Singapore LTA – Circle LineVIPA-DFC Assembly& Standard FASTCLIP®

Operation & Maintenance

SG C830 Manual 02-09-23

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CONTENTS Page1. DESIGN CRITERIA 3

2. GENERAL DESCRIPTION 3

3. LIFE OF FASTCLIP COMPONENTS 3

4. ASSEMBLY OF THE BASEPLATE 3

5. HAND TOOLS FOR FASTCLIP® ASSEMBLY 10330 & STANDARD FASTCLIP® 4

6. NOMENCLATURE 5

7. LIMITED ACCESS – E.G DERAILMENT GUIDE, WAVE GUIDE, THIRD RAIL 6

8. HOW TO USE INSTALLER LP (TBA) – VIPA-DFC – PLAIN LINE & PLAIN LINE IRJ 6

9. HOW TO USE INSTALLER LP 15708 – STANDARD FASTCLIP® – TURNOUT &TURNOUT IRJ 9

10. HOW TO USE EXTRACTOR LP (TBA) (Brown) & LP 15151 (Cream) 11

11. HOW TO USE EXTRACTOR LP 15728 AT PLAIN LINE IRJ and TURNOUT IRJ 13

12. RAIL HEIGHT ADJUSTMENT 15

13. ASSEMBLY DRAWING 10330 16

14. COMPONENT DRAWINGS 8226, 10315 & 10543 16

15. INSPECTION FREQUENCIES & PREVENTATIVE MAINTENANCE 17

16. CARE OF THE 10 MM STUDDED RUBBER PAD 19

17. REPAIRING BROKEN SHOULDERS 20

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1. DESIGN CRITERIA

The Design Criteria of the Singapore LTA for Contract 803 (Circle Line) include at section 5.2.1 TrackForms the requirements:“To enable defective rails to be replaced with new rails, provision shall be made for up to 10 mm ofvertical adjustment of the rail height” and“The method of adjustment shall be so designed that the as-built track has the rail foot at theminimum in the first instance”.The method of adjusting the height is described later in this manual.This height adjustment is achieved by inserting shims under the baseplate and changing the toespacer shims to compensate for the change in clip deflection, due to the changing of the position ofthe baseplate.For the combination of spacers and shims to achieve the different amounts of height adjustment,refer to the tabulations on Assembly drawing 10330.

2. GENERAL DESCRIPTION

The Pandrol Brand FASTCLIP® VIPA®

assembly, in accordance with Pandrol copyright drawing no.10330, is based on a standard FASTCLIP

® assembly, with a baseplate. In accordance with the

Design Criteria of Singapore Land Transport Authority (LTA), this has been modified to enable therail height to be adjusted upwards by 10 mm under the baseplate.

3. LIFE OF FASTCLIP COMPONENTS

For straight track, Clips, Toe Insulators, Toe Spacers, Side-post Insulators and Pads are estimated tolast 1000 MGT or 20 years, Shoulders are estimated to last 2500 MGT or 50 yearsOn high speed curved track, Clips, Toe Insulators, Toe Spacers, Side-post Insulators and Pads areestimated to last 500 MGT or 10 years, Shoulders are estimated to last 2500 MGT or 50 yearsAs an overall rule it is expected that Clips, Toe Insulators, Toe Spacers, Side-post Insulators andPads will last longer than the life of the rail and Shoulders longer than the life of the sleeper.

4. ASSEMBLY OF THE BASEPLATE

FASTCLIP®

clips are delivered with their toe insulators (pt. no, 8494) factory fitted. All the othercomponents are placed as shown on Assembly drawing 10330.

The methods for installing and extracting the FASTCLIP®

clips, using hand tools, is shown later inthis manual.To avoid possible damage to the toe spacer shim, pt. no. 8226, during initial track panel fabrication ispermissible that the toe spacer shims be omitted from the assembly until all track construction iscompleted.Clips should be inserted alternately from gauge and field sides, in order to maintain the rail In arelatively central position within the rail seat, thus preventing the rail from sliding to one side andpushing the Toe Spacer up into the path of the opposing clip.A small amount of distortion of the Toe Spacer is acceptable, but a gap of 4 mm or over between theside post insulator and the side of the shim indicate the shim is over-distorted and must be changed.

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5. HAND TOOLS FOR FASTCLIP® ASSEMBLY 10330 & STANDARD FASTCLIP®

The method for using the standard hand tools is illustrated on the following pages. All the tools are designed to operate adjacent to the wave-guideand conductor rail.Part numbers and colour coding of tools are given in the table, below.

TRACKS IN MAINLINE & DEPOT

SECTION PT. NO COLOUR DESCRIPTION PLAIN LINE TURNOUT PLAINLINEIRJ

TURNOUTIRJ

8 LP (TBA) Green Double FASTCLIP®-VIPA- INSTALLER Yes No Yes No

10 LP (TBA) Brown Double FASTCLIP®-VIPA- EXTRACTOR Yes No No No

9 LP 15708 Blue Standard FASTCLIP® -INSTALLER No Yes No Yes

10 LP 15151 Cream Standard FASTCLIP® -EXTRACTOR No Yes No No

11 LP 15728 Orange Double FASTCLIP®-VIPA& Standard FASTCLIP® -EXTRACTOR

No No Yes Yes

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6. NOMENCLATURE

The Three Captive Stages of FASTCLIP.

Pre-assembled, parked position.All components are captive and the rail isthreaded into place.

Installed position.The FASTCLIP is providing a self-tensioning elastic clamping force.

Insulator Change Position.The FASTCLIP is withdrawn to the reardetent. The clip and toe insulator remaincaptive, the side post insulator can beremoved.

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7. LIMITED ACCESS – E.G DERAILMENT GUIDE, WAVE GUIDE, THIRD RAIL

8. HOW TO USE INSTALLER LP (TBA) – VIPA-DFC – PLAIN LINE & PLAIN LINE IRJ

1. Driving the clip forward from the Extracted or Insulator Change position.

1.1 Locate the jaws over the front of theshoulder.

1.2 If necessary to clear a Huck bolt thetool must first be inserted under thebolt, as shown.

Note 1During initial track panel fabrication,it is possible that toe spacer shim,pt. no. 8226, can be deformed ordamaged if it is not completelyseated on the rail, or baseplate, or ifthere is a gap between rail andbaseplate, or baseplate and sleeper.It is therefore permissible that thetoe spacer shims be omitted fromthe assembly until all trackconstruction is completed.Note 2On installation a gap of up to 4-mmis permitted between the side postinsulator and toe spacer

All hand tools are designed to work on limited access applications.

1.3 Drive the clip to the Parked position.

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2. Driving the clip from the Parked position

2.4 Pull on the handle until refusal.The fully driven position permits the outerlimbs of the clip to touch the rear of thepost insulator, or to be up to 3 mm back.

2.1 Set the pin in the hole shown2.2 Insert one side under the Huck

bolt, if necessary.

2.3 Ensure the jaws are correctlylocated over the front of theshoulder.

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3 If necessary to clear theHuck bolt at an IRJ, leanthe tool, as shown

4 Remove the hand tool

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9. HOW TO USE INSTALLER LP 15708 – STANDARD FASTCLIP® – TURNOUT &TURNOUT IRJ

1. Locate the jaws over the front of the shoulder. At insulated rail joints, it may be necessary toinsert the tool under the head of the Huck bolt, as shown.

2. Drive the clip to the Parked position.

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3. Driving the clip from the Parked position3.1 Re-position the pin, as shown and engage the tool, if necessary, under the Huck bolt

3.2 Pull on the handle until refusal

3.3 Remove the hand tool, if necessary leaningthe tool to clear the IRJ Huck bolt.

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10. HOW TO USE EXTRACTOR LP (TBA) (BROWN) & LP 15151 (CREAM)

(A)Locate the tool on the shoulderwith the handle held back asshown. The nose of the tool isforward of the toe insulator.

Ensure the tool islocated correctly inthe shoulder.

(B)Push forward on the handleuntil the clip reaches thebackstop (parked position).

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(C)Continue to push forwardon the handle. The backstop lifts and the clip iswithdrawn,

Ø first to the Side PostInsulator ChangePosition,

Ø push further and theclip can be completelyremoved.

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11. HOW TO USE EXTRACTOR LP 15728 AT PLAIN LINE IRJ AND TURNOUT IRJ

NOTE. This tool is not recommended for use on plain line, because there is a possibility of theinsulator being removed from the clip.1 Locate the tool so that the hooks engage in the rear arch of the clip

2 Engage the frame over the shoulder

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3 Pull the clip out

4 Release the hooks by means of the foot-operated arm.

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12. RAIL HEIGHT ADJUSTMENT

This is achieved by inserting shims under the baseplate and replacing the toe spacer shims tocompensate for the change in clip deflection, due to the change of the position of the baseplate.METHOD1. Extract the lower, baseplate clips to the “Insulator Change Position” along the length of rail,

which is to be replaced.

2. Release the studded rubber baseplate pads, as advised in the section “Care of the 10 mmStudded Rubber Rail Pad”.

3. Select the combination of spacers and shims as shown on Assembly Drawing 10330, toachieve the height adjustment required to align the new with the existing railheads.

4. The different thicknesses of spacers and shims are identified as shown on the drawings 8226and 10543.

5. Re-assemble using tool LP (TBA).

Baseplate clip

Insulator changeposition

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13. ASSEMBLY DRAWING 10330

14. COMPONENT DRAWINGS 8226, 10315 & 10543

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15. INSPECTION FREQUENCIES & PREVENTATIVE MAINTENANCE

It is recommended that a visual track inspection is carried out every 3 months, or as part of theUser’s, or Maintenance Contractor’s, planned inspection and maintenance of rails, joints, switches,crossings, track alignment, track support, sleepers, bearers, rail fastenings, line-side security, levelcrossings, line-side structures etc.

Under extreme or severe conditions, which are not directly related to the track fastenings, i.e.incorrect track maintenance equipment usage, certain unsatisfactory damage can occur. Byundertaking a regular, routine visual assessment a good indication as to the service performance orincidental damage can be assessed.

The visual assessment should cover all the rail fastening components, the visual inspection areasmarked with a * will require a closer inspection of the rail fastening components and it is suggestedthat a small sample of these components be inspected once every 12 months.

The replacement of isolated damaged, corroded or missing components is not urgent and can bedelayed until a convenient time for track maintenance.

What to look for when visuallyinspecting rail fastenings components

Action to be taken

Cast ShoulderDamaged shoulder head If rail is still laterally and vertically restrained, monitor

during next visual assessment, if not treat as if theshoulder head was missing.

Shoulder head missing Consider drilling out the shoulder stem and gluing in anew shoulder if the adjacent concrete is not damaged

Cast BaseplateDamaged clip housing If rail is still laterally and vertically restrained, monitor

during next visual assessment, if not replace thebaseplate.

PANDROL FASTCLIP® clipWorn clip Monitor #Clip not fully installed Pull clip fully into positionMissing clip Replace clipBroken clip Replace clip

Toe Insulator & SpacerWorn insulator/spacer * Monitor #Broken insulator/spacer Replace insulator/spacerMissing insulator/spacer Replace insulator/spacerDistorted to spacer Monitor and replace if a gap of 4-mm or over appears

between the toe spacer and side post insulator

Side-post InsulatorWorn insulator * Monitor and replace if wear exceeds 3 mm or track

gauge is affectedBroken insulator Replace insulatorMissing insulator Replace insulator

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What to look for when visuallyinspecting rail fastenings components

Action to be taken

PANDROL e - clipWorn clip Monitor #Clip not fully installed Pull clip fully into positionMissing clip Replace clipBroken clip Replace clip

e– clip Nylon InsulatorWorn insulator * Monitor #Broken insulator Replace insulatorMissing insulator Replace insulator

Studded Rubber PadExtruded pad * Consider replacing or repositioning the pad if 75% or

less of the rail foot area is resting on the pad.Worn pad * Monitor #Missing pad Replace pad

Hard (e.g. HDPE) Pad, Shim orSpacerWorn pad * Monitor #Broken pad Replace padMissing pad Replace pad

# = Consider replacing if toe insulator, toe spacer and pad together with the reduction in clip toeheight exceeds 6 mm.

All safety critical defects are detectable by visual inspection. Singapore LTA’s rail clips are colouredyellow to enable monitoring by use of on-board video equipment.

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16. CARE OF THE 10 MM STUDDED RUBBER PAD

PANDROL 10 mm studded natural rubber pads are designed to provide vibration attenuation and toprotect sleepers, ballast and formation from shock loads, which would otherwise cause rapiddeterioration of sleepers, ballast and track geometry. They are tough, but have to be used sensibly.

Under certain environmental conditions the rubber pad type may adhere to the underside of the railfoot as the rail is lifted. A simple spatula type tool can be used to locally free the pad.

Pad distortion resulting frompulling the rail through therail seat.

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17. REPAIRING BROKEN SHOULDERS

In the unlikely event of the FASTCLIP shoulder being damaged, possibly by being struck accidentallyby heavy vehicle tracking machinery on or off the rails, a procedure has been developed to repairsleepers in track. The technique utilises core drilling equipment and epoxy grout to replace shoulderhousings.

The technique requires training and is detailed in a separate method statement.