Overbygning/Sporveksler, kryss og sporforbindelser

Fagområde / Discipline Overbygning / Permanent way
Tilhører rammeavtale / Frame agreement K.xxxxxxxxx
Utarbeidet av / Prepared by Frode Teigen
Godkjent av / Approved Christopher Schive
Revisjon / Revision 09
Utgitt / Issued 14.01.2021

Innhold

1 Scope

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.

This specification applies to switch assemblies, switch components, crossings and crossovers supplied to Bane NOR, but not to any electrical or electronic components of these units.

This specification applies to two traffic conditions:

  1. Switches&Crossings for normal traffic
  2. Switches&Crossings for heavy haul traffic

2 Function/General requirements

A switch is a piece of trackwork used to set the train route when there are two or more options. Switches shall comply with the following general requirements:

2.1 Track structure

Switches&Crossings shall be designed for the following track structure:

  • Nominal track gauge: 1435 mm
  • Design track gauge: 1437 mm
  • Rail inclination: 1:20
  • Rail profile: 60E1 and 54E3
  • Sleeper type: Concrete
  • Sleeper spacing: 60 cm

2.2 Maximum permissible loads

Switches&Crossings shall be designed to tolerate the following combinations of speed and axleload:

2.2.1 Design loads for normal traffic

  • Axleload = 18 tonnes at speed = 250 km/h
  • Axleload = 22.5 tonnes at speed = 200 km/h
  • Axleload = 25 tonnes at speed = 70 km/h

Switches&Crossings shall be designed to withstand axial forces caused by temperature fluctuations of ± 50 °C and braking trains with a total weight of 2000 tonnes max.

2.2.2 Design loads for Heavy haul traffic

  • Axleload = 22.5 tonnes at speed = 130 km/h
  • Axleload = 25 tonnes at speed = 70 km/h
  • Axleload = 35 tonnes at speed = 50 km/h

Switches&Crossings shall be designed to withstand axial forces caused by temperature fluctuations of ± 50 °C and braking trains with a total weight of 7500 tonnes max.

2.3 Wheel profiles

Switches&Crossings shall be designed for use with the following wheel profiles:

2.4 Geometry

Scope of delivery shows the geometry of the different types of switch&crossing.

3 Design/Materials

3.1 General design requirements

  • Switches & crossings shall be designed to comply with the following standards and specifications:
    • EN 13232-2:2003 + A1:2011
    • EN 13232-3:2003 + A1:2011
    • EN 13232-5:2003 + A1:2011
    • EN 13232-9:2006 + A1:2011
    • Commission regulation (EU) No 1299/2014 - TSI Infrastructure, chapter 4.2.5
  • Switches&Crossings with rail profile 60E1 shall be designed with rail inclination 1:20 throughout the switch&crossing.

3.2 Track stiffness optimisation

  • The supplier shall perform analysis for each switch&crossing in order to optimise track stiffness with use of elastic layers in the fastenings and under sleeper pads.

3.3 Crossing

  • Both fixed crossing and swingnose crossing shall be available for 60 E1 switches&crossings with basic geometry 1:9, 1:12, 1:14 and 1:15.
  • Switches with basic geometry 1:18 and 1:26 shall be delivered with swingnose crossing only.

3.3.1 Fixed crossing

  • Fixed crossings shall be cast in one piece from 12–14% manganese steel and manufactured in accordance with EN 15689.
  • The 12-14% manganese steel crossing shall be pre-hardened in accordance with EN 15689, chapter 8.
  • The rail inclination of the running surface shall be 1:20
  • Crossings shall be supplied with welded-on 2,4 meter long rail-ends of grade R350 HT in accordance with EN 13674-1.
  • An 18–20 mm long bridging-piece of INOX shall connect the manganese steel crossing to the rail-ends.
  • Electric resistance welding shall be used to attach the bridging-piece in accordance with EN 14587-3.
  • Dimensional tolerances for the crossing are given in EN 13232-6.
  • The supplier shall provide engineering drawings for templates and tools necessary for checking the dimensions.

3.3.2 Swingnose crossing

  • Swingnose crossings can be made either with movable point or movable wing rails.
  • The crossing shall be designed in a way that a continuous running surface without gap is formed over the area where the two rails are crossing each other.
  • For normal traffic Switches&Crossings, the movable part of the crossing shall be made of rail steel R350 HT in accordance with EN 13674-2.
  • For heavy haul traffic Switches&Crossings, the movable part of the crossing shall be made of rail steel R370CrHT in accordance with EN 13674-2.
  • The fixed part of the crossing shall be cast from 12–14% manganese steel and manufactured in accordance with EN 15689.
  • The 12-14% manganese steel part of the crossing shall be pre-hardened in accordance with EN 15689, chapter 8.
  • For normal traffic Switches&Crossings, the crossing part in manganese steel shall be supplied with welded-on rail-ends of grade R350 HT in accordance with EN 13674-1.
  • For heavy haul traffic Switches&Crossings, the crossing part in manganese steel shall be supplied with welded-on rail-ends of grade R370CrHT in accordance with EN 13674-1.
  • An 18–20 mm long bridging-piece of INOX shall connect the manganese steel crossing to the rail-ends.
  • Electric resistance welding shall be used to attach the bridging-piece in accordance with EN 14587-3.
  • Dimensional tolerances for the crossing are given in EN 13232-7.
  • The rail inclination of the running surface shall be 1:20
  • The supplier shall provide engineering drawings for templates and tools necessary for checking the dimensions.

3.4 Intermediate rails

  • For normal traffic S&C, intermediate rails shall be of grade R350 HT in accordance with EN 13674-1.
  • For heavy haul traffic S&C, intermediate rails shall be of grade R370 CrHT in accordance with EN 13674-1.

3.5 Switch blade assembly

  • Switches shall have flexible blades delivered in accordance with EN 13674-2.
  • The following switch blade profiles shall be delivered:
    • 60E1 switchblade profile 60E1A4
    • 54E3 switchblade profile 54E1A2
    • 49E1 (spare part existing S&C) switchblade profile 49E1A1
  • Material grade for switch blades and stock rails:
    • For normal traffic Switches&Crossings: R350 HT in accordance with EN 13674-2
    • For heavy haul traffic Switches&Crossings: R370 CrHT in accordance with EN 13674-2
  • Switch blade assemblies shall be supplied with blade bearers capable of accommodating switch heating elements.

3.6 Check rails

  • Check rails on all switches shall be 20 mm higher than the railhead or, in the case of obtuse crossings for switch diamonds, 45 mm higher than the railhead.
  • The check rails shall be manufactured in accordance with EN 13674-3
  • Profile:33C1
  • Material grade:C320 Cr

3.7 Sleepers

3.8 Sleeper screws

Sleeper screws shall comply with Bane NOR – Technical specification – Sleeper screws and UIC 864.

3.9 Fastenings

  • Switches shall be supplied with the Pandrol Fastclip/Pandrol e-clip (2039) fastening system with rubber pads.
  • Materials used in springs, insulators and pads must comply with Pandrol’s specifications.

3.10 Insulated rail joints

Insulated rail joints shall comply with Bane NOR – Technical specification – Glued insulated rail joints with steel fishplates.

3.11 Baseplates

  • Baseplates must be made of cast steel with a minimum thickness of 20 mm.
  • Baseplates must be adapted to the coordinates of the switch.
  • Material grade:EN-GJMB-450-6 in accordance with EN 1562

3.12 Slide plates

  • Slide plates shall be cast steel plates with internal fastening, type IBAV.
  • Slide plates shall be lubrication-free, i.e. the external surface must have a friction-reducing coating.

Material grade:EN-GJMB-450-6 in accordance with EN 1562

3.12.1 Surface coating of slide plates

  • The friction coefficient of the surface coating must be sufficiently low to allow the switch to be moved without any lubricant being applied to the slide plate.
  • The coating must be corrosion-resistant in the conditions under which the switch is to be used.
  • The coating must comply with the following requirements over its entire lifetime:
    • Friction coefficient against switch blade in dry conditions: maximum 0.65
    • Lifespan: minimum 10 years
    • Min. number of movements: 700 000

3.13 Bolts

Material grade:Durability category: minimum 8.8

3.14 Blade supports

Material grade:EN-GJMB-450-6 in accordance with EN 1562

4 Manufacture

Prior to machining, the supplier must 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 must be cut using chip-cutting tools. The edges of the cut surfaces must be bevelled at an angle of 45°.

4.2 Bending

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

4.2.1 Cold bending

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

4.2.2 Hot bending

  • Bending exceeding 5° must be performed at a temperature between +640 and +680 °C.
  • The rail must 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 must not be less than 30 minutes.
  • The temperature must be continuously monitored using temperature-sensitive chalk or a temperature meter.
  • To allow the material to cool slowly, the buckling point must be wrapped in thermally insulating sheets.
  • The time taken to cool from +600 to +20 °C must not be less than 7 hours.
  • The pressing blocks must match the rail profile and must 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 must be drilled with undamaged tools and coolant.
  • All drilled holes must be bevelled at an angle of 45°. If the rail is to be bent, holes must always be drilled after bending.
  • Plugging of holes with help of welding or other means is not permitted

4.4 Welding

  • Switch components must be electric arc welded only where indicated on the drawing.
  • Electric arc welding shall be carried out by welders certified in accordance with EN ISO 9606-1.
  • A welding procedure specification in accordance with EN 15607 must be prepared for every welded joint.
  • For aluminothermic welding of rail joints, the requirements set out in section Welding of rail joints apply.

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.

5 Adaption to actuation, locking and detection system

5.1 Switch blade - point machine interface

  • Switch blades in single turnouts shall be drilled according to Siemens ITS 710 with CKA12 template.
  • Switch blades in slip turnouts shall be drilled according to Siemens ITS 710 with CKA15 template.
  • Swing nose crossings shall be designed to accommodate Siemens ITS 710 CMB15 with CKA15 template.
  • On request, switch blades shall be drilled to Alstom MET templates.

5.2 Obstacle detection

  • Switches and crossings shall be designed to only lock and detect with a maximum gap of 10mm between the stock rail and switch blade, according to EN 13232-4, taking into account the following actuation forces:
    • 5 kN +/-0,5 kN at switch blade toe
    • 4 kN +/- 0,5 kN for other point machines

5.3 Minimum flangeway

  • Switches and crossings shall be designed to ensure a minimum flangeway of 58 mm according to EN 13232-4.

6 Switch point heating system interface

Switch blade assembly and movable crossings shall be prepared to accommodate cables and sensors in accordance with specification https://trv.banenor.no/ts/Lavspenning/Sporvekselvarme_-_TS_Switch_point_heating_system.

7 Assembly

7.1 General

7.1.1 Base

The base on which the switch is to be mounted must be stable and sufficiently flat for the assembly tolerances specified in section to be maintained.

7.1.2 Milling marks

All milling marks must be ground away at points where stretchers, blade bearers etc. are to be joined to the rail.

7.1.3 Tightening of bolts/nuts

  • Bolted joints with double circlips must be tightened until a gap of approx. 1 mm remains.
  • In the case of prestressed joints, the nuts must be tightened using a dynamometric wrench until the moment indicated on the drawing or specification is reached.

7.2 Curved switches

Curved switches must always be laid out and assembled for trial purposes at the factory.

7.3 Slip switches

In the case of single slip switches and double slip switches, the intermediate section must always be assembled for trial purposes at the factory. The rail joints are to be marked in a way that facilitates reassembly of the switch.

7.4 Welding of rail joints

Rail joints must be welded in accordance with Bane NOR standard Overbygning/Bygging/Helsveist_spor. The following welding processes may be used:

  • Elektro Thermit SoWos
  • Elektro Thermit SkV Elite L25
  • Railtech PLA

Welding work must be executed in accordance with a written welding procedure by welders trained in the method to be used. Welders and welding procedure shall be approved by Bane NOR prior to the work being carried out.

7.5 Switch blade assembly

  • On installation of the blade assembly, the maximum permitted clearance between blade and stock rail or blade and blade bearer is 1 mm.
  • The distance between the toe of the open blade and the stock rail shall be at least 140 mm.
  • The minimum distance between the open blade and the stock rail shall be 58 mm.
  • The blades shall be manufactured and installed in such a way that they are tension-free at 80 mm from the closed position.
  • The blades shall have the correct shape – straight or curved – when fully closed against the stock rail.
  • The blades shall be able to move unimpeded and connect properly with the stock rail in the closed position.

7.6 Tolerances

  • Acceptance tolerances shall comply with table 3, table 4 and table 6 in EN 13232-9.

7.6.1 Straightness of joints

The tolerances apply to the following types of joint:

  • Welded rail joints, including INOX joints between manganese steel and normal rail
  • Insulated rail joints

Deviations in the straightness of the running surface and running edge are to be checked over a measuring basis of 1 m. Tabell 1 shows the permissible variations.

Tabell 1: Straightness of joints

Running surface + 0,3 mm / - 0,0 mm
Running edge + 0,0 mm / - 0,3 mm

7.6.2 Crossings

The tolerances specified in EN 13232-6 and EN 13232-7 apply to crossings.

7.6.3 Switch blades

The tolerances specified in EN 13232-5 apply to switch blades.

8 Labelling

8.1 Main label

All switches are to be labelled with a manufacturer’s plate containing the following information:

  • Switch type
  • Rail profile
  • Gradient
  • Radius of turnout
  • Supplier
  • Date of installation

The manufacturer’s plate must be attached to the outside of the left-hand stock rail at the rail joint. The type of labelling used must be such that the information remains legible for at least 10 years after installation.

The following abbreviations for switch types must be used:

  • EV - Single switch
  • EKV - Single slip
  • DKV - Double slip

8.2 Slip switches

The individual components and joints of slip switches must be labelled to facilitate installation.

8.3 Marking of blade in neutral position

The position of the blade toe when closed against the stock rail with the switch lying in neutral position must be marked on the stock rail. The marking must comprise a stroke of white paint on the running surface and three centre-punch marks in the side of the stock rail at the point where the blade toe meets it.

9 Transport

9.1 Complete S&C

9.2 Switch and crossing components

  • Switch components must be stored and transported on a wooden base/frame at least 50 mm thick.
  • The base must be flat in order to prevent any permanent deformities.
  • Switch components must always be lifted using equipment that will not cause any permanent deformities.

10 Documentation

10.1 BIM model

  • The supplier must prepare a BIM model for every turnout 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 S&C, 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

10.2 Drawings

10.2.1 System drawings

  • The supplier shall prepare the following drawings prior to manufacture of any switch type:
    • Main drawing of entire switch assembly in plane view – scale 1:50
    • General drawing of switch section in plane view – scale 1:20
    • General drawing of crossing section in plane view – scale 1:20
    • Detail drawing of crossing in plane view, with necessary cross-sections – scale 1:5
    • Detail drawing of switch blade and stock rail in plane view, with necessary cross-sections – scale 1:5
    • Detail drawing of check rail and running rail in plane view, with necessary cross-sections – scale 1:5
    • Drawing of all types of baseplate
  • All text on the drawings shall be in Norwegian.
  • 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.
  • Bane NOR must be assigned all rights to the drawings.
  • All drawings must be approved by Bane NOR before production commences.

10.2.2 Assembly/installation drawings

  • Every switch assembly supplied shall be accompanied by the following drawings:
    • Main drawing of entire switch assembly in plane view – scale 1:50
    • General drawing of switch section in plane view – scale 1:20
    • General drawing of crossing section in plane view – scale 1:20
  • The drawings shall include sleeper numbers and all measurements necessary for assembly of the switch.
  • The drawings shall show the switch “as installed”, i.e. any curvature must be shown.
  • All text on the drawings shall be in Norwegian.
  • All drawings shall be supplied in both of the following electronic formats:
    • dwg (Autocad)
    • pdf
  • In addition to the supplier title block, the drawings shall include a Bane NOR title block.
  • Necessary information in Bane NOR title block in accordance with https://trv.banenor.no/wiki/Felles_bestemmelser/Generelle_bestemmelser#Tittelfelt_for_tekniske_tegninger, shall be given from Bane NOR prior to delivery.
  • Templates for Bane NOR title blocks can be downloaded here: https://trv.banenor.no/PDF/Felles%20bestemmelser-PB/Vedlegg/Nedlastinger/Arkrammer%20og%20tittelfelt.zip
  • Bane NOR must be assigned all rights to the drawings.

10.2.3 Parts lists

  • The supplier shall prepare a comprehensive parts list for each switch type. Parts lists must be supplied in Open Document Format (ODF).
  • For each S&C type, the supplier shall deliver a detailed description with material properties of all elastic layers in the fastenings and under sleeper pads.

10.2.4 Materials certificates

  • The supplier must maintain comprehensive records of each order for switches. These records must include materials certificates for the following components:
    • Switch blades/Stock rails
    • Rails
    • Crossing
    • Check rails
    • Base plates
    • Slide plates
    • Bolts/Nuts
    • Blade bearers
    • Filler material used in welded joints
  • The records are to be retained by the supplier, but must be available for inspection by Bane NOR at any time.
  • On request, the supplier must submit materials certificates to Bane NOR.

10.3 Welding certificates

Before signing the contract, the supplier must furnish Bane NOR with documents confirming the qualifications of welders.

10.4 Welding procedures

  • Before commencing production, the supplier must furnish Bane NOR with approved welding procedure specifications for all joints which are to be electric arc welded.
  • Welding procedures for aluminothermic welding of rail joints must be submitted to Bane NOR for approval before production commences.

10.5 Documentation of final inspection

  • Documents showing that a final inspection has been carried out in accordance with Final inspection 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.

11 Acceptance testing

11.1 General

  • Bane NOR reserves the right of free access to the supplier’s factory for the purposes of inspecting production, materials and documentation.
  • Acceptance testing shall be performed in accordance with EN 13232-9, chapter 8.

The supplier must prepare a set of templates for checking selected profiles within the switch assembly:

  • Distinctive blade profiles
  • Flangeways
  • Distinctive profiles within the crossing

11.2 Qualification tests

  • Prior to series production of any switch type not previously supplied by the supplier to Bane NOR, a prototype of the switch shall be inspected and approved by Bane NOR.
  • The prototype switch shall be assembled complete with sleepers so that the blades can be moved unimpeded.
  • Tests according to EN 13232-4, chapter 5 shall be performed for every type of switch&crossing.

11.3 Special switches

  • Prior to delivery of curved switches, crossovers, crossings or other special switches, Bane NOR may request that the switch is assembled complete with sleepers for inspection purposes.

11.4 Final inspection

The supplier must perform the following checks on each switch&crossing prior to delivery:

12 Reference documents

EN 13674-1:2011 +A1:2017 Railway Applications – Track – Vignole railway rails 46 kg/m and above
EN 13674-2:2019 Railway Applications – Track - Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above
EN 13674-3:2006 + A1:2010 Railway Applications – Track - Check rails
EN 13232-2:2003 +A1 Railway Applications – Track – Switches and Crossings -Requirements for geometric design
EN 13232-3:2003 +A1 Railway Applications – Track – Switches and Crossings -Requirements for wheel/rail interaction
EN 13232-4:2005 +A1 Railway Applications – Track – Switches and Crossings -Actuation, locking and detection
EN 13232-5:2005 +A1 Railway Applications – Track – Switches and Crossings -Switches
EN 13232-6:2005 +A1 Railway Applications – Track – Switches and Crossings - Fixed common and obtuse crossings
EN 13232-7:2006 + A1 Railway Applications – Track – Switches and Crossings - Crossings with moveable parts
EN 13232-9:2006 + A1 Railway Applications – Track – Layouts
EN 15689:2009 Railway Applications – Track – Switches and Crossings – Cast austenitic manganese steel for crossing components
EN 14587-3:2012 Railway Applications – Track Welding in association with crossing construction
Commission Regulation (EU) No 1299/2014 Technical specifications for interoperability - Infrastructure
Commission Regulation (EU) No 1302/2014 Technical specifications for interoperability - Locomotives and passenger rolling stock
Bane NOR Teknisk regelverk/Overbygning/Bygging/Helsveist_spor
Bane NOR Technical standards Bane NOR - Technical specification - Switches & Crossing sleepers
Bane NOR – Technical specification – Glued insulated rail joints with steel fishplates
Bane NOR - Technical specification - Sleeper screws
UIC 864-1 Technical specification - sleeper screws
EN ISO 9606-1:2017 Qualification testing of welders - Fusion welding - Steel
EN 15607:2019 Specification and qualification of welding procedures for metallic materials – General rules
EN 1562 Founding - Malleable cast irons
ISO 2768-1:1989 General tolerances for linear and angular dimensions without individual tolerance indications
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

13 Compliance list

14 Change log

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