glued insulated rail joint components kits no. e-01-0013 · rail joint ("the glued insulated...
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ISRAEL RAILWAYS LTD.
INFRASTRUCTURE DIVISION
Technical Specification
for
Manufacture and Supply of
GLUED INSULATED
RAIL JOINT
COMPONENTS KITS
No. E-01-0013.12
January March 2018
ISRAEL RAILWAYS LTD
KITS of COMPONENTS for GLUED INSULATED RAIL JOINTS
No. E-01-0013.1 2 January March 2018
This technical specification differs from version No. E-01-0013.1 January 2018
as follows:
i. Section 4.1 has been revised;
ii. Section 5.1.1 has been revised;
iii. Section 5.2.1 has been revised;
iv. Section 5.3.1 has been revised;
v. Section 5.4.1 has been revised;
vi. The technical specification has been editorially revised.
ISRAEL RAILWAYS LTD
KITS of COMPONENTS for GLUED INSULATED RAIL JOINTS
No. E-01-0013.1 January 2018
1
CONTENTS
1. SCOPE 22
2. REFERENCE DOCUMENTS 22
3. GENERAL REQUIREMENTS 22
4. KIT - TECHNICAL REQUIREMENTS 33
5. KIT – COMPONENTS REQUIREMENTS 33
5.1. Steel Fishplate 33
5.2. Steel Bolts and Nuts 54
5.3. Steel Washers 66
5.4. Insulating Components – Bolt Insulated Sleeves, Insulted Endpost and Fishplate
Polymer Lamination 77
5.5. Portion of Glue 88
6. MANUFACTURE'S TECHNICAL DRAWINGS 88
7. MANUFACTURE 99
8. KIT COMPONENTS - MARKING 99
9. MANUFACTURING QULIFICATION TESTS 99
10. KIT COMPONENTS - MANUFACTURING 1111
11. LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL 1111
12. LIST OF DOCUMENTS TO BE SUBMITTED BEFORE SIGNING THE
AGREEMENT (Precedent Documentation) 1111
13. LIST OF DOCUMENTS TO BE DELIVERED WITH EACH DELIVERY1111
14. PACKING 1111
TECHNICAL APPENDIX A - ISRAEL CLIMATE AND ENVIRONNEMENTAL
CONDITIONS 1313
ISRAEL RAILWAYS LTD
GLUED INSULATED RAIL JOINTS COMPONENTS KITS
No. E-01-0013.1 2 December March 20172018
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1. SCOPE
1.1 This technical specifications describe the manufacture and supply of
Glued Insulated Rail Joint Components Kits ("The Kit"), to be
assembled and glued together on two rail segments with one of the
following rail profiles: 60E2; 54E1; 50E6; 46E2 into Glued Insulated
Rail Joint ("The Glued Insulated Rail Joint") for use on railway
tracks for appropriate signaling operation.
2. REFERENCE DOCUMENTS
prEN 16843 Railway applications - Mechanical requirements
for joints in running rails;
EN 13674-1 Railway applications - Track - Rail - Part 1:
Vignole railway rails 46 kg/m and above;
UIC 864-2 Technical specification for the supply of steel track
bolts;
UIC 864-4 Technical specification for the supply of fishplates
or sections for fishplates;
EN 10025 Hot rolled products of structural steels. Technical
delivery conditions;
EN 10139 Cold rolled uncoated low carbon steel narrow strip
for cold forming. Technical delivery conditions
ISO/IEC17025 General requirements for the competence of testing
and calibration laboratories;
ISO 9001 Quality management systems – Requirements.
AREMA - Manual for Railway Engineering
Note – the latest edition of the referenced document should be
considered
3. GENERAL REQUIREMENTS
3.1 The Kit shall be manufactured with different design in accordance
with rail profiles: 60E2; 54E1; 50E6 and 46E2 rails. (Rail profiles are
in accordance with EN 13674-1).
3.2 The Kit shall be designed to be part of railway tracks with CWR
enable railway vehicles run safety at maximum speed - 160 [km/h].
3.3 The Kit shall be designed to be part of railway track with maximum
load - 22.5 [ton/axle].
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No. E-01-0013.1 2 December March 20172018
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3.4 The Kit shall be designed to ensure that it cannot be damaged as a
result of rail maintenance work (tamping, dynamic stabilization, etc.)
or by the operations for sleeper replacing.
3.5 All insulted components (including the glue) shall be designed to
resistant Israel climate condition (in accordance with Technical
Appendix A). High corrosion environment shall be considered as
well.
3.6 The Glued Insulated Rail Joints on the track shall have life cycle of
not less than 7 years for tracks with traffic load of 50 [MGT] per year.
A statement shall be submitted with the bidder technical proposal.
4. KIT - TECHNICAL REQUIREMENTS
4.1 The Kit shall have the following Components:
2 Steel Fishplates (fitted with insulating elements);
6 Steel Bolts and Nuts for Type 60 and Type 54 /
4 Steel Bolts and Nuts for Type 50 and Type 46;
6 Steel Washers for Type 60 and Type 54 /
4 Steel Washers for Type 50 and Type 46;
6 Bolt Insulated Sleeves for Type 60 and Type 54 /
4 Bolt Insulated Sleeves for Type 50 and Type 46;
1 Insulted Endpost;
Portion of Glue (quantity define by the manufacturer);
The fastening components shall be design to be assembled with
screwing machine or torque wrenches (both equipped with torque
meter). The components needed to be screwed shall have hexagonal
shape with width across flats of 39 [mm] (steel bolts heads don't have
to be hexagonal).
The measured tightening torque shall be not less than 900 [N*m].
5. KIT – COMPONENTS REQUIREMENTS
5.1. Steel Fishplate
5.1.1 Steel Fishplate – Types
The Kit shall include 2 Steel rolled Fishplates (fitted with insulating
elements) of one of the following types: Type 60 - length of at least 900 [mm] with 6 holes for 60E2 rails;
Type 54 - length of at least 900 [mm] with 6 holes for 54E1 rails;
Type 50 - length of at least 900 [mm] with 6 4 holes for 50E6
rails;
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Type 46 - length of at least 850 [mm] with 6 4 holes for 46E2
rails.
5.1.2 Steel Fishplate – Characteristics
The reference material of the Steel Fishplates shall be rolled steel.
The grade of steel shall fulfil EN 10025-2, Table 7.
The source of steel and the steel making process shall be the
responsibility of the manufacturer.
The steel used for the manufacture of Steel Fishplates shall have
tensile strength of 450-600 N/mm2 and minimum elongation of 17%.
Ladle analysis/ product analysis
Carbon % by mass
Silicon% by mass
Manganese% by mass
Phosphorous% by mass
Sulphur% by mass
Ladle
analysis Manufacturer shall
specify ____
0.55 max
1.60 max
0.035 max
0.035 max
Product
analysis Manufacturer shall
specify ____
0.60 max
1.70 max
0.040 max
0.040 max
The Steel Fishplates shall be manufactured from a hot rolled section,
cut to length and holed.
The rolled bar used shall be cut to length by any suitable method
which does not deform the section or change the properties of the
steel. Each cut shall be clean and free from burrs.
Straightening operation shall be carried out with gradual pressure and
without impact.
Holes in the fishplate shall be produce with smooth drilling. The
edges shall be chamfered.
The fishplate dimensions shall be in according with the manufacturer
typical product. The tolerances and roughness shall be prescribed in
the drawing and shall comply with the requirements of prEN16843,
Annex B.
5.1.3 Steel Fishplate - Tests and Inspection
The Steel Fishplates manufacturer must be in position to carry out all
the tests and inspection prescribed in UIC 864-4.
For every order of Steel Fishplate the manufacturer shall submit
testing certificates showing the source and method of
steelmaking/casting used and the results of the mechanical and
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GLUED INSULATED RAIL JOINTS COMPONENTS KITS
No. E-01-0013.1 2 December March 20172018
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chemical tests and dimensions in accordance with manufacturer
quality control manual and technical drawing.
5.2. Steel Bolts and Nuts
5.2.1 Steel Bolts and Nuts – General
The Kit shall include 6 Steel Bolts and Nuts for Type 60 and Type 54
/ 4 Steel Bolts and Nuts for Type 50 and Type 46 of the following
type:
Steel bolts with suitable hexagonal Nuts with width across flats of 39
[mm].
The Steel Bolts diameter shall be in accordance with the manufacturer
design. And must comply with the technical requirements of section
9.49.4 and 9.69.6 hereinafter.
5.2.2 Steel Bolts and Nuts - Characteristics
The Steel Bolts material, quality, manufacturing tests and acceptance
conditions shall be in accordance with this technical specification and
UIC 864-2.
The steel making process and grade of steel shall obtain the following
mechanical properties:
Tensile strength steel grade 10.9, stress of 1000-1150 [N/mm2] and
minimum elongation 9%.
The sulfur and phosphorus content shall not exceed 0.06%.
The Steel Bolts and Nuts shall be produced by hot or cold forging.
The Steel Bolts shall be manufactured from single piece, without
welding. Their head shall be upset by hot-working.
The steel used for the manufacture of the Nut must be in keeping with
the grade of quality of the Bolt or with the nearest grade below.
The Steel Bolts and Nuts shall be galvanized. The Steel Bolts and
Nuts must be free from any trace of grease, paint, etc. before the
galvanization.
The complete surface of the Steel Bolts and Nuts shall be suitably re-
burred. Care shall be taken to ensure that the re-burring doesn't give
rise to any tearing of the metal or leave any roughness on the contact
surfaces.
The shanks shall be perfectly smooth and straight, without flow or
cracks. The head shall be clearly cut and correctly centered in relation
to the shanks.
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In additional, no folding of the metal shall occur on the head at the
point of junction with the shank. The contact surfaces of the steel
Bolts and Nuts must be level and perpendicular in relation to the
longitudinal axis.
The threads must be clean, uniform and complete. If the threads of
the Steel Bolts and Nuts are stripped or if there is a lack of material,
they shall not be accepted.
5.2.3 Steel Bolts and Nuts - Tests and Inspection
The Steel Bolts and Nuts manufacturer must be in position to carry
out all the tests and inspection prescribed in UIC 864-2.
For every order of Steel Bolts and Nuts the manufacturer shall submit
testing certificates showing the source and method of
steelmaking/casting used and the results of the mechanical tests,
dimensions and finish inspection in accordance with manufacturer
quality control manual and technical drawing.
For every order of Steel Bolts and Nuts the manufacturer shall submit
certificates of galvanization.
5.3. Steel Washers
5.3.1 Steel Washers – General
The Kit shall include 6 Steel Washers for Type 60 and Type 54/
4 Steel Washers for Type 50 and Type 46.
5.3.2 Steel Washers – Characteristics
The Washer shall be manufactured by hot or cold rolled steel process,
with steel category in accordance with EN10025 or EN10139.
The conditions of manufacture of the washer obtained from bars of
the same casting must be identical.
The section shall be of even thickness and slightly rounded at the
edges.
The Steel Washer shall be regular and clean, and free from superficial
cracks, flaws, burrs, and deficiency in metal, folds, or any other
defects likely to affect the use for which they are intended. The
outside surface, in particular, must be smooth and free from burrs.
The Steel Washer shall be galvanized. The Washers must be free from
any trace of grease, paint, etc., before the galvanization.
5.3.3 Steel Washers - Tests and Inspection
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For every order of Steel Washer the manufacturer shall submit testing
certificates showing the source and method of steelmaking/casting
used and the results of the mechanical tests, dimensions and finish
inspection in accordance with manufacturer quality control manual
and technical drawing.
For every order of Steel Washers the manufacturer shall submit
certificates of galvanization.
5.4. Insulating Components – Bolt Insulated Sleeves, Insulted
Endpost and Fishplate Polymer Lamination
5.4.1 Insulted Components – General
The Kit shall include 1 Insulated Endpost of one of the following
types:
Insulated endpost for 60E2 rails,
Insulated endpost for 54E1 rails.
Insulated endpost for 50E6 rails.
Insulated endpost for 46E2 rails.
The insulated post shall be designed with minimum width of 4 mm.
The Kit shall include 6 Bolt Insulated Sleeves for Type 60 and Type
54/ 4 Bolt Insulated Sleeves for Type 50 and Type 46 of one of the
following types:
Insulated endpost Bolt Insulated Sleeves for 60E2 rails,
Insulated endpost Bolt Insulated Sleeves for 54E1 rails.
Insulated endpost Bolt Insulated Sleeves for 50E6 rails.
Insulated endpost Bolt Insulated Sleeves for 46E2 rails.
The Steel Fishplates in the Kit shall be insulated.
5.4.2 Insulted Components – Characteristics
The insulated components mechanical, electrical and thermal
properties values shall be defined and noted be the manufacturer to
fulfill the insulating requirements in this technical specification.
The following information of the insulated components shall be
submitted with the bidder technical proposal:
Material properties
Flexural strength,
Tensile strength,
Compression strength,
Impact strength,
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GLUED INSULATED RAIL JOINTS COMPONENTS KITS
No. E-01-0013.1 2 December March 20172018
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Surface electrical resistance,
Disruptive voltage,
Heat stability.
5.4.3 Insulted Components - Tests and Inspection
The insulated components shall be designed to sustain the Kit
qualification tests.
For every order of Kit the manufacturer shall submit quality testing
certificate of material and mechanical properties and dimensions, in
accordance with manufacturer quality control manual and technical
drawing.
5.5. Portion of Glue
5.5.1 Portion of Glue – General
The Kit shall include 1 portion of glue of one of the following types:
Portion of Glue 60 - for 60E2 rails,
Portion of Glue 54 - for 54E1 rails.
Portion of Glue 50 - for 50E6 rails.
Portion of Glue 46 - for 46E2 rails.
5.5.2 Portion of Glue – Characteristics
The Kit shall be supplied with Portion of Glue used to adhesive the
assembled Steel Fishplates, Steel Bolts and Nuts and the Insulating
Component to the Rails.
The Portion of Glue type, its technical specification and properties
and the MSDS certificate shall be submitted with the bidder technical
proposal.
The Portion of Glue shall preserve its properties for at least one year
from DAP delivery date, (in accordance to the manufacturer storage
instruction), to insure same efficiency and performances.
5.5.3 The Portion of Glue - Tests and Inspection
For every order of Kit the manufacturer shall submit certificate for
glue properties including manufacturing expire date.
6. MANUFACTURE'S TECHNICAL DRAWINGS
6.1 The manufacturer shall submit with the tender proposal, technical
drawings of the assembled Glued Insulated Rail Joints.
6.2 The manufacturer shall submit with the tender proposal the technical
description of every component.
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6.3 A complete set of technical drawings of Glued Insulated Rail Joints
for 60E2, 54E1, 50E6, 46E2 rails profiles and including their Sub-
Components with dimensions, material main characteristics, coating
description, heat treatment, etc., shall be submitted before signing the
agreement.
7. MANUFACTURE
7.1 The Kit Components shall be manufactured in accordance with the
manufacturer technical drawings and galvanization (Bolts, Nuts and
Washers), and with the manufacturer quality management plan
follows by ISO9001 and conforming with this technical specification
and the relevant ISO or EN or UIC standards.
The Kit Components shall present a clean surface, smooth and free
from blow-holes, flaws, cracks, folds or other faults.
8. KIT COMPONENTS - MARKING
8.1 Each Kit components shall be inscribed with at least the following
marks:
The supplier mark,
The last two figures of the year of manufacturer,
The product identification type.
8.2 Each endpost type (60E2, 54E1, 50E6 and 46E2 rails) shall be
marked differently with easy to identified mark.
9. MANUFACTURING QULIFICATION TESTS
9.1 The manufacturer shall submit qualification tests, which shall be
perform by The Laboratory.
9.2 The Laboratory performing the tests shall be certified with at least
one of the following certifications:
A laboratory certified in accordance with ISO/IEC17025 in the
field of steel quality testing;
or
A laboratory accredited by national laboratory accreditation
authority in the field of steel quality testing;
or
A laboratory perform tests on track components for national
railway company.
9.3 The Laboratory shall test three Glued Insulated Rail Joints as follows:
two glued insulated rail joints shall be tested in accordance with
section 9.4.
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GLUED INSULATED RAIL JOINTS COMPONENTS KITS
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The third Glued Insulated Rail Joint shall be first tested in accordance
with section 9.5 than shall be tested in accordance with section 9.6
after completion of the fatigue test the Glued Insulated Rail Joint shall
be electrical resistance retested in accordance with section 9.5.
9.4 Longitudinal Force Test process (for insulated rail joint with Kit
assembled and glued) The manufacturer shall submit longitudinal force test report.
The acceptance criterion for the longitudinal force test shall be as
follows:
At no time shall any of the insulated joints show any indication of
slippage during or before the total prescribed load for the rail section
involved is applied to the joint. At the completion of the test after the
load on the rail has been released, the relative position of the rail and
joint bar shall be within 0.5 mm of its original value.
The Glued Insulated Rail Joint assembled and glued capability to
transfer forces in CWR railway tracks shall be:
For 60E2 rails - at least 1500 [kN];
For 54E1 rail - at least 1500 [kN];
For 50E6 rail - at least 1375 [kN];
For 46E2 rail - at least 1175 [kN].
9.5 Electrical Resistance Test process
9.5.1 A Glued Insulated Rail Joint shall be fully assembled (and glued) in
accordance with manufacture's recommendations on two lengths of
rail for an electrical resistance test. The dry rail and joint assembly
shall be supported on dry nonelectrical conducting material.
9.5.2 MegOhmmeter test:
Apply 500 volts, D.C. rail to rail, each test for duration of 5 second
and there shall be a minimum resistance of 10 [M].
9.6 Fatigue test
9.6.1 The test shall be perform in accordance is one of the following test
procedure:
AREMA Manual for Railway Engineering – Volume 1 – section
3.8.7.4 - Rolling load test process;
or
prEN16843 section 7.2.2. - Repeated bending test.
9.7 The preparation of the test pieces and the tests shall be the
responsibility of the manufacturer.
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No. E-01-0013.1 2 December March 20172018
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9.8 For each design and/or material change and/or subcontractor
replacement, during the agreement, the manufacturer shall be
required to re-perform the qualification tests.
10. KIT COMPONENTS - MANUFACTURING
10.1 Each and every Kit Component shall be manufactured in accordance
to the manufacturer's technical drawing its quality management plan
follows by ISO9001 in conform to this technical specification and
with the relevant ISO or EN or UIC standards.
11. LIST OF DOCUMENTS TO BE SUBMITTED WITH
BIDDER'S PROPOSAL
11.1 As detailed in Appendix E of the "General Terms and Conditions"
document.
12. LIST OF DOCUMENTS TO BE SUBMITTED BEFORE
SIGNING THE AGREEMENT (Precedent Documentation)
12.1 As detailed in section 4 of the "Agreement document.
13. LIST OF DOCUMENTS TO BE DELIVERED WITH EACH
DELIVERY
13.1 Each delivery shall be delivered with the component manufacturer
certificate that each components has manufactured in accordance
with the requirements of this technical specification (section 5.1.3;
5.2.3; 5.3.3; 5.4.3; 5.5.3), the technical drawings submitted and with
the relevant ISO or EN or UIC standards.
13.2 Each delivery shall be delivered with the certificates of galvanization
for the components: Steel Bolts, Nuts and Steel washers (section
5.2.3; 5.3.3), in accordance with the relevant ISO or EN standards.
13.3 The delivery of torque wrench with fitted sockets shall include
calibration certificate, and operation instructions.
14. PACKING
14.1 The manufacturer shall pack each Kit (not including the glue) in a
separately wooden box, the components in the package shall be
packed.
14.2 Each Kit (not including the portion of glue) shall be package
separately.
14.3 Glue - Packing
The portion of glue shall have the exact glue capacity for one Kit type.
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No. E-01-0013.1 2 December March 20172018
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14.4 The wooden boxes shall be tighten by metal bands, and shall be
fastened to one another with plastic nylon. They shall be tied to
wooden platform by plastic bands.
14.5 The dimensions of the wooden boxes shall enable maximum effective
storage capacity in containers.
14.6 It shall be possible to put at least 3 wooden boxes one on the other.
14.7 Extra endposts which shall be ordered shall be packed separately in
carton boxes and tighten by plastic bands
14.8 Each package shall be labeled with the following details:
Component names and types;
Production batch numbers;
date of manufactures;
Component barcodes;
Component quantity in box;
Gross and net weight;
Manufacturer recognition numbers or names;
ISR recognition numbers;
ISR order number;
Ordinal number on the packing list.
The labeling shall be with black letters and shall be on 3 spots on the
package (one on top of the package and the two others on the sides).
14.9 The packed washers must not adhere to one another.
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No. E-01-0013.1 2 December March 20172018
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TECHNICAL APPENDIX A - ISRAEL CLIMATE AND
ENVIRONNEMENTAL CONDITIONS
A.1 Climate and Environmental Conditions
Max. ambient temperature 50 °C (shade)
Min. ambient temperature -5 °C
Relative humidity 10 to 90 %
Altitude -400 to +800 meter
Sunny 3300 hours per year
UV Radiation 360 to 600 MJ/m² per year
Rainfall 400 to 800 mm/year
A.2 Dust Conditions in the atmosphere
Maximum Half Hour
Value*
Maximum Daily
Value*
Average
NOx 1064 560 71
SO2 780 260 21
O3 312 143 84
Suspended
Dust
- 350 100
*(Microgram per m³ atmosphere)
A.3 Suspended Particulate Matter (SPM)
Particle size to 0.5-1 micron
A.4 Sea Salt Concentrations in the Atmosphere
Salt Element Na* Cl* SO4*
Position Dry Wet Dry Wet Dry Wet
Sea Air at Coast Line 7.3 16.0 12.0 22.0 5.3 7.0
600 m from Shore 3.1 4.8 4.2 7.9 1.9 2.0
6000 m from Shore 1.1 1.4 1.5 1.7 1.3 1.4
* (Micrograms per m³ atmosphere)