Crn Cs 220 Rail and Rail Joints

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Engineering Standard Track

CRN CS 220 RAIL AND RAIL JOINTS

Version 1.7

Issued September, 2019

Owner: Manager Engineering Services Approved by: M Wright, Principal Track and Civil Engineer Authorised by: J Zeaiter, Manager Engineering Services

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 JHR.

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CRN Engineering Standard - Track CRN CS 220 Rail and Rail Joints

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Revision Date of Approval Summary of change 1.0 August, 2011 First Issue. Includes content from the following former RIC standards: C 2405, C 2447, C 2501, C 3200, C 3201, C 3361, C 5200, TS 3101, TS 3104, TS 3111, TS 3341, TS 3362, TS 3371, TS 3394, TS 3396, TS 3397, TS 3601, TS 3602, TS 3603, TS 3604, TS 3606, TS 3642, TS 3645, TS 3646, TS 3648, TS 3650, TS 3654, TS 3655, RC.2410, RC.2411, RTS.3602, RTS.3640, RTS.3733, RCSI.019, CTN 01/14, CTN 03/04 1.1 January, 2012 5.1.2 – Removal of limit on concavity of gauge face for recycled rail; 5.2.2.2 – Expansion of requirement for flashbutt welds and joints to be free of defects to include all existing welds; 5.2.2.2 – Reduced requirement to crow rail ends from 800m to 500m and limited crowing to closures less than 6m; 5.4.1.1 – Installation of joints in turnouts in CWR track is not recommended 1.2 July, 2014 2.2 – Added reference; Various - Included note removing approval for 60 UIC rail because of incompatible foot size; 5.1.1 - Added reference to table of rail dimensions and properties for older rails; 5.1.2 – Table 3 inclusion of Category 2 53kg rail for use on Class 3G lines, Addition of requirement for field side of gauge face to be ground prior to transposing rail, Limited use of “French rail” to crossing loops where speed does not exceed 25kph, Added clarification to Figure 2; 5.2.2.1 – Added explanation of limits of welding different rail sizes, Table 7 – Expanded table to include “Welding Group” specifying which rail sizes may be welded together; 5.2.2.2 – Addition of recommended restriction on aluminothermic welds near transom top bridge ends , between sleepers of different types, or near slab track or rigid surface level crossings – Welds subject to additional degradation, Added limit on rate of change of rail head section; 5.4.1.1 – Added reference to table of bolt hole size and location for older rails; 5.4.2 – Reduced limit on joints in concrete sleepered track from 30 days to 7 days.; 5.4.3.1 – Figure 4 – clarification; 5.4.3.3 – Clarification of selection and use of Benkler and Hercules Insulated Plate Joints; 5.4.3.5 – Added restriction on insulated joints in transition between sleeper types, Changed 5m exclusion for insulated joints near transitions between sleeper types to mechanical insulated joints and insulated plate joints; 5.5.1 – Changed code of engine burn defect to match coding in CRN CM 224; 5.7.2 – Changed “alignment marks to Track Control Marks, Changed limit of requirement to install anchors; Appendix 2 – Added heading for Approved Head Repair Welds (Nil current) 1.3 June, 2016 Various - Changed ‘Principal Civil Engineer’ to ‘Principal Track and Civil Engineer’; Removed publication dates from standards references; Rewording for consistency and minor corrections; 2.1 - Added note regarding use of latest version of standards; 2.2 - Updated titles of CRN reference documents; 5.1.2 - Varied requirements for testing rails for reuse; Table 4 – inserted missing dimensions; clarified rail descriptions; 5.2.2.1 - Table 7 - Include 50kg as approved rail for welding (omitted in error); included 47/50kg as approved junction weld; Added requirement for SC weld portions to be used when welding HH rail to SC rail; 5.2.2.2 - Added ultrasonic testing of bolt holes as an alternative method for accepting rail ends for welding; 5.4.1.1 - Changed requirements for joints in turnouts in CWR; 5.4.2 - Clarified time frame for permitted use of temporary joints; 5.4.5 - New section “Alternative fasteners” Included approval for use of Tracksure bolts (includes content from CCT 15/16 and CCW 15/030); 6.1.2 - Added milling as method for achieving rail profile; change “grinding” to “re- profiling” to allow other profiling processes; Appendix 1 - Added statement regarding need to seek advice from Principal Track and Civil Engineer before ordering certain products; Added space for Product Approval numbers; Changed name of “RailCorp Rail Fabrication Centre” to “Bathurst Rail Fabrication Centre” to reflect change of ownership; Included approval for use of Tracksure bolts (includes content from CCT 15/16 and CCW 15/030); Appendix 2 - Added space for Product Approval numbers;

Included Part numbers and hardness for 2 weld kits; included 47/50 junction weld kit; Appendix 4 - Added space for Product Approval numbers 1.4 July, 2016 6.1.2.1 - Added new rail profiles, Appendix 5 - Added new rail profiles and updated existing profiles 1.5 February, 2017 Appendix 1 - Notified by supplier of change of trading name for Avdelok swage fastener systems, Addition of Lifting / Spreader Beam to approved product listing, addition of rail lifting clamps to table previously shown in CRN CM 221 1.6 November, 2017 Appendix 1 - Updates to supplier details, product numbers and drawings; Appendix 2 - Updates to supplier product details 1.7 September, 2019 See Summary of changes below

Summary of changes from previous version

Section Summary of change 5.1.1.2 Inclusion that 60kg/m Head Hardened rail is not to be used in the CRN unless approved by the Principal Track and Civil Engineer 5.3 Included preference for junction rails over junction welds 5.4.2.1 Inclusion of the allowance for the use of Robel Clamps for use as temporary joints 5.4.2.2 Reiterate that the correct plates are to be used with Robel Clamps 5.7 Allowance for variation in Neutral Temperature with approval from the Principal Track and Civil Engineer 6.1.2 Additional commentary on desired rail profile characteristics; reformatted Table 12 to be clearer for rail template to be used in what scenario; Inclusion of reference to applicable CRN Standards for maintaining and applying this standard; Reformatting of tolerances into table format; 6.4.3.1 Revised weld alignment tolerances to be consistent with AS 1085.20

Contents 1 Scope and application ...... 5 1.1 Methods of measurement ...... 5 2 References ...... 5 2.1 Australian and International Standards ...... 5 2.2 CRN documents ...... 5 2.3 Other references ...... 5 3 Engineering authority ...... 6 4 Design & performance criteria ...... 6 5 Allowable configurations ...... 6 5.1 Rail ...... 6 5.2 Rail welds ...... 11 5.3 Junction rails ...... 15 5.4 Rail joints ...... 15 5.5 Rail repair ...... 22 5.6 Rail lubrication ...... 23 5.7 Rail adjustment ...... 24 5.8 Rail anchoring ...... 25 5.9 Rail at friction buffer stops ...... 28 5.10 Connections to rail ...... 28 6 Acceptance standards ...... 28 6.1 Rail ...... 28 6.2 Rail joints ...... 31 6.3 Flashbutt welds ...... 31 6.4 Aluminothermic welds ...... 31 6.5 Rail head repair welds ...... 34 Appendix 1 Approved products ...... 35 Appendix 2 Approved welding processes...... 40 Appendix 3 Approved rail adjustment processes ...... 41 Appendix 4 Approved rail connection methods ...... 42 Appendix 5 Rail templates ...... 43

1 Scope and application This Standard establishes design requirements, approved configurations, acceptance standards, damage limits and repair standards for rail, rail joints, rail welds, rail lubrication, rail anchors and rail adjustment.

It is applicable to all Country Regional Network (CRN) main line and siding tracks.

1.1 Methods of measurement All measurements and testing requirements in this standard shall be undertaken using the methods documented in CRN Engineering Manuals CRN CM 203 “Track Inspection” and CRN CM 224 “Rail Testing and Defects”

2 References 2.1 Australian and International Standards AS 1085.1 Railway Track Material Part 1: Steel rails AS 1085.2 Railway Track Material Part 2: Fish plates AS 1085.4 Railway Track Material Part 4: Fish bolts and nuts AS 1085.7 Railway Track Material Part 7: Spring washers AS 1085.10 Railway Track Material Part 10: Anchors AS 1085.12 Railway Track Material Part 12: Insulated joint assemblies AS 1085.15 Railway Permanent Way Material Part 15: Aluminothermic rail welding AS 1085.18 Railway Track Material Part 18: Screw spikes and threaded inserts AS 1085.19 Railway Track Material Part 19: Resilient fastening assemblies AS 1085.20 - Welding of steel rail AS 2382 - Surface Roughness Comparison Specimens Unless otherwise specified, all references relate to the latest standard versions, including amendments and relevant superseding standards.

2.2 CRN documents CRN CS 200 – Track System CRN CS 230 – Sleepers and Track Support CRN CM 203 - Track Inspection CRN CM 221 – Rail Installation and Repair CRN CM 222 – Rail Welding CRN CM 223 – Rail Adjusting CRN CM 224 - Rail Defects and Testing

2.3 Other references Nil

3 Engineering authority Design and selection of infrastructure detailed in this standard for use on the CRN may only be undertaken by persons who have been granted appropriate Engineering Authority by the Principal Track and Civil Engineer

4 Design & performance criteria To be determined

5 Allowable configurations 5.1 Rail

5.1.1 New rail New rail shall comply with the following criteria: - All new 50 kg and 60 kg rail shall be manufactured to Australian Standard AS 1085.1.

- 47 kg and 53 kg rail cross section shall comply with AS 1085.1(1980). All other properties shall comply with AS 1085.1.

- Rail ends shall be undrilled

Note: 60 UIC rail section does not meet the requirements of AS 1085.1 and is not approved for use in CRN infrastructure.

The dimensions and properties of other, older, rail sizes in use on CRN are documented for reference in CRN Engineering Manual CRN CM 221 “Rail Installation and Repair”.

5.1.1.1 Rail size Rail size shall be selected in accordance with the track class detailed in CRN Engineering standard CRN CS 200 “Track System”. Approved alternative rail sizes for each track class are detailed in Table 1. Selection of a different rail size may impose requirements for rail welding, sleeper type, ballast depth or fastening type. These requirements are detailed in the track element standards referenced in CRN CS 200.

Track Rail Size (kg/m) Class Preferred Approved Alternatives Main Line 1 60 53, 60H 2 50 47, 53 3 41 40, 47 3G 53 5 30 40, 41, Sidings 1 60 53, 50 2 50 47, 53 3 41 40, 47 Table 1 – Selection of Rail size 5.1.1.2 Use of head hardened rail Head hardened 60kg/m rail (60H) shall not be used in the CRN network without the approval from the Principal Track and Civil Engineer.

Head Hardened 60kg/m rail where authorised shall be selected for use in accordance with the existing or proposed track structure class detailed in CRN standard CRN CS 200 and the following requirements.

- On any line where axle loads heavier than 25tonne are to operate at levels > 1 MGT per year

- At other locations selection of head hardened rail will depend on the operational requirements, site conditions and the rail management strategy adopted. Consideration shall be given to the use of head hardened rail on track meeting the annual tonnage and curvature requirements in Table 2.

Curvature Tonnage Sharp Moderate Flat Very Flat (MGT per yr) (<301m) (301-699m) (700-1500m) (>1500m) less than 10 60H 60 60 60 10 to 14 60H 60H 60 60 15 to 19 60H 60H 60H 60 20 or greater 60H 60H 60H 60H Table 2 – Selection of Head Hardened Rail In addition consideration shall be given to the use of 60H rail in the following locations: - Sections of track with excessive rail wear rates

- Curves with 6 yearly renewal cycles or less for standard carbon rail

- Platform and approach tracks with similar renewal cycles caused by heavy train braking

- Grades 1 in 40 or steeper subject to extensive train braking or skidding

- In Turnout Renewals.(for Class 1 mainline track)

5.1.1.3 Installation requirements 1. Drilling of holes in rails should be minimised. 2. Rail shall be installed on plain track with a cant of 1 in 20 towards the centreline of the track. 3. The rail shall be welded into lengths required by the track class using approved welding processes. (See Appendix 2). 4. The minimum rail length to be installed on welded track is 110m, welded from shorter lengths by flashbutt welding. In-situ aluminothermic welds should be kept to a minimum. Short lengths shall not be used except in emergencies. 5. The up and down rail of track shall be the same equivalent rail size. 6. Head hardened rail may be mixed with standard carbon rail on opposing rails. 7. 60kg/m rail shall be fastened only with resilient fastenings. When replacing 53 kg/m with 60 kg/m rail, allowance shall be made for the 13mm increase in rail height. The effects of the increased height of the 60kg/m rail must be checked in such aspects as the setting of tamping tools and structure clearances.

5.1.2 Recycled rail Recycled rail may be selected for use in existing mainline tracks and new or existing sidings in accordance with the requirements detailed in Table 3 below, and subject to the restrictions also detailed below. The recycled rail categories are explained in Table 4.

Recycled rail sections allowed (kg/m) Track Class Category 1 Category 2 Category 3 (White Rail) (Blue Rail) (Red Rail) Main line 1 53(1), (2), (3), (4), 60 53(1), (2), (3), (4), 60 Not permitted 2 47 (3), 50, 53(3), 60 50, 53(3), 60 Not permitted 3 40, 47 47 Not permitted 3G 53 53(3) TBD 5 30, 40, 41 TBD TBD Sidings 1 53 (3), 60 53 (3), 60 Not permitted 2 47 (3), 50, 53(3), 60 50, 53(3), 60 Not permitted 3 41, 40, 47 40, 47 TBD Table 3 - Use of Recycled Rail by Track Class Note- 1. 53kg/m rail which is recycled for use on Class 1 main lines may be used only on lines operating with < 5 MGT per year and which have ≤ 1 MGT per year of 25 tonne axle load freight traffic. 2. on Class 1 main lines operating ≥ 5 MGT per year and > 1 MGT per year of 25 tonne axle load freight traffic, recovered 53kg/m rail may only be used for the repair of rail defects and conversion to CWR to match worn rails on existing 53kg/m track. 3. Or equivalent rail class (see Table 5). 4. Recycled “French" rail (Longwy and Micheville brands) shall not be used on main line tracks. It is suitable for installation in crossing loops where 25kph is not exceeded and in sidings. 5. Category 4 rail is painted GREEN and is not approved for use in track

Recycled rails used for rerailing shall meet the following requirements

- Rail wear shall meet the classification limits given in Table 4.

- Rails shall be visually inspected and have

 No visible web fillet cracks

 No head or foot cracks

 No crush or laminated head

Any visible squats, wheel burns, gauge corner cracking, corrugations or nicks/cuts that are found to be defects in accordance with CRN CM 224 shall be removed. If not classified as defects in accordance with CRN CM 224 they shall be ultrasonically tested. - Rails that cannot be checked for cracks because of grease or from tunnels shall be ultrasonically tested before paintcoding.

- Rails that are intended for transposing shall be ultrasonically tested. All defects shall be removed.

- Rails that are not currently in service shall be ultrasonically tested. All defects shall be marked and removed accordingly.

- Any unground welds on field side head of rails that are intended for transposing shall be ground to create the new gauge face.

- Visible end batter shall be removed or corrected if rail is to classified for reuse in mainlines

- Rail shall not have excessive rust

- Rails with more than 6 aluminothermic welds in a 100m length shall be ultrasonically tested. All defects shall be removed

- The gauge face shall be re-profiled to the correct rail profile by removing any lip that has developed

- The gauge face angle shall not exceed 26° to the vertical when the worn face is within 15mm of the lower edge of the rail head. (See Figure 1).

26°

15mm

1 in 20

Figure 1 – Gauge Face Angle

- The maximum allowable rate of change of rail head sections where it is necessary to grind one rail to match the next shall be 1 in 500. (See Figure 2).

Maximum slope for grinding 1:500

Wider rail head Narrow rail head

Figure 2 – Maximum slope for grinding

Original Category 1 Category 2 Category 3 Category 4 Rail Section dimensions (White Rail) (Blue Rail) (Red Rail) (Green Rail) Kg/m Width Depth Width Depth Width Depth Width Depth Width Depth mm mm mm mm mm mm mm mm mm mm

60 Kg/m 70 44 ≥ 66.5 ≥ 35 ≥ 63.5 ≥ 35 > 46 > 26 ≤ 46 ≤ 26

53 Kg/m * 70 40 ≥ 66.5 ≥ 35 ≥ 63.5 ≥ 35 > 46 > 22 ≤ 46 ≤ 22

50 kg/m 70 40 ≥ 66.5 ≥ 35 ≥ 63.5 ≥ 35 > 47 > 22 ≤ 47 ≤ 22

47 Kg/m * 70 37 ≥ 66.5 ≥ 33 ≥ 63.5 ≥ 33 > 46 > 24 ≤ 46 ≤ 24

41 Kg/m * 63 35 ≥ 60 ≥ 30 ≥ 5 ≥ 30 > 41 > 23 ≤ 41 ≤ 23

80 lb/ yard AS (1928) 64 40 ≥ 60 ≥ 30 ≥ 57 ≥ 30 > 41 > 23 ≤ 41 ≤ 23 “B” (NEW) 80 lb/ yard AS (1928) 70 37 ≥ 66.5 ≥ 27 ≥ 63.5 ≥ 30 > 46 > 23 ≤ 46 ≤ 23 “A” (OLD) 80 lb/ yard AS (1916) 70 37 ≥ 66.5 ≥ 27 ≥ 63.5 ≥ 30 > 46 > 23 ≤ 46 ≤ 23 (OLD) 80 lb/ yard AA (1907) 64 40 ≥ 60 ≥ 30 ≥ 57 ≥ 35 > 41 > 23 ≤ 41 ≤ 23 Table 4 – Rail Categories by Wear Limit * Includes equivalent Classifications (see Table 5)

Size Equivalent 60 kg/m No equivalent rail sizes 53 kg/m 107 AS 1936 103 AS 1936 100 AS 1928 47 kg/m 94 AS 1937 90 AS 1928 90 AS 1925 90 AS 1916 90J 1913 41kg/m 80 AS “B” 1928 80 AS “A” 1928 80 AS 1916 (80 NEW) (80 OLD) (80 OLD) 35 70 AS 1928 70 AS 1925 70 AS 1916 70 1910 31 60 ASB 1928 60 ASA 1928, 60 BA 1907 60 B 1896 60 B 1896 60 AS 1916 Table 5 – Equivalent Rail Sizes

5.1.3 Transposed rails Rails subject to curve wear may be transposed and reused in tangent track, subject to curve wear not exceeding the limits detailed in Table 6 prior to re-use.

Minimum Rail Rail Section Head C Size Width “C” 60 60 AS 1977 1981 49 53 53 AS 1977 1981 49 Running Face 15mm 53 107 AS 1936 1964 49 51 103 AS 1936 49 Measurement of Curve Wear “C” 50 50 AS 1977 1981 50 50 100 AS 1928 52 50 100 AS 1916 58

50 100 C 1907 51 Minimum Rail 50 100 C 1901 52 Rail Section Head Width Size “C” 47 94 AS 1937 49

45 90 AS 1928, 90 AS 37 75 BHP 1917 52 48 1925

45 90 AS 1916 56 36 71 2 D 1875 46

45 90 J 1913 35 70 AS 1928, 70 AS 52 52 1925

41 80 ASB 1928 49 35 70 AS 1916 48

41 80 ASA 1928, 80 A 35 70lb 1910 56 48 1916

41 80 AA 1906 48 31 60 ASB 1928 Not Permitted

41 80 A 1900 31 60 ASA 1928, 60 AS Not Permitted 51 1916

41 80 A(1) 1897 50 31 60 BA 1907 Not Permitted

41 80 A(2) 1895 49 31 60 B 1896 Not Permitted

41 80 A(3) 1890 49 31 60 B 1890 Not Permitted

39 78 H 1903 55 Table 6 - Rail Wear Limits for transposing

5.2 Rail welds

5.2.1 Flashbutt welds Flashbutt welding processes shall meet the following requirements: - Long welded rail strings shall be supplied in accordance with the requirements of AS 1085.20 - Welding of steel rail. Type and proof testing shall be carried out using the method and frequency defined in AS 1085.20.

- Storage, transport and delivery of welded rail strings shall be in accordance with AS 1085.20.

- Approved suppliers of long welded rail strings are detailed in Appendix 1.

5.2.1.1 Rails approved for flashbutt welding Rails approved for flashbutt welding are detailed in Table 7:

For the rail sizes nominated in Table 7, rail manufactured to Australian standards published since the editions listed are also approved for welding.

All other rail sections shall not be welded because of age, wear or suspect chemical composition.

Only rails of the same weight and hardness may be welded by flashbutt welding into welded rail strings.

The minimum distance between flashbutt welds shall be 5m.

5.2.2 Aluminothermic welds Aluminothermic welding processes and materials shall meet the following requirements:

- Aluminothermic weld materials shall be supplied in accordance with the requirements of AS 1085.20. Type and proof testing shall be carried out using the method and frequency defined in AS 1085.20.

- Transport and storage of weld consumables shall be in accordance with AS 1085.20.

- Aluminothermic welding may only be undertaken using approved aluminothermic welds, Approved aluminothermic welds including standard, wide gap and junction welds are detailed in Appendix 2.

- Aluminothermic welding may only be undertaken by persons with competencies documented in CRN Engineering manual CRN CM 222 “Rail Welding”, using approved aluminothermic welding processes. Approved aluminothermic welding processes are detailed in Appendix 2.

5.2.2.1 Rails approved for aluminothermic welding Rails approved for aluminothermic welding are detailed in Table 7.

For the rail sizes nominated in Table 7, rail manufactured to Australian standards published since the editions listed are also approved for welding.

Rails of each specified size may be welded to each other. Rails in each of the groups specified in Table 7 may be welded together (e.g. 53 kg A.S. 1981 with 103 lb A.S. 1936). Some rails, although they are treated as being of equivalent rail size as others, may not be welded to rails of other groups (e.g. 90 lb A.S. 1928 with 90J 1913). This occurs because of differences in original rail dimensions greater than the tolerances permitted for welding in Section 5.2.2.2.

Rail Section Equivalent Welding Group 60 kg A.S. 1981 60 kg A.S. 1981 WG 1 Head Hardened 53 kg A.S. 1981 107 lb A.S. 1936 All treated as 53 kg rail See notes below regarding WG 2 103 lb A.S. 1936 welding of 'French' rail 100 lb A.S. 1928 50 kg A.S. 1981 WG2A 47 kg A.S. 1921 94 lb A.S. 1937 All treated as 47 kg rail WG 3 90 lb A.S. 1928 90 lb A.S. 1925 90 lb A.S. 1916 All treated as 47 kg rail WG 4 90J 1913 41kg A.S. 1977

80 lb A.S. “B” 1928 All treated as 41kg rail WG 5 (commonly called 80 NEW) 80 lb A.S. “A” 1928

80 lb A.S. 1916 All treated as 41kg rail WG 6 (Both commonly called 80 OLD) 80AA (1907) Treated as 41kg rail WG 7 Table 7 - Rails approved for aluminothermic and flashbutt welding, and as junction rails All other rail sections shall not be welded because of age, wear or suspect chemical composition.

Rails of dissimilar section may be welded together using approved junction welds only for the following sections: - 60kg to 53kg

- 53kg to 47kg

- 50kg to 47kg

- 47kg to 41kg

- 30kg to 41kg (Conditions apply - detailed in CRN CM 222)

Welding 60kg Head Hardened (HH) rail to standard carbon (SC) rail lengths shall be done with standard carbon weld portions.

Welding of 'French' rails Because of a high percentage of internal failures in 'French' rails (Longwy and Micheville), particularly vertical split webs, they are NOT to be welded into CWR lengths in main lines.

Field welding of these French rails may be carried out in crossing loops and sidings, provided that ultrasonic testing is carried out and proves the rail satisfactory for welding.

Ultrasonic testing shall include the side of the rail web for a distance of one (1) metre in the vicinity of the proposed weld.

5.2.2.2 Placement and installation requirements The following placement and installation requirements apply to aluminothermic welds: General 1. Welds SHALL NOT be installed when exposed to moisture (rain, fog etc.). 2. Rail ends should not be located within 1.2 m of the centre of a bonded insulated joint 3. Aluminothermic welds shall not be placed within 2.2 metres of any weld (flashbutt or aluminothermic) or mechanical (or glued) joint on plain track (main line or siding) except as indicated below In turnouts, aluminothermic welds may be placed to within 1.2 metres of a flashbutt weld, aluminothermic weld or mechanical rail joint, provided that -  The existing weld or joint has no internal defects.

 The rail length is well secured by two ties with the ties held by more than two rails such that they will not be able to skew if the rail breaks in two places.

 The aluminothermic weld is ultrasonically tested within 6 hours of completion.

4. Aluminothermic welds may be installed opposite each other on adjacent rails as long as the gauge side of each weld is ground prior to passage of trains. 5. Aluminothermic welds are not permitted on a sleeper. 6. Aluminothermic welds shall not sit directly on slab track 7. Aluminothermic welds should not be located within 4m of the approach end of a transom top bridge, nor within 8m of the departure end. 8. Aluminothermic welds should not be located between sleepers of different types 9. Aluminothermic welds should not be located in areas adjacent to slab track and level crossings with rigid surfaces. Closures 1. The minimum length of a closure to be welded into track is 2.2 metres except as detailed below In turnouts, closures shorter than 2.2 metres to a minimum length of 1.2m may be used, provided that  The closure is well secured by two ties with the ties held by more than two rails such that they will not be able to skew if the rail breaks in two places.

 The aluminothermic welds are ultrasonically tested within 6 hours of completion.

2. A flame cut rail end which has been left more than 12 hours (4 hours for Head Hardened rail) shall be re-cut immediately prior to welding, removing a minimum of 25mm. 3. The closure shall conform to existing rail with a maximum 5mm mismatch in height (unless the rail is being welded using an approved junction weld in which case appropriate limits apply) and 5 mm in gauge wear. 4. The maximum allowable rate of change of rail head sections where it is necessary to grind one rail to match the next shall be 1 in 500. (See Figure 2).

5. For curves of 500m radius and under, the last 600mm of each end of closures of less than 6m in length and the last 600mm of each rail end shall be crowed to the correct curvature. Welding near bolt holes 1. Rail ends which have been part of mechanical joints in service in the track shall be removed and replaced with a closure where rail ends have wear >0.3mm or any indication of damage 2. Bolt holes that are being, or have been, used in track to form a mechanical joint shall be closely examined and if there is any damage, no matter how slight, then all the bolt holes shall be removed. If there is no damage then they may be treated as if they were unused. Alternatively, rail may be ultrasonically tested for bolt hole cracks before welding is undertaken. 3. Bolt holes that have not been used in track to form a mechanical joint shall be dealt with as follows:  4 hole pattern - Rails with the 4 hole pattern where only the outer 2 holes are bored on each rail end can be welded straight into track provided that the first bolt hole is maintained at a minimum of 80mm from the weld.

 6 Hole Pattern - Rails which have all 3 holes bored on each rail end must be cut behind the first bolt hole. The distance from the edge of the bolt hole to the end of the rail before welding shall be ≥ 80mm.

80mm Minimum

Figure 3 – Minimum distance of bolt hole from weld Welding near signal bonding holes Aluminothermic welds shall not be placed within 80mm of any holes drilled in the rail web for attachment of signalling bonds. This includes holes currently in use, those no longer in use and those that have been plugged.

5.3 Junction rails Junction rails shall only be used as closures and must be fully welded into the track.

Junction rails shall be used in preference to junction welds where practical

Rails approved for use as junction rails are detailed in Table 7.

Approved configurations are detailed in Appendix 1.

5.4 Rail joints

5.4.1 Mechanical joints Rail joint design shall be in accordance with standard fishplated joints detailed in AS 1085.2, or be equal to or exceed the performance of current proven designs.

Mechanical joints shall be constructed with a gap of 6mm between rail ends at design neutral temperature of 35°C

5.4.1.1 Placement and installation requirements The following placement and installation requirements apply: - Joints shall be installed suspended between adjacent sleepers.

- Joints in Long Welded Rail (LWR) shall be no closer to each other than 10m except in turnouts where shorter lengths (minimum 2.2m) may be used if necessary

- Joints are not permitted in continuously welded track

- Joints are not permitted within turnouts in CWR track. Component replacements such as stock rails and V crossings may be temporarily jointed until welding can be undertaken.

- Permanent mechanical joints are not permitted on bridges

- Temporary mechanical joints on bridges are limited to no more than 7 days

- The following restrictions apply to installation of joints in LWR track in proximity to bridge approaches.

 NOT within 30m of a transom top opening with spans less than 18m

 NOT within 60m of a transom top opening with one or more spans ≥18m long.

 NOT within 30m of a ballast top opening ≥ 4.27m long.

- Joints shall be anchored as required in Section 5.8.

- Permanent Joints shall be fastened through all bolt holes, except for temporary rail joints. (See Section 5.4.2 for temporary joints).

In existing Class 5 lines where 4 hole fishplates are used, the fishplates shall be fastened through all 4 bolt holes. - Rail ends shall be saw cut to the following tolerances.

 Vertical - ≤ 0.7mm variation in the height of the rail

 Horizontal - ≤ 0.7mm variation in the width of the rail

- Bolt holes shall be drilled square to the web.

- The size and location of boltholes for the installation of mechanical rail joints shall be in accordance with the dimensions defined in AS 1085.2 and AS 1085.12.

Note: The size and location of bolt holes in rail sizes not documented in the current versions of Australian Standards are detailed in CRN CM 221.

5.4.1.2 Prohibited configurations The following configurations are specifically prohibited:- - Joints in 60kg rail except in temporary joints (see Section 5.4.2).

- Joints on concrete sleepered track except in temporary joints (see Section 5.4.2).

- Joints bored wide or tight giving a false reading of rail adjustment.

- Slotted plates (except as temporary or emergency rail joints).

- Rail Inserts

- Rails with flame cut ends, except in temporary or emergency rail joints (see Section 5.4.2).

- Rails with flame cut bolt holes, except in temporary or emergency rail joints (see Section 5.4.2).

5.4.2 Temporary joints Temporary joints are not permitted to remain in the track for any extended period. Special conditions apply whilst they remain in track. Temporary joints may be used in the following circumstances: - During rail laying, to allow train operations, prior to welding into CWR

- During track restoration, to allow train operations, prior to full repair of track. 5.4.2.1 Temporary joints during construction 4-hole joints Where rail is required to be joined as a temporary measure during track construction or rerailing and it is intended that the joint will be welded, the bolt hole on each rail nearest each rail end shall not be drilled. The joint will be fastened through the remaining 4 bolt holes. To limit damage to the rail and to the track, these temporary joints shall not remain in track longer than 7 days if installed on concrete sleepers, 6 weeks on steel sleepers, or 12 months if installed on timber sleepers.

Slotted plates Slotted fishplates may be used as an interim measure during the laying of rail, or in emergencies if a rail breakaway occurs and the track cannot be adjusted before use.

They are to be removed as soon as the rail can be adjusted correctly. This will preferably occur on the same day that the rail is laid.

Slotted fishplates shall have properly prepared (machined) holes. Flame cut holes are not permitted.

Robel clamps Robel rail clamps may be used on 41, 47, 53 and 60kg rail in lieu of 4-hole temporary joints for up to 7 days for all track structures unless approved by the Principal Track and Civil Engineer. The track must be

- effectively tied, with elastic fasteners

- inspected every 24 hours

- have a maximum of 60km/h applied. 5.4.2.2 Temporary joints for emergency use Use of flame cut rail ends Running rails with flame cut ends are only permitted in extreme emergencies such as temporary track repairs following a derailment.

A speed restriction of 20kph shall be placed on the section until the flame cut rail end is removed.

This does not restrict the use of flame cut rail ends for aluminothermic welding carried out in accordance with approved practices.

Emergency use of flame cut bolt holes Flame cut bolt holes may be used in an emergency to effect temporary repairs. A speed restriction of 10kph shall be placed on the section and the track continuously monitored until the flame cut bolt hole is removed.

Non-bolted joints Approved rail clamps may be used to clamp fishplates to create a temporary joint at a broken rail. Conditions apply to their use. Approved plates and clamps are detailed in Appendix 1 and approved configurations are detailed in Table 8.

Clamps Plating Conditions of use G Clamps (2 required) Standard Fishplates Maximum Speed of 30kph Bow plates Remove within 12 hours. Robel” Clamps Standard Fishplates Maximum Speed of 60kph (1 or 2 required) Bow plates Remove within 24 hours Table 8 - Approved non-bolted joints Robel rail clamps may be used on 41, 47, 53 and 60kg rail in place of G-clamps for plating broken rails and at other locations where G-clamps are normally used.

1. They shall be installed in accordance with the manufacturer’s instructions 2. The clamp shall be mounted directly at the rail joint by using two fishplates. 3. The correct clamp and fishplate is to be used as per the manufacturer’s instructions for the rail size. 4. Bow plates may be clamped with two (2) Robel rail clamps (one on each side of the bow)

5.4.3 Insulated rail joints Rail joint design shall be in accordance with standard insulated joints detailed in AS 1085.12, or be equal to or exceed the performance of current proven designs.

Approved insulated joint configurations, including proprietary designs are defined in Appendix 1. Only approved configurations shall be installed.

Insulated joint configurations include: - standard mechanical insulated joints

- insulated plate joints

- bonded insulated joints

The following placement and installation requirements apply: 5.4.3.1 General 1. Locations of insulated joints shall be determined to suit the requirements of signal circuiting. 2. Insulated joints shall be installed suspended between adjacent ties with the insulating post placed centrally between the sleepers. 3. Bonded insulated joints shall be welded into the track as rail closures. 4. Bonded insulated joints should not be installed on transom top bridges or within 30m of the bridge ends. 5. Bonded insulated joints should not be installed at the interface of concrete/ steel/ timber track, or locations where additional track disturbance is likely 6. Where 53kg and 60kg insulated joints are to be installed with resilient fastenings, low profile clips shall be used to avoid fouling the bolts. 7. When used with some baseplates in turnouts with timber bearers, low profile clips may still become foul of the joint bolts. Where this is the case the offending clips shall be removed, subject to leaving at least one clip at each track plate set on opposite sides of the rail from one side of the joint to the other (see Figure 4).

Remove these clips   Clips on opposite sides of insulated joint

Figure 4 – Placement of clips at insulated joints 5.4.3.2 Mechanical insulated joints 1. are not recommended for mainline track, 2. shall be anchored in accordance with Section 5.8, 3. shall be fastened through six bolt holes, 4. rail ends must be square.

5.4.3.3 Insulated plate joints (This is the generic term used to describe joints such as Benkler and Hercules) 1. may only be used in the turnout rails within turnout systems on all operating classes. (This excludes any direct connection with CWR plain track), 2. shall be fastened through six bolt holes, 3. shall be anchored as for mechanical insulated joints, 4. curved track sections with insulated joints shall be formed in the field from straight fishplate pieces, 5. rail ends must be square

When selecting the appropriate type of approved Insulated plate joint, the following issues need to be considered; - “Benkler Joints” are robust joints with good insulation performance but are significantly weaker than bonded insulated joints.

- “Hercules Joints - NIJ 600 series” are a stronger joint but have greater potential for insulation failure. Care is needed to ensure that fastenings do not cause signal failure. Some fastenings may have to be omitted.

5.4.3.4 Bonded insulated joints 1. Factory assembled bonded insulated joints are permitted on all Class 1 and Class 2 tracks. 2. All new bonded insulated joints shall be Grade A1 factory assembled bonded insulated joint assemblies in accordance with AS 1085.12 using 6 hole joint bars. Rail ends at the insulating post will be cut at 15° to the right angle of the longitudinal axis (see Figure 5).

15°

90°

Figure 5 – Rail end angle 3. Head Hardened rail shall be used to form bonded insulated joints (except 47kg where HH is not available). 4. Bonded insulated joints (BIJ) shall be pre-curved to suit the radius of the track in accordance with Table 9.

3.43m Bonded Insulated Joints Curve Radius Measured Full Mid-ordinate of Track Versine to be Used 196 - 326 m 7.5 - 4.5 mm 6 326 - 980 m 4.5 - 1.5 mm 3 980 - straight 1.5 - 0 mm 0 4.57m Bonded Insulated Joints Curve radius Measured full Mid-ordinate of Track Versine to be Used 217 - 326 m 12.0 - 8.0 mm 10 326 - 1305 m 8.0 - 2.0 mm 5 1305 - straight 2.0 - 0 mm 0 Table 9 - BIJ configurations 5. In existing bonded insulated joints, rail ends may be square or have a 15° cut to the right angle of the longitudinal axis (see Figure 5). 6. BIJs manufactured with HH rail may be installed in non head hardened rail track

5.4.3.5 Prohibited configurations - Mechanical insulated joints are not permitted in CWR track.

- Insulated plate joints are not permitted in main line CWR track.

- Field assembled bonded insulated joints are not approved for use.

- Mechanical insulated joints and Insulated plate joints are not permitted on bridges and restrictions apply to installation in proximity to bridge approaches.

- Mechanical insulated joints and Insulated plate joints are not permitted within 5m of the transition between different sleeper types

5.4.4 Fishbolts, washers and nuts Fishbolts and nuts used in conjunction with fishplates in mechanical joints shall be supplied in accordance with AS 1085.4 . The length and diameter of standard fishbolts varies according to the rail sections in which they are being used, as detailed in Table 10.

Special fishbolts detailed in Table 11 shall be supplied in accordance with AS 1085.4 with a modified neck shape.

Type 1 Spring Washers shall be supplied in accordance with AS 1085.7. The nominal size shall be the associated bolt diameter.

Rail section Fishbolt Metric Imperial coding Length Diameter 60 140 24 50 - 53 100 AS 28. 100 AS 25, 103 AS 36 140 24 53 AS 78 107 AS 36 140 24 45 - 40 90 AS 28, 90 AS 25, 80 AS ‘B’ 28 140 24 47 AS 78 80 AS 25, 94 AS 37 140 24 45 - 50 100 AS 21, 100 AS 16, 100CA 100C 90 AS 21, 90 AS 16, 90J 140 24 30 - 40 80 AS 21, 80Aa 80A 78H 70 AS 28 60 AS ‘B’ 28 115 22 30 - 40 80 AS 16 80A 60 AS 25 115 22 30 60 AS 16, 60Ba 60B 115 22 30 60 AS 21 (No Washer) 115 22 Table 10 - Fishbolt sizes Rail section Fishbolts Metric Imperial coding Length Diameter Shape of Dimension neck ‘A’ 34 - 40 80A2 80A3 71.5D 80E 100 22 Eye 32 75F Deep plate 75F Sharp plate - no washer 37 75 BHP 110 22 Pear 30 40 80E 100 22 22mm round - 30 60B’ 85 20 Eye 28 30 60B’ 85 20 Eye 28 Table 11 - Special fishbolts The shape of the neck of special fishbolts shall be as shown in Figure 6:

A A

Eye Pear

Figure 6 – Special Fishbolt shapes

5.4.5 Alternative fasteners Where approved, alternative fastening systems may be used. Approved systems are listed in Appendix 1.

5.4.6 Swage fasteners Swage fasteners may be used in lieu of conventional fishbolts at fixed mechanical rail joints

Swage fasteners are suitable for operating conditions with designed axle loads ≤ 25 tonnes at speeds ≤ 120 kph.

Only approved configurations (as documented in Appendix 1) may be used.

Swage fasteners may only be used with fishplates meeting or exceeding the mechanical and chemical properties of AS 1085.2.

The following placement and installation requirements apply: 1. Swage fasteners may only be applied to joints designed for no rail movement. 2. their use is restricted to 47, 50, 53 and 60kg/m rail trackwork 3. Swage fastened mechanical joints may be used within turnouts and diamonds and between adjacent turnouts and diamonds but they shall not be used directly adjacent to CWR plain track 4. The application of the swage fasteners shall be restricted to trackwork in good condition, where the contacting surfaces and components of the joint can support the high clamping forces involved. 5. Swage fastener heads and collars must be fitted with washers made from cast or formed high strength steel to spread the clamping forces of the swage fasteners over a larger area. The hole diameter of the washer under collar must not be larger than 1.5mm in diameter more than the shaft size of the swage fastener.

Prohibited configurations - Swage fasteners shall not be used in open track in lieu of welding.

- Swage fasteners shall not be used where axle loads > 25t operate

- Swage fasteners are not recommended for locations where a high level of 25t axle load traffic operates.

5.5 Rail repair

5.5.1 Wirefeed welding Wirefeed welding processes may be used to: - build up fabricated and welded crossings manufactured from standard carbon and head hardened rail

- repair rail bound manganese and titan crossings

- repair wheel burns, Small TD/EBF, dipped aluminothermic and flash butt welds in standard carbon rail

- repair wheel burns, Small TD/EBF, dipped aluminothermic and flash butt welds in head hardened rail where axle loads DO NOT exceed 27 tonnes.

Wire feed welding processes are NOT approved for

- repair of wheel burns in head hardened rail where axle loads exceed 27 tonnes.

- repairs to switches in turnouts and other special trackwork. This includes the area from the switch tip to the heel (inclusive).

- repair of rail defects more than 12mm below the top of the rail.

5.5.2 Aluminothermic rail head repair Aluminothermic rail head repair processes and materials shall meet the following requirements: - Aluminothermic rail head repair materials shall be supplied in accordance with the requirements of AS 1085.20. Type and proof testing shall be carried out using the method and frequency defined in AS 1085.20.

- Transport and storage of consumables shall be in accordance with AS 1085.20.

- Approved aluminothermic rail head repair processes and materials are detailed in Appendix 2.

5.6 Rail lubrication Rail lubrication systems shall be installed to reduce friction at the rail/wheel interface and consequential rail/wheel wear, noise and unnecessary train energy consumption.

Rail lubrication systems (number, location and spacing of lubricators, and type of lubricant shall be designed to meet the following performance requirements: - The friction coefficient on the gauge face of the high rails should be < 0.30.

- The friction on the running surfaces of both high and low rails should be > 0.35 (> 0.40 preferred) and > 0.40 on grades steeper than 1 in 50. A lower friction level is acceptable on the rail surface in the immediate area of the lubricator (within 50m).

- It is also desirable that the difference in the running surface friction between the high and low rails should be ≤ 0.15.

Lubrication is required wherever there is potential for significant wear, including: - curves of 800m radius or sharper depending on track design, wheel and rail profiles and train operations

- other curves exhibiting, or with a history of, gauge face wear on the high rail

- situations where flanging noise is a problem

5.6.1 Lubricator types Single pump, single blade lubricators are the preferred type of lubricator.

Current approved lubricators are listed in Appendix 1.

5.6.2 Lubricants Only approved lubricants (see Appendix 1) shall be used.

Standard lubricant is the minimum requirement, but a high performance lubricant shall be used under severe grade braking locations (more than about 1:50) or at other locations where it is economically justified. In special environmental areas, a biodegradable lubricant may be required.

5.6.3 Installation 1. Lubricators shall be installed in accordance with manufacturer’s instructions. 2. All trackside lubricators shall be clamped to the rail. New installations are not permitted to be fixed by bolting through the rail. 3. Under very severe grade conditions (more than about 1:50 in either braking or climbing direction), lubricators on the Up and Down rails should not be positioned any closer than 0.5 km of each other. 4. If at all possible lubricators should be located in moderate radius (600m-1000m) feeder curves ahead of the sharper curves which are the main target. 5. Lubricators should not be positioned in tangent track, or the low rails of curves, or on very large radius curves (greater than 1000m) where no wheel flanging occurs 6. Installation should consider environmental aspects. If standard lubricant is used an appropriate mat should be placed to prevent contamination of the ballast and the environment.

5.7 Rail adjustment Rail shall be installed and adjusted to be stress free at a rail temperature of 35°C, except in tunnels as detailed below or where approved by the Principal Track and Civil Engineer. This is the Neutral Temperature adopted for CRN track.

Rail located more than 50m inside tunnels may be welded where it sits without further adjustment

Rail shall be installed as CWR, LWR or Loose Rail in accordance with configuration requirements.

5.7.1 Long Welded Rail (LWR) design and installation requirements 1. Rails shall be longer than 27.4m. 2. Maximum rail length for new installations shall be 110m in curves <600m radius and 220m lengths for tangents and curves ≥600m radius. 3. Maximum rail length for existing installations shall be 220m. 4. Rail shall be fastened to sleepers with non-resilient fastenings and anchors or a mixture of non- resilient fastenings and resilient fastenings. 5. Rails shall not be fitted with more than 1 in 3 resilient fastenings unless a management strategy has been approved by the Principal Track and Civil Engineer in accordance with the requirements detailed in CRN Engineering standard CRN CS 230 “Sleepers and Track Support”. 6. Mechanical joints in LWR track shall have a gap of 6mm at 35°C. 7. An appropriate track configuration, capable of providing the required resistance for the rail stresses is required. This is detailed in CRN CS 200. 8. Where non-resilient rail fastenings and “Fair” type rail anchors are specified in the design the minimum anchoring requirements for LWR shall be as specified in Section 5.8.

5.7.2 Continuous Welded Rail (CWR) design and installation requirements 1. Rails shall be > 220m long 2. Rails shall be adjusted to be stress free at a rail temperature of 35°C, except in tunnels as detailed above or where approved by the Principal Track and Civil Engineer. 3. Rails shall be installed In accordance with an approved alignment design. Track control marks shall be installed using survey control. 4. CWR shall be installed using an approved process. Approved processes are documented in Appendix 3.

5. Creep monitoring points shall be installed within 14 days of adjustment. Creep monitoring facilities shall be located at every kilometre and half kilometre post. Additional monitoring points may be specified. 6. An appropriate track configuration, capable of providing the required resistance for the rail stresses is required. This is detailed in CRN CS 200. 7. Rails may be fitted with resilient fastenings or non-resilient fastenings and anchors. 8. Rails fitted with > 1 in 4 resilient fastenings do not require supplementary anchoring. 9. where non-resilient rail fastenings and “Fair” type rail anchors are specified in the design or where ≤ 1 in 4 resilient fastenings are installed, the minimum anchoring requirements for CWR are as specified in Section 5.8.

5.7.3 Prohibited configurations The following track configurations, in which rail adjustment cannot be assessed with confidence, are prohibited: - Rails longer than 220m which have not been adjusted

- Rails longer than 220m with no creep marks or pegs

- Rails longer than 220m in curved track with no alignment information available.

- Rails longer than 27.4m with resilient fastenings more than 1 in 3 (unless the rails have been correctly adjusted in accordance with requirements for CWR or a management strategy has been approved by the Principal Track and Civil Engineer in accordance with the requirements detailed in CRN CS 230.

5.8 Rail anchoring Rail Anchoring requirements apply to all Class 1 and Class 2 track constructed with timber sleepers and non-resilient fastenings.

On Class 3 and 5 tracks existing anchored track shall be maintained with anchors and existing non- anchored track shall be anchored where necessary to prevent rail creep.

Rail anchoring system configurations include FAIR type rail anchors Only approved configurations shall be installed.

Rail anchors shall meet the requirements of AS 1085.10.

5.8.1 Anchoring of ballasted welded track 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.

5.8.2 Insulated joints in welded track At mechanical insulated joints EVERY sleeper shall 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).

5.8.3 Anchoring of short rails 5.8.3.1 Lengths shorter than 23m The anchoring for these with square and staggered joints on ballasted track and bridges shall be as shown in Figure 7. 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 7 – Anchoring requirements for rail lengths <23m 5.8.3.2 23m and 27m lengths The anchoring for these on open ballasted track and on bridges shall be as shown in Figure 8.

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 8 – Anchoring requirements for 23m and 27m rail lengths

5.8.4 Anchoring of welded track on bridges Transom top openings with spans < 18m 1. Standard anchoring for welded rails on open LWR track as detailed in Section 5.8.1 shall be used on welded rails on these bridges, except as specified below. 2. Anchors shall not be applied on timber bridges where:  transoms are not fixed to the girders with bolts drilled through both the transom and girder.

 transoms are fixed to steel girders by cast iron clip washers, except where an old rail or timber is bolted to the outer ends of the transoms.

In this case anchoring as in (1) shall apply, but if there is a series of spans giving a total bridge length greater than 30m, then clause (1) of ”Transom top openings with spans ≥ 18m long but < 80m” below, shall also apply. 3. 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 spans ≥ 18m long but < 80m. 1. For a distance of 60m from a bridge end, the track shall be double anchored on every second sleeper. 2. On the bridge the track shall be double anchored to every second transom for half the span length, commencing at the fixed end except as indicated in (2) of “Transom top openings with spans <18m”. 3. Anchors shall not be applied to transoms that are not fixed to steel or timber girders by bolts drilled through both the transom and girder. 4. 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 Toe Load resilient fastenings installed on the remaining two thirds of the span. Where spans are located on curves < 400m radius, Zero Toe Load fastenings cannot be used.

Ballast top openings with spans ≥ 4.27m long but < 80m 5. Standard anchoring for LWR on ballasted track as detailed in 5.8.1 shall be used on welded rails on these bridges.

Transom top or Ballast top openings with spans ≥ 80m 1. Expansion switches are to be provided at the expansion end of the span(s). 2. For a distance of 60m from a bridge end, LWR track shall be double anchored on every second sleeper.

3. Between expansion switches the rails shall be double anchored to every fourth transom. 4. On bridges where elastic fastenings are installed in CWR track, normal resilient fastenings are to be installed on the entire length of each span.

Structures with Rail Bearing Girders As the rail on a longitudinal girder cannot be anchored, the number of anchors that cannot be correctly located shall be added to sleepers on each end of the structure.

5.9 Rail at friction buffer stops Friction Buffer Stops operate by sliding on the rail surface and applying progressive retardation in speed. The condition of rail surface shall not interfere with the free movement of the buffer stop. To achieve this, the following configuration requirements apply to the length of rail along which the buffer stop is designed to move: - No joints past the friction buffer stop

- No aluminothermic welds

- No other attachments to the rail that would impact on the device (i.e. the rails shall be free from material between the top of the rail to half way down the web).

5.10 Connections to rail Temporary or permanent connections may be made to rails for: - signalling currents,

- the connection of other track components, or

- the attachment of wayside devices

The method of attachment shall be by approved welding processes, drilling through the web, or clamping.

All methods shall be approved by the Principal Track and Civil Engineer. Approved methods are detailed in Appendix 4.

The following restrictions apply: - Except for holes associated with rail joints, the centre of drilled holes shall be within 5 mm of the neutral axis of the rail and for rail sizes of 41 kg/m and greater shall not be greater than 27 mm in diameter.

- Attachments to the rail foot (web) shall not cause notching

6 Acceptance standards 6.1 Rail

6.1.1 Wheel/rail contact In track circuited areas, any new rail installed in the track must have its surface cleaned and/or ground to ensure that its running surface is shiny. This will ensure that there is sufficient good electrical contact between train wheels and the rail to operate the signalling correctly. It applies to any rail installed in the track that will have train wheels on it and includes turnouts, catchpoints and bonded insulated joints as well as normal rails and closures.

6.1.2 Rail profiles Rail profiles provide improved wheel/rail contact characteristics and nominal contact band widths, as follows: - For passenger traffic - central contact on low and tangent rails with a contact band width of 18mm - 30mm, and conformal gauge corner contact on the high rails of sharper curves extending 0 to 10mm from the centre line towards the field side.

- For mixed passenger/freight traffic - central contact on low and tangent rails with a contact band width of 25mm - 35mm (which depends mainly on the levels of tread hollowing present on freight wheels), and slight gauge corner relief on the gauge corner contact on high rails of sharper curves extending 5mm - 15mm from the centre line towards the field side.

The designed rail shapes required have been converted into matching templates for use with the rail grinding operation and provided in Appendix 1. 6.1.2.1 Profiles and templates The rail profiles to be achieved by rail grinding or milling shall meet the following requirements: - The rail shapes apply to tangent track and curved track (including for high and low rails) in accordance with Table 12.

- The same basic shapes apply to 47 kg/m, 50 kg/m, 53 kg/m, 60 kg/m and 60 kg/m head hardened rail.

- The rail profiles apply to preventive, transitional and corrective rail profiling strategies.

- The rail profiles and their associated templates to be used are summarised in Table 12

- The details of each template design are given in Appendix 5.

Situation High Rail Low Rail Profile Template Profile Template Tangent track and curves with radius  1,000m RTG2000 TGT RTG2000 TGT Curved track (< 1000* m radius), mainly freight RMH2000 H2 RML2000 L2 or coal traffic and >25km/h Curved track (≤1000m radius), passenger or H3 H3 RPL2000 L1 exhibiting moderate/severe gauge corner checking or moderate shelling as part of transitional grinding strategy Curved track (< 1000m radius) and <25km/h RTG2000 TGT RTG2000 TGT Rails in Turnouts RTG2000 TGT RTG2000 TGT Table 12 - Rail Templates It should be noted that some special rail profiles may be applied as part of a transitional rail re- profiling strategy, particularly in cases where severe RCF defects are present in the gauge corner region of the rails and/or when excessive wheel tread hollowing occurs.

The CRN Rail Engineer may approve application of the RTG2000 template in curves with sharper radii down to 800m radius after an assessment of the particulars of the location, the rail performance and the operational requirements. The Rail Profiles have been developed to have the following characteristics

- The H2 profile exhibits a minor undercut in the gauge corner region relative to the new rail, with the aim of reducing the contact stresses in this region in the gauge corner

- The L2 profile exhibits very minor undercut on the field side relative to the new rails, with the aim of centralising the wheel/rail contact on the running surface

- The TGT profile exhibits an even greater undercut in the gauge corner region than the H2 profile, to ensure that wheel/rail contact is made near the centre of the running surface, which enhances vehicle stability at higher operating speeds

- The H3 profile exhibits additional undercut on the gauge corner region relative to the H2 profile, with the aim of further reducing the contact stresses in the gauge corner region

6.1.2.2 Maintaining rail profiles Rails are required to be profiled both after rail installation and on a preventive regime, in accordance with CRN CS 100 “Civil Technical Maintenance Plan” Application of CRN CS 100 is provided in CRN CM 225. 6.1.2.3 Re-profiling tolerances Rail surface finish shall be to the following tolerances Characteristic Tolerance Conformance to design profile within the contact ≤0.20mm band (see Figure 9) Conformance to design profile outside the ≤0.40mm contact band (see Figure 9) Facet width in the gauge corner region (see ≤4mm Figure 10) Facet width in the running surface region (see ≤8mm Figure 10) Facet width in the field side region (see Figure ≤12mm 10) Short pitch corrugation (30-90mm wavelength) Average <15m Maximum 0.05mm amplitude in any 1m length Long pitch corrugation (200-450mm Maximum 0.10mm amplitude in any 1m length wavelength) Roughness 10μm arithmetic mean surface roughness (RA) within 5km of dwellings 15μm RA elsewhere

Table 13 – Re-Profiling tolerances

Contact Band Contact Band

Max Deviation Max Deviation Max Deviation ≤ 0.40mm ≤ 0.20mm ≤ 0.20mm Max Deviations ≤ 0.40mm High Rails in Sharp Curves Low, Tangent and High Rails in Shallow Curves

Figure 9 - Schematic illustration of rail tolerances and templates

C/L Field Side Gauge Corner Running Surface Region Region Region 40 mm Gauge Corner

Figure 10 – Regions in 60kg.m rail 6.2 Rail joints The maximum deviation at a discontinuity such as at a joint (“foul joint”) is to be 1mm. New joints cut into the track shall have matching profiles at the gauge face and running surface.

6.3 Flashbutt welds All welds shall be tested for acceptance to the requirements specified in Table 14 prior to the operation of any rail traffic with the exception of slow speed track machines.

Rail defects Internal Defects ALL ultrasonic indicators shall be below reportable limits as detailed in Table 15 Visual defects In accordance with AS 1085.15 Table 2.1 Weld collar tolerances - deviation from rail profile at rail web and upperside of rail foot In accordance with AS 1085.15 Table 2.1 underside of the rail foot In accordance with AS 1085.15 Table 2.1 Surface alignment tolerances Vertical Tolerance grade The top surface shall be checked with a 1m straight edge as illustrated in Figure 11 and Figure 12. Additional requirements for AT3 testing are detailed in CRN CM 224. The permitted tolerances are shown in Table 16. Horizontal AT3 The rail alignment shall be checked with a 1m straight edge as illustrated in Figure 13 and Figure 14. The permitted tolerances are shown in Table 16. Table 14 – Acceptance criteria for flashbutt welds 6.4 Aluminothermic welds All new aluminothermic welds shall meet the following acceptance requirements:

6.4.1 Internal condition All welds shall be ultrasonically tested. ALL ultrasonic indicators must be below reportable limits as detailed in Table 15.

Defect Type Probe movement for Size definition (mm) Transverse Defects (TD) Head <40 70° Probe Defective Wire Feed Weld (DWFW) Head <25 70° and T/70 Probe Bolt Hole Cracked (BH) Web <20 35° probe Defective Welds (DW) Head <40 70° and 0° Probe Defective Welds Weld Gassing defects Loss of weld base signal over <35mm of width of DW Gassing Full weld weld 0° Probe Defective Welds <15 All horizontal web defects (HSW/HWS/FWS) Defective Welds (DW) Web/Centre foot <25 35° probe When testing new Flashbutt welds remove all non- standard foot centre Defective Welds (DW) Foot <25 Twin 70° Probe Vertical Split Head (VSH) < 50 long or < 3 high 0° & Twin 70° Probe Vertical Split Web (VSW) Any registration in rail length 0° Probe Transverse Split web (TSW) <20 0° Probe Piped Rail (PR) <25 Horizontal Split Web (HSW) <20 35°& 0° Probe Horizontal Split Head (HSH) <25 35°& 0° Probe Head and Web Separated (HWS) <20 35°& 0° Probe Foot and Web Separated (FWS) <20 35°& 0° Probe Table 15 - Internal rail defect reporting limits

6.4.2 Surface condition All welds shall be ground to the profile of the rail each side of the weld with no visible deviations from a straightedge.

6.4.3 Geometry 6.4.3.1 On straight track The top surface and rail alignment shall be checked with a 1m straight edge as illustrated in Figure 11 and Figure 12 (top surface) and Figure 13 and Figure 14 (alignment). The permitted tolerances are as shown in Table 16. 500mm

“A”

Figure 11 – Weld misalignment tolerance in vertical plane (peaking) 500mm

“B”

Figure 12 – Weld misalignment tolerance in vertical plane (hollow) 500mm Gauge Face

“C”

Figure 13 – Weld misalignment tolerance in horizontal plane (tightening) Gauge Face 500mm “D”

Figure 14 – Weld misalignment tolerance in horizontal plane (widening)

“A” “B” “C” “D” Weld Surface/Alignment Limits mm mm mm mm

All new welds 0.5 0.0 0.5 0.5 Table 16 - Weld Surface/Alignment limits 6.4.3.2 On curved track Top surface requirements are as for straight track

The horizontal alignment of the newly welded portion of rail must have a curvature consistent with the curvature of the existing rail, and the gauge face at the weld(s) must be smooth and continuous. . There must be no visible “elbow” at the weld.

6.5 Rail head repair welds All new rail head repair welds shall meet the following acceptance requirements:

6.5.1 Internal condition All welds shall be ultrasonically tested. ALL ultrasonic indicators must be below reportable limits as detailed in Table 15.

6.5.2 Surface geometry and condition All welds shall be ground to the profile of the rail each side of the weld with no visible deviations from a straightedge.

The top surface shall be checked with a 1m straight edge as illustrated in Figure 13 and Figure 14. The permitted tolerances are as shown in Table 15.

“A” “B” Weld Surface Limits mm mm For rail head repair welds 0.6 0.3 Table 15 – Head repair weld surface limits The gauge face will normally be parent rail and shall be visibly smooth and consistent with the curvature of the existing rail

500mm

“A”

Figure 13 – Head Repair misalignment tolerance in vertical plane (peaking) 500mm

“B”

Figure 14 - Head Repair misalignment tolerance in vertical plane (hollow)

Appendix 1 Approved products Approvals for products (Appendix 1), welding processes (Appendix 2), and rail connection processes (Appendix 4) are dependent on both the manufacturer and supplier. If either changes, the product approval may no longer be valid. Seek advice from the Principal Track and Civil Engineer.

Product Approval Numbers are shown for all products approved by JHR CRN. Other products listed were approved for use on CRN prior to January 2012 and have been accepted by JHR CRN.

Product Common Item Manufacturer/ Description Standard/ Drawing Approval No. Name Supplier Rails Rails Railway rails; head hardened and plain AS 1085.1 Liberty OneSteel carbon;47, 50, 53 and 60kg/m CRN 022 Rails Railway rails; head hardened and plain AS 1085.1 Australian Railway carbon; 47kg Supply Company (ARSC) Flashbutt welded Railway rails; head hardened and plain AS 1085.1 Voestalpine VAE rail lengths carbon; 50, 53 and 60kg/m Railway Systems Junction rails Rails, Junction 60 kg HH rail to 53 kg rail; RIC Drawing L 5353 2743mm long Junction rails Rails, Junction 53 kg rail to 47 kg rail RIC Drawing L 5354 Junction rails Rails, Junction 47 kg rail to 41kg raill RIC Drawing L 5355 Fishplates BOW Plates Steel; bowed for welded joint 47kg rail TKL Dwg A3B12988C ARSC (pairs) Westray Eng. RIC Drawing 925-712 BOW Plates Steel; bowed for welded joint 53kg rail Flowserve ARSC (pairs) Westray Eng Westray Eng. RIC Drawing 925-712 BOW Plates Steel; bowed for welded joint 60kg rail TKL Dwg A3B12990E ARSC (pairs) Westray Eng. Fish Plates Joint bar, rail Steel; 60lb; 6 holes: ARSC Fish Plates Joint bar, rail Steel; 80lb; 6 holes: ARSC Fish Plates Joint bar, rail Steel; 47kg; 6 holes: TKL A2B12122/B ARSC AS 1085.2 Westray Eng. Fish Plates Joint bar, rail Steel; 50kg; 6 holes: BHP 2300 ARSC AS 1085.2 Westray Eng. Fish Plates Joint bar, rail Steel; 53kg; 6 holes SRA appr DWG ARSC AS 1085.2 Westray Eng. Fish Plates Joint bar, rail Steel; 60kg; 6 holes AS 1085.2 ARSC SRA appr Dwg BHP Westray Eng. 2301 Slotted Fish Plates Joint bar, rail Steel; 50kg; slotted; 6 holes AS 1085.2 ARSC Westray Eng. Slotted Fish Plates Joint bar, rail Steel; 53kg; slotted; 6 holes AS 1085.2 ARSC Westray CP437 Westray Eng.

Product Common Item Manufacturer/ Description Standard/ Drawing Approval No. Name Supplier Slotted Fish Plates Joint bar, rail Steel; 60kg; slotted; 6 holes AS 1085.2 ARSC Westray Eng. Junction Fish Junction Plate 60lb/80lb (pairs) ARSC Plates Westray Eng. Junction Fish Junction Plate 80lb/47kg (pairs) ARSC Plates Westray Eng. Junction Fish Junction Plate 47kg/53kg (pairs) TKL Dwg No ARSC Plates A2B09396C Westray Westray Eng. Dwg CP479A Junction Fish Junction Plate 53kg/60kg (pairs) TKL Dwg No ARSC Plates A2B08721G Westray Westray Eng. Dwg CP478A Junction Fish Bowed Junction Plate 53kg/60kg (pairs) TKL Dwg A2B113191A ARSC Plates Westray Eng. Rail Fastenings Fishbollts Bolt, fishplate M24; 100mm lg; heat RSA Dwg 205A 323D Greg Sewell treated; oval neck; cup head; c/w hex nut AS 1085.4 ) Forgings & spring washer; Cold Forge ARSC Fishbollts Bolt, fishplate M20; 100mm lg; heat RSA Dwg 205A 323D Greg Sewell treated; oval neck; cup head; c/w hex nut AS 1085.4 ) Forgings & spring washer; Cold Forge ARSC Fishbollts Bolt, fishplate M22; 115mm lg; heat RSA Dwg 205A 323D Greg Sewell treated; oval neck; cup head; c/w hex nut AS 1085.4 ) Forgings & spring washer; Cold Forge ARSC Fishbollts Bolt, fishplate M24; 140mm lg; heat RSA Dwg 205A 323D Greg Sewell treated; oval neck; cup head; c/w hex nut AS 1085.4 ) Forgings & spring washer; Cold Forge ARSC CRN C024 Tracksure Bolt and Fishplate bolt for 31kg/m rail T2236EAS0000AS (VI) Tracksure Limited Locking Device T2240EAS0017AS (VI) CRN C024 Tracksure Bolt and Fishplate bolt for 41kg/m rail T2240E0015AS (V2) Tracksure Limited Locking Device CRN C024 Tracksure Bolt and Fishplate bolt for 50 and 53kg/m rail T2440E0170AS (V2) Australian 50kg.m Locking Device Fishplate CRN C024 Tracksure Bolt and Checkrail bolt for Australian 107AS 1936 T2440EAS0000AS Tracksure Limited Locking Device Checkrails (53kg) (V3) CRN C024 Tracksure Bolt and Crossing bolt Australian Points and T2740EAS0000AS Tracksure Limited Locking Device Crossings (V6) Swage lock fasteners Pin, Huck 1” dia pin; Round Head; Fishplate C50LR-BR32-64 Arconic VAE Pin, Huck 1” dia pin; Thread Head; Fishplate C50LH-BR32-64 Arconic VAE

Product Common Item Manufacturer/ Description Standard/ Drawing Approval No. Name Supplier Lock Collar 1 “Lock Collar for 1” (32) pins LC-2R32G Arconic VAE Avdelok swage Large diameter Avdelok lockbolts ranging PDS 5 Infastech Australia fastener systems from ½” to 1 1/8” Product Data Sheet Pty Ltd t/as Stanley No 25 RT Engineered Fastening Washer 24mm structural washer for 1” (32)bolts M24 Alcoa (pack under collar only) Rail Clamps Robel Clamps Rail clamp for mechanical rail joint; nut Robel part number Robel locking device with safety locking flap and 68.05 KH1 safety locking bar; Blue – 41 and 47kg rail White – 53 and 60kg Brown – 50kg G-Clamps Rail Clamp C "G" Type; Steel RIC Dwg 177A-26A Insulated Joints Insulated Fish Steel; 53kg; 6 holes; for mechanical RIC Dwg M04-216- Thermit Australia, Plates insulated joints 39P91 Westray Eng. Thermit Dwg 06-141C Westray Dwg CP522- 1 Insulated joint kit Benkler kit-53kg-MK1HT; c/w 2 insulated AS 1085.2& Thermit Australia fish plates, endpost, collar, ferrules, AS 1085.12 washer plates, huck bolts

Insulated joint kit Benkler kit-60kg-mk2ht; c/w insulated fish AS 1085.2& Thermit Australia plates; endpost/collars/ferrules/washer AS 1085.12 plates, huck bolts Insulated Joints ‘Hercules’ NIJ 721 series joints (to be used Norfast NIJ-6 Norfast with AS60 rail) Martinus Rail

Bonded Insulated 47kg; 4.57m lg; 0 versine; Std. Carbon; AS 1085.12 Thermit Australia Joints VAE

Bonded Insulated 50kg; 3.43m lg; 0 versine; std. carbon; AS 1085.12 Thermit Australia Joints VAE

Bonded Insulated 53kg; 3.43m lg; 0 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Bonded Insulated 53kg; 3.43m lg; 3 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Bonded Insulated 53kg; 3.43m lg; 6 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Bonded Insulated 53kg; 4.57m lg; 0 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Product Common Item Manufacturer/ Description Standard/ Drawing Approval No. Name Supplier Bonded Insulated 53kg; 4.57m lg; 5 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Bonded Insulated 53kg; 4.57m lg; 10 versine; head AS 1085.12 Thermit Australia Joints hardened; 15° cut; VAE

Bonded Insulated 60kg; 3.43m lg; 0 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Bonded Insulated 60kg; 3.43m lg;3 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Bonded Insulated 60kg; 3.43m lg; 6 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Bonded Insulated 60kg; 4.57m lg; 0 versine; head hardened; AS 1085.12 Thermit Australia Joints 15° cut; VAE

Bonded Insulated 60kg; 4.57m lg; 5 versine; std. carbon; 15° AS 1085.12 Thermit Australia Joints cut; VAE

Bonded Insulated 60kg; 4.57m lg; 10 versine; head AS 1085.12 Thermit Australia Joints hardened; 15° cut; VAE

Rail Lubrication Lubricators P&M (Fessl) Existing Applications only

RTE 25 (clamp-on type) Interphase Engineering WPS Pty Ltd QHI Rail Lubricurve 50 and 10-20 Interphase Engineering WPS Pty Ltd Portec PW Series Lubricators Portec Rail Products Lubricants Lubricants Type Use with lubricators ROCOL Rail Curve High Performance All Lubricators ROCOL Grease CALTEX 904 Standard All Lubricators CALTEX FUCHS 234GOWX High Performance All Lubricators FUCHS Environmentally Friendly Rail Anchors Rail anchors To suit 41, 47 and 53kg/m rail AS 1085.10 Unit

Product Common Item Manufacturer/ Description Standard/ Drawing Approval No. Name Supplier Rail Templates Template 41kg Rail bolt hole marking for drilling and CRN CP 202 cutting Template 47kg Rail bolt hole marking for drilling and CRN CP 202 cutting Template 53kg Rail bolt hole marking for drilling and CRN CP 202 cutting Template 60kg Rail bolt hole marking for drilling and CRN CP 202 cutting Rail Lifting Clamps Rail Lifting Clamp Clamp, Rail, Lifting, Scissor, 3t SWL All-Ways Rigging (Product Code RLT3T Group Melville Rail Lifting Clamp Clamp, Rail, Lifting, Scissor, 14t SWL All-Ways Rigging Product Code PRT14T Group Melville Rail Puller Shackle, Rail, Pulling. 12t SWL Product All-Ways Rigging Code AR.DRPNew or equivalent. Group Melville Rail Lifting Clamp Clamp, Rail, Lifting, 5.5t SWL Product All-Ways Rigging Code RHD5.5-IPS Group Melville Lifting / Spreader Beams and Chains Lifting / Spreader 68kg Lifting / Spreader Beam 7tonne as OEM – see supplier All Lifting Beam and Chains Lifting Beam, 248kn as Spreader Beam, Luke Cross 16mm 2 leg chain sling 15 tonne at 60 degrees, 16mm 1 leg chain sling 8 tonne

Appendix 2 Approved welding processes

Aluminothermic Welds Rail Thermit Railtech (kg/ m) Part Weld Product Part Weld Product Process Hardness Approval Process Hardness Approval Number (HBN) No. Number (HBN) No. SHORT PREHEAT (Standard Gap Welds) 41 SKVE Z70 SU 41 SKVE Z90 SU 404145-03 260-300 47 SKVE Z90 SU 404745-00 260-300 PLK CJ; X 79700007 280-320 50 SKVE Z90 SU 405045-00 260-300 PLK CJ; X 79700009 280-320 50 SKVE Z100 SU 405045-00 50 SKVE Z110 SU 405045-06 53 SKVE Z90 SU 405345-00 260-300 PLK CJ; X 79800006 280-320 60 SKVE Z90 SU 406045-00 260-300 PLK CJ; X 79700003 280-320 60 SKVE Z100 SU 60HH SKVE Z110 SU 406045-02 340-380 PLK CJ; HH 79700002 340-380 LONG PREHEAT (Standard Gap Welds) 31 SMWF Z70 260-300 41 SMWF Z70 260-300 47 SMWF Z90 260-300 AP W 260-300 53 SMWF Z90 260-300 AP W 260-300 60 AP W 260-300 WIDE GAP (Short Preheat) 41 SkV-L65 Z70 140152-50 47 SkV-L65 Z90 140352-51 WG68; X CJ 75800019 280-320 53 SkV-L65 Z90 150352-52 WG68; X CJ 75800016 280-320 60 SkV-L65 Z110 160852-50 WG68; X CJ 75800015 280-320 JUNCTION WELDS (Standard Gap Welds, Short Preheat) 30/40 SKVF Z70 210-250 or 41 41/47 SKVF Z70 260-300 47/50 SKVE Z90 SU JN 260-300 47/53 SKVE Z90 SU JN 405347-00 260-300 PLK CJ; X 79707002 280-320 53/60 SKVE Z90 SU JN 406047-07 260-300 PLK CJ; X 79707004 280-320 HEAD REPAIR WELDS Nil

Appendix 3 Approved rail adjustment processes

Manufacturer/ Common Item Name Description Standard/ Drawing Supplier Long Welded Rail CRN CM 223 Continuous Welded Rail CRN CM 223 Rail Out – Rail In CRN CM 223

Appendix 4 Approved rail connection methods

Product Connection Method Description Standard/ Drawing Manufacturer/ Approval No. Supplier Welding Cad-Welding Erico – Signals approved Erico process Drilling Rail Joint Bolt Holes CS 220 – Section 5.4.1.1 Clamping Clamping attachment Rail Track for Rail Lubricators Equipment P/L Clamping attachment QHI Rail Ltd for Rail Lubricators WPS Ptl Ltd Clamping attachment Portec Rail for Rail Lubricators Products

Appendix 5 Rail templates RTG2000 (TGT) Tangent and shallow curves template with lug

X-Y co-ordinates

X Y X Y X Y 34.26 -20.87 20.40 -3.25 -2.25 -0.27 -20.39 -0.09 34.26 -16.00 19.09 -2.92 -3.12 -0.22 -21.25 -0.12 35.70 -16.00 17.78 -2.62 -3.98 -0.19 -22.12 -0.15 35.70 -12.53 16.46 -2.34 -4.84 -0.16 -22.98 -0.17 33.16 -12.53 15.15 -2.08 -5.70 -0.13 -23.85 -0.21 32.53 -11.34 13.85 -1.83 -6.57 -0.10 -24.71 -0.25 31.90 -10.35 12.53 -1.61 -7.43 -0.08 -25.58 -0.28 31.28 -9.51 11.22 -1.40 -8.29 -0.07 -26.44 -0.33 30.66 -8.78 9.91 -1.21 -9.16 -0.04 -27.30 -0.38 30.03 -8.13 8.60 -1.06 -10.02 -0.03 -28.17 -0.42 29.41 -7.56 7.28 -0.91 -10.88 -0.02 -29.03 -0.47 28.78 -7.04 5.97 -0.79 -11.76 -0.01 -29.89 -0.53 28.16 -6.58 4.66 -0.68 -12.62 -0.01 -30.76 -0.58 27.53 -6.16 3.79 -0.62 -13.48 -0.01 -31.62 -0.65 26.90 -5.79 2.94 -0.56 -14.35 0.00 -32.49 -0.71 25.97 -5.29 2.07 -0.50 -15.21 -0.01 -33.35 -0.78 25.03 -4.84 1.21 -0.45 -16.07 -0.02 -34.58 -0.87 24.10 -4.44 0.54 -0.41 -16.93 -0.02 -35.31 -0.94 23.16 -4.08 0.00 -0.38 -17.79 -0.04 -36.05 -1.00 22.23 -3.76 -0.63 -0.35 -18.67 -0.06 -37.59 -1.23 21.29 -3.49 -1.39 -0.31 -19.53 -0.07 -39.10 -1.44 Note: The above profile template incorporates a cant adjustment of 1:20 (2.86) clockwise rotation.

RMH2000 (H2) High rail template for curved track - without Lug

X-Y Co-ordinates

X Y X Y X Y X Y X Y -40.00 -0.94 -21.76 -0.05 -7.75 -0.15 6.23 -1.03 20.14 -3.03 -36.06 -0.67 -21.26 -0.05 -7.25 -0.17 6.73 -1.07 20.64 -3.14 -34.80 -0.59 -20.76 -0.03 -6.75 -0.19 7.22 -1.12 21.14 -3.25 -34.30 -0.57 -20.26 -0.03 -6.25 -0.21 7.72 -1.16 21.63 -3.37 -33.80 -0.54 -19.76 -0.02 -5.75 -0.23 8.22 -1.22 22.12 -3.50 -33.30 -0.52 -19.25 -0.02 -5.25 -0.25 8.72 -1.26 22.62 -3.66 -32.79 -0.49 -18.75 -0.01 -4.75 -0.27 9.22 -1.32 23.11 -3.81 -32.29 -0.47 -18.25 -0.01 -4.25 -0.30 9.71 -1.37 23.60 -3.98 -31.79 -0.44 -17.75 0.00 -3.75 -0.32 10.21 -1.42 24.09 -4.16 -31.29 -0.42 -17.25 0.00 -3.25 -0.34 10.71 -1.47 24.58 -4.35 -30.79 -0.40 -16.75 0.00 -2.75 -0.37 11.21 -1.54 25.07 -4.55 -30.29 -0.38 -16.25 0.00 -2.25 -0.40 11.71 -1.59 25.56 -4.77 -29.78 -0.35 -15.75 0.00 -1.75 -0.43 12.20 -1.66 26.05 -5.01 -29.28 -0.33 -15.25 0.00 -1.25 -0.45 12.70 -1.72 26.54 -5.27 -28.78 -0.30 -14.75 0.00 -0.75 -0.49 13.20 -1.79 27.03 -5.55 -28.28 -0.28 -14.25 -0.01 -0.26 -0.52 13.70 -1.85 27.51 -5.86 -27.78 -0.25 -13.75 -0.01 0.24 -0.56 14.19 -1.93 28.00 -6.19 -27.28 -0.24 -13.25 -0.02 0.74 -0.58 14.69 -2.00 28.48 -6.56 -26.77 -0.21 -12.75 -0.02 1.24 -0.62 15.19 -2.09 28.96 -6.95 -26.27 -0.19 -12.25 -0.04 1.74 -0.66 15.68 -2.16 29.44 -7.37 -25.77 -0.17 -11.75 -0.04 2.24 -0.70 16.18 -2.25 29.68 -7.60 -25.27 -0.16 -11.25 -0.06 2.74 -0.73 16.68 -2.33 30.63 -8.61 -24.77 -0.13 -10.75 -0.06 3.24 -0.77 17.17 -2.43 31.57 -9.73 -24.27 -0.12 -10.25 -0.08 3.73 -0.81 17.67 -2.52 32.52 -10.86 -23.76 -0.10 -9.75 -0.09 4.23 -0.86 18.16 -2.62 33.46 -11.99 -23.26 -0.09 -9.25 -0.11 4.73 -0.89 18.66 -2.71 34.41 -13.11 -22.76 -0.08 -8.75 -0.12 5.23 -0.94 19.15 -2.82 -22.26 -0.07 -8.25 -0.14 5.73 -0.98 19.65 -2.92 Note: The above profile template incorporates a cant adjustment of 1:20 (2.86) clockwise rotation.

RML2000 (L2) Low rail template for curved track with lug

X-Y co-ordinates

X Y X Y X Y X Y -39.10 -2.74 -17.72 -0.43 0.40 -0.03 23.79 -2.58 -37.10 -2.38 -16.87 -0.38 1.26 -0.04 24.50 -2.78 -35.15 -2.01 -16.00 -0.33 2.13 -0.06 25.19 -2.99 -33.50 -1.84 -15.14 -0.29 2.99 -0.08 25.88 -3.23 -32.77 -1.76 -14.28 -0.25 3.85 -0.10 26.58 -3.49 -31.54 -1.62 -13.41 -0.21 4.72 -0.13 27.27 -3.78 -30.67 -1.52 -12.54 -0.17 5.58 -0.16 28.04 -4.13 -29.81 -1.42 -11.68 -0.15 6.44 -0.19 28.80 -4.54 -28.95 -1.34 -10.82 -0.12 7.76 -0.25 29.57 -5.01 -28.08 -1.25 -9.95 -0.09 9.08 -0.33 30.33 -5.55 -27.22 -1.16 -9.09 -0.08 10.40 -0.43 31.10 -6.17 -26.35 -1.08 -8.23 -0.05 11.72 -0.55 31.87 -6.87 -25.50 -1.00 -7.37 -0.04 13.03 -0.69 32.64 -7.69 -24.63 -0.92 -6.51 -0.03 14.36 -0.85 33.40 -8.64 -23.77 -0.86 -5.64 -0.02 15.67 -1.02 34.17 -9.78 -22.90 -0.78 -4.77 -0.01 16.99 -1.22 34.94 -11.22 -22.04 -0.71 -3.91 0.00 18.31 -1.44 37.54 -11.23 -21.18 -0.65 -3.05 -0.01 19.63 -1.68 37.59 -16.00 -20.31 -0.59 -2.19 0.00 20.95 -1.94 36.25 -16.00 -19.45 -0.53 -1.33 -0.01 22.27 -2.21 36.25 -20.87 -18.58 -0.47 -0.46 -0.02 23.10 -2.41 23.79 -2.58 -39.10 -2.74 -17.72 -0.43 0.40 -0.03 24.50 -2.78 -37.10 -2.38 -16.87 -0.38 1.26 -0.04 Note: The above profile template incorporates a cant adjustment of 1:20 (2.86) clockwise rotation.

RPL2000 (L1) Low rail template for curved track with lug

Rail Centreline 17.2 21.8 mm Max Contact Band (39 mm) (39 Min Contact Band (30 mm)

0 -40 -30 -20 -10 0 10 20 30Gauge 40 -5 Corner

-10 Rail Contact X Template: L1 -15

Not to Scale -20 Y Co-ordinates Y (mm) Co-ordinates -25 X Co-ordinates (mm)

X-Y Co-ordinates

X Y X Y X Y X Y -39.10 -1.70 -18.34 -0.15 0.66 -0.22 21.95 -2.72 -37.00 -1.46 -17.48 -0.12 1.53 -0.27 22.66 -2.88 -35.19 -1.24 -16.61 -0.09 2.39 -0.31 23.35 -3.08 -34.46 -1.18 -15.75 -0.07 3.25 -0.35 24.05 -3.30 -33.74 -1.12 -14.89 -0.06 4.12 -0.40 24.74 -3.54 -33.00 -1.06 -14.03 -0.04 4.99 -0.45 25.43 -3.80 -32.27 -1.00 -13.16 -0.02 5.84 -0.50 26.13 -4.09 -31.53 -0.94 -12.29 -0.02 6.71 -0.56 26.89 -4.45 -30.80 -0.87 -11.43 -0.01 7.57 -0.62 27.66 -4.86 -29.57 -0.78 -10.57 0.00 8.44 -0.68 28.43 -5.33 -28.71 -0.71 -9.70 -0.01 9.51 -0.77 29.20 -5.86 -27.84 -0.65 -8.84 -0.01 10.57 -0.86 29.96 -6.48 -26.98 -0.58 -7.98 -0.01 11.64 -0.97 30.72 -7.18 -26.12 -0.53 -7.11 -0.02 12.70 -1.10 31.49 -8.00 -25.25 -0.47 -6.25 -0.03 13.78 -1.23 32.26 -8.95 -24.39 -0.42 -5.39 -0.04 14.84 -1.38 33.02 -10.09 -23.53 -0.38 -4.52 -0.07 15.92 -1.55 33.79 -11.53 -22.66 -0.33 -3.66 -0.08 16.98 -1.72 36.53 -11.53 -21.80 -0.28 -2.80 -0.10 18.05 -1.90 36.53 -16.00 -20.94 -0.25 -1.93 -0.13 19.11 -2.11 35.03 -16.00 -20.07 -0.21 -1.07 -0.16 20.18 -2.33 35.03 -20.73 -19.21 -0.17 -0.20 -0.19 21.25 -2.55 Note: The above profile template incorporates a cant adjustment of 1:20 (2.86) clockwise rotation.

H3 High rail template for curved track without lug Rail Centreline Max Contact Band 1.5mm Min Contact Band 10.5mm 0 -40 -30 -20 -10-2 0 10 20Gauge 30 40 Corner -4 -6 -8 Rail Contact X Template: H3 -10 Run-Off Not to Scale -12 Y Co-ordinates (mm) Y Co-ordinates -14 X Co-ordinates (mm)

X-Y Co-ordinates

X Y X Y X Y X Y X Y -40.00 -0.89 -21.76 -0.05 -7.75 -0.15 6.23 -1.03 20.13 -3.34 -35.05 -0.60 -21.26 -0.05 -7.25 -0.17 6.73 -1.07 20.62 -3.45 -34.80 -0.59 -20.76 -0.03 -6.75 -0.19 7.22 -1.12 21.12 -3.56 -34.30 -0.57 -20.26 -0.03 -6.25 -0.21 7.72 -1.16 21.61 -3.68 -33.80 -0.54 -19.76 -0.02 -5.75 -0.23 8.22 -1.22 22.11 -3.80 -33.30 -0.52 -19.25 -0.02 -5.25 -0.25 8.72 -1.26 22.60 -3.93 -32.79 -0.49 -18.75 -0.01 -4.75 -0.27 9.22 -1.32 23.10 -4.05 -32.29 -0.47 -18.25 -0.01 -4.25 -0.30 9.71 -1.37 23.59 -4.19 -31.79 -0.44 -17.75 0.00 -3.75 -0.32 10.21 -1.42 24.08 -4.32 -31.29 -0.42 -17.25 0.00 -3.25 -0.34 10.71 -1.49 24.58 -4.49 -30.79 -0.40 -16.75 0.00 -2.75 -0.37 11.21 -1.57 25.07 -4.66 -30.29 -0.38 -16.25 0.00 -2.25 -0.40 11.70 -1.65 25.56 -4.85 -29.78 -0.35 -15.75 0.00 -1.75 -0.43 12.20 -1.72 26.05 -5.03 -29.28 -0.33 -15.25 0.00 -1.25 -0.45 12.70 -1.80 26.54 -5.29 -28.78 -0.30 -14.75 0.00 -0.75 -0.49 13.19 -1.89 27.03 -5.55 -28.28 -0.28 -14.25 -0.01 -0.26 -0.52 13.69 -1.99 27.51 -5.86 -27.78 -0.25 -13.75 -0.01 0.24 -0.56 14.18 -2.09 28.00 -6.19 -27.28 -0.24 -13.25 -0.02 0.74 -0.58 14.68 -2.19 28.48 -6.56 -26.77 -0.21 -12.75 -0.02 1.24 -0.62 15.18 -2.29 28.96 -6.95 -26.27 -0.19 -12.25 -0.04 1.74 -0.66 15.67 -2.40 29.44 -7.37 -25.77 -0.17 -11.75 -0.04 2.24 -0.70 16.17 -2.51 29.68 -7.60 -25.27 -0.16 -11.25 -0.06 2.74 -0.73 16.66 -2.62 30.63 -8.61 -24.77 -0.13 -10.75 -0.06 3.24 -0.77 17.16 -2.72 31.57 -9.73 -24.27 -0.12 -10.25 -0.08 3.73 -0.81 17.65 -2.82 32.52 -10.86 -23.76 - -9.75 -0.09 4.23 -0.86 18.15 -2.92 33.46 -11.99 -23.26 -0.09 -9.25 -0.11 4.73 -0.89 18.64 -3.02 34.41 -13.11 -22.76 -0.08 -8.75 -0.12 5.23 -0.94 19.14 -3.13 -22.26 -0.07 -8.25 -0.14 5.73 -0.98 19.63 -3.23 Note: The above profile template incorporates a cant adjustment of 1:20 (2.86) clockwise rotation.