0032 pandrol user guide edition 8 v6

Track Fastening Systems User Guide - Edition 8

Pandrol Track Fastening Systems User Guide - Edition 8 www.pandrol.com 0201

Contents

Introduction 03

Clip Applications & Colour Coding 04

Insulator Applications & Colour Coding 09

Pad Identification 15

Baseplate Assemblies for Timber Sleepers 18

Concrete and Steel Sleeper Assemblies 19

Special Applications 22

Identification of Pandrol Hand-Tools 27

Use Of Hand-Tools 36

Identification Chart for Anchorage Components 47

Machines for automated installation and extraction of FASTCLIP systems. 40

Track Support baseplates for Noise & Vibration mitigation. 41

Anchorage Systems for Pandrol Baseplates 45

Other PANDROL publications available

Pandrol FASTCLIP system literatureProvides detailedinformation on installingPANDROL FASTCLIP.

Pandrol VANGUARDProvides detailedinformation on Pandrolsvery resilient track formfor the highest vibrationmitigation.

Pandrol VIPAProvides detailedinformation on Pandrolsnoise and vibrationisolation system.

Pandrol FASTCLIP Track Installation GuideProviding practicalinstructions for thesafe installation ofthe FASTCLIP system.

Track Report 2011The journal of Pandrol Rail Fastenings 2011. This technical magazine contains authoritative articles written by railway experts from around the world about high-profile rail projects. It is published every 12 to 18 months.

Pandrol FASTCLIP FE systemThe literature describing the new generation of FASTCLIP.

Pandrol Re systemLiterature describing the new Re system for re-railing applications on older sleepers.

Pandrol SFC baseplatesProvides detailed information about SFC single resilience baseplates.


Introduction and how to contact PANDROL

This guide is intended for use by all those involved in the specification, installation and maintenance of Pandrol products for Network Rail in the UK. The products and systems are not applicable to other railways as system details vary between customers.

History of the CompanyPandrol is owned by the Delachaux Group and has been established in the business of resilient rail fastenings since 1937. Our first rail fastening was the Elastic Rail Spike, the very first resilient rail fastening for timber sleepers.This was manufactured at Worksop, largely for export, with factories being opened in South Africa and Australia in the early 1950s. In the early 1960s European railways began to move to concrete sleepers fitted with continuous welded flat bottom rail. The classic Pandrol PR clip was introduced at this time, firstly in the UK and then around the world.In the mid 1970s the Pandrol e clip was introduced offering a higher clamping force at a lower component cost due to more effective use of the steel section. During this period the number of factories world wide increased to twelve.In the early 1990s the Pandrol FASTCLIP system was introduced which combined the traditional virtues of the Pandrol system with pre-assembly of the fastening at the sleeper factory. This has led to major productivity gains wherever it has been introduced in particular with the new generation of automated track relaying equipment such as the TRT and NTC machines.

New information since Edition 7This edition of the booklet has been revised and many new products and systems have been added, including:

1. Pandrol Re system2. ZLR systems for rail free applications3. Glue-in and replacement shoulders4. Clips around IBJs.5. Clips around Balise units6. More efficient and safer hand-tools for FASTCLIP7. Expanded section on vibration mitigation baseplates for slab track and steel bridges

This booklet is intended to answer the most frequently asked questions relating to our products. However, if further information is needed, Pandrols Customer Support Engineers can be contacted for advice on:

T. 01909 476101 E. [email protected]. 01909 500004 www.pandrol.com

Clip Applications & Colour CodingFINISHES: Clips are available with either STANDARD or CORROSION PROTECTION (previously called SHERARDISED) finishes. CORROSION PROTECTION (CP) finish should be used in the following areas:

Note: 10kN = 1 Tonne Wet tunnels Coastal areas Level crossings Adjacent to heavily salted roads and platforms

Standard Finish: Green 57/48048 CP Finish: Purple 57/48055 Type: FC 1504

Used on G44 and EG47concrete sleepers alsoSeries 560, 560H, 600, HH10, Mk2 and HH12 steel sleepers.Nominal toe load per clip = 10kN

Standard Finish: Red 57/48033 CP Finish: Grey Gloss 57/48056 Type: FC 1501

Used on F41 and EF36 concrete sleepers and Series 500 steel sleepers.Nominal toe load per clip = 10kN

Standard Finish: Cat. No. not allocated. CP Finish: Blue 57/02029 Type: FC 1503

Used only for Pandrol Type SFC baseplates for slab track.Nominal toe load per clip = 10 kN


Type: e-Plus - eP20127 Standard Finish: Red 57/48237 CP Finish: Grey Gloss 57/48307

Used on F27, EF28 and W402 sleepers whereextra resilience and insulator durability isrequired. Fitted with integralType 9903 toe insulator.Nominal toe load per clip = 12.5kN

Type: e-Plus - eP20129 Standard Finish: Green 57/48236 CP Finish: Blue Gloss 57/48308

Used on NR60 S&C, also on EG49 sleepers with 60E1 rail.Nominal toe load per clip = 12.5 kN

Type: e-Plus - eP20130 Standard Finish: Yellow 57/48252 CP Finish: Purple Gloss 57/48309

Left hand version of eP20129.Nominal toe load per clip = 12.5kN

Type: Re Clip - Re1609 Standard Finish: Red 57/48469 CP Finish: Matt Grey Cat No. Not allocatedUsed on F23 to F27, EF28, 5EF28, W402 sleepers for re-railing operations, used in conjunction with pad type 14229. Clip is fitted with integral toe insulator not separately available.Nominal toe load per clip = 9 kN

Standard Finish: Red 57/48255 CP Finish: Matt Grey 57/48031 Type: e1809

For use in F40 sleepers with a Blue (HVN)insulator. For use in all other sleepers with anOrange (Nylon) insulator. Must not be used with Grey Cast Iron PAN Type Baseplates.Nominal toe load per clip = 9kN

Standard Finish: Yellow 57/48256 CP Finish: Black Gloss 57/48043 Type: e1810

Left handed version of e1809.Used in IBJs in various situations, see page 25. Nominal toe load per clip = 9kN

Standard Finish: Purple 57/48247 CP Finish: Bright Red Gloss: 57/48044 Type: e2001

High toe load clip for F27/EF28 sleepers, used in difficult areas where insulator crushing or creep is occurring. Must be used with white insulator, either type 2433 or type 6924.Nominal toe load = 12.5 kN

Standard Finish: Blue 57/48248 CP Finish: Grey Gloss 57/48045 Type: e2007High toe load clip which is interchangeable with either PR401A or e1809 clip types. Should NOT be used in applications fitted with orange insulator type 724a. Also used with IBJs in NR60 S&C. See page 25. Nominal toe load = 12.5 kN

CP Finish: Green 57/48587 Type: e2071Clip only used for Zero Longitudinal Restraint (ZLR), to convert the following sleeper types to rail free assemblies: F23 to F27, EF28, 5EF28, W402, F40 & 5F40, with other specialist components.(See separate section on page 23)




Type: PR401A Standard Finish: Red 57/48239 CP Finish: Matt Grey 57/48253

For concrete sleepers and all PAN plates EXCEPT obsolete PAN1 to PAN5 where PR303 clips were used.Nominal toe load per clip = 6.5kN

Type: PR402A Standard Finish: Blue 57/48243 CP Finish: Grey Gloss 57/48234

Left handed version of PR401A.Nominal toe load per clip = 6.5kN

Type: PR427A Standard Finish: Purple 57/48245 CP Finish: Bright Red Gloss 57/48242

Maintenance replacement for PR303 in PAN 1 to PAN5 baseplates.NOT suitable for other types of baseplate.Nominal toe load per clip = 6.5kN

Type: PR428A Standard Finish: Green 57/48244 CP Finish: Yellow Gloss 57/48249

Maintenance replacement for left handed PR304 in PAN 1 to PAN5 baseplates.NOT suitable for other types of baseplate.Nominal toe load per clip = 6.5kN

Standard Finish: Red 57/48450 CP Finish: Matt Grey 57/48046 Type: Panlock

Clip for Bull Head Rail

Catalogue No. 57/48781 A1 Spike

Original A1 Elastic Rail Spike.Elastic spikes are only supplied in Standard finish. The A1 spike is red colour.

Catalogue No. 57/48785 AL23 Maintenance Spike

Maintenance replacement for A1 SpikeElastic spikes are only supplied in Standard finish. The AL23 spike is supplied in two parts. The inner part is black and the outer part is red, and fit together as shown.

Left-Handed ClipsNon-symmetrical clips (PR, e, e-PLUS, & Re) are normally right-handed and should be inserted into the shoulderanchor point from the right-hand side of the shoulder, when facing the rail. Left-handed variants are required in areas of restricted access around the shoulders, and are fitted from the opposite end of the shoulder (i.e the left-hand side of shoulder). Left-handed clips are typically needed around IBJs and S&C layouts.

The equivalence chart below shows which clips are interchangeable between the standard right-handed and left-handed variants.

Right-Handed Clips Equivalent Left-Handed Clips

PR401A PR402A

PR427A PR428A

e1809 e1810

eP20129 eP20130




Catalogue Number: 57/48118 FASTCLIP Type 8277

Side post insulator (Yellow) 13mm sidepost thickness, for use on HH10 Mark 1 sleepers with Type 9922 hook in shoulders.

Catalogue Number: 57/48111 e-PLUS Type 9132

Sidepost Insulator (Blue)Used with eP20127 clip on F27, EF28, W402 sleepers and NR56V S&C.


Sidepost Insulator (White)Used with eP20129 clips on F40 sleepers and NR60 S&C.


Gauge Management Insulator (Black)10mm sidepost insulator, used for NR60 S&C.


Gauge Management Insulator (Green)6mm sidepost insulator, used for NR60 S&C

FASTCLIP Type 8582 Catalogue Number: 57/48064

Sidepost Insulator (Blue)16.4 mm sidepost thickness. For use on the FIELD side of the 56E1 rail when fitted to G44, EG47, Series 560, 560H, 600, HH10 Mk2 and HH12 sleepers. Also used to replace obsolete insulator type 9373 previously used for hook-in shoulders with steel sleepers.

FASTCLIP Type 7551 Catalogue Number: 57/48021Sidepost Insulator (White)8mm sidepost thickness. Used on G44, EG47, Series 560, 560H, 600, HH10 Mk2 and HH12 sleepers with 60E1 rail. Used on F41, 5F41, 5EF36 and Series 500 steel sleepers with 56E1 rail. Also used to replace obsolete insulator type 8914 previously used for hook-in shoulders with steel sleepers.


Sidepost Insulator (Black)10mm sidepost thickness. For use on the GAUGE side of the 56E1 rail when fitted to G44, EG47, Series 560, 560H, 600, HH10 Mk2 and HH12 sleepers. Also used to replace obsolete insulator type 9374 previously used for hook-in shoulders with steel sleepers.


Sidepost Insulator (Green)6mm sidepost thickness. Used in limited areas where oversize 60E1 rail was supplied. Used in place of the GAUGE side Type 7551 sidepost Insulator.

Insulator Applications & Colour Coding



Toe Insulator (White)For use on all sleeper types fitted with the FASTCLIP system.

e-PLUS Type 9903 Catalogue Number: 57/48113

Toe Insulator (White)Previously coloured blue. Not supplied separately, always supplied already fitted to the e-PLUS clip types

Orange (Nylon) Type 724a Catalogue Number: 57/48424

5mm sidepost thickness x 5mm blade thickness. Used for: F23 , F24 series, EF25, F27, EF28, EF29, EF32, EF33, F34, F35 concrete sleepers and 400 series, steel sleepers with 56E1 or BS110A or BS110A rails.

Blue (Nylon) Type 724a Catalogue Number: 57/484235mm sidepost thickness 5mm blade thickness used where 98lb and 109lb rail is installed.Used for concrete sleeper types: F23, F24, EF25, F27, EF28, EF29, EF33, F34, & F35, as well as steel sleepers 400 Series. note: This insulator is not commonly available, and can be replaced with Pandrol type 6924 provided this is used with clip type e2001.

Insulator Applications & Colour Coding

Catalogue Number: 57/48027 Blue (GRN) Type 4452.

8mm sidepost thickness x 8mm blade thickness used on: F40 and 5F40 sleepers

Catalogue Number: 57/48436 White (GRN) Type 24335mm sidepost x 8mm blade thickness (previously coloured black) used with e2001 clip. Also used on F40 & 5F40 sleepers as part of the range of gauge management insulators to adjust the track gauge, by moving the rail across the rail seat. This insulator can be upgraded to use HVN by substituting insulator type 6924, which is an identical size.

Catalogue Number: Not allocated White Type 6924White (HVN) type 6924, 5mm side post x 8mm blade thickness used with e2001 clip. Also can be used with NR56V S&C to replace composite insulators. This HVN insulator is sufficiently flexible to be used as a replacement for Blue nylon insulator Catalogue No. 57/48423 with either 98lb or 109lb rail, but can ONLY be used with e2001 clips

Catalogue Number: 57/48434 Brown(HVN) Type 758312mm sidepost x 8mm blade thickness. Used as part of the range of Pandrol insulators to provide gauge management by adjusting the position of the rail in the rail seat. A separate data-sheet is available to advise the methods and adjustment range achievable. Gauge management can be provided for concrete sleeper types: F40, & 5F40.


Red (HVN) Type 10274 Catalogue Number: 57/48082

Insulator for 56E1 rail on FIELD side of:1. NRS1/NRS2/Combi baseplates2. EG49 concrete sleepers

Yellow (HVN) Type 10275 Catalogue Number: 57/48081

Insulator for 56E1 on GAUGE side of:1. NRS1/NRS2/Combi baseplates.2. EG49 concrete sleepers

Green (HVN) Type 5720 Catalogue Number: 57/48060

Insulator for use with 60E1 rail using:1) NRS1/NRS2/Combi baseplates

with 60E1 rail.2) 6 Hole IBJs on NR60 S&C3) EG49 Concrete sleepers

Composite Catalogue Number: 57/48427(Nylon with cast iron cover plate) for:1. Concrete S&C bearers.2. As a substitute for ORANGE (Nylon)

insulators where the wear rate is unacceptable. NOTE. This insulator insulator is not commonly available, and can be replaced with Pandrol type 6924 provided this is used with clip type e2001.

Insulator Applications & Colour Coding Catalogue Number: 57/48166 Composite (Black) Type 2786/1

6mm sidepost thicknesses

Catalogue Number: 57/48167 Composite (Blue) Type 2786/2

7.5mm sidepost thicknesses

Catalogue Number: 57/48168 Composite (Red) Type 2786/3

9mm sidepost thicknesses

Catalogue Numbers: 4mm = 57/48169 8mm = 57/48170 12mm = 57/48171 Composite Cover Plates

Composite cover plates Type 2787, to provide 4, 8 and 12mm blade thicknesses

Catalogue Number depends upon insulators and cover plates selected Composite Insulators

For level and gauge adjustment on slab track installations.Plastic insulators and metal cover plates are combined to give a variety of blade and sidepost thicknesses.

Pandrol Track Fastening Systems User Guide - Edition 815

Pad IdentificationPANDROL pads are an important part of the rail fastening system.Rail pads provide a conforming layer between the rail seat and the rail, provide electrical resistance, and protect concrete sleepers from impact loading.Modern pads are 10 mm thick. Low stiffness studded rubber pads are used for 25t axle loads on concrete sleepers. Stiffened pads are used for 30t axle loads on concrete sleepers to prevent excessive dynamic gauge widening. Steel sleepers use hard EVA pads of 10mm thickness.

Catalogue Number: 57/48278 Pad No. 8531

Thickness: 10mmMaterial: Studded EVAUsed on FASTCLIP steel sleepers 56E1 rail.


Thickness: 10mmMaterial: Studded RubberUsed on F40 and 5F40 sleepers.


Thickness: 10mmMaterial: Studded RubberUsed on FASTCLIP concretesleepers with 56E1 rail.


Thickness: 10mmMaterial: Studded RubberUsed on FASTCLIP concretesleepers with 60E1 rail.

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Pad No. 14229 Catalogue Number: 057/48470

Studded EVA rail pad 8mm thick bonded to HVN side insulators of 5.5mm thick.Used with Re1609 clip for re-railing to replace orange insulators on older sleeper types F23 to F27, EF28, 5EF28, W402, HH10 (Mk1).

Pad No. 2061/3 Catalogue Number: 57/48521

Thickness: 5mmMaterial: Flat EVAUsed with W402 sleepers and PAN baseplates.Can also be used with concrete sleeper types: F23, F24 ,EF25, F27, EF28, EF32, EF33, F34, F35.


Thickness: 10mmMaterial: Studded EVAUsed on FASTCLIP steel sleepers with 60E1 rail.Supersedes / interchangeable with 7850.



Thickness: 8mmMaterial: Studded RubberUsed on F27 and EF28sleepers when fitting the e-Plus system.


Thickness: 10mmMaterial: Studded RubberUsed on e-Plus RT60 and NR60 layouts.


Thickness: 10mmMaterial: Studded RubberUsed on EG49 sleepers with either 56E1 or 60E1 rails.


Thickness: 10mmMaterial: Studded RubberUsed on NRS 1, NRS2,and Combi baseplates.

Pad Identification Baseplates for Timber Sleepers

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Baseplate Types

Pandrol Clips Used

Number of Pandrol Housings

Comments

PAN 1 to PAN 5Originally fitted with PR303, can be fitted with PR427A x 2

4 Baseplates no longer available. Only 2 housings and clips should be used

PAN 1 to PAN 12 and PAN 14 PR401A x 2 Either 2 or 4

Only 2 housings and clips should be used in any of these baseplates. Note the extra housings should only be used in the event of the first housings wearing or failing

CC PAN 1 - 44 PR401A x 1PR402A x 1 2 Checkrail baseplates

HO PAN PR401A X 1PR402 X 1 2

PAN 14SG e1809 x 2 4 Only 2 housings should be used. Only use e clips with SGI grade cast-iron.

Various other baseplates including: V, VN, CV, RCV

PR401A x 2 Either 2 or 4 Only 2 housing should be used in any of these baseplates.

NRS1 & NRS2, or Combi baseplates

e2007 2

Dual rail baseplate for either 56E1 or 60E1/2. Other components: Pad Type 7031 Insulator Types: 60E1 = 5720 56E1 = 10274 & 10275

The Vortok Coil is used to refurbish timber sleepers with worn screw spike holes. The coils restore 90% of both the original pull-out strength and the torque of the screw to improve the positioning and dynamic gauge performance of the baseplates.

Catalogue Nos: Standard Coil 057/048034 Large Coil 057/048298


Concrete & Steel Sleeper AssembliesConcrete & Steel Sleeper Assemblies

Sleeper Type(s) Clip Insulators Pad NominalTrack Gauge

Current CONCRETE sleepers

G44, EG47 for 56E1 rails

FC1504 with 8494 toe

FIELD side: 8582 (Blue)GAUGE side: 8690 (Black)

Pad 6650, except: Curves less than 400m

radius, fit EVA type 8531 Low line speed, fit EVA

type 8531

1436mm

G44, EG47 for 60E1/2 rails

FC1504 with 8494 toe Both sides: 7751 (White)


radius , fit EVA type 9970 Low line speed, fit EVA

type 9970

1438mm

Current STEEL sleepers

560H for 56E1 rails NOTE. This sleeper is fitted with hook-in shoulder type 9482.


FIELD side: 8582 (Blue)GAUGE side: 8690 (Black) Pad 8531 1436mm

560H for 60E1 / 2 railsNOTE. This sleeper is fitted with hook-in shoulder type 9482.

FC1504 with 8494 toe Both sides: 7751 (White) Pad 9970 1438mm

Sleeper Type(s)

Clip Insulators Pad NominalTrack Gauge

Discontinued / serviceable older CONCRETE sleeper types

EG49 for 56E1 rails e2007

FIELD side: 10274 (Red)GAUGE side: 10275 (Yellow) Pad 5197 1436mm

EG49 for 60E1/2 e2007 Both sides: 5720 (Green) Pad 5197 1438mm

F41 & EF36 FC1501 with 8494 toe Both sides: 7751 (White)


radius, fit EVA type 8531 Low line speed, fit EVA

type 8531

1435mm

F40e1809 Both sides: 4452 (Blue) Pad 4548 1432mm1435mm5F40

Alternative assemblies for F23 to F27, EF28, EF29, EF33 sleepers:

1. Standard toe-loads

PR401A ore1809

56E1 rail:Both sides: 724a (Orange)98lb or 109lb rails:Both sides: 724a (Blue)

Pad 5mm rubber, or 7.5mm rubber maintenance pad, or EVA Pandrol type 2061/3.

1432mm

2. Increased toe-loads e2001

56E1 rails:Both sides: 2433 (GRN White), or 6924 (HVN White)

Pad 5mm rubber or EVA pad type 2061/3 1432mm

3. e-PLUS system eP20127 56E1 rails:Both sides: 9132 Pad 9286 1432mm

4. Pandrol Re system Re1609

56E1 rails:No separate insulator Composite pad type 14229 1432mm

Concrete & Steel Sleeper Assemblies


Sleeper Type(s) Clip Insulators Pad NominalTrack Gauge

Discontinued / serviceable older STEEL sleeper types

HH10 (Mk 2), HH12, for 56E1 railsShoulder types: HH10 = shoulder 9922 HH12 = shoulder 9482


FIELD side: 8582 (Blue)GAUGE side: 8690 (Black) Pad 8531 1436mm

HH10 (Mk 2), HH12, for 60E1/2 rails HH10 = shoulder 9922 HH12 = shoulder 9482

FC1504 with 8494 toe Both sides: 7751 (White) Pad 9970 1438mm

500 Series FC1501 with 8494 toe Both sides: 7751 (White) Pad 8531 1435mm

W402 Series HH10 (Mk1) for 56E1 rail

PR401A or e1809

56E1 rail:Both sides: 724a (Orange)

Pad 5mm EVA Pandrol type 2061/3. 1435mm

Alternative assembly converting HH10 (Mk1) to FASTCLIP system using shoulder type 9922

FC1504 with 8494 toe Both sides: 8277 (Yellow) Pad 8531 1435mm

Conversion of obsolete fastenings on very old concrete sleepers

The following obsolete sleepers may be converted to Pandrol e clip assemblies: F10 using BJB

fastenings RNB6 also known as

KENITRA sleepers HEYBACK sleepers

Whilst conversions have been available and undertaken in large volumes in the past, the components are no longer readily available, generally regarded as uneconomic, and anyone attempting this process should contact Pandrol directly for advice.

Special Applications1. Replacement shoulders for concrete and steel sleepers, and concrete

slab track. This identifies the shoulders to be used for replacement in the unlikely event of damage in track.

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Shoulder Type Sleeper Type(s) CommentsShoulder type 8888R G44, and EG47

This shoulder is ONLY available as part of a complete supply and replace-ment service provided through the approved specialist subcontractor HOLEMASTERS.

Catalogue No. Not allocated

Modification of standard shoulder.Shoulder type 9922 HH10 Hook-in shoulder for 10mm thick

steel sleepers.

Catalogue No. 057/048072

Shoulder type 9482 HH12, 560H Series. Hook-in shoulder for 12mm steel sleepers.


Shoulder type 7250Concrete slab trackStandard finish:Catalogue No. 057/048071

For slab track in tunnels:Sherardised finishCatalogue No. 057/048063

For use with 10mm pads and either:e clip assembly using GRN insulator type 4452 (blue)Ore-PLUS assembly using eP20129

Special Applications2. Zero longitudinal restraint (ZLR) assemblies to provide rail free

longitudinal movement of the rail.Used to provide differential movement between the rails and long bridge structures, or stressing relief for ground subsidence due to mining activities.ZLR assemblies use normal toe-load clips, but divert the clamping force in other directions providing a gap over the rail foot and allowing the rail to slide longitudinally in the gap. In the event of the rail moving to close gap (such as rail roll) the nominal toe-load is immediately available to prevent further overturning movement.The components below can be used with existing sleeper configurations to alter the fastening assembly into a ZLR assembly.


Special Applications

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Sleeper Type(s)

Pandrol Assembly No. Components & Catalogue Nos.

F23 to F27, EF28 5EF28, and W402

15206 (covers all sleeper types)

EVA 5.5mm pad type 2061 Cast-iron cover plate type 7015

Clip type e2071 NOTE: Sherardised finish ONLY

Catalogue Number: 057/048521



F40 and 5F40 15207 (covers all sleeper types)

EVA 10mm pad type 12697

Cast-iron cover plate type 7015

Clip type e2071 NOTE: Sherardised finish ONLY




Sleeper Type(s)

Pandrol Assembly No. Components & Catalogue Nos.

G44, EG47 and EG47-3R

15208 for 56E1 rail

EVA 10mm pad type 8531 Sub-assembly 15227 comprising clip type FC1504 with ZLR insulator


Catalogue Number: 057/048589 NOTE:The ZLR insulator is BLACK

15229 for 60E1 / 2 rail

EVA 10mm pad type 9970 Sub-assembly 15227 comprising clip type FC1504 with ZLR insulator


Catalogue Number: 057/048589 NOTE:The ZLR insulator is BLACK


Special Applications4. Anchorage for Balise mounting frames.Vortok Balise Mounting System (BMS)The Vortok BMS is fitted to either concrete or steel sleepers using the rail clips to hold the beams in place between the shoulders of the sleepers. The beams are used with either e clip or FASTCLIP as shown below.

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Special Applications3. Insulated Block Joints

FASTCLIP with IBJS

6-hole IBJ on concrete sleeper type EG47.

6-hole IBJ on steel sleepers, showing standard FASTCLIP components. The clips fit snuggly into the recesses of the IBJ, and clip extraction is carried out using a rear-arch FASTCLIP extractor.

e Clips with older concrete sleepers6-hole IBJ on older types of concrete sleepers. The clips should be:Right handed locations: e1809Left handed locations: e1810Both clip types are used with orange or composite insulators , except for F40 sleepers which use blue GRN type 4452 insulators.

Other clips with S&C layoutsNR60 details in e-PLUS (eP20129) layout. NOTE: e-PLUS clips do not fit beneath the IBJ bolts. The clips should be:Right handed locations: e2007Left handed locations: e1810 Both clip types are used with green insulator type 5720

In layouts to NR56V design the IBJ will be mounted on 8mm thick pads, and the clips should be:Right handed locations: e2001Left handed locations: e1810Both clip types are used with orange or composite insulators.

Balise units on FASTCLIP sleepers TYPES G44 / EG47, F41 & EF36

The frame sits beneath the rear arch of the standard FASTCLIP in each sleeper type.

e Clips with older concrete sleepers

The frame is anchored in position using Pandrol clip type e2001. The new clip should replace the original clip on the GAUGE side of the rail seat, and is usually supplied as part of the BMS system by Vortok.


The new tools, which react from the rail, are more efficient, faster and safer because they are not prone to slipping from the shoulder reaction points. Additionally, the tools offer compatibility with a wide range of Pandrol systems, including FASTCLIP FC & FASTCLIP FE and the Pandrol baseplate types VIPA-SP & SFC baseplate. Finally, because the reaction point for the installation tool has been moved to the head of the rail, the installer is able to lift sleepers (about 20mm) as part of the normal action of the tool, lifting from the rear arches of the clip before driving the clip into the installed position.

Installer (FASTCLIP FC, FE, VIPA-SP, SFC) FASTCLIP Installer LP18681Catalogue No. 39/47850

Extractor (FASTCLIP FC, FE, VIPA-SP, SFC) FASTCLIP Installer LP18679Catalogue No. 39/47851

The original version of the sleeper lifter can still be used in conjunction the new installer where sleepers need to be lifted more than 20mm. The rear arch extractor remains available to extract clips around IBJs.

Sleeper lifter for FASTCLIP FC, & FE PANDROL No. LP12608Catalogue No. 39/47852

Rear arch extractor for FASTCLIP FC

PANDROL No. LP15177Catalogue No. not allocated

Identification of Pandrol Hand-Tools

The new range of FASTCLIP tools also for VIPA-SFC

Discontinued FASTCLIP and VIPA-SP tools.

The original versions of the FASTCLIP hand-tools are illustrated below, and these remain suitable for use. Pandrol has discontinued the original versions from sale.

The original FASTCLIP tools have now been superseded with new tools which are more efficient, faster to use and safer. Both of the new tools look different from the earlier tools, because they react from the rail instead of from the shoulder in the sleepers. See the section on the opposite page.

The original versions of the VIPA-SP & SFC hand-tools are illustrated below, and these remain suitable for use. Pandrol has discontinued the original versions shown below.

The original VIPA-SP tools have now been superseded with new tools which are more efficient, faster to use and safer. See FASTCLIP hand-tools on the opposite page The new tools are compatible with FASTCLIP FC and FASTCLIP FE systems, as well as VIPA-SP & SFC baseplates, reducing the risk of the selecting the incorrect tools.


Hyrdaulic tools for VANGUARD and FASTCLIP

Rosenqvist Handy Clipper( Network Rail Acceptance Certificate PA05/03211)

A versatile lightweight clipping/unclipping machine dedicated to Pandrol FASTCLIP. With one man operation, the Handy Clipper is easily transported to site and will fit in the back of an estate car. It incorporates automatic sleeper lifting of up to 10mm. At maximum output 10 sleepers a minute can be achieved.


Vanguard Hydraulic Tool

PANDROL No. LP15647Catalogue No. Not AllocatedVanguard Installer & Extractor

Refer to separate Pandrol instructions for the use of the VANGUARD hydraulic tool.

Fastclip Hydraulic Tool

RAILTECH TYPE CDH 16Catalogue No. Not Allocated

Catalogue Number: Not Allocated PANPULLER Type D For PR, & e Clips

PANDROL No. LP7632Especially for e2001 and e2007clips but NOT for 4-shoulder baseplates. NOTE hook positions for max efficiency:Upper pivot: Clip installationLower pivot: Clip extraction

Catalogue No. 39/42748 PANPULLER Type C for PR, & e Clips

PANDROL No. LP1180And for 4 shoulder baseplates

Catalogue No. Not allocated e-PLUS PANPULLER LP12717

PANDROL No. LP12717Colour: Red working head (matches the appropriate e-PLUS clip type), and yellow handle. For use with eP20127 clips for retrofitting to sleeper types: F27, EF28, 5EF28, and for the new S&C designs to NR56V.

Catalogue No. 39/42749 e-PLUS PANPULLER LP15923

PANDROL No. LP15923Colour: WhiteThe tool is used with the eP20129 green or eP20130 yellow e-PLUS clips, mostly with RT60 and NR60 S&C layouts.


Place curve of gauge into hook. Gauge can be used with out removing the hook from the PANPULLER.

Surfaces A and C in contact and gap at B Hook suitable for use.

Surfaces B and C in contact and gap at A Hook unsuitable for use.

Replacement Hooksfor e-Plus Panpuller:Catalogue Number 39/42742 Pandrol Number 3P16127

Replacement Hooksfor Standard Panpuller:Catalogue Number 39/42743 Pandrol Number 3P2260

It is recommended for safety reasons that contractors should formally check and record the wear of the hooks at intervals of 6-months using the wear gauge described above. The gauge is suitable for all types of PANPULLER or e-PLUS PANPULLER. The wear gauge provides easy Go / No-Go assessment of when to replace the hook.Worn hooks have a tendency to slip off the clips, which can present a significant risk to operators.

Use of Wear Gauges

Catalogue No. 39/42900 PANSETTER for PR, e, e-PLUS & Re clips

PANDROL No. 2-P9559THE PANSETTER is suitable for all Network Rail Sleepers fitted with PR, e & e-PLUS


Tools with cranked handles for operation in the 4-foot.A further option is available on Pandrol hand-tools for operation whilst standing in the 4-foot, typically needed through platform areas, or in track with 3rd rail electrification. Cranked handles alter the swept arc of the handle to operate safely whilst standing in the 4-foot. All the FASTCLIP tools have optional cranked handles.

Optional Handles Catalogue Nos. for tools with straight insulated handles.

All Pandrol hand-tools can be supplied with optional insulated handles, which have recently been upgraded to 35mm diameter cylindrical handles with T cross bars for improved ergonomic and safer use. The photograph shows a typical handle attached to a FASTCLIP sleeper lifter.

PANPULLER type C: Catalogue No. 39/40129

PANSETTER: Catalogue No. 39/40133

PANLOCK Puller: Catalogue No. 39/40135

FASTCLIP installer: Catalogue No. not allocated

FASTCLIP extractor: Catalogue No. not allocated

FASTCLIP lifter: Catalogue No. not allocated

Replacement Hook for Types C and D PANPULLER


PANDROL No. 3-P2260

Replacement Hooks e-Plus PANPULLERS

LP12717 - Catalogue Number: Not AllocatedLP15923 - Catalogue Number: 39/42742

PANDROL No. LP12717use replacement hook type 2P5931

PANDROL No. LP15923use replacement hook type 3P16127

PANPULLER Hook Wear - Gauge Catalogue No. 39/30100

PANDROL No. 3-P6536



Handtools for Panlock and Elastic SpikesHammers should NEVER be used for either insertion or extraction of PANLOCK.

Hammers may be used for the loosening of rusty PANLOCK, but NOT to fully extract.

Hammers can be used for the insertion of elastic spikes.

PANLOCK Puller Catalogue No. 40/60549

PANDROL No. LP8452

Elastic Spike Extractor Catalogue No. 39/17090

Elastic Spike extractor available from Tool and Steel; Product code: TASTE112

Vortok Stressing Roller (VSR)

The VSR is a multi function stressing roller. It combines both the side and under roller requirements for stressing rail. It also incorporates a lift function removing the need for track jacks.

The Vortok Stressing Roller is available for:

FASTCLIP (0094/018014) e clip (0094/018013) FASTCLIP FE (Application

Pending)

Catalogue No. 094/018014 Catalogue No. 94/018013


Side Roller LP16668 for Pandrol Vipa Under Roller LP17469 for Pandrol VipaHooks over the shoulder on the inside of the track curve, and tightens using the screw to adjust the ball-bearing to touch the web of the rail. Use at least one roller every 10 rail seats, depending upon the severity of the curve.

This simple wire roller fits on top of the rail pad once the rail has been lifted out of the rail seat. It is a low friction roller designed to provide an even distribution of the tension from the hydraulic stressing jacks.

Catalogue No. Not allocated Catalogue No. Not allocated


Cat No. 0039/47855 Side Roller FC1500l - 56

Cream with BLUE handle for 113A rail on FIELD side.

Cat No. 0039/47856 Side Roller - FC1500l - 44

Cream with BLACK handle for 113A rail on GAUGE side.

Cat No. 0039/47857 Side Roller FC1500l - 52

Cream all over for CEN60 rail on either side of rail seat.


Discontinued Rollers for FASTCLIPPANDROL UNDER-ROLLER Type 1P10385 is now obsolete and should NOT be used for stressing with FASTCLIP. Pandrol side rollers for dual rail sleeper types have been discontinued. However the original side rollers should only be used with conventional under-rollers. Therefore the recommendation for stressing is to use VSR equipment detailed on page 34.

www.pandrol.com 36

Use Of Hand-Tools

PANDROL PR and e-CLIP & Re clip types Installation Instructions

Instructions for Panpuller LP1180 and e-Plus Panpuller LP12717 Insert centre leg of clip into housing. Place pivoted hook over the inside of the front arch of clip with

foot of Panpuller behind clip housing and ensure lip of the hook is under the front arch.

Taking up a natural stance behind the Panpuller, with both hands on tee handle at top of Panpuller, pull strongly towards chest until refusal.

The Panpuller automatically pulls clip to the correct position

e-Plus Panpuller -eP20129Catalogue No. 39/42749 Pandrol Number - LP15923

e-Clip and Re Clips Pull until refusal. Panpuller does not act as a stop due to shorter centre leg of clip.

e-Plus Clip When correctly installed the centre leg of ALL types of e-PLUS clips, protrude beyond the shoulder to hold the side-insulator in the correct position.

For instructions on the use of FASTCLIP tools and methods, refer to the separate booklet entitled: PANDROL FASTCLIP Track Installation Guide


Use Of Hand-Tools

PANDROL PR and e-CLIP & Re type clips Extraction Instructions

Reverse the Panpuller. Taking up a natural stance on the same side as for installation,

place hook on the outside of the front arch of the clip, the foot of the Panpuller resting on the baseplate/housing just above the centre leg of clip (as illustrated).

Standing behind Panpuller with both hands on the tee handle at the top of Panpuller, give a strong firm push away from your chest.

If clips have been in situ for many years, it may be necessary to use a hammer to loosen them taking safety precautions. If the clips will not move then use the Rusty Clip Extractor can be used for PR clips.

NOTE. It is mandatory to wear eye protection when removing or fitting any clips where hammer assistance might be necessary.

Soft-faced hammers

Soft-faced hammers can be used to extract PR, e e-PLUS and Re type clips, provided the following has been agreed on each site. The use of hammers should only be attempted with the agreement of Network Rail, using suitably trained and supervised track teams. The risks of the inappropriate use of soft faced hammers fall into 2 categories. PR, e and e-PLUS & Re type clips can generally withstand the use of hammers so the risks are:1. PR, e and e-PLUS & Re type clips MUST be caught at the point of extraction to prevent clips flying.See the boot of the operator in the photograph.2. Poorly controlled hammers can injure personnel and damage other components

The photograph shows the typical use of a soft faced hammer to extract any of the following clip types: PR, e, Re, e-PLUS.

Use Of Hand-Tools

Pansetter

Used for lifting the sleeper to the rail foot. It pushes the rail over, leaving the correct gap between the rail foot and the Pandrol housing, so that the insulator can be easily placed in the correct position.

Catalogue Number 39/42900

Pandrol Number 2P9559

PANDROL PR Rusty Clip Extractor

If the clips have not been disturbed for a long time, rust can develop between the centre leg of the clip and the inner face of the housing.This problem has mainly occurred with concrete sleepers in tunnels. With this situation, considerable force may be needed to remove the clips from their housings. By using such force the concrete around the housing may break away, making the sleeper unserviceable.To overcome this difficulty, Pandrol has developed the Rusty Clip Extractor to remove whole clips. If the clip has broken then the tool will remove the clip centre leg. Suitable for PR401A clips only.

NOT suitable for use on slab track.



PANDROL PR , e, e-PLUS and Re Clips


Use Of Hand-Tools


If the Panlock has been installed for a long time, it may be necessary to loosen the fastening with a hammer prior to extraction with the PANLOCK PULLER. NOTE. It is mandatory to wear eye protection when removing or fitting any clips where hammer assistance might

be necessary. For maximum effectiveness Panlocks should not be mixed with other bull head rail fastenings. Also ensure the

chair is square to the rail.

PANDROL PANLOCK Installation Instructions

Place Panlock in chair from right hand side with open curled end to rail web.

Place Panlock-Puller head against rail head and on top of chair jaw with lower arm under rail foot.

Ensure curved toe of handle enters leading curve of Panlock.

Take up a firm stance with both hands on the tee handle and pull until Panlock is fully installed when Panlock-Puller toe will disengage from Panlock.

Remove tool. Check Panlock is located centrally in chair.

Panlock Puller:Catalogue Number 40/60549 Pandrol Number LP8452Insulated Panlock Puller:Catalogue Number 39/040135

PANDROL PANLOCK Extraction Instructions

IMAGE REQUIRED

Place Panlock-Puller head against rail head and on top of chair jaw with lower arm under rail foot.

Ensure curved toe of handle enters right hand curve of Panlock behind centre section.

Take up a firm stance with both hands on the tee handle and pull until Panlock is driven through the chair and out.

Remove tool.

Pandrol Rail Fastenings for Bull Head Rail

Machines for automated installation and extraction of FASTCLIP systems.

www.pandrol.com 40

Most track renewal sites now use FASTCLIP machines to insert or remove the clips and achieve significant productivity and efficiency gains.

Fastclip Clipping Machine Mark 4A: Petrol or Diesel Engine Sleeper Lifting Device Optional Unclipping Module Self Propelled Umbilical Remote Control Suitable for Concrete or Steel Sleepers Clipping Module

(4 clips simultaneously) Clipping Rates about 8 Sleepers per minute with

Sleeper Lifting

Rosenqvist CD500 High Output Clip Driver:

Self-propelled high speed clipping machine Clipping and unclipping actions On & off tracking is self-powered. Clipping / Unclipping rate: up to 75 slprs/min

for stressing. Sleeper lifting capability for renewal work.

Rosenqvist CD400 Clip Driver: Sleeper lifter Clipping / Unclipping action Hydraulically operated attachment or self propelled Ideal for track renewal and stressing Clipping rates: 12 sleepers per Min for renewals.

25 sleepers per Min for stressing. Suitable for concrete or steel sleepers Fits 3rd rail conductor systems without removing

conductor rails

Rosenqvist CD200:

Clipping and unclipping action. Sleeper lifting option Clipping and unclipping rates up to

12 sleepers per Min


Track Support baseplates for Noise and Vibration mitigation.1. Baseplates and Modular AssembliesPandrol provides 3 different baseplate systems incorporating different levels of resilience for different required levels of vibration mitigation. The stiffness can be engineered to achieved different levels of resilience within limits, but generally Pandrol VANGUARD is the softest possible system, followed by VIPA-SP then SFC baseplates the firmest. All of these systems can be supplied in different variants, most of which are already Product Accepted by Network Rail. The baseplates can be installed on concrete slab track or steel structures using a range of anchorage systems shown on the following pages.

Pandrol SFC: Catalogue No. 057/001958

Assembly 14903 for 56E1

Pandrol SFC: Catalogue No. 057/001959

Assembly 15082 for CEN60

Pandrol VANGUARD: Not relevant to loose components

Assembly No. 10395 for CEN60

See pages 43 and 44 for description of loose components

Pandrol VANGUARD: Not relevant to loose components

Assembly No. 10853 for 56E1

See pages 43 and 44 for description of loose components

Catalogue No. 057/001960 Pandrol VIPA-SP:











Track Support baseplates for Noise and Vibration mitigation.1. Vanguard ComponentsThese tables depict the differing components needed for the most frquently used variant of the VANGUARD range being the baseplate variant. Network Rail has formally accepted this variant for either 56E1 or 60E1 or 2 rails but the components are different to reach the differing rail sizes. The Network Rail Product Acceptance certificate is: PA05/00569. This explains and illustrates the differing components.

Common Components for Both RailsBaseplate Type 10396 Hook-In Shoulder Type 9705


Bump-Stop Pad Type 9766 VANGUARD Locking Wdge Type 9242


VANGUARD Retention Clip Type 7920


Remaining Components Unique to Each Rail Size

Rail Size 56E1 Rail Size 60E1 or 60E2

Rubber Wedge Assembly 9456 Rubber Wedge Assembly 9769


Side Arm Type 9413 Side Arm Type 9765



Anchorage Systems for Pandrol Baseplates

Bottom-up MethodBottom-up method on concrete slab track24 Stud Type:M24 Nut Type: 2 Qty. Flat Washers: 2 Qty. Disc Springs:

11249113681124411242

Top-Hat Bush: Serrated Washer: Conforming Pad: Heights Adjusting Shims Type: (Thickness available: 3, 5, 10mm)

11032-249978

10401

10854

Pandrol does NOT supply grout for the anchor stud

Top-Down MethodDrilled and grouted anchors, with poured grout pad beneath baseplateThe Top-down method uses the same components as above, with the exception of swapping the Conforming pad, for a: Construction shim: 11361

Pandrol does NOT supply grout for the anchor stud, NOR the grout for beneath the construction shim

Bottom-up MethodBottom-up method on steel deckM24 Bolt Type:M24 Nut Type: 2 Qty. Flat Washers: 2 Qty. Disc Springs:

13110113681124411242

Top-Hat Bush: Serrated Washer: Conforming Pad: Heights Adjusting Shims Type: (Thickness available: 3, 5, 10mm)

11032-249978

10401

10854

Components List for Each Hold-Down Assembly

Top-Down MethodSlab track concrete poured to beneath the baseplate or set with concrete sleepers.

M24 Bolt Type:Cast Iron Insert: Top-Hat Bush:2 Qty. Flat Washers: 2 Qty. Disc Springs:

131109744

11032-241124411242

Serrated Washer: Construction Shim: (wet poured concrete)Conforming pad:(on sleepers)

997811361

10401

Height adjusting shims are NOT required using this method, unless downward adjustment is later required

Top-Down Method

Slab track concrete poured to beneath the baseplate or set with concrete sleepers.

Anchor Screw 22mm Type: Plastic Insert:Top-Hat Bush:2 Qty. Flat Washers: 2 Qty. Disc Springs:

1088610887

11032-231124411242

Serrated Washer: Construction Shim:(wet poured concrete)Conforming pad:(on sleepers)

997811361

10401

Height adjusting shims are NOT required using this method, unless downward adjustment is later required

Assemby with M24 bolt, and

cast-iron insert.

Assemby with Anchor Screww

and plastic insert.

3. Anchorage AssembliesThe choice of anchorage assembly is determined by the installation method selected by the contractor. The methods listed below describe the techniques used by contractors. The corresponding anchorage should be specified as part of the Pandrol scope of supply to maintain the Product Acceptance validity.

The anchorage assemblies shown below can be used with either method of top-down construction. Installation and the choice is determined by other factors such as track curvature or height adjustment limits required. Generally plastic inserts can used for track where curvature is greater than 400 metres, and height adjustments less than 15 mm.

NOTES. 1. The lengths of anchor studs, bolts, and screws can be calculated with the aid of separate data-sheets from Pandrol.2. The factors of safety for the various Pandrol anchorage systems can be calculated by Pandrol from track and site

parameters. Contact Pandrol for details.


4. Identification Chart for Anchorage Components

Bolts, Studs and Nuts

M24 Anchor StudType 11249 Lengths from 225mm to 320mm


M24 BoltsType 13110 Lengths from 140mm to 210mm


Anchor ScrewType 10886 For use with plastic inserts


M24 NutType 11368


Inserts

Cast-IronType 9744

Note: The blue epoxy finish is optional. Standard finish is natural cast-iron


Plastic InsertType 10887


Washers and Disc Springs

M24 Flat WasherType 11244 For use with plastic inserts


M24 Disc SpringType 11242


The anchorage components identified below form part of the scope of supply only with the relevant Pandrol baseplates. These components are NOT supplied separately, and can only be warranted when used within the defined Pandrol assembly.

NOTE: The standard finish on bolts, anchor studs, screws, and nuts is spun galvanised. NOTE: Washers are zinc plated, and disc springs are additionally passivated yellow colour.

Pandrol Track Fastening Systems User Guide - Edition 849 50

Identification Chart for Anchorage Components

Bushes and Serrated Washers

Top-HatType 11032-23


Top-HatType 11032-24


Serrated WasherType 9978 (Top)


Serrated WasherType 9978 (Bottom)

Pads and Shims

Conforming padType 10401

3mm thick for preformed concrete and steel decks


Height Adjusting Shim

Type 10854-3

3mm thick


Construction Shim

Type 11361

10m thick for poured concrete and grout



Type 10854-5

5mm thick


Steel Half-Shim with Slotted Holes

Type 14954

Range:1,2mm thick

1mm - Catalogue No. 57/01950 2mm - Catalogue No. 57/01951


HDPE Half Shim with Slotted Holes

Type 14953

Range: 3, 5 10mm thick

3mm - Catalogue No. 57/01952 5mm - Catalogue No. 57/01953

10mm - Catalogue No. 57/01954


Type 10854-10

10mm thick

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www.pandrol.com

0032 pandrol user guide edition 8 v6

Documents

pandrol system

pandrol baseplates

pandrol e clip

classic pandrol pr clip

extraction of fastclip

new generation of fastclip

track report

installingpandrol fastclip