Engineering Specification Track MANUFACTURE AND SUPPLY OF INSULATED RAIL JOINTS Version: 2 Issued: December 2015 Owner: Engineering Division Approved By: Liam Palmer Cannon A/Head of Engineering Track and Structures PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
Approval Amendment Record Approval Date Version Description 14/05/2012 1 Initial issue under MTM. Based on and Supersedes PTC Technical Specification Manufacture and Supply of Railway Glued Insulated Joints, ENG-TE-SPE-4402. 02/12/2015 2 Document Corporate number amended to suit organisational structure, previously L1-NAM-SPE-002. Added a requirement to pre-stress fishbolt holes in rail by using the split sleeve expansion process. Amended the IRJ lengths to include 13.7m. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 11
Table of Contents 1 Purpose... 4 2 Scope... 4 3 Abbreviation... 4 4 Definitions... 4 5 Reference & Legislations... 5 6 Responsibilities... 5 7 Materials and Components... 5 7.1. Rail...6 7.1.1 Material Purchased from the Principal...6 7.2. Fishplates...6 7.3. Insulating End Post...6 7.4. Bolts and Nuts/Swage Fasteners...6 7.5. Rail Fishbolt Hole...7 8 Manufacture... 7 8.1. General...7 8.2. Length...7 8.3. Curvature...7 8.4. Manufacture Locations and Facilities...7 8.5. Marking...7 8.6. Adhesives...7 8.7. Rail Ends...7 9 Performance Requirements... 8 10 Testing... 8 11 Quality Assurance... 9 12 Supply... 9 12.1. Handling, Packaging and Transport...9 12.2. Delivery...9 13 Warranty... 9 14 Appendices... 9 Appendix A: Information to be provided by the Superintendent... 10 Appendix B: Material which may be purchased from the Principal... 11 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 11
1 Purpose This specification sets out the material, manufacture and supply requirements for insulated rail joints used for railway track work. 2 Scope This specification is applicable to factory pre-assembled and field assembled insulated joints and covers both glued and mechanical joints. This specification applies to items manufactured for rail tracks controlled by the Principal. This specification is not applicable to non-insulated joints. 3 Abbreviation AS IRJ MGT MTM PTC Australian Standard Insulated Rail Joint Million Gross Tonne Metro Trains Melbourne Pty Limited Public Transport Corporation 4 Definitions Contractor: Principal: Shall Superintendent: Contractor shall include tenderer, manufacturer and supplier. Principal shall mean MTM, and any successors thereof. Is to be interpreted as a requirement that is mandatory to achieve conformance to this specification. Superintendent shall mean the Principal's representative. The term shall include the appointed representative of the Superintendent. Technical Representative Shall mean a suitably qualified and experienced representative appointed by the MTM. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 11
5 Reference & Legislations The following documents are referenced by this specification. AS1085.1-2002 AS1085.2-2002 AS1085.4-2002 AS1085.12-2002 AS1085.14-2003 AS/NZS 1252-1996 Railway Track Material - Steel Rails Railway Track Material - Fishplates Railway Track Material - Fishbolts and Nuts Railway Track Material - Insulated Joint Assemblies Railway Track Material - Prestressed Concrete Sleepers High strength steel bolts with associated nuts and washers for structural engineering AS/NZS ISO 9001 2008/Amdt 1:2012 Quality management systems Requirements ENG-TE-SPE-4301 PTC Infrastructure Specification Manufacture and Supply of Steel Rails (or any document which supersedes this) 6 Responsibilities Contractors shall be responsible for conformance to this document. The Superintendent shall be responsible for ensuring that all works are carried out in compliance with this specification. The Technical Representative of MTM shall be responsible for all technical matters, including Quality Assurance. 7 Materials and Components Insulated joints shall be designed and manufactured to conform in all respects with AS 1085.12 2002 and additional requirements as detailed in this specification, Appendices and orders. The insulated rail joint shall provide an electrical break in the rail for signalling purposes. It shall consist of two lengths of rail rigidly joined by a pair of fishplates, insulating material, an insulating end post separating the two rails, six high strength fasteners and other hardware, such as washers, ferrules and bushes. The Contractor shall be responsible for the purchase of all necessary material for the works of this specification. Material shall be new and of commercial quality, unless otherwise specified or approved in writing. All materials shall be free from defects and conform to the relevant Australian Standards. All scrap material and material damaged during manufacture shall remain the property of the Contractor. The Contractor shall ensure sufficient minimum stock of material to ensure continuity of manufacturing programs. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 11
7.1. Rail Section 7.1 is not applicable for field assembled joints. Rail can be purchased from the principal as shown in Appendix B. Rail which is not purchased from the Principal must conform to PTC Infrastructure Specification Manufacture and Supply of Steel Rails. Rail must be in accordance with AS1085.1 2002 and AS.1085.12 2002 and shall be free from defects considered detrimental to service requirements. Certificate of Conformance shall be provided upon request. Rail shall not be head hardened unless specified. Head hardening of 50kg, 53kg and 60kg rails shall be in accordance with AS1085.12 2002. 47kg rail shall not be head hardened. Rails with a cross-section other than specified in AS 1085.1 2002 shall be supplied only with the written approval of the Superintendant, for use in areas with heavily worn rail. 7.1.1 Material Purchased from the Principal 7.2. Fishplates Material purchased from the Principal shall be used exclusively for the works of this service except for scrap and damaged material. The Contractor shall order this material in writing, through the Superintendent. The Contractor shall arrange and shall be responsible for the cost of delivery of the material from the Principal's supply depot, to his works. All material supplied by the Principal and found to be defective shall be returned to the Principal for credit or replacement, as arranged with the Superintendent. The Contractor shall be responsible for advising the Superintendent of any defective material at the earliest detectable stage of production. The Superintendent shall authorise all material credits or returns. The transport cost of material returns and re-delivery shall be borne by the Principal, as arranged with the Superintendent. Fishplates shall be of the six hole bar type and conform to the general requirements of AS.1085.2 2002. When fixed in position, fishplates shall be capable of supporting and transferring all loadings between rails without relative movement between the rails and fishplates. 7.3. Insulating End Post The profile of the end post shall be in accordance with AS 1085.12 2002. The thickness shall be 6.0mm, with a tolerance of +1/-0 mm. For insulated joints that are manufactured from part worn rail, the profile of the end post is to be modified to conform to the worn rail section. 7.4. Bolts and Nuts/Swage Fasteners Standard M24 fishbolts with anti-back-off washers shall be used. These shall comply with AS1085.4 2002 and AS/NZS.1252 1996. If swage fasteners are used, they shall be C50L type, M24mm high grade. Alternative fasteners may be used with the written permission of the superintendent. New fasteners may be subject to MTM Type Approval or Standard Waiver process PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 11
7.5. Rail Fishbolt Hole Fishbolt holes in rail must be pre-stressed during the manufacturing of new Insulated Rail Joints by using the split sleeve cold expansion process. Field assembled Insulated Rail Joints shall be pre-stressed as directed by the Track Infrastructure Delivery Manager. 8 Manufacture 8.1. General Pre-assembled glued joints shall be Grade A or Grade B in accordance with AS 1085.12 2002. The grade shall be specified by the Principal but would normally be Grade A for main lines and Grade B for sidings. 8.2. Length The preferred overall length of pre-assembled joints shall be 13.7 metres. The procurement and installation of any shortened IRJs (i.e. 4.5m or 6.8m) shall be approved by the Track Infrastructure Delivery Manager. The tolerance allowed on manufacture shall be -0 + 150 mm. 8.3. Curvature Pre-assembled glued joints shall not be curved unless specified by the Superintendant. Where ordered joints are for turnout replacement they shall be curved to meet the specifications for the turnout. 8.4. Manufacture Locations and Facilities The Contractor shall advise the Superintendent in writing of the proposed manufacturing locations and of any change of locations of works. 8.5. Marking Each joint shall be clearly labelled on the web of one rail so that the label is totally contained within 150 mm from the fishplate or on one fishplate as approved by the Superintendent. Labels shall otherwise conform to Clause 8 of AS 1085.12 2002. 8.6. Adhesives Adhesive materials utilised shall be applied strictly in accordance with the adhesive manufacturer's written instructions. A copy of the instructions shall be provided to the Superintendent upon request. 8.7. Rail Ends For factory assembled joints, rail shall be cut at 15 degrees to the right angle of the longitudinal axis (See Figure 1). PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 11
Figure 1: Rail End Angle Field assembled joints shall be cut at the right angle of the longitudinal axis. The rail insulating end post shall be located centrally to the fishplate. The fishplate shall be located centrally to the joint assembly unless otherwise specified. 9 Performance Requirements IRJs shall be designed to meet the operating conditions of the MTM network. This includes: a. Maximum axle load: 30 tonnes b. Design impact loads shall be taken as 150% of the static load, as specified by AS 1085.14-2003 clause 4.2.1.2 c. Minimum curve radius: 120 metres d. Maximum track speed: 160 km/hr e. Type of track and configuration: 1600mm gauge, 685mm sleeper spacing, concrete and timber sleepers. f. Rail cant: all running rails slope towards track centreline at 1 in 20, up to 100mm extra cant can be applied g. Maximum grade:1 in 30 h. Longitudinal stresses are to be as specified by AS1085.12 2002 Table F1. i. 3.5 million load cycles per annum 1 j. Design annual tonnage: 35MGT 10 Testing Testing shall be carried out as specified in AS1085.12-2002. Electrical Testing shall be carried out for each joint as per AS1085.12-2002 Appendix C. Head Hardness Testing shall be carried out for 1 in 10 head hardened joints as per AS1085.12-2002 Appendix H. Joint Curvature and Alignment shall be measured on delivery to the tolerances specified in the order. Tangent joints must comply with Table 1 of AS1085.12-2002. All other testing as specified by AS1085.12-2002 shall be undertaken. 1 Based on axle passes of 7 car sets running at a headway of 5 minutes for 13 hours per day & 2 minutes for 6 hours per day PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 11
11 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 at AS 1085.12 2002 and other relevant standards, for the manufacture of all components of each production batch of insulated joints. These documents shall be available for review by the Superintendant at or after the time of dispatch of a shipment of insulated joints. The Superintendent reserves the right to perform compliance audits of the contractor quality system according to AS 1085.12 at a mutually agreed time. 12 Supply 12.1. Handling, Packaging and Transport The Contractor shall take care to avoid bending and/or distortion of components by ensuring that material is adequately supported and braced at all stages of manufacture, handling and transportation. All items for dispatch shall be adequately packaged to ensure that no damage or loss occurs during handling and transit. Provision shall be made when loading for dispatch to permit unloading by forklift or other suitable mechanical handling equipment. Each consignment shall be labelled with the order number, stock code number, general description and quantity. 12.2. Delivery The insulated joints shall be delivered free into the nominated store. Each joint shall be inspected by the Superintendent or Technical Representative on delivery. Geometric measurements will be made to ensure the joints are as specified. Further inspection and/or testing may be undertaken at the request of the Superintendent or Technical Representative to ensure compliance with this specification and other specified criteria in the Purchase Order. Delivery shall be deemed to be provisional until the Superintendent certifies that the whole of this service is in accordance with this specification and its associated documents and is in every respect to his/her satisfaction. 13 Warranty The Contractor shall be responsible for the total labour and material cost of in-track replacement of and joint which fails due to faulty workmanship or material, except for rails, within the first two (2) years of service life. 14 Appendices Appendix A: Information to be provided by the Superintendent Appendix B: Material which may be purchased from the Principal Rail PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 11
Appendix A: Information to be provided by the Superintendent The following shall be supplied to the contractor by the superintendent as per Appendix B of AS1085.12 2002. a) Designation of insulted joint assembly... Order Specific 2 b) Grade and Type of joint required... Order Specific, Clause 8.1 c) Nominal rail size and type... Order Specific, Clause 7.1 d) Number and Type of Swage Fasteners/Bolts... Clause 7.2 & 7.4 e) If Applicable; i. Length of the assembled insulated joint,... Order Specific, Clause 8.2 ii. Tolerance of the assembled insulated joint,... Clause 8.2 iii. Location and disposition of rail separation... Clause 8.7 f) Thickness of rail end post... Clause 7.3 g) Details of curvature, and tolerances if assembled joints are not straight... Order Specific, Clause 8.3 h) Drawings of rail to sleeper fastening assembly, including required clearances and sleeper spacing, and any other relevant details...order Specific i) Any special or supplementary requirements...order Specific In addition to this, the superintendant shall advise j) If an inspection is required at the Contractor's works prior to despatch. k) The purchase rate for items which may be purchased from the Principal. l) Delivery requirements. 2 Insulated joints shall be specified by grade, type and size of rail, e.g., Grade A1, factory-assembled bonded insulated joint in accordance with AS 1085.12 for 50 kg rail. AS1085.12 2002 Clause 6 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 11
Appendix B: Material which may be purchased from the Principal Rails, 60 kg, (with undrilled ends) - 13.72m lengths Rails, 53 kg, (with undrilled ends) - 13.72m lengths Rails, 50 kg, (with undrilled ends) - 13.72m lengths Rails, 47 kg, serviceable PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 11