Overbygning/Reprofilering av skinner

1 Purpose

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

2 Scope

This specification applies to the reprofiling of rails on the Bane NOR network. A distinction is made between corrective and preventive reprofiling. Corrective reprofiling is performed to improve the longitudinal and transverse profile of the rails. Preventive reprofiling is performed to reduce roughness and unevenness following rolling, inlaying and welding of rails.

3 Requirements for vehicles

3.1 Collection of dust and emissions

Grinding vehicles to be used in tunnels over 1500 m in length must be fitted with equipment for collecting up dust and emissions.

3.2 Fire prevention

• Rail reprofiling is classified as hot work under current regulations on fire prevention and the working environment.
• Reprofiling vehicles must have the necessary equipment for preventing and fighting any outbreak of fire caused by sparks from reprofiling.
• The crew of the reprofiling vehicle have a duty to monitor the sections where reprofiling is taking place, with a view to avoiding fires along the line.
• Minimum 1 operator on the reprofiling vehicle shall have a certificate for hot work issued from the Norwegian Fire Protection Association or a cooperative organisation.

4 longitudinal profile

Acceptance criteria and requirement for measurement are given in EN 13231-3.

Work is to be performed to Class 1 or Class 2, normally depending on the maximum line speed (V_max) on the section to be reprofiled, as shown in Tabell 1. In some cases Class 1 may be chosen even if the line speed is below 130 km/h

Tabell 1: Quality class longtitudinal profile

Vmax	Quality Class (EN 13231-3)
> 130 km/h	Class 1
≤ 130 km/h	Class 2

5 Transverse profile

Acceptance criteria and requirement for measurement are given in EN 13231-3

Work is to be performed to Class 1 or Class 2, normally depending on the maximum line speed (V_max) on the section to be reprofiled, as shown in Tabell 2. In some cases Class Q may be chosen even if the line speed is below 130 km/h. On the Norwegian part of the ore line Kiruna – Narvik (Ofotbanen) Class Q shall apply.

Tabell 2: Quality class transverse profile

Vmax	Quality Class (EN 13231-3)
> 130 km/h	Class Q
≤ 130 km/h	Class R
Ofotbanen (ore-line)	Class Q

For reprofiling on the Norwegian part of the ore line Kiruna – Narvik (Ofotbanen), measurements shall be performed with “Miniprof” instrument. Alternatively, measurement results must be exported to “Miniprof” format.

When reprofiling turnouts, measurements are to be made 3 m beyond the check rails on both the main track and the diverging track.

5.1 Target profiles

• On the main network, the transversal target profile is the original profile (60E1, 54E3, 54E2 or 49E1) with rail inclination 1:20, unless other target profiles are specified.
• On the Norwegian part of the ore line Kiruna – Narvik (Ofotbanen), the transversal target profiles are MB4 and MB1vAss, with rail inclination 1:30. Drawings and coordinates for MB4 and MB1vAss are given in annex A.

6 Metal removal

• A minimum of 0.2 mm of material is to be removed, irrespective of the longitudinal and transverse profile of the rails.
• Requirements for measurements are given in EN 13321-3.

7 Surface quality

• The surface quality of the reprofiled rails shall be according to quality class 2 according to prEN 13231-2:2017. I.e the quality index shall be ≤ 5.
• The quality index shall be measured and determined according to prEN 13231-2:2017

8 Visual appearance

• Acceptance criteria are given in EN 13231-3.
• For reprofiling on the Norwegian part of the ore line Kiruna – Narvik (Ofotbanen), the facet width shall not exceed 5 mm on any part of the rail head, except for the top facet on the MB4 profile from +5⁰ to -5⁰.

9 Reprofiling of switches

The following conditions apply to the reprofiling of switches:

1. Bane NOR may define more than one target profile for a single switch.
2. The reprofiling equipment used must be capable of reprofiling the running rails behind the check rails without removal of the latter.
3. The reprofiling area is to cover the switch and 15–20 m ahead of and beyond the switch.
4. Any snow covers must be removed before reprofiling.
5. Switches shall be reprofiled to a rail inclination 1:20 on the main network and 1:30 on “Ofotbanen”
6. There shall be no reprofiling in the area from A to B shown in Figur 1. Point B is the where the crossing nose width is 67 mm for 49E1 and 54E3 rail profiles and 70 mm for 60E1 rail profile .
7. Between B and C, the crossing nose can be reprofiled from -1⁰ to -70⁰. Point C is where the crossing nose width is 120 mm. From point C the crossing shall be ground as a normal rail.
8. The switch blade is to be reprofiled when it is resting against the stock rail. Before reprofiling, the switch blade shall be lifted 6 mm with shims.
9. The stock rail can be ground from -70⁰ to +12⁰ when the switch blade is not closed to the stock rail.
10. After reprofiling, the adjustment of the switch blade to the stock rail, shall be checked according to Bane NOR regulation Overbygning/Vedlikehold/Sporveksler/Vedlegg/Undersøkelse_av_tungeanordninger
11. After reprofiling, any reprofiling dust must be removed, particularly between the switch blades and stock rails, around insulated rail joints and around switch slide plates.
12. The switch must be lubricated immediately after reprofiling.

Figur 1: Reprofiling of switches

10 Inspection and approval

10.1 Inspection by the supplier

• Reprofiling vehicles must be equipped with instruments for measuring and checking transverse and longitudinal profile, surface roughness and the amount of metal removed.
• The results of these measurements should be capable of processing and comparison with those produced by Bane NOR’s own inspection equipment.
• The reprofiling contractor is responsible for any necessary data conversion.

10.2 Approval

• Completed work will be approved on the basis of daily reports and quality documents.
• If the client so wishes, random checks may be carried out in addition.
• The documents must be signed by the reprofiling supervisor and by a representative of Bane NOR on handover.

10.3 Quality documents

Quality documents must include, as a minimum:

• Measurements of longitudinal profile before reprofiling and after the final pass
• Measurements of transverse profile before reprofiling and after the final pass
• Measurements of surface roughness
• Quantity of material consumed

Q-documents for sections on which reprofiling is complete must be signed and handed over at 14-day intervals. These documents are to be collated every 14 days and after completion of the reprofiling contract. The collated Q-documents are to be accompanied by a summary of the extent to which the work complies with the requirements of this specification.

11 Reference Documents

• EN 13321-3 (2012) - Railway applications – Track – Acceptance of work – Acceptance of reprofiling rails in track.
• prEN 13321-2 (2017) - Railway applications – Track – Acceptance of work – Acceptance of reprofiling rails in plain line, switches, crossings and expansion devices.