SUPPLY OF RESILIENT RAIL FASTENING ASSEMBLIES · SUPPLY OF RESILIENT RAIL FASTENING ASSEMBLIES ......

TRACK SPECIFICATION

SUPPLY OF RESILIENT RAIL FASTENING ASSEMBLIES

MTSP 000003-02 L2-TRK-SPE-004 Version: 4 Effective from: 27th April 2015

Approving Manager: Chief Engineer Approval Date: 27/04/2015 Next Review Date: 27/04/2018

PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION of 13

Approval

Amendment Record

Approval Date Version Description

20/05/2013 1 Initial issue under MTM.

02/08/2013 2 Alterations made to the maximum allowable axle load and line

speed.

13/09/2013 3

Amendments added to include compatibility and

interchangeability of fastenings to satisfy ongoing operational,

maintenance and safety requirements.

27/04/2015 4 Amended the design track speed vs design axle load table to

reflect current network operations.

TRACK SPECIFICATION





Table of Contents

1. Purpose ............................................................................................................................ 3

2. Scope ............................................................................................................................... 3

3. References ....................................................................................................................... 3

4. Abbreviations .................................................................................................................. 3

5. Definitions ....................................................................................................................... 4

6. Responsibilities ............................................................................................................... 4

7. Safety and Environmental .............................................................................................. 5

8. Design Requirements ..................................................................................................... 5

8.1 General ................................................................................................................................ 5

9. Design Management ....................................................................................................... 5

9.1 Design .................................................................................................................................. 5

9.2 Drawings .............................................................................................................................. 5

9.2.1 Drawings Layout Requirements – General ..................................................... 6

9.2.2 Resilient Rail Fastening Assembly Drawing Details & Requirements ............ 6

9.3 Material ................................................................................................................................ 6

9.3.1 Fastenings ....................................................................................................... 6

9.3.2 Insulation (for use with concrete sleepers) ...................................................... 7

9.3.3 Rail pads (for use with concrete sleepers) ...................................................... 7

9.4 Manufacture ......................................................................................................................... 7

9.4.1 Dimension and Tolerances .............................................................................. 7

9.4.2 Finish ............................................................................................................... 8

9.4.3 Coating ............................................................................................................ 8

9.4.4 Marking ............................................................................................................ 8

10. Performance Requirements ............................................................................................ 8

10.1 Testing ................................................................................................................................. 9

10.1.1 Type Testing .................................................................................................. 10

10.1.2 Batch Testing ................................................................................................ 10

10.2 Supply ................................................................................................................................ 10

10.2.1 Handling, Packaging and Transport .............................................................. 10

11. Performance Measures and Reporting ........................................................................ 11

11.1 Quality Assurance .............................................................................................................. 11

11.1.1 ISO 9001 Quality Management System ........................................................ 11

11.1.2 Retention of Documents ................................................................................ 11

11.1.3 Certificate of Conformity ................................................................................ 11

11.1.4 Audit of Supplier ............................................................................................ 12

11.1.5 Provision of Records ..................................................................................... 12

12. Type Approval ............................................................................................................... 12

13. Related Documents ....................................................................................................... 12

14. Appendices .................................................................................................................... 12

14.1 Appendix 1 – Current List of MTM Accepted Fastening Systems ..................................... 12

14.2 Appendix 2 – Typical Rail Fastening Detail ....................................................................... 13

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1. Purpose

This specification sets out the material, design, manufacture, supply and testing requirements for Resilient Rail Fastening Assemblies used for MTM railway track work.

2. Scope

Resilient Rail Fastening Assemblies shall be adequately designed for all sleeper types used by MTM, including; low profile concrete sleepers, heavy duty concrete sleepers, timber sleepers and bearers (clips only), concrete bearers and direct fixation.

This specification covers aspects of the design, manufacture and delivery of Resilient Rail Fastening Assemblies which includes but not limited to insulators, rail pads, clips and base plate assemblies, as well as relevant testing to be conducted to confirm compliance.

This specification does not cover the manufacture/design of non resilient clips (dog and lock spikes).

Conformance with this standard does not ensure product approval. It may be necessary to undergo a Type Approval process if changing manufacturer, manufacturing process and/or design (including material change). This will be undertaken at the discretion of MTM, and shall be determined prior to manufacture.

3. References

AS 1085.1 – 2002 Railway Track Material – Steel Rails

AS 1085.12 – 2002 Railway Track Material – Insulated Joint Assemblies

AS 1085.14 – 2012 Railway Track Material – Prestressed Concrete Sleepers

AS 1085.19 – 2003 Railway Track Material – Resilient Fastening Assemblies

AS 1444 – 2007 Wrought Alloy Steels

AS 1447 – 2007 Hot Rolled Spring Steels

AS/NZS ISO 9001 – 2008/Amdt 1:2012

Quality Management Systems - Requirements

L1-CHE-PRO-004 Type Approval Procedure

MTSP 030100-01 Track Geometry Maintenance Tolerances

4. Abbreviations

AS Australian Standard

CWR Continuous Welded Rail

ITP Inspection and Test Plans

MGT Million Gross Tonnes

MTM Metro Trains Melbourne

MTSP Metro Trains Specification

MURL Melbourne Underground Rail Loop

NAM Network Asset Manager

PTC Public Transport Corporation

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5. Definitions

Axle Load The gross load of a vehicle divided equally by the number of axles.

Bearer A transverse unit supporting rails.

Cast in Shoulder A component that prevents lateral movement of the rail foot and provides anchorage for the resilient fastening system.

Clip Spring steel component having an appropriate stiffness that, when installed, provides for sleeper and fastening assembly dimensional tolerances while providing a particular load upon the foot of the rail. Clips are installed in pairs, located each side of each rail on a sleeper.

Contractor Contractor shall include tenderer, manufacturer and supplier.

Insulator The component that fits between the shoulder, the foot of the rail and the clip. Insulators are installed in pairs.

Pad The component that is located between the foot of the rail and rail seat.

Principal: Principal shall mean MTM, and any successors thereof.

Rail Pad A part of the fastening that fits between the rail and the sleeper and acts to absorb impact, isolate electrically or protect components against abrasion.

Rail Seat The area on the top of the sleeper on which the rail or rail pad (if applicable) sits extending between the field and gauge shoulders.

Resilient Rail Fastening Assemblies

A fastening that provides a degree of elasticity between the sleeper and rail with the aim of avoiding the loosening of the fastening due to vibration, as well as enhancing the ability of the fastening system to resist longitudinal creep forces and buckling forces associated with continuously welded rail (CWR).

Shall Is to be interpreted as a requirement that is mandatory to achieve conformance to this specification.

Technical Representative

Shall mean a suitably qualified and experienced representative appointed by the Chief Engineer from MTM.

Toe Load The force in kilo Newtons (kN) applied on the rail foot by one clip of a pair acting through the insulator (where applicable).

6. Responsibilities

Contractors shall be responsible for conformance to this document.

The Technical Representative of MTM shall be responsible for the management of the technical requirements and ensure compliance in accordance with the MTM documented processes relevant to this specification.

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7. Safety and Environmental

The design and manufacture of Resilient Rail Fastening Assemblies shall consider the safe application and handling of fastening assemblies during installation and ensure the product is safe for use with no adverse impacts on the health and safety of workers who may come in contact with the product. As part of the Type Approval evaluation criteria the product will need to demonstrate that it is suitable for use within the environment. The product shall be free of any hazardous materials and the details of all components including any additives used in the manufacture of the fastening assemblies must be approved by MTM.

8. Design Requirements

8.1 General

Resilient Rail Fastening Assemblies shall be designed and manufactured to conform with all respects of AS 1085.19 (2003) and any other additional requirements as detailed in purchase orders, this specification and appendices. The design of these assemblies are required to achieve the performance requirements set out in Section 10 of this specification.

9. Design Management

9.1 Design

Resilient Rail Fastening Assemblies shall be designed and manufactured to ensure compatibility with existing resilient fastening assemblies used throughout the MTM network, for a list of MTM currently accepted fastenings refer Appendix 1.

The Contractor must prepare, at their own expense, all design drawings required for the manufacture and supply of the rail fastenings, including design drawings of each rail fastening assembly for timber and concrete sleepers and direct fixation. The Contractor shall forward one copy of each drawing to MTM. In the case of any amendments to these drawings the Contractor must provide MTM one copy of the revised drawing prior to the manufacture of the item.

The design shall be approved in writing by MTM prior to manufacture.

The Contractor shall bear full responsibility for the detailed design, accuracy, correctness, practicability and suitability of the manufacture and supply of the product. The Contractor shall provide a design report that details how they have conformed to the Performance Requirements set out in this Specification.

9.2 Drawings

MTM reserves the right, and will give reasonable notice, to request further information not contained or included in delivered drawings to ensure adequate description of supplied Resilient Rail Fastening Assemblies, in accordance with this specification.

The Supplier shall ensure that all pertinent information listed below has been included on the drawings.

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9.2.1 Drawings Layout Requirements – General

All Dimensions and their units in millimetres (mm)

All writing in English

Signatures provided by designer, reviewer and approver and signature dates

Drawing number and title

Drawing version number and details

Explanatory Notes

Supplier title block / name

A soft copy (preferably in Microstation format; DGN file type) and hard copy to be provided for each drawing

9.2.2 Resilient Rail Fastening Assembly Drawing Details & Requirements

The details shall include but not be limited to:

Fully dimensioned drawings showing all the required manufacturing tolerances of assemblies in respect of every component of the assembly and cast in pieces

Type and Grade of Steel

Details showing material compositions of all components

Method of identification of component parts

Branding description

List of conforming standards relevant to the above

9.3 Material

The Contractor shall be responsible for the purchase of all necessary materials for the supply of fastenings relevant to this specification.

Materials shall be new and of commercial quality, unless otherwise specified or approved in writing by MTM.

Steel shall comply in all aspects with either AS 1444 (2007) or AS 1447 (2007) as applicable.

All materials shall be free from defects and conform to the relevant Australian Standards.

The Contractor shall provide the relevant test reports and certificates of compliance for materials used in the manufacture of the resilient fastenings.

The Contractor shall ensure sufficient minimum stock of material to ensure continuity of manufacturing programs to meet MTM supply requirements.

9.3.1 Fastenings

The fastenings and cast-in inserts shall comply with Australian Standard AS 1085.19 – Resilient Fastening Systems.

The fastening shall be an elastic resilient fastening of a type that is internationally proven under operating conditions on a major railway system, or alternatively sound research information must be presented and prepared by an independent recognised institution indicating that the fastening system will meet all the requirements of this specification under simulated railway conditions.

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The fastenings shall be capable of withstanding repeated loading within the service conditions nominated, without fatigue or excessive maintenance of the fastening components including the “cast in” components.

The resilient fastenings assemblies must be compatible with other concrete sleepers currently in service on the MTM network. To allow the interchangability with existing fastening components, the location of the cast hook-in shoulders shall be positioned so the obvert of clip eye is 27mm from the base of the rail seat (top surface of sleeper). Refer to Drawing in Appendix 2.

Mechanical insertion and/or withdrawal should be practical and preference will be given to those fastenings for which a proven clip installation and removal machine or tool is available and in use in the MTM Network.

Fastenings that have not been previously accepted by MTM will have to undergo and meet the MTM Type Approval process.

The cast in components are to share a design life equal to that of the concrete sleepers they shall be used with.

9.3.2 Insulation (for use with concrete sleepers)

Insulation shall be used to prevent interference with the signalling systems and deterioration of the fastening system and concrete sleeper through electrical leakage. This requirement necessitates full insulation between rail and sleeper. The insulation or insulators used shall have a nominal service life of 20 years.

The insulator design shall be compatible with fastening components currently in service on the MTM network whilst not diminishing operational performance of the fastening assembly. As such, the toe pad thickness of the insulator shall be 8mm and the side post of the insulator shall be 8mm (for 53/60kg Rail). Refer to Drawing in Appendix 2.

9.3.3 Rail pads (for use with concrete sleepers)

The rail seat pad shall be manufactured from high density polyethylene, or other suitable material, and shall be designed so that it is self locating on the sleeper between the cast in shoulders of the LPCS. The pad shall be capable of transmitting the rail seat load of 215kN* to the sleepers. The rail pad design shall be compatible and interchangeable with fastening components currently in service on the MTM network. As such, thickness of the pad shall be 7.5mm. The nominal service life of the pads shall be 20 years. Refer to Drawing in Appendix 2.

Pads must possess sufficient edge stiffness to prevent the sleeper tilting (about its longitudinal axis) in order to resist longitudinal track forces arising from thermal expansion, contraction and rail creep.

*Note: 215kN is based on a 30 tonne axel load, multiplied by 10 m/s2, divided by 2 rail pads per sleeper, multiplied by a service factor of 2.5 and multiplied by a distribution factor of 0.57 (as per AS 1085.14 (2012) Section 3.3).

9.4 Manufacture

9.4.1 Dimension and Tolerances

The fastenings shall be manufactured and supplied in accordance with dimensions and tolerances as shown on the relevant drawings. Products supplied that do not conform to the required dimensions, may be rejected.

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9.4.2 Finish

The fastenings shall be free of surface defects, cracks or sharp die/tooling marks which are likely to initiate failure in service. Fastenings must be free of burrs which could cause injury when handled or could prevent efficient application during installation.

9.4.3 Coating

The fastenings must be supplied with a protective coating to prevent corrosion. The coating shall not comprise of any material which may pose a safety hazard or environmental risk. Coatings shall be capable of protecting fastening assemblies from conditions found in the MTM network. They shall not alter the dimensions of the fastening so that it is not compatible with other MTM track components.

9.4.4 Marking

Each fastening must be legibly and durably branded to identify the type and batch number of the manufacturing process. The brands shall be located on the underside of the fastening centre leg.

10. Performance Requirements

Rail fastenings shall be designed to meet the current and future operating conditions of the MTM network. This includes:

General Conditions Description / Detail

Rail Size Rail 47, 50, 53 and 60kg to AS 1085.1 (2002)

Minimum Curve Radius 120m

Maximum Cant Deficiency

85mm

Location of Clip Eye 27mm from top of sleeper to clip eye obvert (Refer to drawing in Appendix 2.)

Insulator Thickness For 53 /60 kg Rail ;

8mm – manufactured from fiber reinforced polyamide or other suitable material

For 47 /50 kg Rail;

17.5mm - manufactured from fiber reinforced polyamide or other suitable material

Rail pad Thickness For 47/ 50/ 53/ 60 kg Rail;

7.5mm - manufactured from high density polyethylene, or other suitable material. (Refer to drawing in Appendix 2.)

Type of Track & Configuration

1600mm gauge, 685mm sleeper spacing, concrete and timber sleepers with resilient type base plates. Refer MTSP 000003-01 Track Specification – Low Profile Concrete Sleepers.

TRACK SPECIFICATION





Design Criterion Description / Detail

Nominal Maximum Applied Cant

100mm

Maximum Track Grade 1 in 30 (3.33%)

Design Line Speed 160 km/hr 115 km/hr 100 km/hr

Design Axle Load 19 tonne 21 tonne 23 tonne

Vertical Design Wheel Load (concrete sleepers)

Refer AS 1085.14 (2012) Section 3.3

Rail Seating Inclination All running rails slope towards track centreline at 1 in 20 (5%)

Longitudinal Design Stresses

As specified by AS 1085.12 (2002) Table F1

Load Cycles per Annum1

3.5 Million

Annual Tonnage 20 MGT

Rail Clip Minimum Toe Load

10kN per clip

1Note: Figure based on axle passes of 6 car sets running at a headway of 5 minutes for 13 hours per day and 2 minutes for 6 hours per day.

10.1 Testing

Rail fastenings must undergo the relevant testing specified by AS 1085.19 (2003). The scope, details and results of testing must be provided by the Contractor.

It shall be the responsibility of the Contractor to determine the following parameters to be used in testing;

1. vertical component of the rail seat load

2. lateral component of the rail seat load

3. the offset of the line of application of the load.

The values shall reflect the performance requirements specified in Section 10. The parameters nominated by the Contractor shall be approved in writing by MTM.

The insert pull out load and insert torque test load shall be conducted as specified in AS 1085.14 (2012).

The Contractor must perform and maintain records of results for all inspection and testing operations to confirm that the rail fastenings are manufactured in accordance with this specification.

Inspection and Test Plans (ITP) must comply with AS 1085.14 (2012), specifically Section 2 Performance Requirements and Testing.

MTM reserves the right to perform compliance audits of the Contractor‘s Quality System and to undertake any or all of the inspection functions.

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10.1.1 Type Testing

In order to achieve compliance for type testing, products must comply with the following:

AS 1085.19 (2003)

o Appendix A – Guidance on Purchasing, Usage and Evaluation

10.1.2 Batch Testing

In order to achieve compliance for batch testing, products must comply with the following:

AS 1085.19 (2003)

o Appendix B – Means for Demonstrating Compliance with this Standard

o Appendix C – Resilient Fastening Assembly and Electrical Tests

o Appendix D – Resilient Fastening Assembly Lateral Load Restraint Test

o Appendix E – Resilient Fastening Assembly Longitudinal Restraint Test

o Appendix F – Resilient Fastening Assembly Uplift Test

o Appendix G – Resilient Fastening Assembly Repeated Load Test

o Appendix H – Clip Spring Rate and Toe Load Test

o Appendix I – Clip Fatigue Test

o Appendix J – Impact Test for Rail Pad Attenuation for Concrete

10.2 Supply

The Supplier shall be responsible for all the materials being supplied and their storage, loading and transport until they are properly stored at the delivery site and accepted by MTM in accordance with the terms specified in the purchase order/contract. Any materials not accepted by MTM after inspection shall be removed from the site by the Supplier at their own cost and such materials shall be replaced with acceptable materials by the Supplier at their own cost.

The point of handover and delivery site will be specified by the MTM Representative.

10.2.1 Handling, Packaging and Transport

The requirements for packaging will be stipulated in the relevant contract. This will be either;

a) Packaged in drums of 600 fastenings, 4 drums to a pallet (2400 fastenings per pallet),

b) Packaged in bags of 25, 48 bags per pallet (1200 fastenings per pallet), or

c) Any other packaging requirement specified in the contract

Each pallet shall weigh less than 1.7 tonnes.

Each package (drum/bag) and pallet shall be labelled clearly showing:

Manufacturer’s name

Certificate of compliance number

Batch Number

Schedule description of item and number of items per package

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MTM purchase order number

Provision shall be made when loading for dispatch to permit unloading by forklift or other suitable mechanical handling equipment.

Labels shall be durable and shall be able to withstand exterior weather conditions to ensure clear identification for a minimum period of 12 months.

11. Performance Measures and Reporting

11.1 Quality Assurance

The Contractor shall have in place a quality management system per AS/NZS ISO 9001 (2008).

The Contractor shall retain documents verifying the testing and compliance certification, as set out in AS 1085.19 (2003) and other relevant standards, for the manufacture of all components of each production batch of rail fastenings. These documents shall be available for review by MTM at or after the time of dispatch of a shipment of rail fastenings.

MTM reserves the right to perform compliance audits of the contractor quality system according to AS 1085.12 (2002) at a mutually agreed time.

11.1.1 ISO 9001 Quality Management System

The Supplier shall

a) Have a quality management system third party certified per AS/NZS ISO 9001 (2008), or

b) Be compliant with the requirements of AS/NZS ISO 9001 (2008).

11.1.2 Retention of Documents

The Supplier shall retain documents verifying the testing and compliance certification for the manufacture and supply of each production batch of Resilient Rail Fastening Assemblies. These documents shall be available for review by MTM’s Representative at or after the time of dispatch of shipment.

11.1.3 Certificate of Conformity

A Certificate of Conformity must be presented by the Supplier with the following statement attached:

“It is certified that the Supplies detailed hereon have been designed, manufactured, tested, inspected, quality controlled/quality assured and, unless otherwise stated above, are strictly in accordance with AS 1085.19 (2003) requirements, MTM specifications and proper packaging, marking and material use standards as specified in the Contract or Purchase Order. The required inspection, analysis and/or test records in compliance with the Contract or Purchase Order are traceable from this document and will be made available for review by MTM at mutually agreed times or as specified in the Contract or Purchase Order.”

It shall be signed by a senior contractor’s management representative such as Quality, Production or Manufacturing Manager.

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11.1.4 Audit of Supplier

Metro Trains Melbourne Pty Ltd or its appointed agent has the right to audit the Supplier at a mutually agreed time to ensure the Suppliers compliance to 11.1 Quality Assurance.

11.1.5 Provision of Records

The Contractor must retain records to confirm compliance with this specification and AS 1085.19 (2003). The Contractor shall provide details of records to MTM on request in the form of a soft and hard copy.

12. Type Approval

The Type Approval process will be in compliance with the MTM document ‘Type Approval Procedure’. It will consist of but not limited to testing performed by an independent qualified party and involve a review period involving sleepers used in-situ. The process will be regulated and approved by MTM’s Chief Engineer.

13. Related Documents

MTSP 000003-01 – Engineering Design Specification – Low Profile Concrete Sleepers

14. Appendices

14.1 Appendix 1 – Current List of MTM Accepted Fastening Systems

Pandrol Type E 2003 Clip – used on Concrete sleepers

Pandrol Type E 1821 Clip – used on Pandrol plated sleepers

Pandrol Type PR401A Fastener – used in the MURL

Pandrol Fastclip FE 1400 – Low Profile Concrete Sleepers

Pandrol Type E 1600 Clip; Concrete Sleeper Insulated Joints; Painted Blue, Brown, Yellow – Various sizes of clip used around IRJs

All clips are available in Standard or Corrosion Protection. Corrosion Protection is listed as appropriate for Wet Tunnels, Coastal Areas, Level Crossings and Areas adjacent to heavily salted roads and platforms.

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14.2 Appendix 2 – Typical Rail Fastening Detail

SUPPLY OF RESILIENT RAIL FASTENING ASSEMBLIES · SUPPLY OF RESILIENT RAIL FASTENING ASSEMBLIES ......

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