Overbygning/Limte isolerte skjøter med stållasker

< Overbygning

1 Purpose

This specification sets out objective requirements concerning the units to be supplied, to enable suppliers to design, manufacture, inspect and deliver a product that meets the expectations of Bane NOR.

2 Scope

This specification consists of requirements concerning the design, production and inspection of prefabricated insulated rail joints for use on the Bane NOR network.

This specification applies to joints made for the following rail profiles (EN 13674-1):

  • 49E1
  • 54E3
  • 60E1

3 Functional requirements

3.1 General requirements

  • Insulated rail joints shall be capable of separating track circuits for signalling purposes and to create breaks between sections in the return path for traction current.
  • The joints must form a connection between the rails which does not allow the passage of electric current.
  • The insulation must be sufficiently effective to break the flow of traction and signal current in all possible weather conditions.

3.2 Rail temperature range

  • The insulated rail joint shall be able to provide sufficient mechanical and electrical resistance in the rail temperature range from -40 0C to +55 0C.

3.3 Axle load and speed

The insulated joints shall be designed to accommodate the following combinations of axle loads and speed:

  • Axleload = 18 tonnes at speed = 250 km/h
  • Axleload = 20 tonnes at speed = 200 km/h
  • Axleload = 25 tonnes at speed = 70 km/h
  • Axleload = 30 tonnes at speed = 50 km/h

3.4 Compatibility with fastening systems

The insulated joint shall be designed to allow the joint and rail to be fully fastened in a concrete sleeper track with sleeper spacing 60 cm and the following fastening clips:

  • Pandrol e 1877
  • Pandrol Fastclip FC 1501
  • Pandrol Fastclip FE 1404
  • Vossloh sytem W30

4 Electrical requirements

4.1 General

  • The creepage space must be at least 6 mm
  • The rail joint must not incur lasting damage following sparkovers

4.2 Electrical requirements – dry conditions

When tested in accordance with Test procedure dry condition, the following requirements apply:

  • rail – rail resistance shall be ≥ 30 MΩ
  • rail – fishplate resistance shall be ≥ 30 MΩ

4.3 Electrical requirements – wet conditions

When tested in accordance with Test procedure wet condition, the following requirements apply:

  • rail – rail resistance shall be ≥ 200 kΩ
  • rail – fishplate resistance shall be ≥ 200 kΩ

4.4 Electrical requirements – after mechanical testing

After Tensile strength test and Repeated 4-point bending test the following requirements apply when tested in acoordance with Test procedure dry condition:

  • rail – rail resistance shall be ≥ 150 kΩ
  • rail – fishplate resistance shall be ≥ 150 kΩ

5 Mechanical requirements

5.1 Tensile strength

The mechanical performance on tension is determined by performing the tensile strength test as described in Tensile strength test

  • The minimum tension strength, FSmin is specified in Tabell 1

Tabell 1: Minimum tension strength
Rail profile FSmin (kN)
60E1 1688
54E3 1526
49E1 1383

The minimum tension strength values above is the longitudinal force in the rail resulting from a temperature difference of 61 0C multiplied with a safety factor 1,5.

The temperature difference is defined from a stress free temperature of +21 0C and a minimum rail temperature of -40 0C.

5.2 Mechanical performance on bending

The mechanical performance on bending is determined by performing the repeated bending test as described in Repeated 4-point bending test. The bending moment Mr which shall be used for the repeated bending test, is specified in Tabell 2

Tabell 2: Minimum bending moment
Rail profile Mr (Nm)
60E1 39800
54E3 35100
49E1 33500

6 Geometrical requirements

6.1 Dimensions

  • The rail joints may be supplied in the following alternative versions, depending on the angle of the profile insert at the railhead in relation to the longitudinal direction of the rails:
  1. 90°
  2. 45°
  3. 30°
  • At the base of the rail, the profile insert must always be at right-angles (90°) to the longitudinal direction of the rails.
  • The insulated joints may be delivered with either 4 or 6 bore holes and bolts. The bore hole distances and dimensions are given in Tabell 3:
  • Unless otherwise specified, the rail joints must be supplied in standard lengths of 6000 mm, 7200 mm and 10800 mm.
Figur 1: Bore hole pattern

Tabell 3: Bore hole pattern
Rail profile Lr1 (mm) Lr2 (mm) Lr3 Dr (mm)
49E1 45 ± 0,5 165 ± 0,5 165 ± 0,5 33 ± 0,5
54E3 45 ± 0,5 165 ± 0,5 165 ± 0,5 33 ± 0,5
60E1 67 ± 0,5 165 ± 0,5 165 ± 0,5 33 ± 0,5

6.2 Straightness

The following tolerances apply in the longitudinal direction:

  • Running surface: +0.3 mm/–0.0 mm
  • Running edge: ±0.2 mm

7 Qualification of joint type

For qualification of the joint type, the supplier must document that the joints meet the following requirements:

8 Electrical insulation test

8.1 Test instrument

For this test, a digital measuring equipment is required that is able to measure electrical insulation at a voltage of 500 V DC. The equipment shall be able to measure accurately in the range of up to at least 50 MΩ with 2 digits.

8.2 Test procedure dry condition

  • Before the test, the test specimen shall have been in a room with temperature (18 - 28 0C) for at least 24 hours.
  • Each end of the test specimen shall be placed on one insulated support.
  • Four measuring points are assigned on the test specimen:
    • One per rail
    • One per fishplate
  • In case of fully coated fishplates, or fishplates of insulating material, it is not necessary to measure the fishplates.

The measuring points shall be dry and free of rust, grease, oil or other substances, so that the probes will make good contact to the steel.

  • Then the following 5 recordings are made (see Figur 2.):
  1. rail A – rail B
  2. rail A – fishplate A
  3. rail A – fishplate B
  4. rail B – fishplate A
  5. rail B – fishplate B
Figur 2: Electrical insulation test
  • The 5 values shall be expressed in MΩ with an accuracy of 0.01 MΩ. If the electrical resistance is larger than the equipment can indicate, then the maximum value of the equipment shall be noted and the text “(max.)” shall be added.
  • Qualification testing:
    • In each recording, the operator shall wait for 1 minute after applying the test voltage and then read the value for the electrical resistance.
    • Each recording is made 3 times, and the minimum value is stored.
  • Acceptance testing
    • Each recording is made one time.
    • The value shall be read directly after applying the current.

8.3 Test procedure wet condition

  1. The test specimen shall be submerged completely for minimum 12 hours in a 5% NaCl solution (5 g NaCl per 100 ml of fresh tap water).
  2. The test specimen shall be placed for 3 hours on one insulated support per rail end in a room with temperature (18 - 28 0C).
  3. The test specimen shall neither be wiped dry, nor be dried by means of convection or heat radiation.
  4. The test procedure as described in Test procedure dry condition shall be followed.

9 Mechanical test

9.1 Tensile strength test (longitudinal)

9.1.1 Test equipment

  • The test equipment shall be able to apply a tension load at a constant rate (load-controlled).
  • The tension load shall be recorded and expressed in kN with an accuracy of 1% of the load capacity.

9.1.2 Test specimen

  • The test specimen shall be produced in accordance with the installation instructions.
    • However no coatings for prevention against corrosion or pollution shall be applied.
  • The length of the test specimen shall be such that the tension load is introduced into the rail at a distance of at least H/2 from the either end of the fishplates.
  • The load shall be applied in and parallel to the centre line of the fishplate bolts with maximum 5 mm offset.
  • No modifications are allowed in the rail and the fishplate within the area starting and ending at H/2 from either end of the fishplate.
Figur 3: Tensile strength test arrangement

9.1.3 Test procedure

  • The test specimen shall be stored at room temperature (18-28 0C) for at least 24 hours before the test.
  • The test shall be performed at a temperature between 18-28 0C.
  • The tension load shall be increased at a constant rate of maximum 20 kN/s until the minimum tension strength Fs,min is achieved. Then the tension load is decreased at the same constant rate until 0 kN
  • After loading and unloading the test specimen shall be inspected for mechanical defects where either of the following visual defects will result the test to fail:
    • Deformation of any element (bolt, insulating bush, nut, fishplate, other parts of the mechanical rail joint)
    • Cracks in any part of the mechanical rail joint
    • Cracking or debonding of adhesives
  • After loading and unloading, Electrical insulation test in dry condition shall be performed.

9.2 Repeated 4-point bending test (vertical)

9.2.1 Test equipment

  • The load generated by the actuator shall be recorded and expressed in kN with an accuracy of 0,1 kN.
  • The test apparatus shall be able to apply a force at a constant rate and a harmonic sinusoid load at a frequency of 3–10 Hz.

9.2.2 Test arrangement

  • The center-to-center distance of the support points LS shall be the length of the fishplate Lf plus minimum 2 and maximum 4 times the height of the rail H.
  • The load shall be applied through a load distribution plate with two load insertion rolls with diameter between 25 and 75 mm.
  • The center-to-center distance of the load insertion points LW shall be between 120 and 175 mm.
  • The length of the test specimen L shall be at least 150 mm longer than the distance between the support points LS.
  • The test arrangement shall be placed on a horizontal surface under a vertically aligned actuator.
  • The test specimen shall be aligned horizontally (longitudinally and laterally), so that the center of the mechanical rail joint (symmetrical) is in line with the center of the actuator.


Figur 4: Bending strength test arrangement

9.2.3 Test procedure

  • The test specimen shall be stored at room temperature (18 - 28 0C) for at least 24 hours before the test.
  • The maximum test load Fmax shall be calculated from the required bending moment Mr (see ) and the dimensions of the test arrangement LS and LW.
    • Fmax = 4Mr / (LS - LW)
  • A cyclic load with minimum value 5 kN and maximum value Fmax shall be applied with a frequency between 3 and 10 Hz.
  • After 3 million load cycles the test specimen shall be inspected for mechanical defects where either of the following visual defects will result the test to fail:
    • Deformation of any element (bolt, insulating bush, nut, fishplate, other parts of the mechanical rail joint)
    • Cracks in any part of the mechanical rail joint
    • Cracking or debonding of adhesives
  • After the repeated bending test, Electrical insulation test in dry condition shall be performed.

10 Materials

10.1 Rails

  • Insulated joints shall be produced with rails in grade R350HT according to EN 13674-1.
  • On request, insulated joints shall be produced with rails in grade R400HT according to EN 13674-1.

10.2 Fishplates

  • Fishplates with a minimum tensile strength of 700 N/mm2 shall be used.

10.3 Bolts

  • Bolts of durability category 10/9 must be used.

10.4 Insulating material

The following requirements apply to the insulating material:

  • Min. tensile strength = 150 N/mm2
  • Min. compression strength = 100 N/mm2
  • Max. water absorption = 0.1 %
  • Min. specific resistance = 1010 Ωcm/cm2
  • The insulating material must be resistant to sunlight
  • The insulating material must not contain substances that form electrolytes when combined with water
  • The insulation material must not be inflammable
  • All chemical components in the insulating material shall comply with Regulation (EC) No 1907/2006 concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH).

10.5 Adhesive

If any adhesive is used in the joint construction, the following requirements apply:

  • Adhesives where aging can affect mechanical properties shall not be used
  • Adhesives which can accelerate corrosion shall not be used
  • All chemical components in the adhesive shall comply with Regulation (EC) No 1907/2006 concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH).

11 Manufacture

11.1 Work instruction

The manufacturer shall draw up a written work instruction describing the production of insulated joints, step by step. This instruction must as a minimum include:

  • Temperature ranges for materials and adhesives to be mounted
  • Description of necessary preparatory works of rails and fish-plates before assembly
  • Procedure for applying any adhesive
  • Procedure for installing and tightening of bolts
  • Necessary curing times
  • Procedure for applying any coating on the joints
  • Procedure for acceptance testing
  • Procedure for labelling of the joints

11.2 Labelling

The rail joints shall be labelled with a manufacturer’s plate attached to the outside of one of the fishplates. This plate must clearly show the following information:

  • Name of manufacturer/supplier
  • Manufacturer’s serial number
  • Date of manufacture (day/month/year)
  • Rail profile
  • Rail grade

12 Acceptance testing

  • The manufacturer of the rail joints has an obligation to inspect the insulated joints in accordance with the points specified below.
  • The results of acceptance tests shall be documented and be available for Bane NOR upon request.

12.1 Geometrical and visual inspection

  • The test frequency is 100%
  • Acceptance criteria is given in Straightness

12.2 Electrical insulation tests in the production plant

12.3 Electrical insulation tests on delivery

  • On delivery at Bane NOR track site or storage location, Bane NOR may require electrical insulation tests
  • Electrical insulation test shall be performed as described in Test procedure dry condition. Requirements for storage at room temperature does not apply here.
  • Acceptance criteria for insulated joints on delivery is min. 150kΩ at measured with a test voltage of 500 V DC.

12.4 Mechanical tests

13 Documentation

13.1 Materials certificates

  • Certificates according EN 10204 for the traceability of steel quality of all parts of the insulated joints must be supplied on customers request.

13.2 Test and quality records

All production and quality records are to be retained by the supplier for a period of minimum 5 years. Bane NOR shall have the right to access to view these records.

13.3 Drawings

  • The supplier must prepare detailed drawings of the insulated joints prior to manufacture.
  • All drawings must be supplied in both of the following electronic formats:
    • dwg (Autocad)
    • pdf
  • The supplier has an obligation to supply files that are compatible with the version of Autocad currently used by Bane NOR.
  • Bane NOR must be assigned all rights to the drawings.
  • All drawings must be approved by Bane NOR before production commences.

14 Transport

  • The finished rail joints must be transported in such a way that damage and permanent deformities cannot occur.
  • The lifting equipment (rail clamps) used for lifting and handling the joints must not damage the surface of the rail.
  • Arrangements and equipment for transporting and handling the rail joints must be approved by Bane NOR prior to delivery.
  • Temporary storage of the rail joints in a corrosion-prone environment (e.g. near the sea) is not permitted.

15 Reference documents

  • EN 13674-1 Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above.
  • Bane NOR – Technical specification – Rails
  • Regulation (EC) No 1907/2006 concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH)

16 Compliance list

17 Change log

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