You are on page 1of 17

ISRAEL RAILWAYS LTD

INFRASTRUCTURE DIVISION
TRACK AND RIGHT OF WAY DEPARTMENT

Technical Specification

of

Rail Fastening System W14 and


Suitable Components,
(for Universal Monoblock Concrete Sleepers)

No. E-01-802

January 2010
Rail Fastening System W14 and Suitable Components

Contents
1. SCOPE 3

2. ISRAEL RAILWAYS TRACK SUPERSTRUCTURE 3

3. ISRAEL RAILWAYS TRACK LOAD 4

4. ISRAEL CLIMATE AND ENVIRONNEMENTAL CONDITIONS 4

5. RAIL FASTENING SYSTEM W14 - GENERAL REQUIREMENTS 5

6. RAIL FASTENING SYSTEM W14 DRAWINGS 6

7. RAIL FASTENING COMPONENTS - REQUIREMENTS 6

7.1 TENSION CLAMPS 6

7.2 ANGLED GUIDE PLATES 8

7.3 SLEEPER SCREWS 10

7.4 SLEEPER SCREWS 11

7.5 HEIGHT ADJUSTMENT PLATE 12

8. RAIL FASTENING SYSTEM W14 - TESTS AND INSPECTION 13

9. LIST OF DOCUMENTS TO SUBBMIT WITH PROPOSAL 14

10. LIST OF DOCUMENTS TO SUBBMIT TO INSPECTOR 15

11. RAIL FASTENING SYSTEM W14 - PACKING 15


12. WARRANTY 16
APPENDIX A - UNIVERSAL MONOBLOCK CONCERETE SLEEPER 17
APPENDIXES B-H - COMPONENTS SKETCHES
APPENDIX B1 - RAIL FASTENING W14 SYSTEMS FOR UIC60-E1 RAILS 18
APPENDIX B2 - RAIL FASTENING W14 SYSTEMS FOR UIC54-E1 RAILS 19
APPENDIX B3 - RAIL FASTENING W14 SYSTEMS FOR U50 RAILS 20
APPENDIX C1 - TENSION CLAMP SKL14 21
APPENDIX C2 - TENSION CLAMP SKL14/92/10 22
APPENDIX C3 - TENSION CLAMP SKL1 23
APPENDIX D1 - ANGLED GUIDE PLATES Wfp 14K FOR UIC60-E1 RAILS 24
APPENDIX D2 - ANGLED GUIDE PLATES Wfp 14K FOR UIC54-E1 RAILS 25
APPENDIX D3 - ANGLED GUIDE PLATES Wfp 14K FOR U50 RAILS 26

1
Rail Fastening System W14 and Suitable Components

APPENDIX E - SLEEPER SCREW Ss25 WITH WASHER Uls7 28


APPENDIX F - WASHER Uls7 29
APPENDIX G1 - RAIL SEAT PAD ZW700/148/165 FOR UIC60-E1 RAILS 30
APPENDIX G2 - RAIL SEAT PAD ZW700/138/165 FOR UIC54-E1 & U50 31
RAILS
APPENDIX H HEIGHT ADJUSTMENT PLATE 32

2
Rail Fastening System W14 and Suitable Components

1. SCOPE
1.1 This technical specification pertains to the manufacture and supply
of elastic rail fastening system w14 and suitable components for
universal monoblock concrete sleeper and different rail types.

1.2 The rail fastening system W14 shall provide support, guidance,
resilience and insulation between rail and sleeper.

1.3 The main components of the rail fastening system W14 shall be:
Tension clamps;
Angled guide plates;
Sleeper screws;
Rail seat pads;
Height adjustment plates.

1.4 The rail fastening system shall be a direct fastening of screwed type
without base plate, simple to install, capable of easy visual
inspection.

1.5 This technical specification doesn't include manufacture and supply


of plastic dowels (which are supplied to ISR separately already
inside the universal monoblock concrete sleepers).

2. ISRAEL RAILWAYS TRACK SUPERSTRUCTURE


2.1 Rails on main line are continuous welded. Some track sections in
main lines are fishplated.

2.2 Rail types: U50, UIC54-E1, UIC60-E1 in accordance with


EN13674-1:2003+A1:2007.

2.3 Standard track gauge: 1435 mm (-2, +5).

2.4 Gauge widening in tight curves: Up to +15 mm.

2.5 Rails inclination: 1:30.

2.6 Type of sleepers: Universal monoblock concrete sleeper, (suitable


for installation of rails types U50, UIC54-E1, UIC60-E1), see
appendix A.

3
Rail Fastening System W14 and Suitable Components

2.7 Minimum number of sleepers of one km of track: 1667.


2.8 Minimum horizontal curve radius:
a. Main line: 141 m.
b. Secondary line: 120 m.

2.9 S-Curve: In some lines there are S-curves with short tangent section
(6 m) and there are some without tangent.

2.10 Minimum vertical curve: 3000 m.

2.11 Vertical geometry: Maximum gradient 30.

2.12 Maximum cross level (superelevation): 150 mm.

3. ISRAEL RAILWAYS TRACK LOAD


3.1 Maximum axle load: 22.5 ton.

3.2 Maximum traffic speed: 160 km/h.

3.3 Potential traffic load: 20 MGT per year.

4. ISRAEL CLIMATE AND ENVIRONNEMENTAL


CONDITIONS
4.1 Climate and environmental conditions
Maximum ambient temperature 50 C (shade)
Minimum ambient temperature -5 C
Relative humidity 10% to 90%
Altitude -400 m to +800 m
Sunny 3300 hours per year
UV Radiation 360-600 MJ/m per year
Rainfall 400-800 mm/year

4.2 Dust conditions in the atmosphere


Maximum half hour Maximum daily Average
value* value*
NOx 1064 560 71
SO2 780 260 21
O3 312 143 84
Suspended Dust - 350 100
*(Microgram per m atmosphere)

4
Rail Fastening System W14 and Suitable Components

4.3 Suspended particulate matter (SPM)


Particle size to 0.5-1 micron

4.4 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 m atmosphere)

5. RAIL FASTENING SYSTEM W14 - GENERAL


REQUIREMENTS
5.1 The manufacturer shall ensure that the Rail Fastening System W14
and Suitable Components supplied comply with requirements of EN
13481-2:2002 +A1:2006.

5.2 The Rail Fastening System W14 and Suitable Components tests
shall be accomplished according EN 13146 parts 1-8, UIC 864-
1:1982, UIC 864-5:1986. Tests procedure shall be applied to a
complete fastening assembly and to the components according to the
relevant standards.

5.3 The Rail Fastening System W14 and Suitable Components shall
meet the following requirements:
Longitudinal rail restraint greater than 9kN;
attenuation of impact loads greater than 30%;
Electrical resistance greater 5 k;
Clamping force greater than 9 kN per tension set;
Clamping force equal or greater than 18 kN per rail set;
Static stiffness of rail seat pads Cstat= 6010 kN/mm.

5.4 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.

5.5 The inspection and acceptance of Rail Fastening System W14 and
Suitable Components will be performed be ISR representative, an
authorized company (inspector), according to ISR instructions.

5
Rail Fastening System W14 and Suitable Components

6. RAIL FASTENING SYSTEM W14 DRAWINGS


6.1 The manufacturer shall submit, together with his proposal, a
complete set of Rail Fastening System W14 and Suitable
Components of the technical specification and manufacturing
drawings with dimensions, tolerances material type, coating
description and heat treatment, etc. which shall be based on the
provided appendixes A,B and sketches in appendixes C-I.

6.2 The manufacturer shall submit, together with his proposal, drawings
of the assembled unit (the interface between the fastening
accessories and the sleeper), for each rail type based on the provided
sketch in appendixes C1, C2, C3 the drawings shall be included
with:
a. The external gauge point of rail fastening system which defines
the track gauge;
b. The dimension and the tolerance between internal and external
gauge points for the rail section for which the fastening
assembly is designed;
c. Drawing with dimensions and tolerances of every components
of the fastening system;
d. The nominal inclination of the rail seat.

6.3 The Rail Fastening System W14 and Suitable Components overall
dimensions shall be designed to avoid interface with vehicles
including track maintenance vehicles according to EN13481-2:2002
paragraph 5.7.

6.4 The manufacturer shall submit calculations to show the maximum


variation in static track gauge which can arise from the fastening
system. The calculations shall be based on the nominal of the rail
section given in EN 13674-1:2003+A1:2007 and shall include any
assumption about the position of the rail within the fastening
assembly and the tolerances on all component parts of the fastening
system. The variation in track gauge, calculated in this way, shall
not exceed 1 mm.

7. RAIL FASTENING COMPONENTS - REQUIREMENTS


7.1 Tension clamps
7.1.a Tension clamps General
The assembled rail fastening system W14 (for each sleeper) shall
include 4 tension clamps of the one of the following types:

6
Rail Fastening System W14 and Suitable Components

Type SKL14 for UIC 60-E1 rails, see sketch in appendix D1;
Type SKL14/92/10 for UIC 54-E1 and U50 rails, see sketch in
appendix D2;
Type SKL1 for fastening sleepers to insulated rails, see sketch
in appendix D3.

7.1.b Tension Clamps - Characteristics


The tension clamp raw material shall be from alloy Silicone-
manganese spring steel according EN 10089:2002 or equivalent with
the following chemical composition:
0.35 C% 0.42
1.5 Si% 1.8
0.5 Mn% 0.8
S% 0.025
P% 0.025

The tension clamps shall be heat treated to achieve a surface


hardness in the range 400-460 Vickers 30 according ISO 6507:2005
or equivalent. It shall be free from surface and internal defects.

The tension clamps mounted on rail must achieve a clamping force


of approx. 2x9kN = 18 kN per rail seat with a spring deflection of
not less than 12 mm.

After a vertical loading of one tension clamp with 25 kN and a


release of 4 mm a test load of minimum 5.5 kN shall remain.

Dynamic requirements of each spring element in final assembly


position minimum 5 million load cycles with an oscillation
amplitude of minimum 2 mm.

The tension clamps shall be provided with protective coating.

7.1.c Tension Clamps - Tests and Inspection


For every order of less than, or equal to 40,000 tension clamps the
manufacturer shall submit testing certificates of dimensions,
strength, surface and structure.
For orders greater than 40,000 tension clamps the manufacturer need
to submit for every batch of up to 40,000 tension clamps certificates
of testing for dimensions, strength, surface and structure.

7
Rail Fastening System W14 and Suitable Components

7.2 Angled guide plates


7.2.a Angled Guide Plates General
The assembled rail fastening system W14 (for each sleeper) shall
include 4 angled guide plates of the following types:
Type Wfp 14K-14.5 on field side and type Wfp 14K-9.5 on
gauge side for UIC60-E1 rails, see sketch in appendix E1;
Type Wfp 14K-20.9 on field side and type Wfp 14K-13.1 on
gauge side for UIC54-E1 rails, see sketch in appendix E2;
Type Wfp 14K-23.6 on field side and type Wfp 14K-10.4 on
gauge side for U50 rails, see sketch in appendix E3.

In additional, angled guide plates shall be manufactured with other


different dimensions to enable changing the gauge widening in tight
curves, from 1436 mm till 1450 mm, for UIC60-E1 and UIC54-E1
rails, according to the following types:

Angled guide plates for UIC60-E1 rails, see sketch in appendix E1:
Type Wfp 14K-7;
Type Wfp 14K-8;
Type Wfp 14K-9;
Type Wfp 14K-9.5
Type Wfp 14K-10;
Type Wfp 14K-11;
Type Wfp 14K-12;
Type Wfp 14K-13;
Type Wfp 14K-14;
Type Wfp 14K-14.5;
Type Wfp 14K-15;
Type Wfp 14K-16;
Type Wfp 14K-17.

Angled guide plates for UIC54-E1 rails, see sketch in appendix E2:
Type Wfp 14K-12.9;
Type Wfp 14K-13.1;
Type Wfp 14K-13.9;
Type Wfp 14K-14.1;
Type Wfp 14K-14.9;
Type Wfp 14K-15.1;
Type Wfp 14K-15.9;
Type Wfp 14K-16.1;

8
Rail Fastening System W14 and Suitable Components

Type Wfp 14K-16.9;


Type Wfp 14K-17.1;
Type Wfp 14K-17.9;
Type Wfp 14K-18.1;
Type Wfp 14K-18.9;
Type Wfp 14K-19.1;
Type Wfp 14K-19.9;
Type Wfp 14K-20.1;
Type Wfp 14K-20.9;
Type Wfp 14K-21.1.

7.2.b Angled Guide Rail - Characteristics


The angled guide rail material shall be made from Polyamide 6/6.6
with approximately 50% fiberglass reinforcement and resistance to
ultraviolet radiation or equivalent material with the same physical
properties.

The angled guide rail material impact strength shall be greater than
40 kJ/m2 according EN ISO 179.

The angled guide rail material density shall be 1.35 1.45 g/cm3
according with EN ISO 1183-1.

The angled guide rail material moisture contents shall be 1%-2.5%.

The angled guide rail material volume resistivety shall be greater


than 108 Ohmcm according with IEC 60093 / IEC 60167.

Tensile strength at maximum force shall be greater than 110 N/mm2,


in accordance with EN ISO 527-2.

Elongation at maximum force shall be greater than 3%, in


accordance with EN ISO 527-2.

The angled guide rail surface must be free of cracks and damages
affecting performances.
7.2.c Angled Guide Plates - Tests And Inspection
For every order of less than, or equal to 40,000 angled guide plates
parts the manufacturer shall submit testing certificates of dimensions,
material density, viscosity, moisture and glass content, volume
resistivety and surface.

9
Rail Fastening System W14 and Suitable Components

For orders greater than 40,000 angled guide plates parts the
manufacturer need to submit for every batch of up to 40,000 angled
guide plates parts certificates of testing for material density,
viscosity, moisture and glass content, volume and surface resistivity.

7.2.d Angled Guide Plates - Marking


The angled guide plates for standard gauge which will be used on
the gauge side (type Wfp 14K 9.5, type Wfp 14K 10.4, type Wfp
14K 13.1) shall be marked with white line.

7.3 Sleeper Screws


7.3.a Sleeper Screws General
The assembled rail fastening system (for each sleeper) shall include
4 sleeper screws with assembled washers of the following type:
Sleeper screw type Ss25 with assembled washer, see sketch in
appendix F.
Washer type Uls7, see sketch in appendix G.

7.3.b Sleeper Screws - Characteristics


The sleeper screws material quality manufacturing and acceptance
conditions shall be according UIC 864-1 O: 1982.

The sleeper screws shall be manufactured from single piece, without


welding. Their head shall be formed by hot-working from the bar-
stock.

The sleeper screws steel category shall be according EN 10139 or


EN 10025.

The sleeper screws tensile strength shall be greater than 500 N/mm2.
The sleeper screws elongation shall be greater than 20%.

The sleeper screws limit of elasticity shall be greater than 300


N/mm2.

The sleeper screws and the washers shall be galvanized. The sleeper
screws and thw washers must be free from any trace of grease, paint,
etc. before the galvanization.

The complete surface of the sleeper screws shall be suitably


trimmed. Care shall be taken to ensure that trimming does not give

10
Rail Fastening System W14 and Suitable Components

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 sleeper screws are stripped or if there is a lack of material in
their shank, they shall not be accepted.

7.3.c Sleeper Screws - Tests and Inspection


The sleeper screws manufacturer must be in position to carry out all
the tests and inspection prescribed in UIC 864-1:1982.

For every order of less than, or equal to 40,000 sleeper screws the
manufacturer submit testing and inspection certificates.
For orders greater than 40,000 sleeper screws the manufacturer need
to submit certificate for every batch of up to 40,000 sleeper screws.

For every order of less than, or equal to 40,000 sleeper screws the
manufacturer shall submit certificates of galvanization.
For orders greater than 40,000 sleeper screws the manufacturer need
to submit certificate of galvanization for every batch of up to 40,000
sleeper screws.

7.4 Rail Seat Pads


7.4.a Rail Seat Pads - General
The assembled rail fastening system (for each sleeper) shall include
2 rail seat pads of the following types (depend on the rail type):
Type Zw700/148/165 for UIC60-E1 rails, see sketch in
appendix H1;
Type Zw700/138/165 for UIC54-E1 and U50 rails, see sketch
in appendix H2;

7.4.b Rail Seat Pads - Characteristics


The rail seat pads material shall be manufactured from TPU
(Thermoplastic Polyurethanes) and shall be design to achieve rail
deflection of approximately 1 mm and more.
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 82-90 shore A in accordance with EN
ISO868:2003.

11
Rail Fastening System W14 and Suitable Components

The rail seat pads density shall be 1.13-1.17 g/cm3 in accordance


with EN ISO 1183.

The rail seat pads static stiffness shall be Cstat= 6010 kN/mm.

The rail seat pads shall have a soft dynamic stiffness < 100 MN/m.

The rail seat pads electrical volume resistivety shall be greater than
108 Ohmcm according with IEC 60093 / IEC 60167.

The surface shall be free of cracks and damages affecting


performances.

7.4.c Rail Seat Pads - Tests and Inspection


The rail seat pads shall be subjected to the tests and inspection
specified in UIC 864-5:1986.

The rail seat pads dynamic stiffness shall be measured accordance


with EN13481-2:2002 annex B.

For every order of less than, or equal to 40,000 rail seat pads the
manufacturer shall submit testing and inspection certificates
according UIC 864-5:1986.
For orders greater than 40,000 rail seat pads the manufacturer need
to submit for every batch of up to 40,000 rail seat pads certificates of
testing and inspection according UIC 864-5:1986.

7.5 Height Adjustment Plate


7.5.a Height Adjustment Plate General
Height adjustment plate needed for eliminating track surface defects.

The height adjustment plate shall the following types, see sketch in
appendix I:
Type Hap140-2;
Type Hap140-4;
Type Hap140-6;
Type Hap140-8;
Type Hap150-2;
Type Hap150-4;
Type Hap150-6;
Type Hap150-8.

12
Rail Fastening System W14 and Suitable Components

7.5.b Height Adjustment Plate Characteristics


The height adjustment plate shall be manufactured from HDPE
(High Density Poly Ethylene) and shall be stabilized against light /
UV damage.

The surface must be free from cracks and damages affecting


performance.

The height adjustment plate shall have approx. 65 Shore - D in


accordance with DIN 53505.

The height adjustment plate shall have (MFR 190/2.16)3.1-18 g/10


minimum in accordance with DIN ISO 1133:2005.

The height adjustment plate shall have density of 0.940-0.960 g/cm3


in accordance with EN ISO 1183.

The height adjustment plate electrical volume resistivety shall be


greater than 108 Ohmcm according with IEC 60093/IEC 60167.

7.5.c Height Adjustment Plate - Tests and Inspection


For every order of less than, or equal to 40,000 height adjustment
plates the manufacturer shall submit testing and inspection
certificates.

For orders greater than 40,000 height adjustment plates the


manufacturer need to submit for every batch of up to 40,000 height
adjustment plate certificates of testing and inspection.

8. THE RAIL FASTENING SYSTEM W14 TEST AND


INSPECTION
8.1 The preparation of the test pieces and the tests shall be the
responsibility of the supplier, who shall place the necessary staff and
equipment. The parts or materials submitted for testing or inspection
shall not be debited to ISR, except in the case of parts used for the
dimensional inspection and found to be satisfactory.

8.2 The supplier shall check the manufactured rail fastening system
W14 as an assembled unit according to EN13481-2:2002 paragraphs
5.1-5.10 and EN13146:2002 parts 1-8, and submit the relevant
certificates to ISR and the inspector.

13
Rail Fastening System W14 and Suitable Components

8.3 The assembly dynamic stiffness shall be measured in accordance


with EN13481-5:2002 annex B.

8.4 The following measurement shall be performed before and after


repeated loading. The change in performance shall not exceed the
values shown:
Longitudinal rail restraint (EN 13146-1) change 20%;
Vertical stiffness (EN 13146-4) change 25%;
Clamping force (EN 13146-7) change 20%.

8.5 The supplier shall submit approval testing, of his rail fastening
system W14 as an assembled unit, provided by the organization
commissioning according to 13481-2:2002 paragraph 6.

9. LIST OF DOCUMENTS TO BE SUBMITTED WITH


BIDDER'S PROPOSAL
9.1 The manufacturer shall submit 3 hard copies and also magnetic copy
of all the drawings pointed out in paragraph 6 above.

9.2 The manufacturer shall add to the drawings hard copies and
magnetic copy the relevant technical descriptions of every
component.

9.3 The manufacturer shall submit calculations to show the maximum


variation in static track gauge which can arise from the fastening
system pointed out in paragraph 6.4.

9.4 The manufacturer shall notify ISR which standard and process
description will be used for carrying out the relevant tests.

9.5 The manufacturer shall state the nature and main characteristics of
the steel making process.

9.6 The manufacturer shall submit to ISR certificate that the non-
metallic materials comply with the requirements.

9.7 The manufacturer shall submit ISR hard copy and also magnetic
copy of installation and maintenance manuals.

14
Rail Fastening System W14 and Suitable Components

10. LIST OF DOCUMENTS TO SUBBMIT TO INSPECTOR


10.1 The manufacturer shall submit copies of all the drawings pointed out
in paragraph 3 above.

10.2 The manufacturer shall add to the drawings the relevant technical
descriptions of the sleeper and all fastening accessory components,
and certificate for sleepers steel type.

10.3 The manufacturer shall notify which standard and process


description will be used for carried out tensile and bend tests on steel
casts and test reports.

10.4 The manufacturer shall state the nature and main characteristics of
the steel making process.

10.5 The manufacturer shall submit a certificate confirming that the non-
metallic materials comply with the requirements.

11. PACKING
11.1 Each rail fastening components shall be packed separately.
Metal components shall be packed in wooden boxes tied by metal
bands.
Non-metallic components shall be packed in carton boxes fastened
to one another with plastic nylon. They shall be tied to wooden
platform by plastic bands.
The dimensions of the wooden and the carton boxes shall be
according to EN standard, to enable maximum effective storage
capacity in containers.
It shall be possible to put at least 3 wooden boxes one on the other.
It shall be possible to put at least 2 carton boxes one on the other.

Each package gross weight shall not exceed 1 tone.

Each package shall be labeled with the following details:


- Component name and type;
- Production batch number;
- date of manufacture;
- Component barcode;
- Component quantity in box;
- Gross and net weight;
- Manufacturer recognition number or name;

15
Rail Fastening System W14 and Suitable Components

- ISR recognition number;


- 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).

11.2 The following marks shall be shown on the upper surface of the
components in permanently legible embossed characters formed
during manufacture:
- The supplier mark;
- The last two figures of the year delivery;
- The type identification mark.

11.3 Each order shall be delivered with certificate that the components
has manufactured according to drawing submitted.

12. WARRANTY
12.1 The manufacturer shall bear full responsibility for all and every
damage and loss to the scope of supply of rail fastening system w14.
and/or suitable components due to faults (including errors and
omissions) of and/or in the scope of supply and any of its sub
contractor(s), normal wear and tear excluded, for a period of 36
months from the delivery date or 24 months from the installation
date, whichever period is shorter.

16

You might also like