Overbygning/Limte isolerte skjøter med stållasker

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 the Norwegian National Rail Administration (Jernbaneverket, JBV).

Scope

This specification consists of requirements concerning the design, production and inspection of glued insulated rail joints with steel fishplates for use on the JBV network.

Function

Insulated rail joints are used to separate 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 current in all possible weather conditions.

Electrical requirements

General

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

Electrical requirements – dry conditions

Sparking voltage:4 kV (RMS value) with 50 Hz alternating potential for one second, repeated five times at three-second intervals

Min. resistance:0.5 M at 500 V PD between rail ends

Electrical requirements – wet conditions

The rail joints must be immersed in water for 48 hours, after which they must be placed 4 m apart and allowed to drain for one minute.

Sparking voltage:2 kV (RMS value) with 50 Hz alternating potential for one second, repeated five times at three-second intervals

Min. resistance:50 k at 500 V PD between rail ends

There must be no change in the insulative capacity of each joint after the wet joint has been subjected 50 times to a force of 10 kN, with the joints placed 4 m apart.

Mechanical requirements

The rail joint must be able to absorb the following tensile forces in the longitudinal direction of the joint without the fishplates coming loose from the rail.

• Rail profile S49/S54/UIC54Emin. 1650 kN
• Rail profile UIC 60min. 1800 kN

Materials

Rails

The rails must be manufactured in accordance with UIC 860 and [JBV – Technical specification – Rails]. Rail joints may be supplied for the following grades of rail:

1. Grade 350 HT rails
2. Grade UIC 900A rails, with the running surface isothermally annealed in the area surrounding the profile insert

[[Image:|thumb|Figure A]]

In case b, the rail must be hardened so that the hardness in an area 70 mm to either side of the profile insert is between 340 and 400 HB (see figure A). Within this area the hardness must exceed 340 HB for a depth of at least 8 mm. Elsewhere, the hardness must not be less than 260 HB at any point on the running surface.

Fishplates

Steel fishplates with a minimum tensile strength of 700 N/mm² must be used.

Bolts

Bolts of durability category 10/9 must be used.

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 cm/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

Adhesive

Two-component epoxy adhesive containing an anticorrosive agent must be used.

Dimensions

Joints for rail profiles S49 and S54 must be produced according to the dimensions specified on drawing Sk 1063.

Joints for rail profile UIC60 must be produced according to the dimensions specified on drawing Sk 1064.

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.

Unless otherwise specified, the rail joints must be supplied in standard lengths of 6000 mm, 7200 mm and 10 800 mm.

Manufacture

Cleaning, bevelling

The surfaces to be glued, i.e. the fishplate cavities and the inside of the fishplates, must be sandblasted.

Immediately prior to application of the adhesive, these surfaces must be cleaned with acetone or methylated spirit, using a clean cloth or paintbrush.

The fishplate holes and the rail-ends at the railhead and running edge must be bevelled 1 mm. Any burrs on the base or web of the rail must be removed.

Gluing

The rail joints must be glued according to the following procedure:

1. A thick layer of adhesive is applied to the fishplates.
2. A layer of woven glass fibre is placed on the glued surface of the fishplates.
3. Adhesive is applied to the woven glass fibre using a rubber spatula.
4. The insulating sleeves are placed on top of the woven glass fibre.
5. Adhesive is applied to the outside of the insulating sleeves using a rubber spatula.
6. A layer of woven glass fibre is placed on top of the insulating sleeves.
7. A thick layer of adhesive is applied to the woven glass fibre.
8. The insulated bushings are installed in the fishplate holes on the rails.
9. The fishplates are installed in the fishplate cavities on the rails.

Tightening of bolts

Immediately after installation of the fishplates, the bolts must be tightened with a moment = 900 Nm. The nuts on the two centre bolts should always be tightened first.

30 minutes after the initial tightening, the bolts must be tightened again with a moment = 900 Nm.

Labelling

The rail joints must 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 (in accordance with section 6.1)

Approval testing

Inspection by the supplier

The manufacturer of the rail joints has an obligation to inspect each individual joint in accordance with the points specified below.

Straightness

The straightness of the joint is to be checked in the vertical and longitudinal directions using a 1 m ruler and blade feeler gauge. The following tolerances apply:

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

Insulation check

The joints must be checked using a 500 V Megger. Three measurements must be made – one from rail to rail and one from each rail to the fishplate. None of the readings must be below 0.5 M.

Care must be taken to clean the measuring surfaces on each rail and fishplate to ensure good contact.

Inspection by JBV

JBV reserves the right of free access to the supplier’s factory for the purposes of inspecting production, materials and finished rail joints.

Documentation

Materials certificates

Materials certificates for rails, fishplates, bolts and insulating components must accompany each delivery.

Quality assurance certificate

A quality assurance certificate containing factual details of test results in accordance with section 9.1 must accompany each delivery.

Changes in design/quality

JBV reserves the right to amend the material and/or design specifications during the contractual period.

Changes of this kind are to be effectuated by drawing up a supplementary agreement, as are any changes implemented as a result of reviews or suggestions made in accordance with section 11.1.

The other party must be notified of any necessary changes at the earliest opportunity, so that there is reasonable time to negotiate a supplementary agreement and implement the changes in question.

R&D, quality improvements

Through a programme of market liaison and technical development, the supplier undertakes to provide JBV with regular information and ideas/suggestions relating to the products to be supplied.

In this connection, the supplier must also keep its own production methods and workmanship under review, with a view to improving the standard and performance of the rail joints.

Any modifications or improvements made in accordance with this section are to be implemented by agreement between the parties on the basis of the review conclusions or suggestions.

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 JBV prior to delivery.

Temporary storage of the rail joints in a corrosion-prone environment (e.g. near the sea) is not permitted.

Reference documents

• UIC 860
• JBV – Technical specification – Rails

Appendices

• Drawing Sk 1063, rev. B
• Drawing Sk 1064, rev. B

Checklist

Description of requirement	Compliant (Yes/No)	Supplier’s references	Supplier’s comments
4.2Electrical requirements – wet conditions 4.3Electrical requirements – dry conditions 5Mechanical requirements 6Materials 6.1Rails 6.2Fishplates 6.3Bolts 6.4Insulating material 6.5Adhesive 7Dimensions 8.4Labelling 9.1.1Straightness 9.1.2Insulation check 9.2Inspection by JBV 10.1Materials certificates 10.2Quality assurance certificate 12Transport