ultrasonic testing) shall be carried out on every flashbutt welding from the rail side in accordance with EN14587-3, Annex G.
11.8.5
11.8.5.1 Magnetic particle testing shall be carried out on every flash-butt welding in
accordance with EN14587-3, section 10.4.5.
11.8.5.2 Internal soundness (ultrasonic testing) shall be carried out on every flashbutt welding in accordance with EN14587-3, section 10.4.6.
12.
DRAWINGS
12.1
36
12.2
12.3
Table list with the following parts: Switch Panel, closure panel,
Crossing Panel, Locking panel. And there drawing numbers.
Drawings shall be submitted for each part type and position in the
Turnout
Sections drawings
The drawings shall include:
12.4
12.5
12.6
Any change in the drawing shall not be allowed without notify to ISR and
having its approval.
13.
QUALITY
CONTROL
PROCEDURES PLAN
13.1
The Turnout and Expansion Switch manufacturer shall submit his ISO9001
certificate on the field of Turnouts.
13.2
The Turnout and Expansion Switch manufacturer shall submit his quality
procedures plan for Turnout and Expansion Switch manufacturing.
13.3
AND
37
QUALITY
ASSURANCE
14.
QUALIFICATION TESTS
14.1
14.3.1
the Turnout manufacturer shall submit qualification tests reports which had
been carried out by The Laboratory on the following Components:
14.3.2
For each of the Components and Sub-components which are not prescribed
aforementioned in section 14.3.1 certificates on the conforming to the
38
QUALITY TESTS
15.1
15.1.1
Each Turnout should be supplied only after performing the Quality Tests in
accordance with EN13232-9 section 8.
15.1.2
The manufacturer shall assemble the Turnout and to enable the Inspector
carried out the measurements to ensure the compliance of its dimensions
and tolerances.
15.1.3
Its the manufacturer responsibility to place the necessary staff and all
measurement devices and equipment to the Inspector activities.
15.1.4
certificates
in
accordance
with
10.1,
39
15.2.1
15.3
15.3.1
15.3.2
In every order, for each of the Components, which are not prescribed
aforementioned in section 15.1.4 and 15.2 and for each of the Subcomponents, certificate on the conforming to the requirements of the
relevant ISO or EN or UIC standards, shall be submitted.
16.
16.1
The Inspection of the Turnouts and the Expansion Switch and Quality Test
reports checking shall be carried out by The Inspector in accordance to the
delivery time which will be defined in ISR orders.
16.2
The manufacturer shall act in full cooperation with The Inspector. The
manufacturer shall be responsible to coordinate inspection process time
table with The Inspector , and shall enable him free access to all places of
work in which the Turnouts, Turnout parts, components and subcomponents are manufactured or stored in the Turnout manufacturer plant.
Providing all necessary assistance to The Inspector and notify him
beforehand of its intention to perform tests.
41
16.3
The manufacturer shall submit all Quality Tests reports and certificates,
and if requested the Qualification Test reports, to The Inspector for
approval for every Turnout and Expansion switch in ISR orders, in
accordance with section 15.1 and 15.2 aforementioned including checking
dimensions of the Turnouts in assembled possition.
16.4
16.5
The Final Inspection Reports which shall include the Quality test reports
(in accordance with the requirements in sections: 15.1, 15.2 and 15.3)
signed by the Turnouts and Expansion Switches manufacturer and The
Inspector shall be submitted.
17.
ACCEPTANCE TESTS
17.1
17.1.1
18.
18.1
A detailed BOM list in an Excel file which will be based on the format
hereinafter shall be submitted:
Turnout, expansion switch , parts ,
components and sub-component designation
1.1.
Quantity for
one
Turnout
The Turnout
and expansion
switch drawing
number
1.1.1.1
1.2.1
1.2.1.1
1.2
example
...
1.1.1
18.2
The Turnout and Expansion Switch manufacturer will fill the cells in the
Ecxel file with every Turnout, Expansion Switch, Parts, Components and
Sub-components which will be included in the agreement. And shall fill
also the quantity, ID number and drawing number.
18.3
19.
19.1
19.2
19.3
The Bearers shall be supplied with the fastening system's base plates
already fastened.
19.4
19.5
42
19.6
The Turnouts with split Concrete Bearers design shall not include Bearers
longer than 3300 [mm]. When longer Bearer is needed, it will be perform
with 2 supplementary Concrete Bearers, which will be assembled in track
with suitable rigid support to ensure the bearers uniform vertical and
horizontal straightness and the adjustment shall guarantee the function of
the 2 supplementary Concrete Bearers as one. The supplementary Concrete
Bearers assembly instructions shall be submitted. Reference list of the
turnouts with the supplementary Concrete Bearers assembled shall be
submitted including supplied quantity, to whom it was supplied and when.
20.
20.1
The Turnouts shall be marked with fixed weatherproof plate, with resistant
painted engraved marking.
20.2
The Turnouts parts shall be marked with paint colors in accordance with
technical appendix G - Color marking guide for Turnouts.
20.3
Manufacturers mark;
Drawing number.
20.4
Each rail, closure rail and switch rail to be used in Turnout manufactured to
grade R350HT (in accordance to EN13674-1, 2) shall be marked with
white paint for easy identification.
20.5
Each Check rail shall have identification marking fixed on it. The
following information shall be marked:
20.6
Manufacturers mark;
Drawing number.
Each Half Set of Switch shall have an identification marking fixed on the
switch rail and/or stock rail. The following information shall be marked:
Manufacturers mark;
43
20.7
20.8
20.9
20.10
Type of switch (radius of switch, main line radius, rail profile and
hand of Turnout);
Drawing number.
Each Crossing Panel shall have an identification marking fixed on it. The
following minimum information shall be marked:
Manufacturers mark;
Drawing number.
Manufacturers mark
Type of Turnout;
Signs to enable the bearers and the rails alignment during the laying.
On each wood bearer, a metal plate shall be permanently attached, with the
following information engraved on it:
Manufacturers mark
Type of Turnout;
Signs to enable the bearers and the rails alignment during the laying.
Manufacturers mark
44
20.11
Type of Turnout;
Signs to enable the bearers and the rails alignment during the laying.
Manufacturers mark;
21.
21.1
21.2
The Turnouts shall be packed with special care to prevent damage and
shipped in flat bed containers only.
21.3
21.4
21.5
21.6
45
21.7
21.8
the holes in the bearers where the actuation system motor will be installed
shall be covered with easy to remove elements which will prevent entrance
of any foreign body to the holes before the actuation system motors.
21.9
21.10
21.11
the Switch panel's stock rail and switch rail in the close position shall be
tighten up in 3 places with steel strapping of at least 1" width, the stock rail
and switch rail in the open position, wooden blocks shall be put in between
them before tighten up in 3 places with steel strapping of at least 1" width.
21.12
The rods which will be installed in the Turnouts shall be protected against
buckling.
21.13
22.
LAYING, MAINTENANCE,
INSTRUCTION MANUALS
22.1
22.2
22.3
REPLACE
AND
INSPECTION
Rails R350HT;
46
22.4
22.5
23.
23.1
23.2
23.3
23.4
23.5
23.6
23.7
23.8
23.9
23.10
Technical drawings for each type of Check Rails for each Turnout and
speed. (section 10.3.5).
23.11
23.12
23.13
23.14
23.15
23.16
The Concrete Bearer with USP technical data including: drawing with
dimension and tolerances of the bearer section, including prestressed
elements in the bearer; dimensions and tolerances for each individual
bearer; tolerances for installing (fastening position and geometrical
dimensions); presstressing design calculations; bearer identification.
(section 10.6)
23.17
23.18
The Wood Bearer technical data, including: drawing with dimension and
tolerances of the Bearer section; dimensions and tolerances for each
individual bearer; tolerances for installing (fastening position and
geometrical dimensions); preservation process; Bearer identification.
(section 10.7.2).
23.19
23.20
23.21
23.22
23.23
23.24
Manganese
Crossing
23.25
23.26
23.27
23.28
The Concrete Bearers with USP drawings with dimension and tolerances of
the Bearer with USP, including prestressed elements in the bearer;
dimensions and tolerances for each individual bearer; tolerances for
installing (fastening position and geometrical dimensions); prestress design
calculations; bearer identification shall be submitted (section 10.6.13.5).
23.29
23.30
23.31
List of all the Components and Sub-components, the relevant EN, UIC and
ISO standards they comply with, test method, test frequency and the
standard it manufactured in accordance shall be submitted. (section
10.12.2).
23.32
23.33
23.34
Turnout general layout drawings for each type of Turnout (section 12.1).
23.35
Part assembly drawings for each part type and position in the Turnout
(section 12.2).
23.36
23.37
23.38
The Turnout and Expansion Switch manufacturer shall submit his quality
procedures plan for Turnout and Expansion Switch manufacturing (section
13.2).
23.39
23.40
Devices testing ensuring safe and comfort passage at the speeds and
geometry and safety dimensions prescribed in technical appendixes A, B
and C (section 14.1)
23.41
23.42
qualification tests reports which had been carried out by The Laboratory on
the following Components: Rails; Check Rails; Monoblock cast austenitic
manganese crossing; Pre-Hardened Monoblock cast austenitic manganese
crossing; Central Monoblock Crossing Nose; Glue Insulating Rail Joints;
Concrete Bearers; Fastening System; Actuation System, Locking And
Detection Device. (section 14.3.1).
The tests reports which wouldnt be submitted with bidder's proposal must
be submitted before signing the agreement.
23.43
for each of the Components and Sub-components which are not prescribed
aforementioned in section 13.4.1 certificates on the conforming to the
requirements of the relevant ISO or EN or UIC standards, in reference to
the requirements of section 9.11 aforementioned. (section 14.3.2)
23.44
23.45
23.46
23.47
23.48
23.49
23.50
23.52
23.53
23.54
23.55
23.56
51
24.1
24.2
24.3
A complete set for each type of all other Component and Sub-component
technical specification and manufacturing drawings with dimensions,
tolerances, mechanical and chemical properties, material type, coating and
heat treatment process details, method of welding (actuation system and
locking device relevant Components and Sub-components) , etc. shall be
submitted. (section 10.12.1).
24.4
Qualification tests reports which had been carried out by The Laboratory
on the following Components: Rails; Check Rails; Monoblock cast
austenitic manganese crossing; Pre-Hardened Monoblock cast austenitic
manganese crossing; Central Monoblock Crossing Nose; Glue Insulating
Rail Joints; Concrete Bearers; Fastening System; Actuation System,
Locking And Detection Device. (section 14.3.1)
The tests reports which didnt submit with bidder's proposal shall be
submitted before signing the agreement.
24.5
24.6
24.7
24.8
24.9
52
24.10
The Protective Coating Wax safety data sheet (MSDS) shall be submitted.
(Technical Specification for concrete bearers screws protective coating
wax_No. E-01-0023.T June 2015, section 3 (Technical Attachment B)).
25.
25.1
25.2
25.2.1
25.2.2
25.2.3
25.2.4
25.3
25.3.1
25.3.2
25.3.3
25.3.4
25.3.5
25.3.6
The Final Inspection Reports signed by the manufacturer and The Inspector
25.4
25.5
25.6
25.7
Turnout general layout drawings for each type of Turnout (section 12.1).
25.8
Part assembly drawings for each part type and position in the Turnout
(section 12.2).
53
and
chemical
25.9
25.10
120
120
MAXIMUM
PERMISSIBLE
SPEED
IN BRANCH
LINE [KM/H]
CROSSING
30
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Central
Monoblock
Crossing Nose
30
RADIUS
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Central
Monoblock
Crossing Nose
SWITCH RAIL
RAIL
GRADE
full depth
R260
190
shallow depth
RAIL
TYPE
54E1
INCLINATION
18/S
R350HT
Wood
full depth
R260
shallow depth
BEARERS
250/190
54E1
full depth
R350HT
shallow depth
54
1/8L
120
30
120
30
180
40
180
40
180
70
180
70
180
100
180
100
200
40
200
40
200
70
200
70
200
100
200
100
200
40
200
70
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Central
Monoblock
Crossing Nose
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Central
Monoblock
Crossing Nose
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock
Cast Austenitic
Manganese
Crossing
full depth
R260
shallow depth
0520912
60E2
1/8
full depth
R350HT
shallow depth
full depth
05280/2
R260
54E1
shallow depth
1/9
full depth
0528021
R350HT
60E2
shallow depth
full depth
42686/5
shallow depth
R350HT
full depth
42286/2
shallow depth
full depth
022281322
1222813//
R260
60E2
R260
54E1
1/20
R260
60E2
R350HT
full depth
05280/2
shallow depth
R260
54E1
R350HT
full depth
0528021
shallow depth
1/9
R260
60E2
R350HT
full depth
42686/5
shallow depth
R260
54E1
R350HT
full depth
42286/2
shallow depth
1/12
concrete
R260
60E2
R350HT
full depth
022281322
R260
54E1
R350HT
full depth
shallow depth
1810
R350HT
shallow depth
shallow depth
54E1
R350HT
shallow depth
full depth
R260
1222813//
1802
R260
60E2
R350HT
full depth
0528021
R260
shallow depth
0528021
R350HT
full depth
42286/2
R260
shallow depth
42286/2
R350HT
60E2
1/9
Slab
Track
60E2
1/12
A.2 DIAMONDS
MAXIMUM
SPEED
IN MAIN
LINE [KM/H]
MAXIMUM
SPEED
IN BRANCH
LINE [KM/H]
CROSSING
SWITCH
RADIUS
55
RAIL
GRADE
RAIL
TYPE
Track
center
to track
center
[mm]
INCLINATION
BEARERS
30
102
30
102
30
102
30
180
40
180
40
180
40
180
40
180
70
180
70
180
70
180
70
180
100
180
100
180
100
180
100
102
30
102
30
102
30
102
30
180
40
180
40
180
40
180
40
102
30
102
30
102
30
102
30
200
40
200
200
40
40
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
R260
190/190
54E1
R350HT
R260
190/190
4700;
5000;
6000
Scissor
Crossover 1/8
4700;
5000;
6000
Scissor
Crossover 1/9
4700;
5000;
6000
Scissor
Crossover
1/12
60E2
R350HT
R260
280/250
54E1
R350HT
R260
290/250
60E2
R350HT
R260
485/600
54E1
R350HT
R260
489/600
60E2
R350HT
Wood
1300/
2000
1300/
2000
R260
54E1
R350HT
R260
4700;
5000;
6000
Scissor
Crossover
1/20
----
Double Slip
1/8
----
Double Slip
1/9
4700;
5000;
6000
Scissor
Crossover 1/8
60E2
R350HT
1528122
R260
1528122
R350HT
54E1
1528122
R260
1528122
R350HT
12280//
R260
12280//
R350HT
60E2
54E1
12280//
R260
12280//
R350HT
60E2
R260
190/190
54E1
R350HT
R260
190/190
60E2
Concrete
R350HT
R260
280/250
54E1
R350HT
290/250
56
R260
60E2
4700;
5000;
6000
Scissor
Crossover 1/9
200
Manganese
Crossing
40
200
70
200
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
70
200
70
200
70
200
100
200
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
100
200
100
200
100
102
30
102
30
102
30
102
30
200
40
200
40
200
40
200
40
022
/2
022
/2
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
full
depth
shallow
depth
R350HT
R260
485/600
54E1
R350HT
R260
489/600
4700;
5000;
6000
Scissor
Crossover
1/12
4700;
5000;
6000
Scissor
Crossover
1/20
----
Double Slip
1/8
----
Double Slip
1/9
60E2
R350HT
R260
1300/
2000
54E1
R350HT
R260
1300/
2000
60E2
R350HT
1528122
R260
1528122
R350HT
54E1
1528122
R260
1528122
R350HT
12280//
R260
12280//
R350HT
60E2
54E1
12280//
R260
12280//
R350HT
489/600
R260
60E2
Scissor
Crossover
1/12
60E2
489/600
4700
R350HT
Slab
Track
MAXIMUM
SPEED
IN MAIN
LINE
[KM/H]
MAXIMUM
SPEED
IN
BRANCH
LINE
[KM/H]
CROSSING
62
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
SWITCH
RAIL
RADIUS
RAIL
GRADE
RAIL
TYPE
INCLINATION
54E1
1/9 +
1/12 in-curve
superelevation 55[mm];
special flexible blades
- 13.910 [m]
special stock rail
/5
R260
full
depth
573
R350HT
57
wood
142
MAXIMUM
SPEED
IN MAIN LINE
[KM/H]
MAXIMUM
SPEED
IN
BRANCH
LINE
[KM/H]
180
70
200
70
32
1/2
/2
80
30
CROSSING
Pre-Hardened
Monoblock Cast
Austenitic
Manganese Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
120
30
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
1/2
62
PreHardened
Monoblock
Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock
Cast
Austenitic
Manganese
Crossing
R260
full
depth
54E1
R350HT
R260
full
depth
R350HT
152
R260
RAIL
GRADE
RAIL
TYPE
full
depth
R260
54E1
shallow
depth
R350HT
full
depth
R260
shallow
depth
R350HT
60E2
full
depth
R260
54E1
SWITCH
RADIUS
60E2
54E1
shallow
depth
R350HT
60E2
full
depth
R260
54E1
shallow
depth
R350HT
60E2
full
depth
R260
54E1
shallow
depth
R350HT
60E2
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
full
depth
R260
shallow
depth
R350HT
Pre-Hardened
Monoblock Cast
full
depth
R260
58
54E1
60E2
54E1
68G1
Diamond
Crossover
Tg. 0.264
Scissor
Crossover 1/12
4700 mm with 3
LH turnouts
wood
Turnout 1/8
20m length
grooved
Track
center to
track
center
[mm]
INCLINATION
4700
mm
Scissor
Crossover
1/12 with 3
LH turnouts
4700;
5000;
6000
Special
Scissor
Crossover 1/8
with 1 Double
Slip + 3
turnouts
4700;
5000;
6000
Special
Scissor
Crossover 1/8
with 2 Double
Slips + 2
turnouts
4700;
5000;
6000
Special
Scissor
Crossover 1/8
with 3 Double
Slips + 1
turnout
4700;
5000;
6000
wood
Special
Scissor
Crossover 1/8
with 4 Double
Slips
4700;
5000;
6000
Special
Scissor
Crossover 1/9
with 1 Double
Slip + 3
turnouts
4700;
5000;
Special
Scissor
BEARERS
wood
concrete
wood
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
102
32
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
102
32
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
022
62
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
54E1
shallow
depth
R350HT
full
depth
R260
shallow
depth
R350HT
full
depth
R260
shallow
depth
R350HT
60E2
full
depth
R260
54E1
shallow
depth
R350HT
60E2
full
depth
R260
shallow
depth
R350HT
full
depth
R260
shallow
depth
R350HT
60E2
full
depth
R260
54E1
60E2
54E1
60E2
54E1
4700;
5000;
6000
4700;
5000;
6000
R350HT
60E2
full
depth
R260
54E1
shallow
depth
R350HT
60E2
full
depth
R260
54E1
shallow
depth
R350HT
60E2
full
depth
R260
shallow
depth
R350HT
54E1
60E2
Special
Scissor
Crossover 1/9
with 3 Double
Slips + 1
turnout
Special
Scissor
Crossover 1/9
with 4 Double
Slips
0222
7000
Special
Scissor
Crossover 1/8
with 4 Double
Slips
4700;
5000;
6000
Special
Scissor
Crossover 1/8
with 1 Double
Slip + 3
turnouts
4700;
5000;
6000
Special
Scissor
Crossover 1/8
with 2 Double
Slips + 2
turnouts
4700;
5000;
6000
Special
Scissor
Crossover 1/8
with 3 Double
Slips + 1
turnout
60E2
54E1
Crossover 1/9
with 2 Double
Slips + 2
turnouts
Special
Scissor
Crossover 1/8
with 3 Double
Slips + 1
turnout
54E1
shallow
depth
59
6000
4700;
5000;
6000
4700;
5000;
6000
Special
Scissor
Crossover 1/8
with 4 Double
Slips
Special
Scissor
Crossover 1/9
with 1 Double
Slip + 3
turnouts
concrete
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
Pre-Hardened
Monoblock Cast
Austenitic
Manganese
Crossing
full
depth
R260
shallow
depth
R350HT
full
depth
R260
shallow
depth
R350HT
full
depth
R260
shallow
depth
R350HT
54E1
60E2
54E1
60E2
54E1
60E2
4700;
5000;
6000
Special
Scissor
Crossover 1/9
with 2 Double
Slips + 2
turnouts
4700;
5000;
6000
Special
Scissor
Crossover 1/9
with 3 Double
Slips + 1
turnout
4700;
5000;
6000
Special
Scissor
Crossover 1/9
with 4 Double
Slips
1/20 54E1
28966
37382
37399
Tg 0.05
Tg 0.05
1868
1867
37396
37382
1/12 60E2
19592
1/12 54E1
19592
24413
23414
Tg 0.085
Tg 0.085
1984.5
2070
23414
24413
1/9 60E2 R
14363
1/9 54E1
14346
18918
Tg 0.11
Tg 0.11
2005.8
2072
18318
18918
1/8 60E2
13564
1/8L 54E1
15896
13556
Tg 0.13
15904
Tg 0.13
2054
15896
18318
61
2054.5
15904
1/8S 54E1
73331
6618
10216
15904
Tg 0.13
Tg 0.13
2054.5
1725.2
15904
13382
DIAMONDS
Scissors Crossover 1/8 54E1
Tg0.13
4.7
13.56
Tg0.13
4.7
R 190/190
R 190/190
13.56
36.15
10.22
63.27
R 190/190
10.22
13.56
38.46
Tg0.13
R 190/190
13.56
65.58
R 190/190
13.56
13.56
46.15
R 190/190
10.22
R 290/250
Tg0.11
4.7
R 280/250
14.35
14.35
71.43
R 280/250
14.35
45.45
14.35
74.15
R 280/250
14.35
54.55
14.35
83.25
Tg0.085
4.7
R 489/600
55.29
19.59
R 485/600
19.59
94.47
R 489/600
19.59
58.82
R 489/600
70.59
19.59
R 485/600
19.59
61
Tg0.085
19.59
19.59
Tg0.085
19.59
74.15
6
55.29
94.47
Tg0.085
14.35
Tg0.085
19.59
54.55
83.25
14.35
Tg0.11
R 290/250
14.35
45.45
74.15
Tg0.11
14.35
Tg0.11
R 290/250
14.35
42.73
71.43
Tg0.11
10.22
Tg0.11
42.73
46.15
66.59
14.35
10.22
Tg0.13
73.27
4.7
38.46
58.9
Tg0.13
10.22
56.59
Tg0.13
36.15
58.82
74.15
19.59
Tg0.085
R 485/600
19.59
19.59
70.59
109.77
4.7
R 1300/2000
28.97
94
Tg0.05
28.97
28.97
28.97
100
151.94
Tg0.05
R 1300/2000
R 1300/2000
28.97
157.94
120
28.97
177.94
17397
1944
77171
Tg0.13
15207
37373
73773
17
17397
1870.7
Tg0.11
17083
17083
34166
8913
Tg 0.264
2298
8913
17826
62
21486
21486
32664
7230
23414
2006
Tg.0.11
1609
Tg.0.085
1985
18318
Tg0.085
6360
R 485/600
19592
55294
4700
19592
94408
Tg0.13
4700
4700
Tg0.13
5000
5000
6000
6000
Tg. 0.13
Tg. 0.13
4700
4700
63
Tg. 0.13
Tg. 0.13
5000
5000
Tg. 0.13
Tg. 0.13
6000
6000
4700
4700
5000
5000
6000
6000
64
Tg. 0.11
Tg. 0.11
4700
4700
Tg. 0.11
Tg. 0.11
5000
5000
Tg. 0.11
Tg. 0.11
6000
6000
1
2
3
4
5
max speed
[km/h]
160-022
120-160
80-120
40-80
0-40
Twist
(measured
every 2.5
meter)
3
4
4
6
6
longitudinal superelevation
level
(cross level)
10 m chord
3
6
7
10
10
10 m chord
2
4
5
8
8
65
alignment
3
3
4
7
7
Table 2.1 Turnout 60E2 rail profile safety dimensions and permissible
tolerances during Turnout Quality test in the manufacturing plant
66
permissible
tolerance
90/
dimensions
permissible
tolerance
901
dimensions
permissible
tolerance
9090
dimensions
permissible
tolerance
dimensions
9002
1435
1435
1435
1435
d1
1370
1395
1370
End of Planning
On Heal
d2
e1
e2
l1
l2
j1
j2
-0.5, +0.5
1370
1395
Entrance
Switch Toe
m1
-3, +3
1370
1370
1395
1435
1445
1435
1445
1435
1445
-0.5, +0.5
1370
1370
1395
1445
-3, +3
1370
1395
1435
1435
1435
1435
1435
1435
-0.5, +0.5
1395
1395
1435
-3, +3
1395
1435
1435
1435
1435
1435
1435
-0.5, +0.5
1435
1435
1435
1435
1435
1435
1435
-3, +3
1435
0, +2
1435
1439
1435
1443.5
0, +2
1435
1435
1435
1435
0, +2
1435
1435
1435
1435
0, +2
1435
1435
1435
1435
n1
m2
n2
Table 2.2 Turnout 54E1 rail profile safety dimensions and permissible
tolerances during Turnout Quality Test in the manufacturing plant
67
permissible
tolerance
90/
Dimensions
permissible
tolerance
901
dimensions
permissible
tolerance
9090
dimensions
permissible
tolerance
dimensions
9002
1437
1435
1445
1445
d1
1370
1395
1370
68
e1
e2
l1
l2
j1
j2
-0.5, +0.5
1370
1395
Entrance
Switch Toe
End of Planning
On Heal
d2
m1
-3, +3
1370
1370
1395
1445
1435
1445
1435
1445
1435
-0.5, +0.5
1370
1370
1395
1435
-3, +3
1370
1395
1445
1435
1445
1435
1445
1435
-0.5, +0.5
1395
1395
1435
-3, +3
1395
1435
1435
1435
1435
1435
1435
-0.5, +0.5
1437
1437
1435
1435
1435
1435
1435
-3, +3
1437
0, +2
1435
1439
1443.5
1435
0, +2
1435
1439
1435
1435
0, +2
1435
1435
1435
1435
0, +2
1437
1437
1435
1437
n1
m2
n2
69
71
69.90 mm
HOLE 28 mm
230 mm
71
76.25 mm
HOLE 28 mm
230 mm
72
73
74
75
76
77
J.2
Maximum Daily
Value*
560
260
143
350
J.3
J.4
78
Wet
22.0
7.9
1.7
SO4*
Dry
5.3
1.9
1.3
Average
71
21
84
100
Wet
7.0
2.0
1.4
TECHNICAL ATTACHMENT A
- TECHNICAL SPECIFICATION FOR MANUFACTURE AND SUPPLY OF
54E1 AND 60E2 RAILS R260 AND R350HT GRADES
NO.E-01-0004.T_JUNE_2015
79
Technical Specifications
for Manufacture
of
CONTENTS
1.
2.
3.
4.
5.
6.
7.
SCOPE
STANDARDS REFERENCES
DEFINITIONS
GENERAL REQUIREMENTS
QUALITY CONTROL AND QUALITY ASSURANCE
PROCEDURES PLAN
QUALIFICATION TESTS
QUALITY TESTS
81
1.
SCOPE
1.1
1.2
The Rails shall be have the 60E2 and 54E1 rail profiles with Grade
R260 or R350HT to be used in Turnouts and Expansion Switches.
2.
EN 13674-2
EN 13232-1
DEFINITIONS
Rails
turnout
Diamond
Turnouts
Expansion Switch
The laboratory
28
4.
GENERAL REQUIREMENTS
4.1
4.2
The Rails shall be made of steel profile 54E1 or 60E2 and Grade
R260 or R350HT (based on ISR order details) in accordance with
EN 13674-1. The manufacturing process shall be continuous
casting and no other process shall be approved.
4.3
4.4
The Rails dimension tolerances shall be according with EN 136742, paragraph 9.2
4.5
The size and location tolerances of drilled holes and the squareness
of Rail ends tolerance shall be in accordance EN13674-2 Table 8.
4.6
4.7
5.
QUALITY CONTROL
PROCEDURES PLAN
AND
QUALITY
ASSURANCE
QUALIFICATION TESTS
6.1
6.2
7.
QUALITY TESTS
7.1
28
TECHNICAL ATTACHMENT B
TECHNICAL SPECIFICATION FOR MANUFACTURE AND
SUPPLY OF GLUED INSULATING RAIL JOINTS FOR
TURNOUTS NO.E-01-0023.T_JUNE_2015
28
Technical Specifications
for Manufacture of
GLUED INSULATED RAIL
JOINTS
for TURNOUTS
No. E-01-0023.T
June 2015
85
Contents
1
2
3
4
5
SCOPE
STANDARDS REFERENCES
DEFINITIONS
GENERAL REQUIREMENTS
SUB-COMPONENTS REQUIREMENTS
5.1
5.2
5.3
5.4
STEEL FISHPLATE
STEEL BOLTS AND NUTS
WASHERS
INSULATING SUB-COMPONENTS: BOLT INSULATED SLEEVES,
INSULTED ENDPOST AND FISHPLATE POLYMER LAMINATION
GLUE
5.5
6
7
8
9
10
TECHNICAL DRAWINGS
MANUFACTURE
MARKING
QULIFICATION TESTS
QUALITY TESTS
86
1.
SCOPE
1.1
1.2
2.
EN 13232-1
UIC 864-2
UIC 864-4
EN ISO 898-1
EN ISO 898-2
EN ISO 4759-3
EN 10025
ISO/IEC 17025
28
3.
DEFINITIONS
ISR
Israel Railways
turnout
Diamond
Turnout
Sub-Component
The Laboratory
4.
GENERAL REQUIREMENTS
4.1
4.2
The Glued Insulated Rail Joints shall be designed in such a way that
it cannot be damaged as a result of rail maintenance work (tamping,
dynamic stabilization etc.) or by the operations of bearers replacing.
4.3
4.4
The Glued Insulated Rail Joints shall have life cycle of not less than
10 years.
22
4.5
The Glued Insulated Rail Joints shall include 2 rails, each rail length
shall be at least of 3 meters, with one of the following types:
The Glued Insulated Rail Joints shall have the following main SubComponents:
4.7
5.
SUB-COMPONENTS REQUIREMENTS
5.1
STEEL FISHPLATE
5.1.1
Types
The Glued Insulated Rail Joints shall include 2 Polymer Lamination
Steel Fishplates of one of the following types:
5.1.2
Characteristics
28
5.2
5.2.1
General
The Glued Insulated Rail Joints shall include 6 Steel Bolts and Nuts.
89
5.2.2
Characteristics
The Steel Bolts and Nuts material, quality, manufacturing tests and
acceptance conditions shall be in accordance with this technical
specification and these standards: UIC 864-2, EN ISO 898-1 and EN
ISO 898-2.
The steel making process and grade of steel shall obtain the
following mechanical properties:
Tensile strength steel grade 10.9 and tensile stress of 1000-1150
N/mm2 and minimum elongation 9%.
The sulfur and phosphorus content shall not exceed 0.035%.
The Steel Bolts shall be manufactured from single piece, without
welding. Their head shall be upset by hot-working.
The steel used for the manufacture of the Nut must be in keeping
with the grade of quality of the Steel Bolt or with the nearest grade
below.
The Steel Bolts and Nuts shall be galvanized. The steel bolts and
nuts must be free from any trace of grease, paint, etc. before the
galvanization.
5.2.3
5.3
WASHERS
5.3.1
General
The Glued Insulated Rail Joints shall include 6 steel washers.
5.3.2
Characteristics
The washer shall be manufactured by hot or cold rolled steel process,
with steel category according to EN 10139 or EN 10025.
The washer dimensions and tolerances shall be in accordance with
EN ISO 4759-3 or equivalent.
The conditions of manufacture of the washer obtained from bars of
the same casting must be identical.
The section shall be of even thickness and slightly rounded at the
edges.
89
The washer shall be regular and clean, and free from superficial
cracks, flaws, burrs, and deficiency in metal, folds, or any other
defects likely to affect the use for which they are intended. The
outside surface, in particular, must be smooth and free from burrs.
The washer shall be galvanized. The washers must be free from any
trace of grease, paint, etc. before the galvanization.
5.3.3
5.4
5.4.1
5.4.1.1
General
The Glued Insulated Rail Joints shall include an Insulated Endpost of
one of the following types:
5.4.1.2
The Glued Insulated Rail Joints shall include 6 Bolt Insulated Sleeves
of the following type:
5.4.1.3
5.4.2
Characteristics
The insulated Sub-Components mechanical, electrical and thermal
properties values shall be submitted.
5.5
GLUE
5.5.1
Characteristics
The Glue type, its technical specification and safety data sheet
(MSDS) shall be submitted.
6.
TECHNICAL DRAWINGS
88
6.1
7.
7.1
MANUFACTURE
The Glued Insulated Rail Joints shall be manufactured in accordance
with the technical drawings and with this technical specification and
shall present a clean surface, smooth and free from blow-holes,
flaws, cracks, folds or other faults.
8.
8.1
MARKING
Each Glued Insulated Rail Joints shall be inscribed with at least the
following marks:
9.
9.1
QULIFICATION TESTS
The qualification tests shall be carried out by The Laboratory on
three Glued Insulated Rail Joints as follows:
9.2
88
9.4
Megohmeter test:
Apply 500 volts D.C. rail to rail, each test for duration of 5 second
and there shall be a minimum resistance of 10M.
9.5
9.6
9.7
10.
10.1
QUALITY TESTS
Each Glued Insulated Rail Joint shall be tested with: Megohmeter
test - Applying 500 volts, D.C. rail to rail, each test for duration of 5
second, and there shall be a minimum resistance of 10M.
88
A.2
Maximum Daily
Value*
560
260
143
350
A.3
A.4
89
Wet
22.0
7.9
1.7
SO4*
Dry
5.3
1.9
1.3
Average
71
21
84
100
Wet
7.0
2.0
1.4
89
TECHNICAL ATTACHMENT C
TECHNICAL SPECIFICATION FOR MANUFACTURE AND SUPPLY
FASTENING SYSTEMS FOR TURNOUTS
NO.E-01-0026.T_JUNE_2015
88
Technical Specification
for Manufacture
of
Fastening Systems for Turnouts
and Expansion Switch
82
No. E-01-0026.T
June 2015
88
CONTENTS
1.
2.
3.
4.
5.
SCOPE
STANDARDS REFERENCES
DEFINITIONS
GENERAL REQUIREMENTS
SUB-COMPONENTS REQUIREMENTS
5.1
TENSION CLAMPS
5.2
5.3
BEARERS SCREWS
5.4
5.5
5.6
5.7
BASE PLATES
5.8
5.9
5.10
WASHERS
5.11
Plastic Dowels
5.12
6. DRAWINGS
14. QUALIFICATION TESTS
TECHNICAL APPENDIX A ISRAEL CLIMATE AND
ENVIRONNEMENTAL CONDITIONS
111
1.
SCOPE
1.1
1.2
1.3
1.4
Tension Clamps;
Angled Guide Plates (if applicable);
Bearers Screws;
Track Bolts (if applicable);
Rail Seat Pads;
Base Plates (if applicable);
Base Plates Pads (if applicable);
Double Spring Washer (if applicable);
Spring Washers (if applicable);
Washers (if applicable);
Plastic Dowels (if applicable);
Height Adjustment Plates;
Other Sub-components.
999
1.5
1.6
2.
EN 13481-4
EN 13481-5
EN 13481-7
EN 13146-1
EN 13146-2
EN 13146-3
EN 13146-4
998
EN 13146-5
EN 13146-6
EN 13146-7
EN 13146-9
EN 13674-1
prEN 16730
UIC 864-1
UIC 864-2
UIC 864-3
UIC 864-5
UIC 864-6
EN 10139
EN 10025
EN ISO 898-1
EN ISO 898-2
998
EN ISO 4759-3
EN ISO 179
Plastics properties;
EN ISO 527-2
EN ISO 868
EN ISO 1183-1
ISO 6507
IEC 60093
IEC 60167
ISO/IEC 17025
Determination
of
Charpy
impact
DEFINITIONS
ISR
Israel Railways
ISRTS
turnout
Diamond
Turnouts
Expansion Switch
Sub-Component
or
31.
or
32.
Prfamt
Fr
Bau
Von
Landverkehrswegen,
Technische
Universitt, Mnchen.
4.
4.1
GENERAL REQUIREMENTS
The Fastening Systems shall comply with requirements of EN 13481-2,
3, 4, 5, 7.
4.2
4.3
4.4
4.5
All parts which are non-metallic shall be made of hot weather resistant
materials, suitable for use at temperature of up to 70C and under high
corrosion conditions. Plastic parts shall be UV protected.
999
5.
5.1
5.1.1
SUB-COMPONENTS REQUIREMENTS
TENSION CLAMPS
Characteristics
The Tension Clamp raw material shall be from alloy Siliconemanganese spring steel according EN 10089 or equivalent with the
following chemical composition:
0.35 C% 0.42
S% 0.025
P% 0.025
The tension clamps shall be heat treated to achieve a surface hardness in
the range 400-460 HV 30 in accordance with ISO 6507 or equivalent. It
shall be free from surface and internal defects.
The tension clamps shall be provided with protective coating.
5.1.2
5.2
5.2.1
999
5.3
5.3.1
BEARERS SCREWS
Characteristics
The Bearers Screws material quality manufacturing and acceptance
conditions shall be in accordance with UIC 864-1.
The Bearers Screws shall be manufactured from single piece, without
welding. Their head shall be formed by hot-working from the bar-stock.
The Bearers Screws steel category shall be in accordance with EN
10139 or EN 10025.
The Bearers Screws tensile strength shall be greater than 500 N/mm2.
The Bearers Screws elongation shall be greater than 20%.
The Bearers Screws limit of elasticity shall be greater than 300 N/mm2.
The Bearers Screws shall be galvanized. The Bearers Screws must be
free from any trace of grease, paint, etc. before the galvanization.
The complete surface of the Bearers Screws shall be suitably trimmed.
Care shall be taken to ensure that trimming does not give rise to any
tearing of the metal or leave any roughness on the contact surfaces.
The threads must be clean, uniform and complete. If the threads of the
Bearers Screws are stripped or if there is a lack of material in their
shank, they shall not be accepted.
998
5.3.2
5.4
5.4.1
5.4.2
5.5
5.5.1
992
The rail pads shall be water oil and grease resistant, and shall be
stabilized against light/ UV damage.
It shall be protected against oxidation and rotting.
The rail seat pads shall have 32 - 47 shore hardness-D in accordance
with EN ISO 868.
The rail seat pads shall have Melt Flow Rate (MFR 190/2.16) 5.2 g/10
min in accordance with ISO 1133.
The rail seat pads shall have density 0.932- 0.952 g/cm3 in accordance
with EN ISO 1183.
The rail seat pads static stiffness shall be Cstat 450 kN/mm.
The rail seat pads electrical volume resistivety shall be greater than 10 8
Ohmcm according with IEC 60093.
The surface shall be free of cracks and damages affecting performances.
5.6
5.6.1
998
The rail seat pads electrical volume resistivety shall be greater than 10 8
Ohmcm according with IEC 60093 / IEC 60167.
The surface shall be free of cracks and damages affecting performances.
5.7
5.7.1
BASE PLATES
Characteristics
The base plates material quality manufacturing, tests and acceptance
conditions shall be according UIC 864-6.
The base plates tensile strength shall be greater than 410 N/mm2.
The base plates elongation at fracture shall be greater than 24%.
The base plates yield strength shall be greater than 265 N/mm2.
The base plates on the bearers shall guarantee rail inclination of 1/30.
5.7.2
5.8
5.8.1
5.9
5.9.1
0.35 C% 0.42
1.5 Si% 1.8
0.5 Mn% 0.8
S% 0.045
P% 0.045
5.9.2
5.10
5.10.1
WASHERS
Characteristics
The washer shall be manufactured by hot or cold rolled steel process,
with steel category according to EN 10139 or EN 10025.
The washer dimensions and tolerances shall be according with EN ISO
4759-3.
The washer shall be galvanized. The washers must be free from any
trace of grease, paint, etc. before the galvanization
5.10.2
5.11
5.11.1
PLASTIC DOWELS
Characteristics
The Plastic Dowel material shall be design to guarantee the pull out
force from the Bearers of minimum 70 [kN].
The Plastic Dowel Density shall be greater than 0.950 g/cm3 in
accordance with EN ISO 1183.
The Plastic Dowel Density electrical volume resistivity shall be greater
than 108 Ohmcm according with IEC 60093 / IEC 60167.
The surface shall be free of cracks and damages affecting performances.
999
5.11.2
5.12
5.12.1
5.12.2
6.
6.1
DRAWINGS
The Turnout manufacturer shall submit a complete set of technical
specification and manufacturing drawings of Fastening Systems for
Turnouts (for every type) with dimensions, tolerances material type,
coating description and heat treatment, etc.
998
6.2
6.3
6.4
7.
7.1
QUALIFICATION TESTS
The qualification tests shall carried out by The Laboratory on fastening
systems for Turnouts as an assembled unit according to EN13481-2
sections 5.1-5.10 and 5.12; EN13481-3 sections 5.1-5.9 and 5.11;
EN13481-4 sections 5.1-5.9 and 5.11; EN13481-5 sections 5.1-5.8 and
5.10; EN 13481-7 sections 5.1-5.11 and 5.13, and EN13146 parts 1-7
and 9. Test report shall be submitted the relevant certificates to ISR.
7.2
998
8.
8.1
8.2
The manufacturer shall add to the drawings hard copies and magnetic
copy the relevant technical descriptions of every Sub-component.
8.3
8.4
The manufacturer shall state the nature and main characteristics of the
steel and the non-metallic materials making process.
8.5
The manufacturer shall submit ISR hard copy and also magnetic copy of
installation and maintenance manuals.
9.
9.1
9.2
9.3
9.4
The manufacturer shall state the nature and main characteristics of the
steel making process.
9.5
The manufacturer shall submit a certificate confirming that the Subcomponents materials comply with the requirements.
998
A.2
Maximum Daily
Value (**)
560
260
143
350
A.3
A.4
999
Average
71
21
84
100
SO4 (**)
Dry Wet
5.3 7.0
1.9 2.0
1.3 1.4
TECHNICAL ATTACHMENT D
TECHNICAL SPECIFICATION FOR MANUFACTURE AND SUPPLY OF
WOOD BEARERS NO. E-01-321A.2.T_JUNE_2015
999
Technical Specification
for Manufacture
of
WOOD BEARERS
for Turnouts
No. E-01-321A.2.T
998
June 2015
992
CONTENTS
1.
2.
3.
4.
5.
6.
GENERAL
STANDARDS REFERENCES
DEFINITIONS
DIMENSIONS
PRESERVATION TREATMENT
QUALIFICATION TEST
7.
8.
QUALITY TEST
OTHER REQUIRMENTS
119
1.
GENERAL
1.1.
1.2.
1.3.
1.4.
2.
EN 13991
EN 13232-1
DEFINITIONS
turnout
Diamond
Turnout
4.
DIMENSIONS:
4.1.
989
4.3.
5.
PRESERVATION TREATMENT
5.1.
5.2.
Preservative material:
The preservative material must comply with EN13991 grade B or
C.
The Material Safety Data Sheet (MSDS) shall be submitted.
5.3.
Seasoning:
Prior to the preservation treatment the Wood Bearers and shall be
completely air seasoned for not less than 8 month. Maximum
period between felling and delivery shall be 12 month.
5.4.
Method of treatment
The Wood Bearers are to be impregnated with Pressure process to
match hazard class 4 preservatives according EN13145, section
7.2.2. (The specific process shall be indicated).
5.5.
Penetration
Treated Wood Bearers shall meet the requirements of penetration
class 8 (P8: full sapwood penetration), according EN13145,section
7.2.3.
989
5.6.
Retention
The Wood Bearers minimum retention requirement shall be equal
to the critical value for hazard class 4 of the preservative used,
according EN13145, section 7.2.4.
6.
QUALIFICATION TEST
The following documents shall be submitted:
6.1.
6.2.
6.3.
6.4.
7.
QUALITY TEST
7.1.
8.
OTHER REQUIRMENTS
8.1.
8.2.
988
TECHNICAL ATTACHMENT E
TECHNICAL SPECIFICATION FOR MANUFACTURE AND
SUPPLY OF STEEL HOLLOW BEARERS FOR ALD (ACTUATION
SYSTEM, LOCKING DEVICE AND DETECTION DEVICE)
INTEGRATION NO. E-01-0025.T_JUNE_2015
988
Technical Specification
for Manufacture of
STEEL HOLLOW
BEARERS
for
ALD (Actuation System, Locking
Device and Detection Device)
INTEGRATION
No. E-01-0025.T
June 2015
988
CONTENTS
1. SCOPE
2. STANDARDS REFERENCES
3. DEFINITIONS
4. GENERAL REQUIREMENTS
5. TECHNICAL REQUIREMENTS
6. MANUFACTURE'S TECHNICAL DRAWINGS
7. QULIFICATION TESTS
TECHNICAL APPENDIX A ISRAEL CLIMATE AND
ENVIRONEMENTAL CONDITIONS
TECHNICAL APPENDIX B SKETCH OF THE HOLES
DIMENSIONS AT THE BOTTOM OF THE STEEL HOLLOW
BEARERS
125
1.
1.1
SCOPE
This technical specification prescribes the technical requirements of
manufacturing the Turnout Components Steel Hollow Bearers.
1.2
1.3
The Steel Hollow Bearers will be equipped with indirect elastic rail
fastening system, with tension clamp SKL-W (one of the types
defined in the ISRTS E-01-0026.T_November 2014), design for
track with 60E2 and 54E1 rails.
2.
EN13232-1
UIC 842-4
ISO/IEC 17025
DEFINITIONS
ISR
Israel Railways
ISRTS
ALD
turnout
Diamond
Turnouts
989
Sub-Component
The Laboratory
or
34.
A
laboratory
certified
in
accordance
with
ISO/IEC17025:2005 in the field
of relevant Component testing.
A laboratory accredited by
national laboratory accreditation
authority in the field of
Component quality testing.
4.
4.1
GENERAL REQUIREMENTS
The Steel Hollow Bearer shall be designed for use with 60E2 and
54E1 rails in Turnouts.
4.2
The Steel Hollow Bearers and their fastening system set shall be
designed for use on standard gauge 1435 mm railway track. The rail
seats on each Bearer shall have nominal inclination of 1:30 (sleeper
with zero inclination and Base Plate with inclination of 1:30).
4.3
The Steel Hollow Bearers and their fastening system set shall be
designed to enable railway vehicles run safety at speed up to 200
km/h.
4.4
The Steel Hollow Bearers and their fastening system set shall be
design for loads of 22.5 ton/axle.
4.5
The Steel Hollow Bearer and the fastening system set design shall
also include insulation elements which shall enable the proper
attachment to 60E2 and 54E1 rails.
4.6
4.7
988
4.8
4.9
4.10
4.11
4.12
The Steel Hollow Bearers top body shall be covered with steel plates
including the ALD. The plates shall be screwed to the Steel Hollow
Bearers body.
4.13
4.14
4.15
4.16
The Steel Hollow Bearers body, steel cover stud plates shall be
corrosion protected and painted in accordance with UIC842-4 or
equivalent standard.
4.17
The steel cover stud plates between the rails and both sides outside
the rails and shall be reflective painted in accordance with UIC842-4
or equivalent standard.
982
4.18
The Steel Hollow Bearers life cycle shall not be less than 25 years.
5.
5.1
TECHNICAL REQUIREMENTS
STEEL HOLLOW BEARERS
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
the height between the top of the rail and the bottom of the hollow
bearer shall be the same as the neighboring bearers, so the bottom of
the hollow bearer should be aligned at the same level as the bottom
of the adjacent bearers in order to guarantee stability (mounting on
same ballast level);
5.1.6
5.1.7
5.1.8
Cover must be fixed to the Steel Hollow Bearer in such away, that it
should be easy to dismantle, but it should be able to prevent the
unauthorized intervention.
5.1.9
The covers should be strong enough to bear the worker weight (100
kg) stepping on them without permanent deformation.
5.2
5.2.1
The Fastening Systems shall comply with requirements of ISRTS ENo. 01-0026.T_June_2015.
6.
988
7.
7.1
The steel hollow sleeper body including steel pipes, and steel stud
plates;
Elastic rail fastening system with tension clamp SKL-W.
QULIFICATION TESTS
The qualification test reports for Steel Hollow Bearers shall be
submitted, it shall include the following tests:
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6
Bending test for the body, as defined in EN 16431, section 5.3 and
6.2;
7.1.7
989
A.2
Maximum Daily
Value*
560
260
143
350
A.3
A.4
989
Wet
22.0
7.9
1.7
SO4*
Dry
5.3
1.9
1.3
Average
71
21
84
100
Wet
7.0
2.0
1.4
Dimensions in millimeters
30
R 15
4 holes R15
430
60
580
2600
988
TECHNICAL ATTACHMENT F
TECHNICAL SPECIFICATION FOR MANUFACTURE AND
SUPPLY OF CONCRETE BEARERS SCREWS PROTECTIVE
COATING WAX NO. E-01-0027.T_JUNE_2015
988
Technical Specifications
for
CONCRETE BEARERS SCREWS
PROTECTIVE COATING WAX
No. E-01-0027.T
June 2015
988
1.
1.1
GENERAL
This technical specification prescribes the technical requirements of
Concrete Bearers Screws Protective Coating Wax based on
petrolatum and synthetic products and free of solvents.
It shall be used to release the screws without damage to the
Concrete Bearers and for screws corrosion protection.
1.2
DECOMUTATION
The Protective Coating Wax safety data sheet (MSDS) shall be
submitted.
989
TECHNICAL ATTACHMENT G
TECHNICAL SPECIFICATION FOR MANUFACTURE AND
SUPPLY OF MANUAL SWITCH STAND
NO.E-01-0028.T_JUNE_2015
989
Technical Specifications
for Manufacture
of
Manual Switch Stand
No. E-01-0028.T
June 2015
988
CONTENTS
1.
2.
3.
4.
5.
6.
7.
SCOPE
STANDARDS REFERENCES
DEFINITIONS
GENERAL REQUIREMENTS
MANUFACTURE
MARKING
DOCUMENTATION
1.
SCOPE
1.1
1.2
2.
3.
DEFINITIONS
turnout
Diamond
Turnouts
Switch Panel
Actuation System
Component
Sub-component
4.
GENERAL REQUIREMENTS
4.1
4.2
The Manual Switch Stand design shall enable Switch and Stock
Rails adjacent (proper closing) of at least 3 [m] from the switch rail
toe.
4.3
4.4
4.5
The Manual Switch Stand lever movement shall not be more than
120 degrees.
988
4.6
4.7
4.8
5.
MANUFACTURE
5.1
5.2
6.
MARKING
6.1
Manufacturers mark;
7.
DOCUMANTATION
7.1
989