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Rail Fastening System KS with SKL W12 for Wooden Sleepers and Bearers

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Rail Fastening System KS with SKL W12 for Wooden Sleepers and Bearers 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 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 1 ISRAEL RAILWAYS LTD Rail Fastening System KS with SKL W12 for Wooden Sleepers No. E-01-0001.1 December 2019 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; 2 ISRAEL RAILWAYS LTD Rail Fastening System KS with SKL W12 for Wooden Sleepers No. E-01-0001.1 December 2019 EN13146-2 Railway applications - Track - Test methods for fastening systems - Part 2: Determination of torsional resistance; EN13146-4 Railway applications - Track – Test methods for fastening systems - Part 4: Effect of repeated loading; EN13146-6 Railway applications - Track – Test methods for fastening systems - Part 6: Effect of severe environmental conditions; EN13146-7 Railway applications - Track – Test methods for fastening systems - Part 7: Determination of clamping force and uplift stiffness; EN13146-9 Railway applications - Track – Test methods for fastening systems - Part 9: Determination of stiffness; EN13146-10 Railway applications - Track – Test methods 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; ISO898-2 Mechanical properties of fasteners made of carbon steel and alloy steel - Part 2: Nuts with specified property classes - Coarse thread and fine pitch thread; 3 ISRAEL RAILWAYS LTD Rail Fastening System KS with SKL W12 for Wooden Sleepers No. E-01-0001.1 December 2019 ISO898-3 Mechanical properties of fasteners made of 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; 4 ISRAEL RAILWAYS LTD Rail Fastening System KS with SKL W12 for Wooden Sleepers No. E-01-0001.1 December 2019 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; 3.6. Rail Profile 54E1 as defined in EN13674-1, Annex A, figure A.15; 3.7. Rail Profile 60E1 as defined in EN13674-1, Annex A, figure A.23; 3.8. Rail Profile 60E2 as defined in EN13674-1, Annex A, 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.
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