rail fastening system ks with skl w12 for wooden ......4.3 the rail fastening system ks shall be...

ISRAEL RAILWAYS LTD.

INFRASTRUCTURE DIVISION

Technical Specification

for

Manufacture and Supply

of

Rail Fastening System KS

with SKL W12

for Wooden Sleepers and

Bearers

No. E-01-0001.1

December 2019

ISRAEL RAILWAYS LTD

Rail Fastening System KS with SKL W12 for Wooden Sleepers

No. E-01-0001.1 December 2019

1

CONTENTS

1. SCOPE ........................................................................................................ 2

2. REFERENCE DOCUMENTS ........................................................................ 2

3. DEFINITIONS ............................................................................................. 4

4. GENERAL REQUIREMENTS ....................................................................... 5

5. SUB-COMPONENTS - REQUIREMENTS ..................................................... 6

5.1. TENSION CLAMPS ..................................................................................... 6

5.2. BASE PLATES............................................................................................. 7

5.3. DOUBLE SPRING WASHERS ...................................................................... 8

5.4. SLEEPER SCREWS ................................................................................... 10

5.5. T-HEAD BOLT AND NUTS........................................................................ 11

5.6. FLAT WASHERS ....................................................................................... 13

5.7. RAIL SEAT PADS...................................................................................... 15

6. TECHNICAL DRAWINGS AND CALCULATIONS ..................................... 16

7. QUALITY CONTROL AND QUALITY ASSURANCE ................................. 17

8. QUALIFICATION TESTS ........................................................................... 17

9. QUALITY TESTS ...................................................................................... 18

10. LABORATORY ......................................................................................... 18

11. INSPECTION BY A REPRESENTATIVE OF ISR ......................................... 19

12. MARKING ................................................................................................ 19

13. PACKING AND DELIVERY ....................................................................... 20

14. LIST OF DOCUMENTS TO SUBBMIT TO INSPECTOR .............................. 20

15. LIST OF FILES (in PDF Format) TO BE SUBMITTED WITH BIDDER'S PROPOSAL 21

16. LIST OF FILES (in PDF Format) TO BE SUBMITTED WITH EVERY ORDER22

TECHNICAL APPENDIX A - ISRAEL CLIMATE AND ENVIRONMENTAL CONDITIONS

........................................................................................................... 23

TECHNICAL APPENDIX B - RAIL FASTENING KS SYSTEM SET ........................ 24

TECHNICAL APPENDIX C - TENSION CLAMP SKL W12 ..................................... 25

TECHNICAL APPENDIX D - BASE PLATE ........................................................... 26

TECHNICAL APPENDIX E - DOUBLE SPRING WASHER Fe6 ............................... 27

TECHNICAL APPENDIX F - SLEEPER SCREW Ss8 ............................................... 28

TECHNICAL APPENDIX G - T-HEAD BOLT Hs32-55 ............................................ 29

TECHNICAL APPENDIX H - WASHER Uls6 .......................................................... 30

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No. E-01-0001.1 December 2019

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TECHNICAL APPENDIX I - RAIL SEAT PADS ...................................................... 31

1. SCOPE

1.1 Theses technical specifications describe the requirements for

manufacture and supply of:

Elastic Rail Fastening System KS with Tension Clamp SKL W12

("Rail Fastening System KS"), to assemble rails with 60E2, 60E1,

54E1 and 50E6 rail profiles to Wooden sleepers and Bearers for

use on Railway tracks and turnouts.

1.2 The Rail Fastening System KS shall be indirect fastening with

Base Plate, simple to install, capable of easy visual inspection and

of screwed type, and shall provide support, guidance, resilience

between rail and sleeper.

1.3 The Rail Fastening System KS Sub-Components shall be:

Tension Clamps SKL W12;

Base Plate;

Double Spring Washers;

Sleeper Screws;

T-Head Bolts

Washers;

Rail Seat Pads.

2. REFERENCE DOCUMENTS

EN10025 Hot rolled products of structural steels;

EN10089 Hot rolled steels for quenched and tempered

springs. Technical delivery conditions;

EN10168 Steel products – Inspection documents;

EN10204 Metallic products - Types of inspection

documents;

EN13145 Railway applications - Track – Wood sleepers

and bearers;

EN13146-1 Railway applications - Track - Test methods

for fastening systems - Part 1: Determination

of longitudinal rail restraint;

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EN13146-2 Railway applications - Track - Test methods


of torsional resistance;

EN13146-4 Railway applications - Track – Test methods

for fastening systems - Part 4: Effect of

repeated loading;


for fastening systems - Part 6: Effect of severe

environmental conditions;



of clamping force and uplift stiffness;



of stiffness;


for fastening systems - Part 10: Proof load test

for pull-out resistance;

EN13481-1 Railway applications - Track – Performance

requirements for fastening systems – Part 1:

Definitions;

EN13481-3 Railway applications - Track – Performance

requirements for fastening systems – Part 3:

Fastening systems for wood sleepers;

EN13674-1 Railway applications - Track – Rail – Part 1:

Vignole railway rails 46 kg/m and above;

ISO868 Plastics and ebonite — Determination of

indentation hardness by means of a durometer

(Shore hardness)

ISO898-1 Mechanical properties of fasteners made of

carbon steel and alloy steel Part 1: Bolts,

screws and studs with specified property

classes - Coarse thread and fine pitch thread;


carbon steel and alloy steel - Part 2: Nuts with

specified property classes - Coarse thread and

fine pitch thread;

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carbon steel and alloy steel - Part 3: Flat

washers with specified property classes;

ISO965 General-purpose metric screw threads —

Tolerances;

ISO6157-1 Fasteners -- Surface discontinuities - Part 1:

Bolts, screws and studs for general

requirements;

ISO6157-2 Fasteners -- Surface discontinuities - Part 2:

Nuts;

ISO6305-2 Railway components — Technical delivery

requirements — Part 2: Non-alloy carbon steel

baseplates;

ISO6507 Metallic materials -- Vickers hardness test

ISO10684 Fasteners — Hot dip galvanized coatings;

ISO9001 Quality management systems - Requirements;

ISO/IEC17025 General requirements for the competence of

testing and calibration laboratories;

UIC864-3 Technical specification for the supply of

spring steel washers for the use in the

permanent way;

UIC864-6 Technical specification for the supply of

baseplates or sections of plates made of rolled

steel;

IEC 62631-3 Dielectric and resistive properties of solid

insulating materials - Part 3: Determination of

resistive properties (DC methods)

Note – the latest edition of the referenced document should be

considered

3. DEFINITIONS

3.1. ISR Israel Railways Ltd.;

3.2. Sub-Component any constituent of the Fastening Systems;

3.3. The Inspector shall have the meaning assigned to it in

Section 10 aforementioned;

https://www.iso.org/contents/data/standard/01/24/12401.html





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3.4. The Laboratory shall have the meaning assigned to it in

Section 9 aforementioned;

3.5. Rail Profile 50E6 as defined in EN13674-1, Annex A,

figure A.13;


figure A.15;


figure A.23;


figure A.24;

4. GENERAL REQUIREMENTS

4.1 The Rail Fastening System KS shall be manufactured with

different design in reference to the rail profiles: 60E2; 60E1; 54E1

and 50E6 (rail profiles are in accordance with EN13674-1), to

enable fasten the rails to wood sleepers and bearers (wood sleepers

and bearers are in accordance with EN13145).

4.2 The Rail Fastening System KS shall comply with the requirements

of EN 13481-3.

The Rail Fastening System KS Sub-Components shall be

manufactured in accordance to the Manufacturer's quality

management plan complying with ISO9001 and based on the

relevant EN, UIC and ISO standards and these Technical

Specifications.

4.3 The Rail Fastening System KS shall be designed to comply with

fastening category C in accordance with EN13481-3, section 1.

4.4 All the Sub-Components shall be designed to resistant Israel

climate condition, in accordance with Technical Appendix A. High

corrosion environment shall be considered as well.

4.5 All Sub-Components which are non-metallic shall be made of hot

weather resistant materials, and UV protected, suitable for use at

temperature of up to 50 [°C] (ambient temperature).

4.6 The Rail Fastening System KS installation and maintenance

manual, shall be submitted.

4.7 Detailed List of subcontractors, which are the Sub-Components

Manufacturers, shall be submitted (Name and Factory address, E-

mail, experience).

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Sub-Components shall be manufactured only by the Sub-

Components Manufacturers, which are listed in the Detailed List.

5. SUB-COMPONENTS - REQUIREMENTS

5.1. TENSION CLAMPS

5.1.1 Tension Clamps - General

The assembled Rail Fastening System KS shall include 2 Tension

Clamps (to fasten one rail to a sleeper) of the following type:

Type SKL W12 - for 60E1, 60E2, 54E1 and 50E6 rail

profiles.

See sketch in the Technical Appendix C;

5.1.2 Tension Clamps - Characteristics

The Tension Clamp raw material shall be from alloy silicone-

manganese spring steel – 38Si7, in accordance with EN10089,

with the following chemical composition:

Property class

Chemical composition limit

(cast analysis, %)

C

min. – max.

Si

min. – max.

Mn

min. – max.

P

max.

S

max.

38Si7 0.35 – 0.42 1.5 – 1.8 0.5 – 0.8 0.025 0.025

And with the following mechanical properties:

The tensile limit elasticity shall be greater than 1150[MPa].

The tensile strength shall be greater than 1300[MPa].

The elongation at fracture shall be greater than 8%.

The Tension Clamps shall be heat treated to achieve a surface

hardness in the range 400-460 HV 30 in accordance with

ISO6507 or equivalent. It shall be free from surface and

internal defects.

The Tension Clamps shall be provided with protective coating.

The protective coating type and the relevant standard shall be

submitted.

5.1.3 Tension Clamps – Technical Drawings and Technical Descriptions

The Technical Drawings and Technical Descriptions of Tension

Clamps, including dimensions, material main characteristics,

coating description, heat treatment, marking, etc., complying with

EN10089, ISO6507, and the relevant standard for preventive

coating and these technical specifications, shall be submitted.

5.1.4 Tension Clamps – Quality Tests

For every order of less than, or equal to 40,000 Tension Clamps -

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visual inspection, surface finish, geometry, mechanical properties

and chemical composition, and protective coating tests results shall

conform with the requirements of these technical specification and

EN10089; ISO6507, and in additional EN 10204, Type 3.1; or

Type 3.2, these results shall be submitted.

For every order greater than 40,000 Tension Clamps, for every

batch of up to 40,000 Tension Clamps - visual inspection, surface

finish, geometry, mechanical properties and chemical composition

tests results shall conform with the requirements of these technical

specification and EN10089; ISO6507, and in additional EN 10204,

Type 3.1; or Type 3.2, these results shall be submitted.

5.2. BASE PLATES

5.2.1 Base Plates – General

The assembled Rail Fastening System KS shall include 1 Base

Plate (to fasten one rail to a sleeper) of the following types:

Type Rp_1/30 150/30/160 - for 60E1 and 60E2 rail profiles;

Type Rp_1/30 140/30/160 - for 54E1 and 50E6 rail profiles.

see sketch in the Technical Appendix D.

5.2.2 Base Plates - Characteristics

The Base Plates shall be manufactured by cutting to length a rolled

section.

The steel category shall be in accordance with EN10025, with the

following mechanical properties:

The Base Plates tensile limit elasticity shall be greater than

265[MPa].

The Tension Clamps tensile strength shall be greater than

410[MPa].

The Tension Clamps elongation at fracture shall be greater

than 22%.

The Base Plates shall have inclination of 1/30.

The Base Plates shall possess smooth and level surfaces and be

free from breaks in continuity, repairs, cracks, scratches, deep

flaws or any other faults.

5.2.3 Base Plates – Technical Drawings and Technical Descriptions

The Technical Drawings and Technical Descriptions of the Base

Plates, including dimensions, material main characteristics, coating

description, heat treatment, marking, etc., complying with

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ISO6305-2, UIC864-6, and these technical specifications, shall be

submitted.

5.2.4 Base Plates - Quality Tests

For every order of less than, or equal to 40,000 Base Plates - visual

inspection, surface finish, geometry, mechanical properties and

chemical composition, and protective coating tests results shall


ISO6305-2; UIC 864-6, and in additional EN10204, Type 3.1; or


For every order greater than 40,000 Base Plates, for every batch of

up to 40,000 Base Plates - visual inspection, surface finish,

geometry, mechanical properties and chemical composition tests

results shall conform with the requirements of these technical

specification and ISO6305-2; UIC 864-6, and in additional

EN10204, Type 3.1; or Type 3.2, these results shall be submitted.

5.3. DOUBLE SPRING WASHERS

5.3.1 Double Spring Washers – General

The assembled Rail Fastening System KS (for each rail) shall

include 4 Double Spring Washers of the following type:

Type Fe6 - for 60E1, 60E2, 54E1and 50E6 rail profiles.

See sketch in Technical Appendix E.

5.3.2 Double Spring Washers – Characteristics

The Double Spring Washers shall be from alloy Silicone-

manganese spring steel – 38Si7, in accordance with EN10089,

with the following chemical composition:

Property class


(cast analysis, %)

C

min. – max.

Si

min. – max.

Mn

min. – max.

P

max.

S

max.

38Si7 0.35 – 0.42 1.5 – 1.8 0.5 – 0.8 0.025 0.025




The elongation at fracture shall be greater than 8%.

The Double Spring Washer shall be hardened and tempered to

achieve a surface hardness in the range 430-515 HV 30 in

accordance with ISO6507 or equivalent.

The Double Spring Washers shall be manufactured by helicoidal

coiling of steel bar. The spiral shall be entirely regular.

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The conditions of the Double Spring Washers obtained from bars

of the same casting shall be identical.

The internal and external surfaces of the Double Spring Washers

of rectangular section shall be parallel to the coiling axis when the

Double Spring Washer is in flatted position; the section shall be

slightly rounded at the edges.

The Double Spring Washer surface shall be knurled.

When fully compressed, the coils shall be fully superimposed one

above the other. The end surfaces shall then be situated on the

plane running through the axis of the coiling spiral.

The Double Spring 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 Double Spring Washer shall be hot dip galvanized, to conform

the requirements of ISO10684, all surfaces shall be thoroughly

covered.

5.3.3 Double Spring Washers – Technical Drawings and Technical

Descriptions

The Technical Drawings and Technical Descriptions of Double

Spring Washer, including dimensions, material main

characteristics, coating description, heat treatment, marking, etc.,

complying with EN10089, UIC 864-3, ISO6507 and ISO10684

and these technical specifications, shall be submitted.

5.3.4 Double Spring Washers - Quality Tests

For every order of less than, or equal to 40,000 Double Spring

Washers - visual inspection, surface finish, geometry, mechanical

properties, chemical composition and hot dip galvanized tests


specification and EN10089; UIC864-3; ISO6507, ISO10684 and in

additional EN 10204, Type 3.1; or Type 3.2, these results shall be

submitted.

For every order greater than 40,000 Double Spring Washers, for

every batch of up to 40,000 Double Spring Washers - visual

inspection, surface finish, geometry, mechanical properties,

chemical composition and hot dip galvanized tests results shall


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EN10089; UIC864-3; ISO6507, and in additional EN 10204, Type

3.1; or Type 3.2, these results shall be submitted.

5.4. SLEEPER SCREWS

5.4.1 Sleeper Screws – General


include 4 Sleeper Screws of the following type:

Sleeper Screw type Ss8-150 - for 60E1, 60E2, 54E1 and 50E6

rail profiles.

See sketch in Technical Appendix F.

5.4.2 Sleeper Screws - Characteristics

The Sleeper Screws shall be made from carbon steel with property

class of 5.6, in accordance with ISO898-1, with the following

chemical composition, which conform the requirements of

ISO898-1, table 2:

Property class


(cast analysis, %)

C

min. – max.

P

max.

S

max.

5.6 0.13 – 0.55 0.05 0.06




The elongation shall be greater than 20%.

The Sleeper Screws shall be hot dip galvanized coated to conform


covered.

The Sleeper Screws tolerances shall conform with the

requirements of ISO965.

The Sleeper Screws shall be manufactured from single piece,

without welding. The head shall be upset by hot-working.

The Sleeper Screw 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.

The complete surface of The Sleeper Screws shall be suitably re-

burred. Care shall be taken to ensure that the re-burring does not

give rise to any tearing of the metal or leave any roughness on the

contact surfaces.

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The threads shall be clean, uniform and complete. If the threads of

The Sleeper Screws are stripped or if there is a lack of material,

they shall not be accepted.

5.4.3 Sleeper Screws – Technical Drawings and Technical Descriptions

The Technical Drawings and Technical Descriptions of Sleeper

Screws, including dimensions, material main characteristics,


ISO898-1, ISO965, ISO6157-1, ISO10684 and these technical

specifications, shall be submitted.

5.4.4 Sleeper Screws - Quality Tests

For every order of less than, or equal to 40,000 Sleeper Screws -

visual inspection, surface finish, geometry, mechanical properties,

chemical composition, and hot dip galvanized tests results shall

conform with the requirements of these technical specifications

and ISO898-1, ISO965, ISO6157-1, ISO10684, and in additional

EN 10204, Type 3.1; or Type 3.2, these results shall be submitted.

For every order greater than 40,000 Sleeper Screws, for every

batch of up to 40,000 Sleeper Screws - visual inspection, surface

finish, geometry, mechanical properties, chemical composition and

hot dip galvanized tests results shall conform with the

requirements of these technical specification and ISO898-1,

ISO965, ISO6157-1, ISO10684, and in additional EN 10204, Type

3.1; or Type 3.2, these results shall be submitted.

5.5. T-HEAD BOLT AND NUTS

5.5.1 T-Head Bolt and Nuts – General


include 2 T-bolt screws type Hs32 with suitable 2 Nuts M22 Width

across flats 39[mm], for 60E1, 60E2, 54E1 and 50E6 rail profiles.

See sketch in Technical Appendix G.

5.5.2 T-Head Bolt and Nuts - Characteristics

The T-Head Bolts shall be manufactured from single piece,

without welding. Their head shall be upset by hot-working, and

shall have steel property class of 5.6, in accordance with ISO898-

1,

with the following chemical composition, which conform the

requirements of ISO898-1, table 2:

Property class Chemical composition limit

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(cast analysis, %)a

C

min. – max.

P

max.

S

max.

5.6 0.13 – 0.55 0.05 0.06




The elongation shall be greater than 20%.

The Nuts shall have Hexagon shape, and be made from carbon

steel with property class of 5, in accordance with ISO898-2,

with the following chemical composition, which conform the

requirements of ISO898-2, table 3:

Property class


(cast analysis, %)

C

max.

Mn P

max.

S

max.

5.6 0.58 0 0.06 0.15


Proof load values for Nuts with coarse thread shall be greater

than 190,900 [N].

Hardness properties for Nuts with Coarse Thread 146-302 HV

in accordance with ISO6507 or equivalent.

The T-Head Bolts and Nuts shall be galvanized, to conform the

requirements of ISO10684, ISO965. The T-Head Bolts and Nuts

must be free from any trace of grease, paint, etc. before the

galvanization.

The complete surface of the T-Head 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.

The same shall be applying in the case of the Nuts.

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 T-

Head Bolts and Nuts must be level and perpendicular in relation to

the longitudinal axis.

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The threads must be clean, uniform and complete. If the threads of

the T-Head Bolt and Nuts are stripped or if there is a lack of

material, they shall not be accepted.

5.5.3 T-Head Bolts and Nuts – Technical Drawings and Technical

Descriptions

The Technical Drawings and Technical Descriptions of T-Head

Bolts and the Nuts, including dimensions, material main

characteristics, coating description, heat treatment, marking, etc.,

complying with ISO898-1, ISO898-2, ISO965, ISO 6157-1, ISO

6157-2, ISO10684, and these technical specifications, shall be

submitted.

5.5.4 T-Head Bolts and Nuts - Quality Tests

For every order of less than, or equal to 40,000 T-Head Bolts and

the Nuts - visual inspection, surface finish, geometry, mechanical

properties, chemical composition, and hot dip galvanized tests


specification and ISO898-1, ISO898-2, ISO965, ISO6157-1,

ISO6157-2 ISO10684, and in additional EN 10204, Type 3.1; or


For every order greater than 40,000 T-Head Bolts and the Nuts, for

every batch of up to 40,000 T-Head Bolts and the Nuts - visual

inspection, surface finish, geometry, mechanical properties,



ISO898-1, ISO898-2, ISO965, ISO6157-1 ISO6157-2, ISO10684,

and in additional EN 10204, Type 3.1; or Type 3.2, these results

shall be submitted.

5.6. FLAT WASHERS

5.6.1 Flat Washers – General


include 2 Flat Washers of the following type:

Flat Washer type Uls6 – for 60E1, 60E2, 54E1 and 50E6 rail

profiles.

See sketch in Technical Appendix H;

5.6.2 Flat Washers – Characteristics

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The Flat Washer material selection shall be at the manufacturer

discretion, provided that it fulfills the requirements of ISO898-3.

table 2 and table 3,


Hardness properties for Flat Washers 100-250 HV in

accordance with ISO6507 or equivalent.

The Flat Washers shall be hot dip galvanized coated to conform


covered.

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 Flat Washers 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.

5.6.3 Flat Washers – Technical Drawings and Technical Descriptions

The Technical Drawings and Technical Descriptions of Flat

Washers, including dimensions, material main characteristics,


ISO898-3, ISO 4759, ISO10684, and these technical

specifications, shall be submitted.

5.6.4 Flat Washers - Quality Tests

For every order of less than, or equal to 40,000 Flat Washers -

visual inspection, surface finish, geometry, mechanical properties,


conform with the requirements of these technical specifications

and ISO898-3, ISO4759, ISO10684, and in additional EN 10204,

Type 3.1; or Type 3.2, these results shall be submitted.

For every order greater than 40,000 Flat Washers, for every batch

of up to 40,000 Flat Washers - visual inspection, surface finish,

geometry, mechanical properties, chemical composition and hot

dip galvanized tests results shall conform with the requirements of

these technical specification and ISO898-3, ISO4759, ISO10684,

and in additional EN 10204, Type 3.1; or Type 3.2, these results

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shall be submitted.

5.7. RAIL SEAT PADS

5.7.1 Rail Seat Pads - General


include 1 Rail Seat Pads of the following types:

Type Zw687-148/165 for 60E2 and 60E1 rail profiles,

Type Zw-138/165 for 54E1 and 50E6 rail profiles,

See sketches in Technical Appendixes I;

5.7.2 Rail Seat Pads - Characteristics

The Rail Seat Pads material shall be manufactured from EVA

(Ethylen-Vinylacetat-Copolymerisat).

The Rail Seat Pads shall be stabilized against light/ UV damage.

The Rail Seat Pads shall have 32 - 47 Shore – D in accordance

with ISO868 or equivalent standard.

The Rail Seat Pads shall have melt flow rate (MFR 190/2, 16) less

than or equal to 5.2[g/10] in accordance with ISO1133.

The Rail Seat Pads density shall be 1.13-1.17 [g/cm3] in

accordance with ISO1183.

The Rail Seat Pads static stiffness shall be greater than or equal to

450 [kN/mm].

The Rail Seat Pads electrical volume resistivity shall be greater

than 108 [Ohm·cm] according with IEC62631-3.

The surface shall be free of cracks and damages affecting

performances.

5.7.3 Rail Seat Pads – Technical Drawings and Technical Descriptions

The Technical Drawings and Technical Descriptions of Rail Seat

Pads, including dimensions, material main characteristics,

marking, etc., complying with ISO 868, ISO1133, ISO1183, IEC

62631-3, shall be submitted.

5.7.4 Rail Seat Pads – Quality Tests

For every order of less than, or equal to 40,000 Rail Seat Pads -

visual inspection, surface finish, geometry, mechanical properties

and chemical composition tests results shall conform with the

requirements of these technical specification and ISO898-2,

ISO1133, ISO1183, IEC62631-3, these results shall be submitted.

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For every order greater than 40,000 Rail Seat Pads, for every batch

of up to 40,000 Rail Seat Pads - visual inspection, surface finish,

geometry, mechanical properties and chemical composition tests


specification and ISO898-2, ISO1133, ISO1183, IEC62631-3,

these results shall be submitted.

6. TECHNICAL DRAWINGS AND CALCULATIONS

6.1. The Technical Drawings of the assembled unit (the interface

between the Rail Fastening System KS and the sleeper), based on

the sketches in the Technical Appendixes B-I, shall be submitted.

The following details shall be included in the drawings:

6.1.1. The external gauge point of rail fastening system which

defines the track gauge;

6.1.2. The dimension and the tolerance between internal and

external gauge points for the rail section for which the

fastening assembly is designed;

6.1.3. Drawing with dimensions and tolerances of every

components of the fastening system;

6.1.4. The nominal inclination of the rail seat.

6.2. The Technical Drawings of each Sub-Component, based on the

provided Sub-Components sketches in the Technical Appendixes

C-I, and the Technical requirements for each Sub-Components in

section 4, shall be submitted.

6.3. The Technical Drawings shall include dimensions, tolerances,

material type, coating description and heat treatment, etc.

6.4. The Rail Fastening System KS overall dimensions shall be

designed to avoid interface with vehicles including track

maintenance vehicles in accordance with EN13481-3 section 5.7,

drawings shall be submitted.

6.5. The calculations to show the maximum variation in static track

gauge which can arise from the Rail Fastening System KS shall be

submitted.

The calculations shall be based on the nominal of the rail section

given in EN 13674-1, and shall include any assumption about the

position of the rail within the Rail Fastening System KS assembly

and the tolerances on all component parts of the Rail Fastening

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System KS. The variation in track gauge, calculated in this way,

shall not exceed ±1 [mm].

7. QUALITY CONTROL AND QUALITY ASSURANCE

7.1. The Rail Fastening System KS shall be manufactured, in

accordance with the manufacturer technical drawings, under a

comprehensive quality control management system, which shall

ensure confidence consistently compliance in the conformity of the

finished product, including documented evidences, all in

accordance with these technical specifications and ISO9001,

EN13481-3, EN13146 parts: 1-10 (excluding parts – 3; 5; 8),

EN10025, ISO6305-4, ISO898-1, ISO898-2, ISO10684, ISO965-1,

ISO965-4, ISO4759-1, ISO 6157-1 and ISO 6157-2, DIN65151,

EN10204, EN10168 and any other relevant standard to provide

assurance of product safety in track.

7.2. The production control management system procedures, and

ISO9001 certificate shall be submitted.

8. QUALIFICATION TESTS

8.1. The Fastening Systems KS tests shall be accomplished in

accordance to EN 13146 parts: 1-10 (excluding parts - 3; 5 and 8),

8.2. The Qualification Tests procedure shall be applied to a complete

fastening assembly, and shall met the following requirements:

Longitudinal rail restraint (EN13146-1) > 12 [kN];

Torsional resistance (EN13146-2) --

for the rail displacement of 1 [⁰], moment force of more

than 0.9 [kNm] shall be apply,

for the rail displacement in the opposite direction of 1[⁰], moment force of more than 0.65 [kNm] shall be apply.

Effect of repeated loading, for fastening category C

(EN13146-4) --

Longitudinal rail restraint changes - less than or equal to

20%,

Vertical stiffness change - less than or equal to 25%,

Clamping force change - less than or equal to 20%;

Severe environmental conditions (EN13146-6) – following

the test, the fastening assembly shall be capable of being

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dismantled, without failure of any component and re-

assembled using manual tools;

Clamping force and uplift stiffness (EN13146-7) greater

than or equal to 12 [kN] per tension clamp, and greater

than or equal to 24 [kN] per rail set;

Pad low frequency dynamic stiffness (EN13146-9) greater

than or equal to 450 [kN/mm] at room temperature.

assembly high frequency dynamic stiffness (EN13146-9);

Attenuation of noise and vibration (EN13146-9);

Proof load test for pull-out resistance (EN13146-10).

8.3. The Qualification Test Report carried out by the Laboratory on a

complete fastening assembly of Rail Fastening System KS in

accordance with EN13481-3 sections 5.1-5.9; 5.11; 6 and

EN13146 parts: 1-10 (excluding parts: 3; 5 and 8), shall be

submitted.

9. QUALITY TESTS

9.1. The Quality Tests shall be carried out on each Rail Fastening

System KS Sub-Components, in accordance with the requirements

of these Technical Specifications, sections 6.1.4; 6.2.4; 6.3.4;

6.4.4; 6.5.4; 6.6.4; 6.7.4.

10. LABORATORY

10.1. The Qualification Tests

10.1.1. The Laboratory, that is carrying out the Qualifying Tests shall be

one of the following:

"Prüfamt für Verkehrswegbau" of the Technical University of

Munich (TUM), in Munich, Germany;

or

Alternative University Laboratory, with proven experience and

capability to perform technical tests on Fastening System in

accordance with EN13416 parts 1-10. The experience and

capability, to perform all the Qualification Tests, of the Alternative

University Laboratory shall be submitted.

10.2. The Quality Tests

10.2.1. The Laboratory, that is carrying out the Quality Tests is certifying

with at least the following certifications:

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The Laboratory certified in accordance with ISO/IEC17025 in

the field of material quality testing in reference with the Sub-

Component;

or

The Laboratory accredited by national laboratory

accreditation authority in the field of material quality testing

in reference with the Sub-Component;

10.2.2. The Laboratory certificate, include its appendixes, approving its

compliance with the requirements of section 10.1.1, above, shall be

submitted.

11. INSPECTION BY A REPRESENTATIVE OF ISR

11.1. The ISR technical team and/or an inspection body appointed by the

ISR ("The Inspector") shall the privilege to inspect the

manufacture processes and/or the Rail Fastening System KS,

during or after production.

11.2. It is the manufacturer’s responsibility to guarantee dimensional

accuracy and to ensure that the inspection is carried out with the

appropriate measuring instruments.

11.3. The Manufacturer shall be responsible to coordinate inspection

process time table with The Inspector in accordance to the delivery

date defined in the purchase order.

11.4. The Manufacturer shall extend, to The Inspector, all necessary

assistance and cooperation, and shall give access to all test records,

calibrations and calculations that contribute to the final results.

11.5. All the gauge/measuring instruments for manufacture verification

and inspection of The Rail Fastening shall be made available by

The Manufacturer to The Inspector on request.

11.6. The Manufacturer shall provide, for every purchase order, all Tests

results to The Inspector on request.

11.7. The Calibration Certificates of the gauge/measuring instruments

signed shall be made available to The Inspector on request.

12. MARKING

Each of the Rail Fastening System KS Sub-Component shall be

inscribed with at least the following marks:

The product identification type;

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The supplier mark or name;

The month and year of manufacture.

13. PACKING AND DELIVERY

13.1. Each rail fastening metal components shall be packed separately.

Sub-Components shall be packed in wooden boxes tied by metal

bands.

The dimensions of the wooden shall be according to EN standard,

to enable maximum effective storage capacity in containers.

It shall be possible to put at least 3 wooden boxes one on the other.

wooden boxes will be tied to one another, and to wooden platform

by metal bands, and all shall be wrapped with Stretch wrap.

Each package gross weight shall not exceed 1 [ton].

Each package shall be labeled with the following details:

o Component name and type;

o Production batch number;

o date of manufacture;

o Component barcode;

o Component quantity in box;

o Gross and net weight;

o Manufacturer recognition number or name;

o ISR recognition number;

o ISR order number;

o 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).

The packed Double Spring Washers and Washers shall not adhere

to one another.

13.2. Each order shall be delivered with certificate that the components

has manufactured in accordance with the Technical Specifications

E-01-0001.1 and the supplier drawing.

14. LIST OF DOCUMENTS TO SUBBMIT TO INSPECTOR

14.1. The inspection and acceptance of rail fastening system KS will be

performed be ISR representative, an authorized company

(inspector), according to ISR instructions.

14.2. The manufacturer shall submit copies of all the drawings pointed

out in paragraph 6 above.

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14.3. The manufacturer shall add to the drawings the relevant technical

descriptions of the sleeper and all fastening accessory components,

and certificate for sleepers steel type.

14.4. The manufacturer shall notify which standard and process

description will be used for carried out tensile and bend tests on

steel casts and test reports.

14.5. The manufacturer shall state the nature and main characteristics of

the steel making process.

14.6. The manufacturer shall submit a certificate confirming that the

non-metallic materials comply with the requirements.

15. LIST OF FILES (in PDF Format) TO BE SUBMITTED

WITH BIDDER'S PROPOSAL

15.1. The Rail Fastening System KS installation and maintenance

manual. (see section 4.6)

15.2. Detailed List of subcontractors, which are the Sub-Components

Manufacturers, shall be submitted (Name and Factory address, E-

mail, experience). (see section 4.7)

15.3. The Tension Clamps protective coating type and the relevant

standard. (see section 5.1.2)

15.4. The Technical Drawings of the assembled unit (the interface

between the Rail Fastening System KS and the sleeper), based on

the sketches in the Technical Appendixes B-I. (see section 6.1)

15.5. The Technical Drawings of each Sub-Component, based on the

provided sketches in the Technical Appendixes C-I, and the

Technical requirements for each Sub-Components in section 4.

(see sections: 5.1.3; 5.2.3; 5.3.3; 5.4.3; 5.5.3; 5.6.3; 5.7.3 and 6.2)

15.6. The drawing of the Rail Fastening System KS overall dimensions

avoiding interface with vehicles including track maintenance

vehicles in accordance with EN13481-3 section 5.7. (see section

6.4)

15.7. The calculations showing the maximum variation in static track

gauge which can arise from the Rail Fastening System KS. (see

section 6.5)

15.8. The Rail Fastening System KS production control management

system procedures. (see section 7.2)

15.9. The Rail Fastening System KS manufacturer ISO9001 certificate.

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(see section 7.2).

15.10. The Qualification Test Report carried out by the Laboratory on a

complete fastening assembly of Rail Fastening System KS in

accordance with EN13481-3 sections 5.1-5.9; 5.11; 6 and

EN13146 parts: 1-10 (excluding parts: 3; 5 and 8). (see section 8.3)

15.11. The experience and capability, to perform all the Qualification

Tests, of the Alternative University Laboratory. (section 10.1.1)

16. LIST OF FILES (in PDF Format) TO BE SUBMITTED

WITH EVERY ORDER

16.1. The Sub-Components Quality Tests results, as specified for each

Sub-Component. (see sections: 5.1.4, 5.2.4, 5.3.4, 5.4.4, 5.5.4,

5.6.4, 5.7.4)

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TECHNICAL APPENDIX A - ISRAEL CLIMATE AND

ENVIRONMENTAL 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)

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TECHNICAL APPENDIX B - RAIL FASTENING KS SYSTEM SET

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TECHNICAL APPENDIX C - TENSION CLAMP SKL W12

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TECHNICAL APPENDIX D - BASE PLATE

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TECHNICAL APPENDIX E - DOUBLE SPRING WASHER Fe6

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TECHNICAL APPENDIX F - SLEEPER SCREW Ss8

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TECHNICAL APPENDIX G - T-HEAD BOLT Hs32-55

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TECHNICAL APPENDIX H - WASHER Uls6

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TECHNICAL APPENDIX I - RAIL SEAT PADS

Rail Seat Pad Zw687/148/165 for 60E1 and 60E2 Rail Profiles

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Rail Seat Pad Zw-138/165 for 54E1 and 50E6 Rail Profiles

rail fastening system ks with skl w12 for wooden ......4.3 the rail fastening system ks shall be...

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