GLUED INSULATED RAIL JOINT COMPONENTS KITS No. E-01-0013 · Rail Joint ("The Glued Insulated Rail...

ISRAEL RAILWAYS LTD.

INFRASTRUCTURE DIVISION

Technical Specification

for

Manufacture and Supply of

GLUED INSULATED

RAIL JOINT

COMPONENTS KITS

No. E-01-0013.12

January March 2018

ISRAEL RAILWAYS LTD

KITS of COMPONENTS for GLUED INSULATED RAIL JOINTS

No. E-01-0013.1 2 January March 2018

This technical specification differs from version No. E-01-0013.1 January 2018

as follows:

i. Section 4.1 has been revised;

ii. Section 5.1.1 has been revised;

iii. Section 5.2.1 has been revised;

iv. Section 5.3.1 has been revised;

v. Section 5.4.1 has been revised;

vi. The technical specification has been editorially revised.

ISRAEL RAILWAYS LTD

KITS of COMPONENTS for GLUED INSULATED RAIL JOINTS

No. E-01-0013.1 January 2018

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CONTENTS

1. SCOPE 22

2. REFERENCE DOCUMENTS 22

3. GENERAL REQUIREMENTS 22

4. KIT - TECHNICAL REQUIREMENTS 33

5. KIT – COMPONENTS REQUIREMENTS 33

5.1. Steel Fishplate 33

5.2. Steel Bolts and Nuts 54

5.3. Steel Washers 66

5.4. Insulating Components – Bolt Insulated Sleeves, Insulted Endpost and Fishplate

Polymer Lamination 77

5.5. Portion of Glue 88

6. MANUFACTURE'S TECHNICAL DRAWINGS 88

7. MANUFACTURE 99

8. KIT COMPONENTS - MARKING 99

9. MANUFACTURING QULIFICATION TESTS 99

10. KIT COMPONENTS - MANUFACTURING 1111

11. LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL 1111

12. LIST OF DOCUMENTS TO BE SUBMITTED BEFORE SIGNING THE

AGREEMENT (Precedent Documentation) 1111

13. LIST OF DOCUMENTS TO BE DELIVERED WITH EACH DELIVERY1111

14. PACKING 1111

TECHNICAL APPENDIX A - ISRAEL CLIMATE AND ENVIRONNEMENTAL

CONDITIONS 1313

ISRAEL RAILWAYS LTD

GLUED INSULATED RAIL JOINTS COMPONENTS KITS

No. E-01-0013.1 2 December March 20172018

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1. SCOPE

1.1 This technical specifications describe the manufacture and supply of

Glued Insulated Rail Joint Components Kits ("The Kit"), to be

assembled and glued together on two rail segments with one of the

following rail profiles: 60E2; 54E1; 50E6; 46E2 into Glued Insulated

Rail Joint ("The Glued Insulated Rail Joint") for use on railway

tracks for appropriate signaling operation.

2. REFERENCE DOCUMENTS

prEN 16843 Railway applications - Mechanical requirements

for joints in running rails;

EN 13674-1 Railway applications - Track - Rail - Part 1:

Vignole railway rails 46 kg/m and above;

UIC 864-2 Technical specification for the supply of steel track

bolts;

UIC 864-4 Technical specification for the supply of fishplates

or sections for fishplates;

EN 10025 Hot rolled products of structural steels. Technical

delivery conditions;

EN 10139 Cold rolled uncoated low carbon steel narrow strip

for cold forming. Technical delivery conditions

ISO/IEC17025 General requirements for the competence of testing

and calibration laboratories;

ISO 9001 Quality management systems – Requirements.

AREMA - Manual for Railway Engineering

Note – the latest edition of the referenced document should be

considered

3. GENERAL REQUIREMENTS

3.1 The Kit shall be manufactured with different design in accordance

with rail profiles: 60E2; 54E1; 50E6 and 46E2 rails. (Rail profiles are

in accordance with EN 13674-1).

3.2 The Kit shall be designed to be part of railway tracks with CWR

enable railway vehicles run safety at maximum speed - 160 [km/h].

3.3 The Kit shall be designed to be part of railway track with maximum

load - 22.5 [ton/axle].

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3.4 The Kit shall be designed to ensure that it cannot be damaged as a

result of rail maintenance work (tamping, dynamic stabilization, etc.)

or by the operations for sleeper replacing.

3.5 All insulted components (including the glue) shall be designed to

resistant Israel climate condition (in accordance with Technical

Appendix A). High corrosion environment shall be considered as

well.

3.6 The Glued Insulated Rail Joints on the track shall have life cycle of

not less than 7 years for tracks with traffic load of 50 [MGT] per year.

A statement shall be submitted with the bidder technical proposal.

4. KIT - TECHNICAL REQUIREMENTS

4.1 The Kit shall have the following Components:

2 Steel Fishplates (fitted with insulating elements);

6 Steel Bolts and Nuts for Type 60 and Type 54 /

4 Steel Bolts and Nuts for Type 50 and Type 46;

6 Steel Washers for Type 60 and Type 54 /

4 Steel Washers for Type 50 and Type 46;

6 Bolt Insulated Sleeves for Type 60 and Type 54 /

4 Bolt Insulated Sleeves for Type 50 and Type 46;

1 Insulted Endpost;

Portion of Glue (quantity define by the manufacturer);

The fastening components shall be design to be assembled with

screwing machine or torque wrenches (both equipped with torque

meter). The components needed to be screwed shall have hexagonal

shape with width across flats of 39 [mm] (steel bolts heads don't have

to be hexagonal).

The measured tightening torque shall be not less than 900 [N*m].

5. KIT – COMPONENTS REQUIREMENTS

5.1. Steel Fishplate

5.1.1 Steel Fishplate – Types

The Kit shall include 2 Steel rolled Fishplates (fitted with insulating

elements) of one of the following types: Type 60 - length of at least 900 [mm] with 6 holes for 60E2 rails;

Type 54 - length of at least 900 [mm] with 6 holes for 54E1 rails;

Type 50 - length of at least 900 [mm] with 6 4 holes for 50E6

rails;

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Type 46 - length of at least 850 [mm] with 6 4 holes for 46E2

rails.

5.1.2 Steel Fishplate – Characteristics

The reference material of the Steel Fishplates shall be rolled steel.

The grade of steel shall fulfil EN 10025-2, Table 7.

The source of steel and the steel making process shall be the

responsibility of the manufacturer.

The steel used for the manufacture of Steel Fishplates shall have

tensile strength of 450-600 N/mm2 and minimum elongation of 17%.

Ladle analysis/ product analysis

Carbon % by mass

Silicon% by mass

Manganese% by mass

Phosphorous% by mass

Sulphur% by mass

Ladle

analysis Manufacturer shall

specify ____

0.55 max

1.60 max

0.035 max

0.035 max

Product

analysis Manufacturer shall

specify ____

0.60 max

1.70 max

0.040 max

0.040 max

The Steel Fishplates shall be manufactured from a hot rolled section,

cut to length and holed.

The rolled bar used shall be cut to length by any suitable method

which does not deform the section or change the properties of the

steel. Each cut shall be clean and free from burrs.

Straightening operation shall be carried out with gradual pressure and

without impact.

Holes in the fishplate shall be produce with smooth drilling. The

edges shall be chamfered.

The fishplate dimensions shall be in according with the manufacturer

typical product. The tolerances and roughness shall be prescribed in

the drawing and shall comply with the requirements of prEN16843,

Annex B.

5.1.3 Steel Fishplate - Tests and Inspection

The Steel Fishplates manufacturer must be in position to carry out all

the tests and inspection prescribed in UIC 864-4.

For every order of Steel Fishplate the manufacturer shall submit

testing certificates showing the source and method of

steelmaking/casting used and the results of the mechanical and

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chemical tests and dimensions in accordance with manufacturer

quality control manual and technical drawing.

5.2. Steel Bolts and Nuts

5.2.1 Steel Bolts and Nuts – General

The Kit shall include 6 Steel Bolts and Nuts for Type 60 and Type 54

/ 4 Steel Bolts and Nuts for Type 50 and Type 46 of the following

type:

Steel bolts with suitable hexagonal Nuts with width across flats of 39

[mm].

The Steel Bolts diameter shall be in accordance with the manufacturer

design. And must comply with the technical requirements of section

9.49.4 and 9.69.6 hereinafter.

5.2.2 Steel Bolts and Nuts - Characteristics

The Steel Bolts material, quality, manufacturing tests and acceptance

conditions shall be in accordance with this technical specification and

UIC 864-2.

The steel making process and grade of steel shall obtain the following

mechanical properties:

Tensile strength steel grade 10.9, stress of 1000-1150 [N/mm2] and

minimum elongation 9%.

The sulfur and phosphorus content shall not exceed 0.06%.

The Steel Bolts and Nuts shall be produced by hot or cold forging.

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 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.

The complete surface of the Steel Bolts and Nuts shall be suitably re-

burred. Care shall be taken to ensure that the re-burring doesn't give

rise to any tearing of the metal or leave any roughness on the contact

surfaces.

The shanks shall be perfectly smooth and straight, without flow or

cracks. The head shall be clearly cut and correctly centered in relation

to the shanks.

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In additional, no folding of the metal shall occur on the head at the

point of junction with the shank. The contact surfaces of the steel

Bolts and Nuts must be level and perpendicular in relation to the

longitudinal axis.

The threads must be clean, uniform and complete. If the threads of

the Steel Bolts and Nuts are stripped or if there is a lack of material,

they shall not be accepted.

5.2.3 Steel Bolts and Nuts - Tests and Inspection

The Steel Bolts and Nuts manufacturer must be in position to carry

out all the tests and inspection prescribed in UIC 864-2.

For every order of Steel Bolts and Nuts the manufacturer shall submit

testing certificates showing the source and method of

steelmaking/casting used and the results of the mechanical tests,

dimensions and finish inspection in accordance with manufacturer

quality control manual and technical drawing.

For every order of Steel Bolts and Nuts the manufacturer shall submit

certificates of galvanization.

5.3. Steel Washers

5.3.1 Steel Washers – General

The Kit shall include 6 Steel Washers for Type 60 and Type 54/

4 Steel Washers for Type 50 and Type 46.

5.3.2 Steel Washers – Characteristics

The Washer shall be manufactured by hot or cold rolled steel process,

with steel category in accordance with EN10025 or EN10139.

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.

The Steel 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 Steel Washer shall be galvanized. The Washers must be free from

any trace of grease, paint, etc., before the galvanization.

5.3.3 Steel Washers - Tests and Inspection

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For every order of Steel Washer the manufacturer shall submit testing

certificates showing the source and method of steelmaking/casting

used and the results of the mechanical tests, dimensions and finish

inspection in accordance with manufacturer quality control manual

and technical drawing.

For every order of Steel Washers the manufacturer shall submit

certificates of galvanization.

5.4. Insulating Components – Bolt Insulated Sleeves, Insulted

Endpost and Fishplate Polymer Lamination

5.4.1 Insulted Components – General

The Kit shall include 1 Insulated Endpost of one of the following

types:

Insulated endpost for 60E2 rails,

Insulated endpost for 54E1 rails.



The insulated post shall be designed with minimum width of 4 mm.

The Kit shall include 6 Bolt Insulated Sleeves for Type 60 and Type

54/ 4 Bolt Insulated Sleeves for Type 50 and Type 46 of one of the

following types:

Insulated endpost Bolt Insulated Sleeves for 60E2 rails,

Insulated endpost Bolt Insulated Sleeves for 54E1 rails.



The Steel Fishplates in the Kit shall be insulated.

5.4.2 Insulted Components – Characteristics

The insulated components mechanical, electrical and thermal

properties values shall be defined and noted be the manufacturer to

fulfill the insulating requirements in this technical specification.

The following information of the insulated components shall be

submitted with the bidder technical proposal:

Material properties

Flexural strength,

Tensile strength,

Compression strength,

Impact strength,

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Surface electrical resistance,

Disruptive voltage,

Heat stability.

5.4.3 Insulted Components - Tests and Inspection

The insulated components shall be designed to sustain the Kit

qualification tests.

For every order of Kit the manufacturer shall submit quality testing

certificate of material and mechanical properties and dimensions, in

accordance with manufacturer quality control manual and technical

drawing.

5.5. Portion of Glue

5.5.1 Portion of Glue – General

The Kit shall include 1 portion of glue of one of the following types:

Portion of Glue 60 - for 60E2 rails,

Portion of Glue 54 - for 54E1 rails.



5.5.2 Portion of Glue – Characteristics

The Kit shall be supplied with Portion of Glue used to adhesive the

assembled Steel Fishplates, Steel Bolts and Nuts and the Insulating

Component to the Rails.

The Portion of Glue type, its technical specification and properties

and the MSDS certificate shall be submitted with the bidder technical

proposal.

The Portion of Glue shall preserve its properties for at least one year

from DAP delivery date, (in accordance to the manufacturer storage

instruction), to insure same efficiency and performances.

5.5.3 The Portion of Glue - Tests and Inspection

For every order of Kit the manufacturer shall submit certificate for

glue properties including manufacturing expire date.

6. MANUFACTURE'S TECHNICAL DRAWINGS

6.1 The manufacturer shall submit with the tender proposal, technical

drawings of the assembled Glued Insulated Rail Joints.

6.2 The manufacturer shall submit with the tender proposal the technical

description of every component.

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6.3 A complete set of technical drawings of Glued Insulated Rail Joints

for 60E2, 54E1, 50E6, 46E2 rails profiles and including their Sub-

Components with dimensions, material main characteristics, coating

description, heat treatment, etc., shall be submitted before signing the

agreement.

7. MANUFACTURE

7.1 The Kit Components shall be manufactured in accordance with the

manufacturer technical drawings and galvanization (Bolts, Nuts and

Washers), and with the manufacturer quality management plan

follows by ISO9001 and conforming with this technical specification

and the relevant ISO or EN or UIC standards.

The Kit Components shall present a clean surface, smooth and free

from blow-holes, flaws, cracks, folds or other faults.

8. KIT COMPONENTS - MARKING

8.1 Each Kit components shall be inscribed with at least the following

marks:

The supplier mark,

The last two figures of the year of manufacturer,

The product identification type.

8.2 Each endpost type (60E2, 54E1, 50E6 and 46E2 rails) shall be

marked differently with easy to identified mark.

9. MANUFACTURING QULIFICATION TESTS

9.1 The manufacturer shall submit qualification tests, which shall be

perform by The Laboratory.

9.2 The Laboratory performing the tests shall be certified with at least

one of the following certifications:

A laboratory certified in accordance with ISO/IEC17025 in the

field of steel quality testing;

or

A laboratory accredited by national laboratory accreditation

authority in the field of steel quality testing;

or

A laboratory perform tests on track components for national

railway company.

9.3 The Laboratory shall test three Glued Insulated Rail Joints as follows:

two glued insulated rail joints shall be tested in accordance with

section 9.4.

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The third Glued Insulated Rail Joint shall be first tested in accordance

with section 9.5 than shall be tested in accordance with section 9.6

after completion of the fatigue test the Glued Insulated Rail Joint shall

be electrical resistance retested in accordance with section 9.5.

9.4 Longitudinal Force Test process (for insulated rail joint with Kit

assembled and glued) The manufacturer shall submit longitudinal force test report.

The acceptance criterion for the longitudinal force test shall be as

follows:

At no time shall any of the insulated joints show any indication of

slippage during or before the total prescribed load for the rail section

involved is applied to the joint. At the completion of the test after the

load on the rail has been released, the relative position of the rail and

joint bar shall be within 0.5 mm of its original value.

The Glued Insulated Rail Joint assembled and glued capability to

transfer forces in CWR railway tracks shall be:

For 60E2 rails - at least 1500 [kN];

For 54E1 rail - at least 1500 [kN];

For 50E6 rail - at least 1375 [kN];

For 46E2 rail - at least 1175 [kN].

9.5 Electrical Resistance Test process

9.5.1 A Glued Insulated Rail Joint shall be fully assembled (and glued) in

accordance with manufacture's recommendations on two lengths of

rail for an electrical resistance test. The dry rail and joint assembly

shall be supported on dry nonelectrical conducting material.

9.5.2 MegOhmmeter test:

Apply 500 volts, D.C. rail to rail, each test for duration of 5 second

and there shall be a minimum resistance of 10 [M].

9.6 Fatigue test

9.6.1 The test shall be perform in accordance is one of the following test

procedure:

AREMA Manual for Railway Engineering – Volume 1 – section

3.8.7.4 - Rolling load test process;

or

prEN16843 section 7.2.2. - Repeated bending test.

9.7 The preparation of the test pieces and the tests shall be the

responsibility of the manufacturer.

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9.8 For each design and/or material change and/or subcontractor

replacement, during the agreement, the manufacturer shall be

required to re-perform the qualification tests.

10. KIT COMPONENTS - MANUFACTURING

10.1 Each and every Kit Component shall be manufactured in accordance

to the manufacturer's technical drawing its quality management plan

follows by ISO9001 in conform to this technical specification and

with the relevant ISO or EN or UIC standards.

11. LIST OF DOCUMENTS TO BE SUBMITTED WITH

BIDDER'S PROPOSAL

11.1 As detailed in Appendix E of the "General Terms and Conditions"

document.

12. LIST OF DOCUMENTS TO BE SUBMITTED BEFORE

SIGNING THE AGREEMENT (Precedent Documentation)

12.1 As detailed in section 4 of the "Agreement document.

13. LIST OF DOCUMENTS TO BE DELIVERED WITH EACH

DELIVERY

13.1 Each delivery shall be delivered with the component manufacturer

certificate that each components has manufactured in accordance

with the requirements of this technical specification (section 5.1.3;

5.2.3; 5.3.3; 5.4.3; 5.5.3), the technical drawings submitted and with

the relevant ISO or EN or UIC standards.

13.2 Each delivery shall be delivered with the certificates of galvanization

for the components: Steel Bolts, Nuts and Steel washers (section

5.2.3; 5.3.3), in accordance with the relevant ISO or EN standards.

13.3 The delivery of torque wrench with fitted sockets shall include

calibration certificate, and operation instructions.

14. PACKING

14.1 The manufacturer shall pack each Kit (not including the glue) in a

separately wooden box, the components in the package shall be

packed.

14.2 Each Kit (not including the portion of glue) shall be package

separately.

14.3 Glue - Packing

The portion of glue shall have the exact glue capacity for one Kit type.

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14.4 The wooden boxes shall be tighten by metal bands, and shall be

fastened to one another with plastic nylon. They shall be tied to

wooden platform by plastic bands.

14.5 The dimensions of the wooden boxes shall enable maximum effective

storage capacity in containers.

14.6 It shall be possible to put at least 3 wooden boxes one on the other.

14.7 Extra endposts which shall be ordered shall be packed separately in

carton boxes and tighten by plastic bands

14.8 Each package shall be labeled with the following details:

Component names and types;

Production batch numbers;

date of manufactures;

Component barcodes;

Component quantity in box;

Gross and net weight;

Manufacturer recognition numbers or names;

ISR recognition numbers;

ISR order number;

Ordinal number on the packing list.

The labeling shall be with black letters and shall be on 3 spots on the

package (one on top of the package and the two others on the sides).

14.9 The packed washers must not adhere to one another.

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TECHNICAL APPENDIX A - ISRAEL CLIMATE AND

ENVIRONNEMENTAL CONDITIONS

A.1 Climate and Environmental Conditions

Max. ambient temperature 50 °C (shade)

Min. ambient temperature -5 °C

Relative humidity 10 to 90 %

Altitude -400 to +800 meter

Sunny 3300 hours per year

UV Radiation 360 to 600 MJ/m² per year

Rainfall 400 to 800 mm/year

A.2 Dust Conditions in the atmosphere

Maximum Half Hour

Value*

Maximum Daily

Value*

Average

NOx 1064 560 71

SO2 780 260 21

O3 312 143 84

Suspended

Dust

- 350 100

*(Microgram per m³ atmosphere)

A.3 Suspended Particulate Matter (SPM)

Particle size to 0.5-1 micron

A.4 Sea Salt Concentrations in the Atmosphere

Salt Element Na* Cl* SO4*

Position Dry Wet Dry Wet Dry Wet

Sea Air at Coast Line 7.3 16.0 12.0 22.0 5.3 7.0

600 m from Shore 3.1 4.8 4.2 7.9 1.9 2.0

6000 m from Shore 1.1 1.4 1.5 1.7 1.3 1.4

* (Micrograms per m³ atmosphere)

GLUED INSULATED RAIL JOINT COMPONENTS KITS No. E-01-0013 · Rail Joint ("The Glued Insulated Rail...

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