Pandrol" Type Resilient Fastenings

Engineering Manual Track

CRN CM 231 SLEEPERS AND FASTENINGS

Version 1.1

Issued January, 2012

CRN DMS REFERENCE: CRN-EMN-AMS-017

Owner: Asset Management & Engineering Services Manager Approved by: C Francis, Principal Civil Engineer Authorised by: G Dewberry, Asset Management & Engineering Services Manager

Disclaimer. This document was prepared for use on the CRN Network only. John Holland Rail Pty Ltd makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user‟s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by JHR. JHR accepts no liability whatsoever in relation to the use of this document by any party, and JHR excludes any liability which arises in any manner by the use of this document. Copyright. The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of JHG.

UNCONTROLLED WHEN PRINTED Page 1 of 76

CRN Engineering Manual - Track CRN CM 231 Sleepers and Fastenings

Document control

Revision Date of Approval Summary of change 1.0 November, 2011 First Issue. Includes content from the following former RIC standards: TS 3341, TS 3397, RTS 3648, CTN 01/06, CTN 02/04, CTN 04/06, CTN 04/17, CTN 04/28, TS 20 540 3 01. 1.1 January, 2012 Additions and Correction of errors (See Summary of changes below)

Summary of changes from previous version

Section Summary of change C1-4.1 Additional reference for steel sleepers C4-1 Deletion of duplicated sentence C4-2 Table 11 – Correction of missing heading C5-2 Correction of Table 16 “clumping of steel sleepers” to match CRN CS 230. Refinement of definition of “track length” Appendix 1 Addition of steel sleepers and steel sleeper components to approved products

Contents Chapter 1 Introduction ...... 4 C1-1 Purpose ...... 4 C1-2 Context ...... 4 C1-3 How to read the Manual ...... 4 C1-4 References ...... 5 Chapter 2 Management requirements ...... 6 C2-1 Proximity of plates to sleeper and bearer ends in turnouts ...... 6 C2-2 Restriction on resleepering in summer months ...... 6 C2-3 Variation of acceptance limits ...... 6 C2-4 Anchoring requirements ...... 6 C2-5 Sleeper installation strategy ...... 6 C2-6 Re-use of steel sleepers ...... 6 Chapter 3 Competencies ...... 7 Chapter 4 Manual timber resleepering ...... 8 C4-1 Planning ...... 8 C4-2 Lift method ...... 10 C4-3 The “NO lift” method (Boodling)...... 18 Chapter 5 Installing steel sleepers ...... 20 C5-1 Introduction ...... 20 C5-2 Planning ...... 20 C5-3 Installing sleepers ...... 24 Chapter 6 Replacing defective fastenings on timber sleepers...... 28 C6-1 Planning ...... 28 C6-2 Replacing fastenings ...... 28 Chapter 7 Use of "Pandrol" type resilient fastenings ...... 31 C7-1 Selection of fastenings ...... 31 C7-2 Identification of fastenings ...... 32 C7-3 Installation procedure ...... 33 Chapter 8 Installing Pandrol E clips at insulated joints ...... 34 Chapter 9 Installing resilient fastenings on bridges ...... 36 Chapter 10 Installing 'Fastclip' fastenings ...... 37 C10-1 Identification of fastenings ...... 37 C10-2 Installation ...... 38 Chapter 11 Installing and removing dogscrews and lockscrews ...... 39 C11-1 Identifying dogscrews and lockscrews ...... 39 C11-2 Installation ...... 40 C11-3 Removal ...... 40 Chapter 12 Use of reclaimed sleeper plates ...... 41 C12-1 Sleeper plates with dogspike holes ...... 41 C12-2 Sleeper plates for Pandrol fastenings ...... 41 Chapter 13 Assessment of damaged steel sleepers for use ...... 43 C13-1 Criteria for reuse of damaged steel sleepers ...... 43 Chapter 14 Assessment of fatigue life ...... 44 Chapter 15 Storing timber sleepers ...... 45 Chapter 16 Replacing Fastclip cast-in shoulders ...... 46 Chapter 17 Installing Fastclip Weld-on shoulders ...... 68 Appendix 1 Approved sleeper and fastening products ...... 71

Chapter 1 Introduction

C1-1 Purpose This manual provides requirements, processes and guidelines for the installation and maintenance of sleepers and sleeper fastenings.

It applies to timber, steel and concrete sleepers installed on the Country Regional Network (CRN). C1-2 Context The manual is part of CRN's engineering standards and procedures publications. More specifically, it is part of the Civil Engineering suite that comprises standards, installation and maintenance manuals and specifications.

Manuals contain requirements, processes and guidelines for the management of track assets and for carrying out examination, construction, installation and maintenance activities.

The manual is written for the persons undertaking installation and maintenance activities.

It also contains management requirements for the Civil Maintenance Engineer and Superintendents needing to know what they are required to do to manage sleeper installation and repair activities on their area, and production managers needing to know what they are required to do to manage the renewal activity their teams are undertaking. C1-3 How to read the Manual The best way to find information in the manual is to look at the Table of Contents starting on page 4. Ask yourself what job you are doing? The Table of Contents is written to reflect work activities.

When you read the information, you will not need to refer to CRN Engineering standards. Any requirements from standards have been included in the sections of the manual and shown like this:

The following acceptance requirements are extracted from CRN Standard CRN CS 230. • Treated sleepers are not approved for use. • Recycled sleepers may be used in crossing loops and in sidings

Reference is however made to other Manuals.

Throughout this manual reference is made to the following levels of Engineering Authority: - Principal Civil Engineer - Civil Maintenance Engineer - Superintendent - Supervisor

These are general descriptors only. For an explanation of the positions in the CRN organisation that perform these functions, refer to Engineering Manual CRN CM 001 “Civil Technical Competencies and Engineering Authority”

C1-4 References

C1-4.1 Australian and International Standards AS 1085.8 -2002: Railway Track Material Part 8: Dogspikes AS 1085.13 -2002: Railway Track Material Part 13: Spring fastening spikes for sleeper plates AS 1085.14 -2003: Railway Track Material Part 14: Prestressed Concrete Sleepers AS 1085.17 -2003; Railway Track Material Part 17: Steel Sleepers AS 1085.18 -2003: Railway Track Material Part 18: Screwspikes and threaded inserts AS 3818.2 -2010: Timber - Heavy structural products - Visually graded; Part 2: Railway track timbers

C1-4.2 CRN Documents CRN CS 210 – Track Geometry & Stability CRN CS 220 – Rail System CRN CS 230 – Sleepers and Track Support CRN CS 240 – Ballast CRN CS 330 – Track Slabs CRN CS 250 – Turnouts and special Trackwork CRN CM 001 – Civil Technical Competencies and Engineering Authority CRN CM 203 – Track Inspection CRN CM 211 – Track Geometry & Stability CRN CP 231 – Timber Sleepers and Bearers

Chapter 2 Management requirements

C2-1 Proximity of plates to sleeper and bearer ends in turnouts The Civil Maintenance Engineer shall determine acceptance of the reduction in distance between the edge of timber sleepers and bearers and fastenings (see Section C4-1) C2-2 Restriction on resleepering in summer months The Civil Maintenance Engineer shall provide appropriate "Work in Summer Months" instructions regarding the restrictions on resleepering that apply during the period 1st November and 31st March in accordance with CRN CM 211. C2-3 Variation of acceptance limits The Civil Maintenance Engineer may authorise the following limited variations to acceptance limits: - Correction of wide gauge on curve worn rail by tightening the “foot gauge. - Greater than 5mm tight gauge where rail flow is present. C2-4 Anchoring requirements The Civil Maintenance Engineer shall determine requirements for additional anchoring at resleepering locations. C2-5 Sleeper installation strategy Where resilient fastened sleepers are proposed for installation interspersed with non-resilient fastened sleepers in LWR track, the Civil Maintenance Engineer shall develop a strategy for approval by the Principal Civil Engineer. The strategy shall be developed and documented in accordance with the requirements of CRN CS 230. C2-6 Re-use of steel sleepers

C2-6.1 Assessment of Fatigue life The Civil Maintenance Engineer shall arrange an assessment of the remaining life of steel sleepers that are proposed for re-use. Guidelines for the assessment of fatigue are provided in Section Chapter 14.

C2-6.2 Assessment of damaged sleepers The Civil Maintenance Engineer shall arrange: - assessment of the condition of steel sleepers damaged by derailment or extraction to determine their suitability for repressing in accordance with the requirements detailed in Section Chapter 13. - inspection of repressed sleepers to determine if they meet the acceptance criteria detailed in Section Chapter 13.

Chapter 3 Competencies NOTE: These competencies may enable activities to be carried out in other manuals. For a comprehensive list of all activities that are covered by a given competency see CRN Engineering Manual CRN CM 001– Civil Technical Competencies and Engineering Authority.

To carry out this You need these competencies work Remove and install TLIS2031A - Install railway sleepers AND TLIS2034A - Install and repair rail sleepers fastening systems Remove and install TLIS2031A - Install railway sleepers AND TLIS2034A - Install and repair rail sleeper plates, pads fastening systems and insulators Rebore and regauge TLIS2031A - Install railway sleepers AND TLIS2034A - Install and repair rail sleepers fastening systems Restore ballast profile TLIS2030A - Carry out track ballasting after resleepering Restore track TLIB3094A - Check and repair track geometry geometry Certify track during or TLIS2031A - Install railway sleepers AND TLIB3094A - Check and repair after resleepering track geometry

Chapter 4 Manual timber resleepering This chapter describes the methods used in CRN to install or remove timber sleepers using manual methods and minor plant and equipment.

There are two manual methods used to renew sleepers, the “Lift” and the “No Lift” method. The procedure for both these methods is described below: C4-1 Planning 1. Consider the key technical risks of undertaking resleepering work. This includes:  Incorrect gauge after the work.  Top, twist, line and/or superelevation defects after the work.  Sleepers, ballast or equipment foul during work.  Site obstructions.  Sleeper spacing and skew.  Fastenings, Sleeper plates.  Ballast condition and profile.  Sleeper support (packing) and fastenings.  Track Stability especially during Summer Months. (See CRN CM 211)  Incorrect clip type shorting out insulated joints.  Shorting out insulated joints (e.g. sleeper plates, fastening, scrap left behind).  Ballast fouling points operation.  Damage to trackside signal equipment from material placement or movement, sleeper insertion and removal equipment.  Damage to train monitoring equipment (See CRN Engineering Manual CRN CM 211 – Track Geometry & Stability).

2. Check the length of existing sleepers. If sleepers have been cut short to avoid an obstruction, arrange for removal of the obstruction, if possible. If it cannot be removed, check the available length

The following acceptance requirements are extracted from CRN CS 230. Proximity of plates to sleeper and bearer ends in turnouts The outer end of sleeper plates shall, normally, be located no closer than 200mm to the end of timber sleepers or bearers. The Civil Maintenance Engineer may approve a reduction to no less than 50mm in constrained situations at turnouts and special trackwork To determine acceptance, the Civil Maintenance Engineer shall consider the following:  Increased probability of failure of lockspikes or screwspikes due to splitting.  Reduced bearing of the sleeper or bearer leading to increased top degradation. To some extent this is offset by the increased ballast pressure from lateral confinement from the obstruction.

At locations where short sleeper/bearer ends have been approved, inspect condition of the sleepers during detailed walking and annual sleeper inspection to confirm that the timber is not prone to splitting and that the ballast support is adequate with good confinement laterally.

3. Check the quality of new sleepers. Are they marked as suitable for where you are going to install them? Are they in good condition? See Table 1 and Table 2.

The following acceptance requirements are extracted from CRN CS 230. Timber sleepers Standard sleeper size Dimensions and acceptance tolerances for timber sleepers shall be in accordance with the requirements of Table 1. Dimension (mm) Acceptance Tolerance (mm) Length 2 440 +75 - 0 Width 230 +25 - 0 Depth 130 +10 - 0 Table 1 – Timber sleeper dimensions The following acceptance requirements are extracted from CRN CP 231. Timber Sleeper Usage Only use timber sleepers that have been marked on the end with a 25mm paint mark as shown in Table 2. Group Mark Group 1 1 white dot Group 2 1 red dot Table 2 – Timber Acceptance marking The following acceptance requirements are extracted from CRN CS 230. Treated sleepers are not approved for use. Recycled timber sleepers (i.e. sleepers that have previously been used in track) may not be used on main lines with the following exception: • Sleepers are fitted with resilient plates, and • Sleepers have been assessed as having a minimum remaining life of 5 years at the new location, and • The connection between the plates and the sleeper is sound with no evidence of plate movement. Recycled sleepers may be used in crossing loops and in sidings under the following conditions: • Sleepers have been assessed as having a minimum remaining life of 5 years at the new location

4. Are the new sleepers bored with the correct sleeper boring pattern for the location and the sleeper plates being used? See Table 10, Figure 1 and Figure 2. 5. Identify sleepers to be removed. If traffic will operate over the track before the resleepering is completed, plan the work so that the track will remain tied in accordance with the operating limits in CRN Engineering Manual CRN CM 203– Track Inspection. DO NOT unfasten and remove more sleepers than can be tied in the available time.

If the work is being carried in summer months, restrictions apply to the spacing between sleepers that can be removed unless written authority is provided by the Civil Maintenance Engineer. The "Work in Summer Months" Instructions are detailed in CRN CM 211.

C4-2 Lift method 1. Remove sleeper fastenings and anchors. Place sleeper fastenings and anchors clear of the track and stack them so that they are ready for re-use or removal from site. Leaving them near or on the track will interfere with the resleepering process and may result in them being "buried" in the track.

2. Remove shoulder ballast from the end of the sleeper. Dig sleeper end ballast clear through to the edge of the shoulder and loosen ballast along sleeper sides for easy removal.

3. Install jacks under the rail. 4. Jack up the rail.  BE extremely careful when lifting the track with jacks.  DON‟T lift the track higher than is absolutely necessary.  DON‟T lift the track between 1st November and 31st March, unless written instructions are issued to do so by the Civil Maintenance Engineer. (See CRN CM 211).  DON‟T lower the jacks without warning other staff.  DON‟T leave jacks in place and unattended.

5. Remove sleeper plates. Place sleeper plates clear of the track and stack them so that they are ready for re-use or removal from site. Leaving them near or on the track will interfere with the resleepering process and may result in them being "buried" in the track.

Check sleeper plates to determine if they can be re-used by following the procedures in Chapter Chapter 12.

Stack re-usable and scrap sleeper plates separately and secure scrap plates so that they will not be re-used by mistake.

6. Remove sleeper/s. You may be able to remove more than one sleeper with one lift.  Remove the sleeper with sleeper tongs.  Place it clear of the track and stack sleepers for disposal.

During removal, DO NOT disturb the track geometry.

7. Clean and loosen the bed.  Loosen the sleeper bed with a pick.  Excavate to at least 50mm larger than replacement tie dimensions. Smooth the bed beyond the shoulder, free of obstructions sufficient to allow for free drainage to cess or six-foot drain.

8. Install new sleeper.  Lay the sleepers, heart centre down.  Push the new sleeper into place.  Minimise disturbance to rail geometry.

9. Check the location of new sleeper for spacing and skew (See Table 3).

Sleepers shall be spaced in accordance with the requirements of Table 3 which have been extracted from CRN CS 230. Track Class Sleeper Acceptance Tolerance Limit Spacing Tolerance (spacing No. of sleepers/rail (mm) or skew) length (m) (mm) (Note 1) (Note 2) ALL Track (mainline & sidings) 1 600(Note 3) ± 20 (Note 4) 25/15 (±50mm) 2 600(Note 3) ± 20 (Note 4) 25/15 (±50mm) 3/3G 623(Note 3) ± 20 (Note 4) 24/15 (±50mm) 5 610(Note 3) ± 20 25/15 (±50mm) Table 3 - Sleeper spacing in plain track Note 1 Installation tolerance for new or face resleepering of track sections. 2. Skew is the variation from square from one side of the sleeper to the other 3. Except at rail joints (See Table 4). 4. Up to 50mm for spacing to allow for missing a thermit weld (only over two sleepers) Spacing at rail joints Spacing of sleepers at rail joints in plain ballasted track shall be adjusted in accordance with Table 4. Design Spacing Acceptance Rail (Kg/m) (mm) Tolerance (mm) 53 Insulated 430 ± 20 53 Mechanical 510 ± 20 Bonded Insulated Joints (any rail 600 ± 20 size) All Others 510 ± 20 Table 4 - Sleeper spacing at joints On certain lighter sections of track where angle fishplates are used, it may be necessary to adjust the sleeper spacing at joints to ensure dogspikes can be correctly located at the fishplate. Spacing at bridge ends Spacing of rail support (sleepers, abutment and transoms) at transom topped bridge ends shall be adjusted in accordance with Table 5. Design Spacing Acceptance Track Class (mm) Tolerance (mm) All classes – New bridge structures 600 ± 20 All classes – Existing bridge 600 preferred but will ± 20 structures accept up to 900 subject to approval of Track and Civil Manager Table 5 - Support spacing at bridge ends

Space the sleepers evenly. Move adjacent sleepers if practical. It may even be necessary to install extra sleepers or remove sleepers if the required spacing cannot be maintained.

10. Replace the sleeper plate.  Apply sleeper plates so that the rail leans towards the track centre.  Position the plate so that all holes in sleeper are visible through the holes in the plate.

11. Lower the rails and remove the jacks. 12. Check Gauge

The following construction/renewal acceptance limits for gauge are extracted from CRN CS 210. Main line Sidings (mm) (mm) Class All Classes 1 2 3 5 Gauge Wide Gauge 5 6 6 NA 6 Tight Gauge -3 -3 -3 NA -3 Gauge variation in 2m 5 6 7 NA 7 Table 6 - Construction Acceptance limits for gauge The following construction/renewal acceptance limits for gauge are extracted from CRN CS 210. Main line Sidings (mm) (mm) Gauge Variation to design Wide 5 5 gauge Tight (including 5 5 head flow) Limiting tight gauge 1430mm Variation in 1m (due to rail wear) 2 2 maximum deviation at a discontinuity 1 1 (e.g. a joint) Table 7 - Maintenance Acceptance limits for gauge Where gauge widening has been applied on curves by design, the limit applies to the widened design gauge. Rail play is not permitted except small amounts arising from construction tolerances (e.g. 1mm between insulator and foot of rail). Work shall be carried out to correct “foot gauge” ± 5mm Rail Size (kg/m) Cant 47 50 53 60 1:20 Plain Track 1390 1391 1373 1374 Zero In Turnouts 1379 1379 1360 1360 Table 8 – Foot Gauge

The Civil Maintenance Engineer may authorise the following limited variations:  Correction of wide gauge on curve worn rail by tightening the “foot gauge.  Greater than 5mm tight gauge where rail flow is present.

Gauge must not exceed the BOS limits in CRN CM 203 without appropriate protective action. The maximum deviation at a discontinuity such as at a joint (“foul joint”) shall be in accordance with Table 7 Particular care is required to ensure that new joints cut into the track have matching profiles at the gauge face and running surface.

13. Bore holes in the sleeper (if required) Sleeper boring requirements are detailed in Table 9, Table 10 and Figure 1and Figure 2. Maintain a consistent sleeper boring pattern with adjacent sleepers.

The following acceptance requirements are extracted from CRN CS 230. Boring requirements in timber sleepers, transoms and bearers Sleepers, transoms and bearers shall be bored to match the track plates used in the approved configuration. The patterns for sleeper plates using dogspikes, lockspikes, dogscrews and lockscrews are detailed below. Hole sizes shall be as detailed in Table 9. Holes shall be bored completely through the timber

Fastening type Hole diameter (mm)

Dogspikes 21 ± 0.5 Lockspikes 16 ± 0.5 Dogscrews 17 ± 0.5 Lockscrews 14 ± 0.5 Screwspikes 27 mm dia 25 ± 0.5 24 mm dia 18 ± 0.5 22 mm dia 18 ± 0.5 Table 9 – Fastening hole diameters Sleeper Boring Patterns Plate Cat A B Rail Section Comment No. (mm) (mm) 53 kg DF 30 New 1348 171 Lockspike and dogspike Pattern arrangement is a mirrored and inverted image of Old Pattern 53 kg DF 30 Old 1348 171 Pattern 100lb AS DF 30 Old 1348 171 Pattern 100lb AS 1916 DF 1 Old 1354 171 Pattern AS 50, AS 47, 90lb DF 10 1366 152 1925/28, 80lb AS ‟A‟ 1928 90lb AS 1916 1346 162 Unplated. i.e. not on tapered base or cant adzed and no lockspike 90 „J‟ 1913 1343 162 holes 80lb AS ‟B‟ 1928, A, 1346 152 A1,2&3 71½lb „D‟ 1875 1346 146 60lb AS 1916, AS „A‟, 1365 133 AS „B‟ 60lb B 1896 & „BA‟ 1907 1366 127 Table 10 – Sleeper Boring patterns For cant adzed increase „A‟ by 6mm „A‟ dimension based on tapered base sleeper plates except for unplated All dimension tolerance are + - 1mm

The following acceptance requirements are extracted from CRN CS 230.

Figure 1 - 53 kg NEW pattern boring details

Figure 2 - Boring pattern for Pandrol for 53 & 60kg/m rail

14. Reinstall fastenings.

The following acceptance requirements are extracted from CRN CS 230. Fastenings for timber sleepers Standard configurations of fastening assemblies for timber sleepers are detailed in Table 11. Sleeper Lockspikes( Fastening Type Plates Note 2) Track Class No. per Plate/ Rail BHP Dwg. No. per No. Plate Non Resilient Main Lines 1 2 Dogspikes(Note 1) DF 30 2 2 2 Dogspikes(Note 1) DF 10 2 3 2 Dogspikes(Note 1) DF 10 2 3G 2 Dogspikes(Note 1) DF 30 2 5 2 Dogspikes(Note 1) DF 10 Nil Sidings 1 2 Dogspikes(Note 1) DF 30 2 2 2 Dogspikes(Note 1) DF 10 2 (curves only) 3 2 Dogspikes(Note 1) Nil Nil

The following acceptance requirements are extracted from CRN CS 230. Sleeper Lockspikes( Fastening Type Plates Note 2) Track Class No. per Plate/ Rail BHP Dwg. No. per No. Plate Resilient Main Lines Class 1 and 2 2 Resilient E2003 DF 62 & 4 cast plates 3 TBA 3G 2 Resilient E2003 DF 62 4 Insulated Joints in ALL Low profile clips DF 62 4 classes e1627 (timber) Sidings ALL classes 2 Resilient E2003 DF 62 4 Table 11 - Timber sleeper fastening configuration Note 1 Round shank dogspikes or approved alternative fastenings may be used. 2 Lockspikes (L6) or approved alternative fastenings may be used.  Install dogspikes square to the rail, vertical and flush on the rail foot.  Install lockspikes with hole parallel to rail, driven so that a distance of 0-5mm exists between head and plate.  If dogscrews and lockscrews are being used, follow the installation instructions in Chapter Chapter 11.  If sleepers are being replaced at insulated joints and resilient fastenings are being used, make sure that low profile clips are used. (See Chapter Chapter 8).  If transoms are being replaced on bridges and resilient fastenings are being used, make sure that Zero Load Restraint (ZLR) fastenings are used where required. (See Chapter Chapter 9).  DO NOT overdrive elastic fastenings (clips). Refer to Chapter Chapter 7 for installation instructions.  Renew any „sprung” or overdriven clips. 15. Reinstall anchors in non resilient fastened track.

The requirements for anchors are detailed in the following extract from CRN CS 220 Welded track shall meet the following minimum anchoring requirements. • Double (or box) anchor every fourth sleeper except at mechanical joints • Double anchor every second sleeper for a distance of 32 sleepers either side of mechanical joints, starting at the second sleeper from the joint. • Basic anchoring is to be so that sleepers are anchored on both sides on each rail (double or box anchor), except for steep grades as detailed below. • On track with a falling grade steeper than 1 in 80 in the direction of traffic, or at other locations where considered necessary to control rail creep, the anchoring shall be increased by adding single anchoring each second sleeper (or on every sleeper, if necessary) throughout the welded rail length, to prevent rail creep. Insulated Joints in Welded Track • At mechanical insulated joints EVERY sleeper is to be double anchored for a distance of 32 sleepers on each side of the joint. • Bonded Insulated Joints are treated as if they were plain track, and anchored in the same pattern as the track in which they are placed (e.g. 1 in 4 when laid in 110m rails or CWR, or every 2nd if

within 32 sleepers of a turnout). Anchoring of Short Rails Lengths shorter than 23m The anchoring for these with square and staggered joints on ballasted track and bridges shall be as shown in Figure 3. . Using these patterns, all anchored sleepers have anchors on both rails 12m rails - square joints - • 6 double anchored sleepers per rail length, placed 5th, 6th, 10th, 11th, 15th and 16th from each joint. 12m rails - staggered joints - • 6 double anchored sleepers per rail length, placed 2nd, 5th, 9th, 12th, 15th and 19th from each joint.

SQUARE JOINTS - 12m Rails – Angle Fishplates

STAGGERED JOINTS - 12m Rails – Angle Fishplates

Figure 3 – Anchoring requirements for rail lengths <23m 23m and 27m lengths The anchoring for these on open ballasted track and on bridges shall be as shown in Figure 4. 23m rails - staggered joints - • 12 double anchored sleepers per rail length, placed 2nd, 5th, 8th, 12th, 15th, 18th, 21st, 24th, 27th, 31st, 34th and 37th from each joint. 27.5m rails - staggered joints - • 14 double anchored sleepers per rail length, placed 2nd, 5th, 8th, 11th, 15th, 18th, 21st, 24th, 27th, 30th, 34th, 37th, 40th and 43rd from each joint.

Mechanical Joint Mechanical Joint

Welded Joint 27.5m rails – 14 double anchors per rail length Welded Joint Mechanical Joint Mechanical Joint

Welded Joint 23.0m rails – 12 double anchors per rail length Welded Joint

Figure 4 – Anchoring requirements for 23m and 27m rail lengths The requirements for anchors are detailed in the following extract from CRN CS 220 Anchoring of Welded Track on Bridges Ballast top openings with spans ≥ 4.27m long but <80m Standard anchoring for LWR on ballasted track shall be used on welded rails on these bridges. Transom top or Ballast top openings with spans ≥80m For a distance of 60m from a bridge end, LWR track shall be double anchored on every second sleeper. Between expansion switches the rails shall be double anchored to every fourth transom. On bridges where elastic fastenings are installed in CWR track, normal resilient fastenings shall be installed on the entire length of each span.

 Install anchors flush against the side of the sleepers.  If the existing anchor pattern is more extensive than the requirements above, check with the Civil Maintenance Engineer to determine if the extra anchors need to be re-installed.  Renew any „sprung” or overdriven anchors.

16. Lift, pack and line track, using the methods described in CRN CM 211.  Pack each sleeper tight up to the base of the rail.  Pack the sleepers uniformly and evenly under the rail and at least 200mm either side of the rail, NOT in the centre or at the ends.

17. Measure and record geometry. 18. Restore ballast profile.  Make sure you restore the standard ballast profile. See Table 12.

The construction and maintenance acceptance limits detailed in Table 12 are extracted from CRN CS 240. Ballast shoulder width (mm) Track Rail Design Acceptance Class Length Minimum Maximum Minimum Maximum Main line 1 CWR /LWR 400 700 390 700 2 CWR /LWR 400 700 390 700 3/3G CWR /LWR 400 700 390 700 3 Loose 250 700 240 700 5 Loose TBA TBA TBA TBA Siding 1 CWR /LWR 400 700 390 700 2 CWR /LWR 400 700 390 700 3 CWR /LWR 400 700 390 700 3 Loose 250 700 240 700 Table 12 - Ballast shoulder width design and acceptance limits

19. Check the worksite.  Do not block drainage systems with old sleepers, fastenings or plates.  Stack all used material neatly where it is not in the way.

20. Certify track.  Certify the track using the procedure in CRN CM 211.  If work has not been completed and sleepers are left untied, assess whether a speed restriction is required using the operating limits in CRN CM 203.  If sleepers have not been packed, or geometry has not been corrected, apply appropriate restrictions in accordance with the operating limits in CRN CM 203.

C4-3 The “NO lift” method (Boodling) This process is basically the same as the lift method except that the track is not lifted with jacks. This method reduces the disturbance to track stability. 1. Remove fastening/anchors. 2. Remove shoulder ballast from end of sleeper. 3. Remove the ballast and dig a trench next to the sleeper to be removed. 4. Remove sleeper plates. 5. Push the old sleeper into the trench without lifting the rail. 6. Remove the sleeper.  Remove the sleeper with sleeper tongs.  Place it clear of the track and stack sleepers for disposal. During removal, DO NOT disturb the track geometry.

7. Clean and loosen the track bed. 8. Install new sleeper. 9. Check the location of new sleeper for spacing and skew. (See Acceptance limits in Section C4-2 Item 9). 10. Replace sleeper plate. 11. Check gauge (see Acceptance limits in Section C4-2 Item 12). 12. Bore holes in the sleeper (if required). 13. Reinstall fastenings (see fastening requirements in Section C4-2 Item 14).  If dogscrews and lockscrews are being used, follow the installation instructions in Chapter Chapter 11.  If sleepers are being replaced at insulated joints and resilient fastenings are being used, make sure that low profile clips are used. (See Chapter Chapter 8).  If transoms are being replaced on bridges and resilient fastenings are being used, make sure that Zero Load Restraint (ZLR) fastenings are used where required. (See Chapter Chapter 9).  DO NOT overdrive elastic fastenings (clips). Refer to Chapter Chapter 7 for installation instructions.  Renew any „sprung” or overdriven clips.

14. Reinstall anchors in non resilient fastened track (see anchoring requirements in Section C4-2 Item 15).  Install anchors flush against the side of the sleepers.  If the existing anchor pattern is more extensive than the requirements above, check with the Civil Maintenance Engineer to determine if the extra anchors need to be re-installed.  Renew any „sprung” or overdriven clips and anchors.

15. Pack sleepers using the methods described in CRN CM 211.  Pack each sleeper tight to rail.  Pack the sleepers uniformly and evenly under the rail and at least 200mm either side of the rail, NOT in the centre or at the ends.

16. Measure and record geometry.

17. Restore ballast profile (see acceptance limits in Section C4-2 Item 18). 18. Check worksite.  Do not block drainage systems with old sleepers, fastenings or plates.  Stack all used materials neatly where it is not in the way.

19. Certify track.  Certify the track using the procedure in CRN CM 211.  If work has not been completed and sleepers are left untied assess, whether a speed restriction is required using the operating limits in CRN CM 203.  If sleepers have not been packed, or geometry has not been corrected apply appropriate restrictions in accordance with the operating limits in CRN CM 203.

Chapter 5 Installing steel sleepers

C5-1 Introduction This chapter describes the methods used in CRN to install steel sleepers using manual methods and minor plant and equipment.

When inserting steel sleepers by mechanical means take care not to damage the sleeper. Damage can occur if excessive force is used to grip the sleeper, or the sleeper is gouged by the installation equipment.

Steel sleepers are different to timber and concrete sleepers. They rely on the ballast in the sleeper “pod” to add to their effective mass. Because of this the amount of and degree of compaction of the ballast in the pod is critical to the sleeper‟s in-service performance.

Steel sleeper installation is different to timber resleepering in two ways: - the requirement for additional ballast to fill the pods, and - the tamping needed to get the ballast into the pods and to support the sleeper. C5-2 Planning 1. Consider the key technical risks of undertaking resleepering work. This includes:  Incorrect gauge after the work.  Top, twist, line and/or superelevation defects after the work.  Sleepers, ballast or equipment foul during work.  Site obstructions.  Sleeper pattern if steel sleepers are interspersed with timber sleepers  Resilient fastening pattern if steel sleepers are interspersed with timber sleepers with non-resilient fastenings in LWR track.  Sleeper spacing and skew.  Fastenings, Sleeper plates.  Ballast condition and profile.  Sleeper support (packing) and fastenings.  Track Stability especially during Summer Months. (See CRN CM 211)  Incorrect clip type shorting out insulated joints.  Shorting out insulated joints (e.g. sleeper plates, fastening, scrap left behind).  Ballast fouling points operation.  Damage to trackside signal equipment from material placement or movement, sleeper insertion and removal equipment.  Damage to train monitoring equipment (See CRN Engineering Manual CRN CM 211 – Track Geometry & Stability).

The method of installation should not compromise the function or effective service life of steel sleepers. In general they perform best if they are installed to a consistent pattern.

In addition, consider future sleeper installation during planning current installation pattern to ensure that subsequent spacing is not compromised.

Adopt a closer tie pattern if:  there is backcanting, depending on the degree of backcanting.  the condition of surrounding timber sleepers is poor Where possible, remove the following track defects that may lead to excessive sleeper disturbance and reduce the effectiveness of the completed works:  Localised situations where the ballast/ formation is poor and where deflection under load is high  Rail surface anomalies such as dipped welds, wheelburns or corrugations

In circuited track install or repair drainage so that water does not lay around the rails and fastenings.

2. Check the type of sleepers for installation. Are they suitable for where you are going to install them?

The following requirements are extracted from CRN CS 230. Selection There are three types of steel sleepers • Type M10 – to suit Class 1 tracks with 25t axle loads • Type M8.5 – to suit Class 1 tracks and some Class 2 regimes. • Type M7.5 – for Class 2, 3, 3G and 5 tracks Sleeper type shall be selected in accordance with Table 13. Track Class Curve radius (m) (Note 1) Annual Tonnage (MGT) ≥400 < 400 <3 ≥ 3 1(Note 2) M8.5 M8.5 M8.5 M8.5 2 M7.5 M8.5 M7.5 M8.5 3 M7.5 M7.5 M7.5 M7.5 3G M7.5 M7.5 M7.5 M7.5 5 M7.5 M7.5 M7.5 M7.5 Table 13 – Selection of steel sleeper type Note 1 for lines with a significant proportion of curved track, especially sharp curves <400m radius 2 On lines with a significant tonnage of 25t axle load traffic, M10 steel sleepers shall be used.

Compatibility with rail type Current approved steel sleeper types are able to accommodate variations in rail size as detailed in Table 14 below: M10 M8.5 M7.5 Punched for foot size 146 146 146 Used without spacers for 53, 60kg 53, 60kg 53, 60kg Used with spacers for 47kg 50, 47, 41, 30kg Table 14 – Hole punching and spacer selection

Steel sleepers may only be interspersed with timber sleepers in LWR track where they are in accordance with a specific strategy approved by the Principal Civil Engineer.

If they are second-hand sleepers, check that they have been assessed for damage and approved for re-use in accordance with Chapter 13 and that the sleepers have been stamped with the letter “R” Check that second-hand sleepers (whether damaged or not) have been assessed for fatigue life by the Civil Maintenance Engineer. 3. Identify sleepers to be removed. There are restrictions on locations where steel sleepers can be used.

The following requirements are extracted from CRN CS 230. Steel sleepers may be installed: • In a face in long sections or in a full curve, • Interspersed with timber sleepers as PRS • As replacements for isolated timber sleepers Conditions may be applied to their use. These are detailed in this section Steel sleepers shall be insulated where track circuits are present e.g. at approaches to level crossings with active protection. Even with insulators fitted, contamination by conducting material around the fastenings or under the rail can cause signalling problems. This includes locations:- • where contaminants regularly invade the track area (coal, minerals, mud, clay, dirt etc) • locations where the track is continually wet Where these conditions exist in track circuited areas DO NOT use steel sleepers. Steel sleepers are not recommended for use in locations where corrosion/ chemical damage is likely to be a problem. Such locations include:- • Slag ballast • Areas of frequent sanding (eg steep grades) • Areas of high salinity • Continually wet or moist areas such as some tunnels or some types of level crossings • Areas where corrosive materials invade the track area (coal, minerals, mud, clay dirt etc) Steel sleepers are not recommended for use in the following situations • Where the ballast/ formation is poor and where deflection under load is high • At locations where track dynamic forces are high, such as at joints or where the inherent rail surface condition is poor. Steel sleepers shall not be used as transoms Steel sleepers shall not be used at mechanical rail joints (i.e one sleeper each side of the joint). Steel sleepers that have been welded, cut or otherwise altered from an approved design shall not be used. Steel sleepers that have been bent or otherwise damaged by derailment or extraction process may be reused on sidings and lines carrying <3MGT (on curves >1000m radius and tangent rack) subject to engineering inspection and assessment in accordance with Chapter 13. They may be installed at intervals no closer than 1 in 2. The following interfaces are not permitted within the body of curves < 600m radius: • 100% steel sleepers with timber sleepers or a timber-steel mix • steel sleepers and concrete sleepers The full extent of any curves shall be resleepered in all cases (e.g. all timber, all steel, all concrete, all interspersed timber and steel etc.).

When steel sleepers are mixed with timber sleepers they must be installed in approved patterns

The following requirements are extracted from CRN CS 230. Mixing steel and timber sleepers Steel sleepers may be interspersed with timber sleepers in accordance with the following requirements: Minimum tie patterns are detailed in Table 15. Denser tie patterns may be used to address sleeper fatigue and fastening failure issues. Curvature Track MGT/year Class < 400m Radius <600m radius >600m radius & tangent track 1 1 in 4 (Note 2) 1 in 4 1 in 4(Note 3) 2 ≥ 2 1 in 4 1 in 4 1 in 4(Note 3) <2 1 in 4 1 in 6 1 in 6 3, 5 1 in 4 1 in 6 1 in 6

Table 15 - Minimum tie patterns for steel sleepers in timber sleepered track Note 1: A variation in the tie placement of one sleeper is still considered to be to pattern as long as the pattern is generally maintained (e.g. 1 in 4 would allow odd sleepers to be 3rd or 5th sleeper) excepting that clumping should be avoided. 2. Steel sleepers not recommended. Concrete sleepers preferred as they provide better lateral stability. If steel ties are installed, use a denser tie pattern. 3. may be extended to 1 in 6 if sleeper condition permits. When undertaking planned PRS sleeper replacement shall be planned to meet “clumping requirements detailed in Table 16 Track General Steel 2 together ≥3 together Class Sleeper Pattern 1, 2 1 in 2 Permitted Permitted 1 in ≥3 Not recommended Prohibited 3,3G 1 in 2 Permitted Permitted 1 in ≥3 Permitted Prohibited 5 1 in ≥2 Permitted Permitted Siding 1 in ≥2 Permitted Permitted Table 16 – “Clumping” of steel sleepers Where face renewal is normal practice at special locations such as level crossings, this practice is exempt from clumping requirements. Single sleepers may be installed as required A track length is considered “face resleepered” (not clumped) when the rail length with 100% steel sleepers reaches 110m on straights or the full curve (TP to TP) in curved track. This also applies to shorter lengths of face resleepering on “whole” structures e.g. ballast top bridges and level crossings.

If traffic will operate over the track before the resleepering is completed, plan the work so that the track will remain tied in accordance with the operating limits in CRN CM 203. DO NOT unfasten and remove more sleepers than can be tied in the available time. If the work is being carried in summer months, restrictions apply to the spacing between sleepers that can be removed unless written authority is provided by the Civil Maintenance Engineer. The "Work in Summer Months" Instructions are detailed in CRN CM 211.

Remember – Steel sleepers are NOT PERMITTED each side of a mechanical joint C5-3 Installing sleepers 1. Remove sleeper fastenings and anchors. Place sleeper fastenings and anchors clear of the track and stack them so that they are ready for re-use or removal from site. Leaving them near or on the track will interfere with the resleepering process and may result in them being "buried" in the track.

2. Remove shoulder ballast from the end of the sleeper. Dig sleeper end ballast clear through to the edge of the shoulder and loosen ballast along sleeper sides for easy removal.

3. Remove the old timber sleeper using the “lift” or “no lift” method described in Chapter 4 Remember - DON‟T lift the track between 1st November and 31st March, unless written instructions are issued to do so by the Civil Maintenance Engineer. (See CRN CM 211).

4. Clean and loosen the bed. In circuited track prepare the worksite to reduce the potential for signal failures.  Remove ballast fines, filings, and conductive objects (such as old fastenings) from around the fastenings and insulators  Remove foul ballast material or other contamination that may contact the rail foot

At all sites  Remove any material that is likely to cause corrosion of steel sleepers (such as spillage from derailments)  Loosen the sleeper bed with a pick.  Excavate to at least 50mm larger than replacement tie dimensions. Smooth the bed beyond the shoulder, free of obstructions sufficient to allow for free drainage to cess or six-foot drain.

5. Install new sleeper.  Push the new sleeper into place.  Minimise disturbance to rail geometry.

For new construction, lay steel sleepers on ballast that has previously been laid, levelled and compacted. DO NOT place steel sleepers on a bare, level formation and subject to train loads including ballast trains. If new track is being constructed on bare formation, support the steel sleepers under the rail with a gap under the centre of the sleeper to prevent the sleepers being centre-bound.

6. Check the location of new sleeper for spacing and skew (See Table 3). Spacing at bridge ends shall be in accordance with Table 5. Space the sleepers evenly. Move adjacent sleepers if practical. It may even be necessary to install extra sleepers or remove sleepers if the required spacing cannot be maintained.

7. Lower the rails and remove the jacks.

8. Check Gauge Gauge shall be in accordance with Table 6 for construction where new rail has been used, or Table 7 for maintenance. The Civil Maintenance Engineer may authorise the following limited variations:  Greater than 5mm tight gauge where rail flow is present. Gauge must not exceed the BOS limits in CRN CM 203 without appropriate protective action.

9. Reinstall fastenings. DO NOT use deformed fastenings or crushed insulators as these will reduce the effective toe load on the steel sleepers. Use a spot tamper to hold sleepers up so they can be clipped up.

10. Reinstall anchors in non resilient fastened track. Steel sleepers are attached to the rail with resilient fasteners that provide resistance to rail creep. Steel sleeper resilient fasteners typically provide at least equivalent creep resistance to fair type anchors. Re-install fair type anchors against timber sleepers after PRS to restore the pre-existing anchor pattern or, a minimum of one in three sleepers anchored (including both fair type anchors and resilient fasteners) whichever is greater.  Install anchors flush against the side of the sleepers.  If the existing anchor pattern is more extensive than the requirements above, check with the Civil Maintenance Engineer to determine if the extra anchors need to be re-installed.  If required by the Civil Maintenance Engineer restore the anchor pattern by placing the additional anchors on adjacent timber sleepers (not the steel sleepers)  Renew any „sprung” or overdriven anchors. 11. Ballast and regulate Minimum ballast requirements for resleepering with 1:4 steel sleepers is about 3 tonne per 20m of track (this includes the additional required to fill the pods). Higher tie densities require proportionately more. Additional ballast is required to address any existing deficiencies and to provide for any track lifting carried out in association with PRS. If there is additional ballast on the track to begin with it should be ploughed off prior to PRS and used at this point.

12. Tamp, line and level all track Tamp steel sleepers with two insertions of tynes. The objective of the track resurfacing stage of the steel sleeper installation process is to apply the design track geometry, to fill the steel sleeper pod with ballast, to pack ballast under remaining timber sleepers, and to regulate ballast to the required profile. When installing PRS, make sure that adjoining sleepers are also tamped so that they provide good vertical support for the new sleepers. DO NOT subject newly installed steel sleepers to excessive vertical loads or high levels of deflection. During the resurfacing operation following resleepering, correct any centre binding in adjoining sleepers. Using a dynamic stabiliser will provide better initial lateral (as well as vertical) stability but only if sleeper condition permits. In curves less than 400m radius consider additional measures to enhance stability and reduce the likelihood and extent of curve pull-ins. Such measures could include shoulder ballast compaction and increasing shoulder width .

It should be noted that curve pull-in is more likely if resleepering is carried out in the colder months (this also applies to timber sleepers). If you install a single sleeper you don‟t need to resurface all track. Tamp the steel sleeper and the sleepers immediately adjacent to it DO NOT tamp sleepers by hand except in an emergency. If you have to install steel sleepers in an emergency take appropriate measures to bring the installation to standard as well as take any short term protective action required. DO NOT allow trains to run over sleepers that are supported only by the spade ends.

13. Measure track geometry and check ballast pod height for acceptance. Track geometry shall comply with the geometry maintenance acceptance limits specified in CRN CM 211

In addition the work shall comply with following acceptance limits extracted from CRN CS 230. Following resurfacing • the height of the ballast in the sleeper pods shall be such that the gap between the underside of the sleeper deck and the ballast in the sleeper pod shall be ≤ 25mm. • The ballast within the sleeper shall be “tight” • Deflection of steel and timber sleepers under normal traffic loadings should be consistent and no more than 5mm, • There should be no cyclic top or line in evidence Measure the ballast height in the sleeper pod at an inspection hole adjacent to each rail. The tape measure or alternate measuring tool shall not be pointed as it could penetrate the ballast. It should have a flat, blunt end as large as allowed by the 20mm inspection holes. 14. Regulate again. 15. Tamp, line and level again if further track geometry correction is required or steel pods are not yet full. 16. Measure geometry and check ballast pod height again for acceptance. 17. Undertake a final squeeze of steel sleepers only with 5mm nominal lift. This could avoid the need for follow up resurfacing because of the sleeper settling as ballast migrates to the centre of the sleeper. Alternatively a light squeeze from a turnout tamper in the centre of the sleeper and carried out in conjunction with tamping in Step 12 can address this issue. Follow up resurfacing may be required after about 0.5mgt

18. Ballast, regulate and broom to achieve correct ballast profile.  The ballast profile for steel sleepers shall meet the requirements specified in Table 12.  Extra ballast may be placed on the outside of the sleeper ends but shall be no higher than the superelevated rail height.

19. Check the worksite.  Do not block drainage systems with old sleepers, fastenings or plates.  Stack all used material neatly where it is not in the way.

 If sleepers have not been packed, or geometry has not been corrected, apply appropriate restrictions in accordance with the operating limits in CRN CM 203.

21. Record the following information as part of the installation process and send it to the Civil Maintenance Engineer for entry into the Asset Information System:  Location of sleepered sections  Date of installation  Type of steel sleepers used, including fittings used to adjust for different rail sizes and whether insulated or non-insulated  The PRS tie pattern used and the tie pattern resulting  Any non-conformances

Chapter 6 Replacing defective fastenings on timber sleepers This chapter describes the methods used in CRN to replace sleeper plates and fastenings and cross bore timber sleepers. C6-1 Planning 1. Consider the key technical risks of undertaking the work. This includes:  Incorrect gauge after the work.  Ballast or equipment foul during work.  Site obstructions.  Fastenings, Sleeper plates.  Ballast condition and profile.  Sleeper support (packing) and fastenings.  Track Stability especially during Summer Months. (See CRN CM 211).  Incorrect clip type shorting out insulated joints.  Shorting out insulated joints (e.g. sleeper plates, fastening, scrap left behind).  Ballast fouling points operation.  Damage to trackside signal equipment from material placement or movement.  Damage to train monitoring equipment (See CRN CM 211).

2. Identify Fastenings and/or sleeper plates to be replaced. If traffic will operate over the track before the work is completed, plan the work so that the track will remain tied in accordance with the operating limits in CRN CM 203. DO NOT unfasten more sleepers than can be tied in the available time. If the work is being carried in summer months, restrictions apply to the spacing between fastenings that can be removed unless written authority is provided by the Civil Maintenance Engineer. The "Work in Summer Months" Instructions are detailed in CRN CM 211. C6-2 Replacing fastenings 1. Remove excess ballast from sleepers. 2. Remove fastenings/anchors. Place fastenings clear of the track and stack them so that they are ready for re-use or removal from site. Leaving them near or on the track will interfere with the resleepering process and may result in them being "buried" in the track.

3. Install Jacks (where required). 4. Jack up rail (where required).  BE extremely careful when lifting the track with jacks.  DON‟T lift the track higher than is absolutely necessary.  DON‟T lift the track between 1st November and 31st March, unless written instructions are issued to do so by the Civil Maintenance Engineer. (See CRN CM 211).  DON‟T lower the jacks without warning other staff.

 DON‟T leave jacks in place and unattended.

6. Check sleeper condition Check condition of sleeper to determine if it can be rebored. If not the sleeper must be replaced

7. Install new sleeper plate  If the sleeper plates are „second-hand‟ check the plates to determine if they can be re- used by following the procedures in Chapter Chapter 12.  Apply sleeper plates so that the rail leans towards the track centre. 8. Remove Jacks (where used). 9. Establish correct rail gauge (see Acceptance limits in Section C4-2 Item 12). 10. Drill spare holes on sleeper to match sleeper plate. 11. Re-install existing (or new) fastenings (see fastening requirements in Section C4-2 Item 14).  If dogscrews and lockscrews are being used, follow the installation instructions in Chapter Chapter 11.  If sleepers are being replaced at insulated joints and resilient fastenings are being used, make sure that low profile clips are used. (See Chapter Chapter 8).  If transoms are being replaced on bridges and resilient fastenings are being used, make sure that Zero Load Restraint (ZLR) fastenings are used where required. (See Chapter Chapter 9).  DO NOT overdrive elastic fastenings (clips). Refer to Chapter Chapter 7 for installation instructions.  Renew any „sprung” or overdriven clips.

12. Reinstall anchors in non resilient fastened track (see anchoring requirements in Section C4-2 Item 15).  Install anchors flush against the side of the sleepers.  If the existing anchor pattern is more extensive than the requirements above, check with the Civil Maintenance Engineer to determine if the extra anchors need to be re-installed.  Renew any „sprung” or overdriven anchors.

13. Lift, pack and line track (if required) using the methods described in CRN CM 211.  Pack each sleeper tight to the rail.  Pack the sleepers uniformly and evenly under the rail and at least 200mm either side of the rail, NOT in the centre or at the ends.

14. Measure and record geometry. 15. Restore ballast profile (if required) (see acceptance limits in Section C4-2 Item 18).  Make sure you restore the standard ballast profile.

16. Check the worksite.  Do not block drainage systems with old sleepers, fastenings or plates.

 Stack all used material neatly where it is not in the way.

17. Certify track.  Certify the track using the procedure in CRN CM 211.  If work has not been completed and sleepers are left untied assess, whether a speed restriction is required using the operating limits in CRN CM 203.  If sleepers have not been packed, or geometry has not been corrected apply appropriate restrictions in accordance with the operating limits in CRN CM 203.

Chapter 7 Use of "Pandrol" type resilient fastenings

C7-1 Selection of fastenings Use the correct Pandrol resilient clips for the sleeper and sleeper plate type.

The following requirements are extracted from CRN CS 230. Fastenings for timber sleepers and bearers Standard configurations of fastening assemblies for timber sleepers and turnout bearers are detailed in Table 17. Fastening Type Sleeper Plates Lockspikes (Note 2) Track Class No. per Plate/ Rail Dwg. No. No. per Plate Resilient Main Lines Class 1 and 2 2 Resilient E2003 DF 62 & cast 4 plates 3 TBA 3G 2 Resilient E2003 DF 62 4 Turnouts in ALL 2 Resilient Appropriate 4 classes baseplates Transoms in ALL 2 Resilient E2003 DF 62 & cast 4 (Note 4) classes plates Transoms in ALL 2 Resilient Type ISP95098 4 X 24mm screw classes plates spikes Sidings ALL classes 2 Resilient E2003 DF 62 4 Turnouts in ALL 2 Resilient Appropriate 4 classes baseplates Table 17 - Timber sleeper fastening configuration Note 2 Lockspikes (L6) or approved alternative fastenings may be used. Fastenings for Steel Sleepers Standard configurations of fastening assemblies for steel sleepers are detailed in Table 18 All classes 2 Trak-Lok 2 Lock in shoulders Table 18 - Steel sleeper fastening configuration Fastenings for Concrete Sleepers and bearers Conforming fastening systems shall use Pandrol E-2003 clips, Fastclip or other approved alternatives. Rail pads of nominal thickness 5mm shall be used. Rail pads of nominal 7.5mm thickness for E-clip fastenings and 10mm thickness for Fastclip fastenings shall be used. Resilient fastenings are interchangeable for 53 and 60kg rail sections. Standard configurations of fastening assemblies for concrete sleepers and turnout bearers are detailed in Table 19. Sleeper Design Fastening Type No. per Plate/ Rail Medium Duty (Low Profile) 2 Resilient E2003 or 2 Fastclip FC1507 Heavy Duty 2 Resilient E2003 or 2 Fastclip FC1507 Table 19 - Concrete sleeper fastening configuration

C7-2 Identification of fastenings To identify the fastenings, look for the marking on the end of the clip. The markings form a code that identifies the clip type and year of manufacture.

The coding system used to identify clips is shown in Figure 5, Table 20 and Table 21.

Figure 5 - Clip Identification

Use Type Code General use on timber sleepered track and no insulation pad using BHP.DF62 e2003 03 plate - also timbered turnouts. General use on concrete sleepers e2003 03 Low profile clips for use at Insulated Joints on timber sleepers and on concrete e1627 bearers with baseplates (Red/Brown colour, round non flattened toe) Low profile clips for use at Insulated Joints on concrete sleepers/bearers with e1629 cast in shoulders and insulating material (blue colour, flattened toe area) normal and reverse application possible Table 20 - Selection of pandrol fastenings The Year of Manufacture Identification Code is shown in Table 21:

1983 - A 1989 - H 1995 - N 2001 - W 1984 - B 1990 - I 1996 - O 2002 - X 1985 - C 1991 - J 1997 - P 2003 - Y 1986 - D 1992 - K 1998 - S 2004 - Z 1987 - F 1993 - L 1999 - T 2005 - 5 1988 - G 1994 - M 2000 - V 2006 - 6 Table 21 - Year of Manufacture Identification Code

Figure 6 – e2003 clip

C7-3 Installation procedure 1. Install resilient fastenings fully home into their fittings or housings, using the method appropriate to the type of fastening. 2. If a special tool is necessary to fit and/or remove the fastenings, DO NOT fit or remove them without using the tool. 3. DO NOT overdrive fastenings. Limits are shown in Figure 7 and Figure 8. 4. DO NOT overstress resilient fastenings by lifting rail vertically off the sleeper plate with the fastenings in place, or by levering upward between the toe of the fastening and the foot of the rail. 5. Remove fastenings completely when adjusting rail fitted with resilient fastenings. DO NOT try to pull rail through resilient fastenings. 6. Where wrap round insulated rail pads are fitted, lift the rail free from the pad to allow unimpeded longitudinal movement of the rail lengths for adjustment.

Figure 7 - Installation of PR type Pandrol clips

Figure 8 - Installation of 'e' series Pandrol clips

Chapter 8 Installing Pandrol E clips at insulated joints Special low profile Pandrol E clips are available for use at insulated joints.

The clips are designed to be clear of bolts and plates but have a lower toe load than normal clips.

The main advantage of the low profile clips is that, when installed properly, they rest clear of the fishbolts, removing the need to remove the 2nd and 5th bolts.

There are two types of clips. The clips can be identified by material, diameter, colour when new and clip toe area shape. (See Table 22 and Figure 9 below.)

Clip Clip Usage Special Features Number Colour „e‟1627 RED Timber /Steel sleepers and concrete bearers with 16 mm Dia baseplates „e‟1629 BLUE Concrete sleepers/bearers with cast in shoulders and 16 mm Dia with clip insulating material toe area flattened. Table 22 – Low profile Pandrol E clips Install the clips in the standard manner. Make sure that there is no contact between fishbolts and the clip. (See Figure 10, Figure 11 and Figure 12.)

Figure 9 - Low profile Pandrol E clips

Warning Clearances are compromised with the low profile clips in timber bearers with baseplates type PZ 147 and Type I baseplates. These are the ones with the pressed steel lugs forming the clip housing. Any clips that may become foul may be removed as long as sufficient fastenings retain in place to retain gauge security

Figure 10 - Low profile clips in use

Figure 11 - „e‟ Clip joint bar assembly to suit AS53kg / AS60kg rail with „e‟1629 Clip on Concrete Sleepers Courtesy PANDROL AUSTRALIA) (

Figure 12 - „e‟ Clip joint bar assembly to suit AS53kg / AS60kg rail with „e‟1627 Clip on Timber Sleepers (Courtesy PANDROL AUSTRALIA)

Chapter 9 Installing resilient fastenings on bridges Install resilient fastenings on bridges as follows:

The following requirements are extracted from CRN CS 230. Resilient fastenings on bridges Transom top openings with spans less than 18m (centre of bearings) On bridges where resilient fastenings are installed in CWR track, normal resilient fastenings are to be installed on the entire length of each span. Transom top openings with one or more spans 18m long and greater, but less than 80m. On bridges where resilient fastenings are installed in CWR track, normal resilient fastenings shall be installed on one third of the span from the fixed end and Zero Load Restraint (ZLR) fastenings installed on the remaining two thirds of the span (see Figure 13). Where spans are located on curves <400m radius, Zero Load Restraint (ZLR) fastenings cannot be used. Provision shall be made for play at the movable end of a bridge for the guard rail "V" to expand and contract (depending on length). This can be achieved when using medium duty concrete termination sleepers by setting the lock-in shoulders 6mm clear of the nose end rail. Zero Load Restraint (ZLR) fastenings are used to secure the guardrail nose ends, allowing limited vertical movement. Bridges with expansion switches On bridges where resilient fastenings are installed in CWR track, normal resilient fastenings shall be installed on the entire length of each span.

Figure 13 - Resilient fastenings on transom top bridges

Chapter 10 Installing 'Fastclip' fastenings

C10-1 Identification of fastenings To identify the fastenings, look for the marking on the end of the clip. The markings form a code that identifies the clip type and year of manufacture.

The coding system used to identify clips is shown in Figure 14, Table 23 and Table 24.

Figure 14 - Clip Identification

Use Type Code Fastclip – general use with concrete sleepers (including at insulated joints) - FC1507 S normally supplied with the toe insulator attached Table 23 - Selection of Pandrol fastenings The Year of Manufacture Identification Code is shown in Table 24:

1998 - S 2001 - W 2004 - Z 1999 - T 2002 - X 2005 - 5 2000 - V 2003 - Y 2006 - 6 Table 24 - Year of Manufacture Identification Code

Figure 15 - Fastclip FC 1507 (with insulator attached R)

C10-2 Installation Use the Pandrol Fastclip "Track Installation Guide" supplied by Pandrol Australia to install "Fastclip" sleepers.

Some key points from the guide include: 1. Special tools and equipment are needed for manual or mechanised installation. 2. Install sleepers on a good level ballast bed so that most sleepers directly support the rail. 3. If there is a gap between the rail seat and the sleeper, lift the sleeper up against the rail seat before it can be clipped up. (Tools are available to facilitate this). 4. There are CRN approved methods available for replacing cast-in shoulders and welding on replacement shoulders. These are detailed in Chapter Chapter 16 and Chapter 17. 5. Check ballast regulator blades to ensure that they will not hit the fastening assembly (the Fastclip assembly is wider than conventional Pandrol clips and shoulders). The blade needs to be cut out to give a clear area, 80mm above the rail seat and 135mm either side of the rail centre line (see Figure 16).

Figure 16 - Ballast regulator blade cut out details for Fastclip fastenings An allowance needs to be added to the cut-out to account for the throw of the regulator blade arising from curvature of the track. This will be different for different regulator designs. Note: there will also be a difference in the cut-out required for different rail sizes. If the blade is set up for 60kg/m rail an additional 13mm will need to be cut out to allow for its use with 53kg/m rail.

Chapter 11 Installing and removing dogscrews and lockscrews

C11-1 Identifying dogscrews and lockscrews

C11-1.1 Dogscrew The dogscrew is an alternative fastener to the dogspike.

The dogscrew consists of a 19mm threaded shank with a 22mm shoulder below the flange. On top of the flange is a 6-lob head designed to fit an E24 drive socket.

The dogscrew provides greater vertical holding force than the dogspike.

Figure 17 - Dogscrew

C11-1.2 Lockscrew The lockscrew can be used instead of lockspikes. The lockscrew consists of a 16mm threaded shank with a flange and 6-lob head, the same as the dogscrew.

There are two types of lockscrew: Small flange – for general use.

Figure 18 – Small flange lockscrew Large flange – for use with the automatic magnet pickup machine used by production gangs. This type cannot be used on rolled Pandrol plates because of the flange interferes with the rolled shoulder and does not sit flush on the plate.

Figure 19 – Large flange lockscrew

The lockscrew provides similar cross-sectional strength to the lockspike.

C11-1.3 Advantages and disadvantages The benefits of using the dogscrew/lockscrew include: - The dogscrew/lockscrew uses a screwing action for insertion reducing potential injuries from flying objects and swinging of hammers. - The dogscrew has greater vertical holding power and should remain tight for a longer time in comparison to a dogspike. - The dogscrew/lockscrew only requires to be placed upright in the hole before screwing-in where as the standing of a dogspike requires tapping in. - The dogscrew/lockscrew is galvanised for longer life.

The disadvantages are: - Sleeper boring hole sizes are different to dog/lockspikes and care will be required when ordering prebored sleepers. The dogscrew has a 17mm diameter bored hole (21mm for dogspike) and 14mm diameter hole for the lockscrew (16mm lockspike). - Additional equipment is required to insert and remove these screws. C11-2 Installation 1. Bore a 17mm diameter hole in the sleeper for a dogscrew and a 14mm diameter hole for the lockscrew. 2. DO NOT insert dogscrews or lockscrews in prebored dogspike or lockspike holes. 3. Place the dogscrew or lockscrew vertically in the bored hole (hammering or twisting should not be required). Place the E24 drive socket on the 6-lob head and rotate clockwise until the flange touches the rail or baseplate. As a guide, between 150 and 300Nm of torque is required. A standard ¾ inch or 19mm Hex socket will fit the E24 head and can be used if the correct socket is not available, however it is unlikely to last as long as the correct fitting socket. C11-3 Removal Place the E24 drive socket over the screw head and rotate anticlockwise to remove. The E24 socket has a 1/2inch female drive, a ½ to ¾ inch adaptor may be required to fit existing drive equipment.

If the head has been damaged (e.g. derailment), an extractor tool is available that grips the outer edge of the flange and when rotated will unscrew the dogscrew.

Chapter 12 Use of reclaimed sleeper plates Reclaimed sleeper plates MUST meet the following requirements for acceptance and re-use on CRN track (main line and sidings). C12-1 Sleeper plates with dogspike holes 1. Only double shouldered sleeper plates may be re-used.

2. Only New pattern sleeper plates may be re-used.

In NEW pattern plates the In OLD pattern plates the lockspike lockspike hole is on the RIGHT hole is on the LEFT of the centreline of the centreline of the plate of the plate

3. DO NOT use any sleeper plates with evidence of excessive corrosion, notch marks or oxyacetylene burn marks. 4. Check that the plate at a distance of 30 mm from the edge where the rail foot on the rail gauge side contacts the plate, is not cracked. 5. This is the location where bending moment is highest and the plate section is relatively thin. 6. Use a straight edge to check that plate underside concavity, convexity or unevenness is not greater than 1mm. This includes worn ridges on the underside of the sleeper plate. 7. Check the following dimensions.  The lockspike holes shall be no wider than 19 mm at bottom surface.  The dosgspike holes shall be no wider than 25.5 mm at bottom surface.  The rail seat width shall be no greater than 150 mm. C12-2 Sleeper plates for Pandrol fastenings 1. DO NOT use reformed plates. 2. DO NOT use any sleeper plates with evidence of excessive corrosion, notch marks or oxyacetylene burn marks.

3. Check that the plate at a distance of 30 mm from the edge where the rail foot on the rail gauge side contacts the plate, is not cracked. 4. This is the location where bending moment is highest and the plate section is relatively thin. 5. Use a straight edge to check that plate underside concavity, convexity or unevenness is not greater than 1mm. 6. Check the following dimensions:  The lockspike holes shall be no wider than 19 mm at bottom surface.  The rail seat width shall be no greater than 149.5 mm.

Chapter 13 Assessment of damaged steel sleepers for use Where re-use of damaged sleepers has been approved, the damaged sleepers shall meet the following requirements. C13-1 Criteria for reuse of damaged steel sleepers Damaged sleepers selected for repressing shall meet the following requirements:  No visible cracking, splitting, sharp edges or any other defects around the lock-in shoulder holes.  Deformation at the edge of the lock-in shoulder hole. shall not exceed 10mm from the upper plane surface level.  No cracking or fatigue indications in other areas of the section  No evidence of bending and distortion, corrosion, pitting and other loss of section.

Localised heat shall not be used during repair.

After repressing steel sleepers shall meet the following requirements  lock-in shoulder holes shall be round.  rail seat area shall be flat with a rail cant of 1:20.  No convexity in the top surface.  No gouging to the underside flange to web radius.  No visible cracking around the lock-in shoulder holes.  hold the correct track gauge within allowable limits when installed.

Repressed steel sleepers shall be stamped with a permanent „R‟ alongside the manufacturers stamp for identification purposes. This stamp location shall not be within the rail seat or lock-in shoulder hole areas.

Chapter 14 Assessment of fatigue life Steel sleepers have a nominal design life of 50 years. Whilst there is a degree of uncertainty as to the actual life that can be achieved in service, the design life should be realised if normal limits and guidelines within this manual are followed. Working guidelines for service life under typical operational situations are provided in Table 25.

Curve M7.5 M8.5 21t axle 23t axle 21t axle 23t axle <400m radius 100mgt 50mgt 200mgt 100mgt 400m to 800m radius 200mgt 100mgt 400mgt 200mgt >800m to tangent track 300mgt 150mgt 600mgt 300mgt Table 25 - Fatigue Life Guidelines for Steel Sleepers The assessment Table 25. is based on 100% steel sleepers.

The service life of steel sleepers is governed by fatigue that is not apparent until the sleeper has started to fail. Fatigue failure involves cracking of the steel sleeper in and around the rail seat.

The life of the steel sleeper will generally be a function of fatigue effects. Situations causing high levels of fatigue could shorten the life of the sleepers. These could include: - Sleeper support deficiencies - Where there is backcanting in the adjoining timber sleepers (unless this is compensated for by a denser tie pattern of the steel sleepers) - Where there is wide or tight gauge in adjoining timber sleepers that would result in a high level of gauge variation (which in turn induces additional fatigue loads in the steel sleepers) - Where the steel sleeper will be required to carry an excessive share of the load due to the poor condition of adjacent timber sleepers

The fatigue impact of the above situations could cause premature failure of the sleepers, fasteners, or insulators (where fitted).

Chapter 15 Storing timber sleepers When new sleepers are received into stock and are not required for immediate use, stack them heartwood down on old sleepers in order to keep them off the ground and free from the effects of moisture and, possibly, white ants. Sleeper stacks generally contain 10 in every row so that the number of sleepers can be easily counted if required.

Chapter 16 Replacing Fastclip cast-in shoulders The following method of replacing cast in shoulders is approved for use in CRN.

Chapter 17 Installing Fastclip Weld-on shoulders The following method of installing Fastclip Weld-on shoulders is approved for use in CRN.

Appendix 1 Approved sleeper and fastening products

Common Item Manufacturer/ Description Standard/ Drawing Name Supplier Non Resilient Fastenings

Dogspike Spike, track; round shank; 22mm shank dia; AS 1085.8 119mm long; forged; steel (dogspike) SRA Dwg CV0046205

Dogspike Spike, track; round shank; 22mm shank dia; AS 1085.8 Imported by 119mm long; forged; steel (dogspike) SRA Dwg CV0046205 Westray Eng.

Dogspike Spike, track; round shank; 22mm shank dia; AS 1085.8 Manufactured by 119mm long; forged; steel (dogspike) SRA Dwg CV0046205 Greg Sewell Forgings Gauge Lockspike Spike, track, square shank lock type L6, AS 1085.13 Pandrol XS1070

Lockspike Spike, track, square shank lock type L1, , AS 1085.13 Pandrol XS1070

Dogscrew DogScrew 22mm Shouldered; 9mm Thick Ajax Fasteners Dwg No Ajax / Pandrol Flange; Galvanised SRSG19.135 19/10/04

Lockscrew LockScrew 16mm; Galvanised Ajax Fasteners Dwg No Ajax / Pandrol TLSB16.125 10/11/03

Screw spike Spike, track Screw spike; 27mm dia 165mm SRA Dwg 205A-374 (CV long. For timber, galvanized 0024139) AS 1085.18

Screw spike Spike, track Screw spike; 24mm dia; 122mm SRA Dwg 885-067b or Delkor long; galv; For half polymer/concrete Delkor Dwg HSR-602e sleepers and 90mm nylon insert; galvanized to as 1214 Screw spike Spike, track Screw spike; 24mm dia; 165mm SRA W&W 205a-381b or Delkor long; galv; For concrete sleepers; Delkor Dwg HSR-602d Galvanized to as 1214 Screw spike Spike, track Screw spike; 24mm dia PRE Manufacturer Jinstar Fastener Co Ltd (Tekway) Washer, lock 25mm ID; 46mm OD; 6mm thick; high Delkor Dwg DSW - 01 tension double helical spring type;fe6; Galvanized to as 1214 Screw spike Spike, track Screw spike; 22mm dia; 150mm RSA Consult. long; galv; For timber sleepers; city Dwg 885-066b underground; Galvanized to as 1214 Resilient Fastenings Track-Lok II Clip Track-Lok II – for use with steel sleepers Onesteel Part No. B296

Lock in shoulder Track-Lok II – for use with M10 steel Onesteel sleepers –– insulated and non insulated - Part No.2408 Lock in shoulder Track-Lok II – for use with M8.5 steel Onesteel sleepers –– insulated - Part No. 2409

Common Item Manufacturer/ Description Standard/ Drawing Name Supplier Lock in shoulder Track-Lok II – for use with M8.5 steel Onesteel sleepers –– non insulated - Part No. 2410

Lock in shoulder Track-Lok II – for use with M7.5 steel Onesteel sleepers –– non insulated - Part No. 2411

Steel sleeper spacers Track-Lok spacers for 47, 50kg rail - Part Onesteel No. 2530

Steel sleeper spacers Track-Lok spacers for 47, 50kg rail in Onesteel insulated sleepers in association with insulator 2212 - Part No. 2509 Steel sleeper spacers Track-Lok spacers for 47, 50kg rail at joints - Onesteel Part No. 2537

Steel sleeper spacers Track-Lok spacers for 60B and 60BA rail - Onesteel Part No. 2554 (gauge side), Part No. 2545 (field side) Steel sleeper spacers Track-Lok spacers for 31kg rail - Part No. Onesteel 2554 (gauge side), Part No. 2553 (field side)

Steel sleeper spacers Track-Lok spacers for 80A, 80B and 80AA Onesteel rail - Part No. 2552 (gauge side), Part No. 2551 (field side) Steel sleeper spacers Track-Lok spacers for 71½lb rail - Part No. Onesteel 2556 (gauge side), Part No. 2555 (field side)

Pandrol Clip E series Rail clip Type e2003; 20 mm dia; 106 mm l; Pandrol e-21027 Pandrol 103 mm w; material XK 9261b; AS 1444;

Pandrol Clip E series Rail clip E1600 series; timber sleeper Pandrol Dwg e16-20002 Pandrol insulated Joints; painted red; 16 mm dia; 100 mm l; 85 mm w; type e1627 Pandrol Clip E series Rail clip E1600 series; concrete insulated Pandrol Dwg e16-20021 Pandrol Joints; painted blue; 16 mm dia; 100 mm l; 85 mm w; type e1629 Pandrol Clip E series Rail clip E1829 series;18mm dia;98mm Pandrol e18-20002 Pandrol lg;90mm w; 52.5mm 47mm heel;54mm toe; steel; black; (non insulated joints on timber sleepers); Pandrol Clip E series Rail clip e2079 series; 20mm dia; 106mm l; Pandrol e-21108 Pandrol 102.5 mm w; material XK 9261b; AS 1444

Pandrol Zero Load Zero Load Restraint Plate 41027 to suit 60kg PMP-41027 Pandrol Restraint (ZLR) Plate rolled steel sleeper plate and e2079clip.

Pandrol Zero Load Plate, ZLR Cap 12731 to suit 60kg Delkor Pandrol 12730 Pandrol Restraint (ZLR) Cap Cologne Egg

Fastclip FC1507 Pandrol fastclip; type FC1507; silico- Pandrol FC 1507 and Pandrol manganese spring steel XK9261b with Pandrol 8494 plastic toe insulator Fastclip type FC1509 Pandrol fastclip; type FC1509; silico- Dwg No 10291 Pandrol manganese spring steel XK9261b with toe insulator 10293 (white) and Sidepost Insulator 10292 (white)

Common Item Manufacturer/ Description Standard/ Drawing Name Supplier Sliding shoulder head For concrete guard rail sleepers; e-clip Amatek Rocla Pandrol fastening (multilok system); to suit 47-60kg Dwg SSP 1456 rail Rail clip, railway Track; tunnel clips; scheridised; Pandrol Rail Clip, Railway „A‟ Clip for guardrails, SG Iron Delkor S.85.745 Delkor Pads and Insulators Rail Insulator for steel Track-Lok insulators – for use with 53 and Onesteel sleepers 60kg rail in M8.5 and M10 steel sleepers - not adjustable - rail foot width 146mm for use with 41, 47, 50 kg rail in M8.5 steel sleepers – not adjustable rail foot width 127mm Part No. 2213 Rail Insulator Insulator, rail 2 piece: composite insulator in- Pandrol In-55061 55058 with a slope of 1 in 45; including cover Plate in-55057;125mm long x 54mm w; 53/60kg rail; Insulator, rail, concrete Glass reinforced nylon insulator ;for use Pandrol In-55088 Pandrol sleeper with concrete sleeper having pandrol e-clip fastenings;to suit 53/60kg rails Rail Insulator Insulator, rail, concrete sleeper Dual function spacer/insulator for use with 47kg rail in 60kg rail seat;glass reinforced nylon; Rail Insulator G.R.H. Insulator to suit insulated joint Pandrol In-55186 Pandrol Assemblies; 108mm long x 40mm w x 20mm h; 53/60kg rail; Rail Insulator side post Pandrol side post insulator type 7551; for Pandrol 7551 Pandrol Fastclip use with concrete sleeper having Pandrol Fastclip fastenings Rail Insulator toe Pandrol toe insulator type 8494;for use with Pandrol 8494 Pandrol Fastclip concrete sleeper having Pandrol Fastclip fastenings Rail Insulator Heavy duty insulator assembly type hda2; Pandrol In-55185 Pandrol 8mm pad x 110mmw; Rail pad Rail pad, railway Fabreeka/rubber;190mm lg x 170mm w x 7mm thk Rail pad Grooved;HDPE plastic;180mm w x 186mm lg x 7.5mm thk; black; for 53/60kg rail/ concrete sleeper; Rail pad 163mm wide x 180mm long x 7.5mm thick; Pandrol RP-65184C Pandrol HDPE.; Used with 53kg and 60kg rails Rail pad 190mm wide x 190mm long x 5mm thick; Pandrol RP-65026 Pandrol H.D.P.E.; Used with 53kg and 60kg rails Rail pad Pandrol HDPE rail pad; type 8853; for use Pandrol 8853 Pandrol with concrete sleeper having pandrol e-clip fastenings Rail pad Pandrol HDPE rail pad;type 9154;for use Pandrol 9154 Pandrol Fastclip with concrete sleeper having pandrol fastclip fastenings

Common Item Manufacturer/ Description Standard/ Drawing Name Supplier Sleeper plates Sleeper Plate Screw spike; clip type; 146mm rail base; 1 Pandrol isp95086 Screwspike in 20 cant; cat no 086s; Sleeper Plate Clip type; 4hole; 146mm rail base; 1 in 20 Pandrol ISP95486 Clip type cant; cat no 486; Sleeper Plate Double shoulder type; 127 mm rail base; 1 in BHP 2705 dogspike 20 cant; Cat no 430; 127dstb-df10 Sleeper Plate Double shoulder type; 146mm rail base; 1 in BHP 2706 dogspike 20 cant; cat no 420; 146dstb-df30 Sleeper Plate Clip type; 6hole; 127mm rail base; 1 in 20 Pandrol isp-95064 Clip type cant; Sleeper Plate Screw spike; clip type; 148mm Rail base; 1 Pandrol ISP95054 Screwspike in 20 cant; cat no 054 Sleeper Plate Screwspike clip type; 148mm rail base; 1 in Pandrol ISP95098 Clip type 20 cant; cat no 098s; bridge type; Sleeper Plate Clouth alternative 1; 60kg rail; cast Iron- Delkor RF 0. 02 192 CLA Delkor Clouth alternative 1 rubber; sound damping, double Shouldered 1:20 cant, end holes at 130mm centres Sleeper Plate Clouth alternative 1; 60kg rail; cast Iron- Delkor RF 0.10.092 CL Delkor Clouth alternative 1 rubber; sound dumping, double Shouldered 1:20 cant, end holes at 95mm centres Sleeper Plate Clouth alternative 1; 60kg rail; cast Iron- Delkor RF 0.29.092 CLA Delkor Clouth alternative 1 rubber; sound damping, double Shouldered 1:20 cant, side holes Timber Sleepers Timber Sleeper Sleeper, railway Timber; unbored; 230mm x AS 3818.2 130mm x 2440mm ironbark or approved hardwood Timber Sleeper Sleeper, railway Timber; 230mm x 130mm x AS 3818.2 2440mm lg; bored 47kg/80lb AS "A"; ironbark or approved hardwood Timber Sleeper Sleeper, railway Timber; 230mm x 130mm x AS 3818.2 2440mm; Bored; 53kg new pattern; Ironbark or approved hardwood Timber Sleeper Sleeper, railway Timber; 230mm x 130mm x AS 3818.2 2440mm; Bored for Pandrol fastenings Timber Sleeper Timber, Dog Screw, new pattern, 230mm x AS 3818.2 130mm x 2440mm, Bored Timber Sleeper Timber, Dog Screw, Pandrol pattern, 230mm AS 3818.2 x 130mm x 2440mm, Bored Steel Sleepers M7.5 Steel – 7.5mm thick 1435mm gauge Non- AS 1085.17 Onesteel Non-insulated insulated Track Lok II fastening system – Onesteel Drawing 2072 Part No. 7.5SG2072TSS M8.5 Steel - – 8.5mm thick 1435mm gauge Non- AS 1085.17 Onesteel Non-insulated insulated Track Lok II fastening system – Onesteel Drawing 12142 Part No. 8.512142TSS

Common Item Manufacturer/ Description Standard/ Drawing Name Supplier M8.5 Steel - – 8.5mm thick 1435mm gauge AS 1085.17 Onesteel Insulated Insulated Track Lok II fastening system – Onesteel Drawing 12125 Part No. 8.5SG12125 M10 Steel - – 10mm thick 1435mm gauge Non- AS 1085.17 Onesteel Non-insulated insulated Track Lok II fastening system – Onesteel Drawing 12126 Part No. 10SG12126 M10 Steel - – 10mm thick 1435mm gauge AS 1085.17 Onesteel Insulated Insulated Track Lok II fastening system – Onesteel Drawing 12195 Part No. 10SG12195TSS Concrete Sleepers Concrete Sleeper Concrete; Medium duty low profile 25t axle AS 1085.14 Rocla Medium Duty Fastclip load; Pandrol Fastclip fastening system; (MDFC), 25T mass 232kg Concrete Sleeper Concrete; Medium duty low profile 25t axle AS 1085.14 Rocla Medium Duty E-clip load; Pandrol e2003 fastening system; (MDEC), 25T mass 232kg Concrete Sleeper Concrete;Heavy Duty Type 5 30t axle load AS 1085.14 Rocla Heavy Duty E-clip ;Pandrol e-clip fastening system; mass (HDEC), 30T 285kg; Concrete Sleeper Concrete; Heavy Duty 30t axle load; AS 1085.14 Rocla Heavy Duty Fastclip Pandrol Fastclip fastening system; mass (HDFC), 30T 285kg Concrete Sleeper Concrete; Type 6M 30t axle load; 20 wire AS 1085.14 Rocla Type 6M 30t E-clip Pattern; Pandrol e2003 fastening system; (mass 275kg); Concrete Sleeper Concrete; track circuit sleeper; Medium duty AS 1085.14 Rocla track circuit Fastclip 25t axle load; Pandrol Fastclip fastening Concrete Guardrail Sleepers Concrete Guardrail Concrete, Heavy Duty E-clip Guardrail AS 1085.14 Sleeper sleeper, GR1, 30T axle load, Pandrol E-clip Heavy Duty E-clip 30T fastening system No.1 Concrete Guardrail Concrete, Heavy Duty E-clip Guardrail AS 1085.14 Sleeper sleeper, GR2 to GR6, 30T axle load, Heavy Duty E-clip 30T Pandrol E-clip fastening system No. 2 to No.6 Concrete Guardrail Concrete, Medium Duty E-clip Guardrail AS 1085.14 Sleeper sleeper, GR1, 25T axle load, Pandrol E-clip Medium Duty E-clip fastening system 25T No. 1 Concrete Guardrail Concrete, Medium Duty E-clip Guardrail AS 1085.14 Sleeper sleeper, GR2 to GR6, 25T axle load, Medium Duty E-clip Pandrol E-clip fastening system 25T No. 2 to No.6 Concrete Guardrail Concrete, Heavy Duty Fastclip Guardrail AS 1085.14 Sleeper sleeper, GR1, 30T axle load, Pandrol E-clip Heavy Duty Fastclip fastening on guardrail and fastclip on 30T running rail No. 1

Common Item Manufacturer/ Description Standard/ Drawing Name Supplier Concrete Guardrail Concrete, Heavy Duty Fastclip Guardrail AS 1085.14 Sleeper sleeper, GR2 to GR6, 30T axle load, Heavy Duty Fastclip Pandrol E-clip fastening on guardrail and 30T fastclip on running rail No. 2 to No.6 Concrete Guardrail Concrete, Medium Duty Fastclip Guardrail AS 1085.14 Sleeper sleeper, GR1, 25T axle load, Pandrol E-clip Medium Duty Fastclip fastening on guardrail and fastclip on 25T running rail No. 1 Concrete Guardrail Concrete, Medium Duty Fastclip Guardrail AS 1085.14 Sleeper sleeper, GR2, 25T axle load, Pandrol E-clip Medium Duty Fastclip fastening on guardrail and fastclip on 25T running rail No. 2 to No.6 Concrete bearer Concrete bearer, FLAT 1, 30T, 8 ferrules AS 1085.14 cast in for cant reducing sleeper plates Concrete Guardrail Concrete Guardrail Bearer, Type AGR1 for AS 1085.14 Bearer “Alternative 1” sleeper plates under running rail, „A‟ clips hold the guardrail Ordinary AGR1 guardrail sleeper and no. 1 in termination set Concrete Guardrail Concrete Guardrail Bearer, Type AGR2 to AS 1085.14 and drawings Bearer AGR7 for “Alternative 1” sleeper plates 785 030 and 785 031 under running rail