Overbygning/Limte isolerte skjøter med stållasker
| Fagområde / Discipline | Overbygning / Permanent way |
| Tilhører rammeavtale / Frame agreement | K.xxxxxxxxx |
| Utarbeidet av / Prepared by | Frode Teigen |
| Godkjent av / Approved | Christopher Schive |
| Revisjon / Revision | 11 |
| Utgitt / Issued | 22.04.2024 |
Innhold
1 Purpose
This specification sets out objective requirements to enable suppliers to design, manufacture, inspect and deliver a insulated rail joints 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 = 32,5 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 Electrical requirements – dry conditions
When tested in accordance with EN 16843:2024 chapter 7.3.4, the following requirements apply:
- rail – rail resistance shall be ≥ 10 MΩ
- rail – fishplate resistance shall be ≥ 10 MΩ
4.2 Electrical requirements – wet conditions
When tested in accordance with EN 16843:2024 chapter 7.3.5, the following requirements apply:
The test specimen shall be submerged completely for minimum 12 hours in a 5% NaCl solution
- rail – rail resistance shall be ≥ 200 kΩ
- rail – fishplate resistance shall be ≥ 200 kΩ
4.3 Electrical requirements – after mechanical testing
After mechanical testing according to EN 16843:2024 chapter 7.2, the following requirements apply when tested in acoordance with EN 16843:2024 chapter 7.3.4:
- 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 EN 16843:2024, chapter 7.2.1
The minimum tension strength, Ft,min shall be calculated according to EN 16843:2024, chapter 5.2.2.1 with the following parameters:
- Temperature difference ΔT1 = 61 0C
- Safety factor γs = 1,5
5.2 Mechanical performance on bending
The mechanical performance on bending is determined by performing the repeated bending test as described in as described in EN 16843:2024, chapter 7.2.2.
The bending moment Mr which shall be used for the repeated bending test, is specified in Tabell 1
| 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:
- 90°
- 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 2:
- Unless otherwise specified, the rail joints must be supplied in standard lengths of 6000 mm, 7200 mm and 10800 mm.
| 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 perform type approval stages in accordance with EN 16843:2024, chapter 6.3.
8 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.
8.1 Geometrical and visual inspection
- Test shall be carried out in accordance with EN 16843:2024 chapter 8.2
- Tolerances for straightness is given in Straightness
8.2 Electrical insulation tests in the production plant
- Test shall be carried out in accordance with EN 16843:2024 chapter 8.3
- Acceptance criteria is given in Electrical requirements – dry conditions
8.3 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 EN 16843:2024 chapter 7.3.4. Requirements for storage at room temperature does not apply here.
- Acceptance criteria for insulated joints on delivery is min. 150kΩ when measured with a test voltage of 500 V DC.
8.4 Mechanical tests
- Test shall be carried out in accordance with EN 16843:2024 chapter 8.4
9 Materials
9.1 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.
9.2 Fishplates
- Fishplates with a minimum tensile strength of 690 N/mm2 shall be used.
9.3 Bolts
- Bolts of durability category 10/9 must be used.
9.4 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).
9.5 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).
10 Manufacture
10.1 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
10.2 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
- QR code with a hyperlink to the information listed above
11 Documentation
11.1 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.
11.2 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.
11.2.1 Test reports
- After tensile strength test, a report according to EN 16843:2024 chapter 7.2.1.5 shall be produced
- After repeated bending test, a report according to EN 16843:2024 chapter 7.2.2.5 shall be produced
- After electrical insulation test, a report according to EN 16843:2024 chapter 7.3.6 shall be produced
11.3 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)
- 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.
11.4 BIM model
- The supplier must prepare a BIM model 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 insulated joint.
- Object libraries shall be available to Bane NOR and 3rd party suppliers
- Structured information shall be connected to the BIM model.
12 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.
13 Reference documents
- EN 16843:2024 Railway applications - Infrastructure - Mechanical requirements for joints in running rails
- EN 13674-1:2011 + A1:2017 Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above.
- Regulation (EC) No 1907/2006 concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH)
