Overbygning/Glideskjøter

Fagområde / Discipline	Overbygning / Permanent way
Tilhører rammeavtale / Frame agreement	K.xxxxxxxxx
Utarbeidet av / Prepared by	Frode Teigen
Godkjent av / Approved	Christopher Schive
Revisjon / Revision	03
Utgitt / Issued	01.11.2021

1 Purpose

This specification sets out objective requirements to enable suppliers to deliver expansion devices that meet the expectations of Bane NOR.

2 Scope

This specification applies to delivery of expansion devices with movable stock rails on the Bane NOR network with the following expansion capacity, basic rail profiles and bearer types .

2.1 Expansion capacity

Tabell 1: Expansion capacity

Designation	Expansion capacity [mm]	Displacement [mm]	Basic rail profile	Bearer type
GL-60-200B	200	± 100	60E1	Concrete bearers
GL-60-600B	600	± 300
GL-60-1200B	1200	± 600
GL-60-1800B	1800	± 900
GL-54-200B	200	± 100	54E3
GL-54-600B	600	± 300
GL-54-200T	200	± 100		Wooden bearers

3 Design

The expansion devices shall be produced and delivered in accordance with EN 13232-8:2007+A1 with the following design inputs according to the standard.

3.1 Axle load and speed

The expansion devices with basic rail profile 60E1 shall be designed to accommodate the following combinations of axle loads and speed:

• Axleload = 17 tonnes at speed = 300 km/h
• Axleload = 18 tonnes at speed = 250 km/h
• Axleload = 20 tonnes at speed = 200 km/h
• Axleload = 25 tonnes at speed = 70 km/h

The expansion devices with basic rail profile 54E3 shall be designed to accommodate the following combinations of axle loads and speed:

• Axleload = 20.5 tonnes at speed = 160 km/h
• Axleload = 22,5 tonnes at speed = 90 km/h

3.2 Nominal track gauge

The expansion devices shall be designed to a nominal track gauge of 1435 mm

3.3 Sleeper design track gauge

Sleepers for use in the expansion devices shall have a design track gauge of 1437 mm

3.4 Direction of traffic

The expansion devices shall be designed for bidirectional traffic.

3.5 Track geometry

The expansion devices shall be designed to accommodate a minimum horizontal curve radius of 250 meter.

3.6 Expansion device type

The expansion devices shall be designed with movable stock rails.

3.7 Basic rail section and grade

The expansion devices shall be designed with basic rail section 60E1 or 54E3 according to EN 13674-1. The rail grade shall be R350HT according to EN 13674-1.

3.8 Rail inclination

The expansion devices shall be designed with rail inclination 1:20

3.9 Sleepers

3.9.1 Concrete sleepers

• The design and manufacture of the sleepers shall comply with the requirements in EN 13230-1
• Concrete sleepers shall be delivered with Under Sleeper Pads in accordance with EN 16730 with Bedding Modulus Cstat 0,15 - 0,20 N/mm³
• Concrete sleepers shall be designed to the following characteristic bending moments:
  • Positive characteristic bending moment for rail seat section M_k,r,pos:16,80 kNm
  • Positive characteristic bending moment for centre section M_k,c,pos:7,80 kNm
  • Negative characteristic bending moment at centre section M_k,c,neg:10,50 kNm
  • Positive test bending moment for rail seat section M_t,r,pos:21,38 kNm
  • Negative test bending moment at centre section M_t,c,neg:14,30 kNm
  • Static impact coefficient due to exceptional and random load k_1s: 2,20
  • Dynamic impact coefficient due to exceptional and random load k_1d: 1,83
  • Static impact coefficient due to accidental load k_2s: 3,05
  • Dynamic impact coefficient due to accidental load k_2d: 2,68
  • Fatigue test coefficient: k₃: 3,05
• Concrete sleepers shall be designed to accomodate guard rails when required.

3.9.2 Wooden sleepers

Wooden sleepers shall comply with requirements in Bane NOR Technical specification - Wooden sleepers

3.10 Fastening system

• The expansion devices shall be designed with Pandrol Fastclip fastening system, except for parts of the switch area where special fastenings are necessary.
• The electrical insulation of fastening system and sleeper shall be not less than 5 kΩ when measured in accordance with EN 13146-5.

3.11 Nominal support spacing

The expansion devices shall be designed with a nominal support spacing of 600 mm c-c.

4 Manufacture

Prior to machining, the supplier shall ensure that rails and switch blades comply with the maximum permissible variations in straightness and curvature specified in EN 13674-1 and EN 13674-2

4.1 Cutting

All rails and switch blades shall be cut using chip-cutting tools. The edges of the cut surfaces shall be bevelled at an angle of 45°.

4.2 Bending

A hydraulic press shall be used if bending of components is necessary. To minimise detrimental stresses in the steel, reshaping shall be performed slowly and steadily. Pressing blocks shall follow the entire rail/blade profile and shall be designed so that they do not leave localised indentations in the rail. Any necessary holes shall be drilled only after bending has been completed.

4.2.1 Cold bending

Bending of up to 5° shall be performed at normal temperature, provided the temperature of the material is at least +15 °C.

4.2.2 Hot bending

Bending exceeding 5° shall be performed at a temperature between +640 and +680 °C. The rail shall be heated from both sides so that the material reaches approximately the same temperature over its entire profile. The area heated should be 15–20 cm long. The time taken to heat the material from +20 to +600 °C shall not be less than 30 minutes.

• The temperature shall be continuously monitored using temperature-sensitive chalk or a temperature meter.
• To allow the material to cool slowly, the buckling point shall be wrapped in thermally insulating sheets. The time taken to cool from +600 to +20 °C shall not be less than 7 hours.
• The pressing blocks shall match the rail profile and shall be wide enough not to leave an indentation in the rail.

4.3 Drilling

• The distance between two holes, edge to edge, shall not be less than 2xdiameter of the minimal hole
• The distance between the edge of a hole and the edge of the switch blade/rail or a profile transition, shall not be less than the diameter of the hole
• Holes shall be drilled with undamaged tools and coolant.
• All drilled holes shall be bevelled at an angle of 45°. If the rail is to be bent, holes shall always be drilled after bending.
• Plugging of holes with help of welding or other means is not permitted

4.4 Welding

Components shall be electric arc welded only where indicated on the drawing. Electric arc welding shall be carried out by welders certified in accordance with EN 287-1.

A welding procedure specification in accordance with EN 15607 shall be prepared for every welded joint.

4.5 Machining

All machining shall be performed in such a way that the specified tolerances and requirements for surface roughness are maintained. In the case of measurements for which no tolerances are defined, the provisions of ISO 2768-1 will generally apply. All burrs shall be removed after machining.

4.6 Anticorrosive treatment

• All surfaces that come into contact with one another shall be thoroughly cleaned and coated with a layer of anticorrosive paint prior to bolting together. The coating shall be completely dry before the components are assembled.
• All welding seams shall be coated with anticorrosive paint or oil.
• All machined sliding surfaces on the blade bases, slide plates, lever mechanism etc. shall be thoroughly cleaned prior to assembly and coated with anticorrosive lubricant.
• All machined, exposed and isolated parts of a switch assembly – i.e. blades and stock rails shall be thoroughly cleaned and coated with a layer of anticorrosive paint after the switch has been assembled and inspected.
• Unmachined surfaces (with mill scale) and the cut ends of the rails do not require painting.

5 Tolerances and inspection

Requirements for tolerances and inspection of the expansion devices are given in EN 13232-8.

5.1 Track gauge tolerance

Permissible variations from the design track gauge of 1437 mm is +/- 2 mm .

6 Identification

The expansion devices shall be marked in accordance with EN 13232-8.

7 Documentation

7.1 BIM model

• The supplier must prepare a BIM model for every expansion joint type prior to delivery.
• The BIM model shall be based on Bane NORs requirements - GEN-00-A-00005
• The BIM model shall be based on open standard, IFC version 4.3 or newer as described in ISO 16739
• The Model shall include all details in the expansion joint, including main parts, baseplates, fastening components and bolts.
• Object libraries shall be available to Bane NOR and 3rd party suppliers
• Structured information shall be connected to the BIM model

7.2 Drawings

The supplier shall prepare geometry plan, assembly documents and detailed component plans according to EN 13232-8.

The supplier shall deliver drawings necessary for assembly and installation for each individual expansion device.

All drawings shall 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.

All drawings shall be approved by Bane NOR before production commences.

7.3 Parts lists

The supplier shall prepare a comprehensive parts list for each switch type. Parts lists shall be supplied in Open Document Format (ODF).

7.4 Materials certificates

The supplier shall maintain comprehensive records of each order for switches. These records shall include materials certificates for the following components:

• Switch blades/Stock rails
• Rails
• Base plates
• Slide plates
• Bolts/Nuts
• Blade bearers

The records are to be retained by the supplier, but shall be available for inspection by Bane NOR at any time. On request, the supplier shall submit materials certificates to Bane NOR.

7.5 Documentation of final inspection

Documents showing that a final inspection has been carried out in accordance with EN 13232-8 and that the outcome has been approved, shall be retained by the supplier for each individual switch. These documents shall be available for inspection by Bane NOR at any time. On request, the supplier shall submit any documents relating to the final inspection to Bane NOR.

8 Reference Documents

• EN 13232-8 - Railway applications - Track - Switches and crossings - Part 8: Expansion devices
• EN 13674-1 - Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above
• EN 13674-2 - Railway applications - Track - Rail - Part 2: Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above
• EN 13230-1 Railway applications - Track - Concrete sleepers and bearers - Part 1: General requirements
• EN 16730 - Railway applications - Track - Concrete sleepers and bearers with under sleeper pads
• EN 13146-5 Railway applications - Track - Test methods for fastening systems - Part 5: Determination of electrical resistance
• Bane NOR - Technical specification for wooden sleepers
• EN ISO 16739-1:2020 - Industry Foundation Classes (IFC) for data sharing in the construction and facility management industries - Part 1: Data schema
• GEN-00-A-00005 - Bane NOR requirement for model based design and BIM