AS 1085.21:2020
Railway track material Part 21: Turnouts, switches and crossings
crossings
and
Infrastructure Standard
switches
Please note this is a RISSB Australian Standard® draft
Document content exists for RISSB product development1085.21 purposes onlyComment and should not be relied upon or considered as final published content. Turnouts, AS 21: Any questions in relation to this document or RISSB’s accredited development process should be referred to RISSB. Public Part for RISSB Office Phone: Email: Web: (07) 3724 0000 Draftinfo@ri ssb.com.au www.rissb.com.au Overseas: +61 7 3724 0000 material
AS 1085.21 Assigned Standard Development Manager
Name:track Phone: Email: Risharda Robertson 0438 879 916 [email protected]
Railway
AS 1085.21:2020 Railway track material Part 21: Turnouts, switches and crossings
Notice to users
This RISSB product has been developed using input from rail experts from across the rail industry and represents good practice for the industry. The reliance upon or manner of use of this RISSB product is the sole responsibility of the user who is to assess whether it meets their organisation’s operational environment and risk profile.
AS 1085.21:2020
Railway track material Part 21: Turnouts, switches and crossings crossings
Draft history (Draft history applies only during development) and
Draft version Draft date Notes
PC Draft 20/12/2019 Draft for Public Comment
Copyright switches
© RISSB
All rights are reserved. No part of this work can be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of RISSB, unless otherwise permitted under the Copyright Act 1968. 1085.21 Comment Turnouts, Objective AS 21: The objective of this Standard is to provide information and requirements for the design and manufacture of turnouts, switches and crossings, and their components. Public Turnout switches and crossings are vital trackPart components that allow and control the safe diversion of rail vehicles from one track to another or to cross other tracks. for
Compliance Draft There are two types of control contained within Australian Standards developed by RISSB: 1. Requirements.material 2. Recommendations. Requirements – it is mandatory to follow all requirements to claim full compliance with the Standard. Requirementstrack are identified within the text by the term ‘shall’. Recommendations – do not mention or exclude other possibilities but do offer the one that is preferred. Recommendations are identified within the text by the term ‘should’. Recommendations recognise that there could be limitations to the universal application of the control, i.e. the identified control is not able to be applied or other controls are more appropriate or better. For compliance purposes, where a recommended control is not applied as written in the standard it could be Railwayincumbent on the adopter of the standard to demonstrate their actual method of controlling the risk as part of their WHS or Rail Safety National Law obligations. Similarly, it could also be incumbent on an adopter of the standard to demonstrate their method of controlling the risk to contracting entities, or interfacing organisations where the risk may be shared. Controls in RISSB standards address known railway hazards are addressed in a Appendix A.
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AS 1085.21:2020 Railway track material Part 21: Turnouts, switches and crossings
Contents 1 Scope and general ...... 4 1.1 Scope ...... 4 1.2 Referenced documents ...... 4 1.3 Definitions ...... 5 2 Turnout design ...... 7 2.1 General ...... 7 2.2 Design parameters ...... 7 2.3 Tangential ...... 15 2.4 Secant ...... 20 3 Interfaces ...... 23 3.1 General ...... 23 3.2 Operating equipment ...... 23 3.3 Insulation ...... 24 3.4 Installation ...... 24 3.5 Track and structure interfaces ...... 24 4 Manufacture ...... 25 4.1 Materials, tests and standards ...... 25 4.2 Rails, fishplates and sleeper plates ...... 25 4.3 Castings ...... 25 4.4 Steel and iron castingsAS ...... 1085.21 ...... 26 4.5 Manganese steel castings ...... 26 4.6 Fastening ...... 30 4.7 Flame cutting ...... 31 4.8 Welding ...... 31 4.9 Hardening ...... 31 4.10 Rail drilling ...... 32 4.11 Sawing and machiningDraft ...... for Public...... Comment ...... 32 4.12 Riveting ...... 32 4.13 Fitting ...... 32 4.14 Forgings ...... 32 4.15 Cast iron blocks ...... 32 4.16 Cast steel blocks ...... 32 4.17 Special heel bolt ferrules ...... 33 4.18 Nylon bushes ...... 33 Railway4.19 track Epoxy material gluing of cro Partssings ...... 21: Turnouts,...... switches and...... crossings 33 4.20 Switch assembly ...... 33 4.21 Crossing assembly ...... 33 4.22 Tolerances ...... 34 4.23 Stamping ...... 36 4.24 Match marking ...... 37 4.26 Final assembly and inspection ...... 37
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4.27 Preparation for dispatch ...... 37 5 Product acceptance ...... 38 5.1 General ...... 38 5.2 Type approval ...... 38 5.3 Certificate of compliance ...... 38 5.4 Trial assembly ...... 38 5.5 Assembly maintenance manuals and drawings ...... 38
crossings Appendix Contents Appendix A Hazard register ...... and 39 Appendix B Terminology and drawings ...... 40 Appendix C Information to be supplied by the purchaser ...... 59 Appendix D Bibliography ...... 63 switches
1085.21 Comment Turnouts, AS 21: Public Part for
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AS 1085.21:2020 Railway track material Part 21: Turnouts, switches and crossings
1 Scope and general
1.1 Scope This standard specifies requirements for the design and manufacture of turnouts, switches and crossings, and their components. This standard does not cover management of turnouts, switches and crossings during other stages of the asset’s lifecycle such as installation and maintenance.
1.2 Referenced documents crossings 1.2.1 Normative references and The following documents are referred to in the text in such a way that some or all of their content constitutes requirements of this document: • AS 1085.1 Railway track materials, Part 1: Steel rails • AS 1085.2 Railway track materials, Part 2: Fishplates • AS 1085.3 Railway track materials, Part 13: Sleeper platesswitches • AS 1085.4 Railway track materials, Part 4: Fishbolts and nuts • AS 1085.12 Railway track materials, Part 12: Insulated joint assemblies • AS 1085.14 Railway track materials, Part 14: Prestressed concrete sleepers 1085.21 Comment • AS 1085.17 Railway track materials, Turnouts,Part 17: Steel sleepers • AS 1442 Carbon steels ASand carbon -manganese steels—Hot rolled bars and semi- finished products. 21: • AS 1816 Metallic materials. Public • AS 1830 Grey cast ironPart. for • AS 1831 Ductile cast iron. • AS 1988 Welding of ferrous castings. • AS 2074 Cast steels. Draft • AS 2205material.1 Methods for destructive testing of welds in metal, Part 1: Macro metallographic test for cross-section examination. • AS/NZS 1252 High strength steel bolts with associated nuts and washers for structural trackengineering . • AS/NZS 1554.1 Structural steel welding, Part 1: Welding of steel structures. • AS/NZS 3679.1 Structural steel, Part 1: Hot-rolled bars and sections. • AWS 5.13 Specification for Surfacing Electrodes for Shielded Metal Arc Welding. Railway• AWS 5.21 Specification for Bare Electrodes and Rods for Surfacing.
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1.3 Definitions For the purposes of this document, the terms and definitions given in RISSB Glossary: https://www.rissb.com.au/products/glossary/ and the following apply: (a) anti creep device a device used to minimize and monitor longitudinal creep between switch blade and stockrail (b) asymmetric rail non-symmetric shaped rail of low height and thick web (c) block crossings casting or fabricated steel component used to support rail components at a fixed distance apart (d) cant deficiency and The difference between the applied cant on the track and the equilibrium cant for the rolling stock at a particular speed. (e) check rail a steel section placed inside the running rail which comes into contact with the back of the wheel flange, to guide the wheels throughswitches points and crossings. NOTES: 1. check rails can be manufactured from rail. 2. A checkrail may be raised above the level of the running rail (i.e. the top of the checkrail is above the running rail). (f) closure rails 1085.21 Comment rails making up a turnout or specialTurnouts, trackwork diamond configuration that are apart from those in the switchAS assemblies, crossings and checkrail units (g) crossing 21: a track component that enablesPublic a wheel travelling along one rail to pass through the rail of a trackPart which crossesfor its path. NOTE: The most common types are ‘V’ and ‘K’. See section X for further information. (h) heat affected zone section of the parent rail outside the fusion zone that has mechanical properties altered by the weldingDraft process (i) interlocmaterialking interaction of equipment controlling switches and/or signals to prevent conflicting movements, and to make sure that routes are set correctly. track(j) machining allowance extra material required as a raw casting (k) stockrail A length of rail providing support for the switch and acts as the running rail when switch is open. Railway (l) switch assembly a track component that provides a path for a wheel to transfer from one track to another and usually consists of a section of bent and planed rail (known as the switch rail) and its connecting parts (for example switch rod brackets, reinforcing bars and high strength tips where appropriate).
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(m) switchblade a machined tapered rail that allows the direction of a train to be altered to another line. (n) turnout a complete track assembly that allows rolling stock to converge or diverge into or from a single track (respectively)
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AS 1085.21:2020 Railway track material Part 21: Turnouts, switches and crossings
2 Turnout design
2.1 General The aim of turnout design is to provide a suitable product for the purchaser’s application. The factors for consideration include, but are not limited to: (a) minimizing dynamic wheel/rail forces; (b) optimizing whole-of-life turnout and reduced maintenance; (c) ensuring that there is an adequate safety factor for design speed throughcrossings turnouts, for given cant deficiencies, turnout angle and radii; and (d) interfacing with other structures or equipment. (Refer to Sectionand 3 on interfaces). There are a number of design geometric configurations. Two typical geometric designs are covered in this Section (secant and tangential). See Figure 2-1 for a high-level schematic representation of turnouts and the associated rail components. switches
1085.21 Comment Turnouts, AS 21: Public Part for
Figure 2-1 overviewDraft of right -hand turnout and associated rail components NOTE: Additional terminologymaterial and drawings associated with turnouts, switches and crossing is given in Appendix B. 2.2 Design parameters
2.2.1 trackGeneral Section 2 provides criteria that the purchaser should specify to enable efficient and effective design to suit a specific application for turnout design. NOTES: Railway1. Additional requirements specified by rail infrastructure managers should also be taken into account. 2. An example form summarising all design inputs to be provided by the purchaser is provided in Appendix C.
2.2.2 Geometry Geometry is defined by the following: (a) tangential/secant/other geometry;
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AS 1085.21:2020 Railway track material Part 21: Turnouts, switches and crossings
(b) crossing/turnout angle; (c) turnout handing; (d) turnout radius; (e) mainline radius (if applicable); (f) track layout.
2.2.3 Gauge Generally, the track gauge will be one of the following: (a) broad (1600 mm); crossings (b) standard (1435 mm); (c) narrow (1067 mm); and (d) other gauge to be nominated.
2.2.4 Rail weight/section Refer to AS 1085.1 for current Australian rail section rail weight. Other rail sections may be nominated with reference to the relevant standard: switches (a) Switchblade - in certain applications, typically tangential turnouts, the switchblade may use an asymmetric rail section which varies from the rail used in the turnout. (b) Crossing - some swing nose and fixed nose crossings may use a non-standard rail. This section is to be1085.21 nominated. Comment (c) Checkrail - elevated checkrail sectionTurnouts, may be used in place of standard full depth rail section. This sectionAS is to be nominated. 21: 2.2.5 Crossing type Public The crossing type is determined according to rail infrastructure manager’s specifications. (Refer to section B.7 for crossing-type options.)Part for 2.2.6 Switch type The switch type is determined according to rail infrastructure manager’s specifications. (Refer to B.21.3 and B.21.5). Draft
2.2.7 Bearer materialtype The bearer type is determined according to rail infrastructure manager’s specifications. (Refer to B.2). track 2.2.8 Fastening system The fastening system type is determined according to rail infrastructure manager’s specifications. (Refer to section B.11). Railway2.2.9 Wheel rail interface The wheel rail interface is determined according to rail infrastructure manager’s specification for: (a) wheel sections; (b) wheel back-to-back dimension; (c) flangeway width;
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AS 1085.21:2020 Railway track material Part 21: Turnouts, switches and crossings
(d) flangeway depth; (e) check rail effectiveness
2.2.10 Operating parameters The operating parameters are determined from the rail infrastructure manager’s requirements for: (a) axle load - maximum tonnage per axle; (b) speed - maximum mainline and diverge operating speeds. 2.2.11 Cant deficiency crossings Generally, the following cant deficiencies will apply unless otherwise nominated: (a) Broad gauge (1600 mm) cant deficiency - 90 mm. and (b) Standard gauge (1435 mm) cant deficiency - 75 mm. (c) Narrow gauge (1067 mm) cant deficiency - 55 mm.
2.2.12 Nominal design life Measured in years and/or million gross tonnes. switches 2.2.13 Signalling interfaces The following signalling interfaces: (a) Switch machine type and location. (b) Locking mechanism. 1085.21 Comment Turnouts, (c) Detection type. AS (d) Location and details of fixing21: points for switch, stock, swing nose crossing, drilling and machining. Public (e) Location and detailsPart of fixing points for bearers. (f) Requirements for insulatedfor joints. (To be nominated.) (Refer to Section 3 for other interfacing considerations.)
2.2.14 Railway infrastructureDraft clearances Railway infrastructurematerial clearances as calculated in accordance with AS 7633. 2.2.15 Noise and vibration When switch and crossing assemblies are to be installed in residential or built-up areas where noise and vibrationtrack can be an issue, consideration should be given to the use of slab track and an attenuation type system. Introduction of swing nose crossings can also reduce noise and vibration.
Railway
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2.2.16 Bearer layout and spacing Bearer layout and spacings shall be determined with consideration of the track conditions or relevant network standards. Bearer designs should be undertaken in accordance with AS 1085.14 or AS 1085.17, as appropriate. See Figure 2-2.
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Figure 2-2 Bearer layout and spacing track
Railway
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2.2.17 Plating and/or shoulder footprint Plating and/or shoulder footprint positioning is the detail of the fastening system for interfacing between the rail and bearers. The fastening system will generally be screw spike or direct cast in shoulder, with a resilient fastening system. Figure 2-3 is a typical plating footprint zone for concrete bearers Figure 2-4 – Zone 1- Switch plate and to Figure 2-9 detail the different plate types applicable to each zone.
crossings and
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Figure 2-3 Typical turnout plating zone locations 1085.21 Comment Turnouts, AS 21: Public Part for
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Figure 2-4 – Zone 1- Switch plate Figure 2-5 – Zone 2 – Special heel plate
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RailwayFigure 2-6 – Zone 3 – No switch plate Figure 2-7 – Zone 4 – Elevated check rail plate
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switches
Figure 2-8 -Type E – Standard rail plate (STD. 380 mm Centre rail plates)
1085.21 Comment Turnouts, AS 21: Public Part for
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Figure 2-9 Crossing plates Railway
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2.2.18 Transitioning cant/rail/sleeper/gauge Some turnouts require a length of transition between the end of the stockrails or at the back of the crossings to the plain track. Such transitions could be for variations due to the changing of the following: (a) Uncanted to canted rails. (b) One sleeper type to another (change in track stiffness). (c) Gauge tolerances. (d) Rail weight or profile. crossings The aim of the transitions is to ensure that there is minimal impact from such changes, i.e. to avoid any sudden variations or impacts. and
switches
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2.3 Tangential
2.3.1 General In tangential geometry designs, the turnout curve begins at the tangent point of radius and finishes at a nominated point that determines the turnout rate/angle. See Figure 2-10.
crossings and
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1085.21 Comment Turnouts, AS 21: Public Part for
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Legend: Railway 1 – Overall length 4 – Turnout angle 2 – Tangential length R1 – Turnout centre line radius 3 – Turnout intersection R2 – Turnout centre line secondary radius
Figure 2-10 Tangential layout
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Figure 2-11 shows the geometry used for tangential turnout parameters.
crossings and
switches
1085.21 Comment Turnouts, AS 21: Public Part for
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track
Figure 2-11 Tangential turnout geometry (with straight crossing) NOTE: For notations used in this Figure, see Table 2-1. Railway
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Table 2-1 Definitions – tangential turnout
Symbol Definition
Gauge A = Gauge of track, in millimetres
B = Angle of the crossing in degrees.
1 (퐵) = 푇푎푛−1 ( ) 푁
C = Straight length, distance in millimetres
Switch thickness = 0 mm crossings
Entry angle = 0°
G + K = 90° and
K =
L = 퐶 × 푆𝑖푛 퐵
M = 퐶 × 퐶표푠 퐵 switches N = 퐴 − 퐿
W = 푁 × 퐶표푠푒푐 퐵
X = 푁 × 퐶표푡 퐵 O = 푁 + 푋 1085.21 Comment −1 K = 푇푎푛 푁 ∕ 0 Turnouts, AS G = 퐽 21: = 90 − 퐾 Public B = 퐹 = 180Part− 2퐺 for Radius = 푊 퐶표푡(0.5 × 퐹) Lead = 푂 +Draft푀
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2.3.2 Typical tangential geometric configurations The typical tangential geometric configurations for the various gauges are shown in Table 2-2, Table 2-3 and Table 2-4. NOTE: The speeds shown in Tables Table 2-2 to Table 2-4 are: 1. nominal only and may be subject to operational constraints; and 2. based on cant deficiency specified in section 2.2.11.
Table 2-2 Broad gauge (1600 mm) turnout data
Radius Turnout rate Intersection Lead length Crossing Nominal diverge point (mm) (mm) angle speed throughcrossings
turnout km/h
160 7.52 10592 22187 7.574680° and35
190 7.52 12578 24170 7.425273° 35
250 8.25 15096 27794 6.475376° 40
250 9 13846 27800 6.340200° 40 switches 260 9 16155 28399 6.340200° 40
600 15 19978 43115 3.814075° 65
720 15 26642 47565 3.814075° 65 800 15 26637 1085.2149506 Comment3.622496° 70 1200 21 28571 Turnouts,60481 2.727855° 85 AS 21: Table 2-3 Standard gaugePublic (1435 mm) turnout data Radius Turnout rate Intersection Lead length Crossing Nominal diverge point Part(mm) for(mm) angle speed through turnout km/h 160 6.6 Draft12052 20939 7.662236° 30 160 8.25 9662 21054 6.911227° 30
190 7material 13503 22862 7.033006° 35
190 9 10523 22988 6.340192° 35
250 track8.25 15096 26296 6.133080° 40
250 10.5 11878 26489 5.440332° 40
300 9 16616 28853 5.599601° 45 Railway300 12 12478 29238 4.763642° 45 500 12 20797 37391 4.763642° 60
500 15 16648 37707 3.814075° 60
800 15 26637 46827 3.814.75° 75
800 18.5 21606 47083 3.094058° 75
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Radius Turnout rate Intersection Lead length Crossing Nominal diverge point (mm) (mm) angle speed through turnout km/h
1000 20 25000 52790 2.86419° 75
1200 18.5 32409 56996 2.801473° 85
1200 24 24989 57754 2.385957° 85
Table 2-4 Narrow Gauge (1067mm) turnout data crossings Radius Turnout rate Intersection Lead length Crossing Nominal diverge point (mm) (mm) angle speed through
turnoutand km/h
130 8.25 7850 16308 6.911227° 25
200 10 9975 20205 5.710593° 25
280 12 11646 23920 4.763642° 40 switches 300/250 12 12060 24402 4.763642° 40
500 16 15610 31960 3.576334° 50
1235 25 24684 50213 2.290610° 80 1085.21 Comment Turnouts, AS 21: Public Part for
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2.4 Secant
2.4.1 General The secant turnout, see Figure 2-12, was the first geometric layout configuration developed. The turnout geometry was very simple and comprised straight switches followed by a circular curve. The secant turnout is widely used in many railways as it is simple in design, cost effective and easily installed, however their general application is used in low speed minor lines or yards.
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NOTE: 1. For notationtrack used in this Figure, see Section 2.4.2. 2. The lead (L) will be longer for straight leg crossings and the radius (r) sharper. Figure 2-12 Secant turnout
Railway2.4.2 Secant turnout design 2.4.2.1 Definitions The following definitions are used when calculating the geometry of a secant turnout where there is a curve tangent at the heel to the theoretical point of the crossing, indicated in diagram as curved crossing. See Figure 2-12.
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Table 2-5 Definitions – secant turnout
Term Symbol Definition
Heel of switch HS The switch end having full rail section
Toe of switch TS The thin end of the switch (opposite end to heel).
Theoretical point TPC Intersection of gauge lines at crossing of crossing
Radius R Radius of the centre-line of main line curve. Radius r Radius of the turnout curve measured to the rail on which the crossingscrossing lies. To calculate (r) see Equation 2-2. Gauge G Gauge of track. and Crossing rate N Rate of crossing, expressed as the side of a right-angled triangle on unit base.
Crossing angle A Angle of the crossing in degrees.
1 (퐴) = 푇푎푛−1 ( ) 푁 switches
Switch angle B Angle between switch gauge line and stockrail gauge line
푑 − 푇ℎ𝑖푐푘푛푒푠푠 표푓 푠푤𝑖푡푐ℎ푡𝑖푝 (퐵) = 푠𝑖푛−1 ( ) 1085.21 Comment푆 Heel centres d The distanceTurnouts, between gauge lines at the heel of the switch Switch length S ASLength of the switch from heel to toe. 21: Short lead H Distance fromPublic heel of switch to TPC measured along the main line. Lead L Distance from toe of switch to TPC of crossing measured along main line. PartTo calculate for (L) see Equation 2-1. Offset Y Distance between the straight track and the diverging track at a nominated point see Equation 2-3. NOTE: Offsets are generally calculated at one-metre intervals to allow Draftaccurate installation of the turnout in the field. 2.4.2.2 Formulamaterial Equation 2-1 track 1 (퐿) = (퐺 − 푑)퐶표푡 ( ) + 푆 2(퐴 + 퐵) Equation 2-2
(퐺 − 푑) Railway (푟) = (퐶표푠 퐵 − 퐶표푠 퐴)
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Equation 2-3
1 푂푓푓푠푒푡 푦 = 푑 + 푥 푇푎푛 ( 푥 ) 2 (퐵 + 푆𝑖푛−1 ( + 푆𝑖푛 퐵)) 푟 Example: This example is calculated for a turnout using the same parameters as that depicted in Figure 2-12, except the crossing is straight from the theoretical point of the crossing on the turnout leg. Equationcrossings 2-4
푌퐶 = 1000 푠𝑖푛 퐵 and = 99.50 mm Equation 2-5 푋푐 = 1000 푐표푠 퐵 switches = 995.04 mm
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AS 1085.21:2020 Railway track material Part 21: Turnouts, switches and crossings
3 Interfaces
3.1 General This section covers the interfaces that should be considered together with the geometric and loading factors when designing new turnouts, switches and crossings. These features are an integral part of the assembly and are essential in most situations. Items to be taken into account include the following: (a) Specific handing of the assembly. (b) Location, handing and type of switch operating equipment. crossings (c) The positioning and type of insulated joints, where required (see seciton3.3). (d) Compliance with structure outline. and
3.2 Operating equipment
3.2.1 General There is a wide variety of operating mechanisms available. Considerationswitches should be given to interfacing with the turnout, switches and crossings. This section (3.2) covers components commonly used in the operation of switches and crossings.
3.2.2 Operating devices Operating devices are designed to set the1085.21 switch position. TheseComment devices can be manually operated, electric motor, hydraulic or electro-pneumatic or Turnouts,trailable. Operating devices shall be designedAS to suit each specific application. 21: 3.2.3 Operating rodding Public Operating rodding is designed specifically to match the switch machine type selected. It is also used in situations where synchronized operationPart for of the switches and crossing is required, e.g. swing nose crossing installations.
3.2.4 In-bearers In-bearers allow for the rodding andDraft other equipment to be incorporated within the bearer and permits tamping of materialswitches without removing the operating equipment. 3.2.5 Switch locking Switch locking is used to ensure the switches are locked and remain in that position while being normally traversedtrack by a train.
3.2.6 Switch detection Switch detection is used to detect and signal that the switch, or movable point crossing, is correctly positioned. Railway 3.2.7 Condition monitoring Sensors may be installed at certain locations to monitor the condition of the turnout.
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3.3 Insulation
3.3.1 General Where assemblies are to be installed in track circuited territory, track insulation is essential. Generally, all components, including fastenings, rodding and bearers require insulation to ensure electrical separation between running rails.
3.3.2 Insulated joints For the conditions described above, insulated joints will also be required and the positioning within the layout/assembly will be critical to the operation of the signalling system. (Refer AS 1085.12.) crossings 3.4 Installation The proposed installation methodology should be considered in determining design,and manufacturing and delivery of turnouts, switches and crossings to the site. This can influence how the assembly is delivered to site and could also help to mitigate against damage that could occur during the installation process.
3.5 Track and structure interfaces switches The final position in which the turnout will be located should be detailed including: (a) other trackwork and structures which may encroach on the turnout placement; (b) structure and gauge clearances; (c) interface with other structures1085.21 (i.e. platforms, Comment tunnels, bridges, level and pedestrian crossings); Turnouts, AS (d) interface with existing/adjacent21: trackwork; and (e) catchpoints, run-off zones. Public Part for
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4 Manufacture
4.1 Materials, tests and standards All the materials and processes supplied by the manufacturer shall, unless otherwise specified, conform to the requirements and test methods of the relevant current Australian Standards or other applicable recognized standards. The purchaser may approve the use of a Standard other than an Australian Standard.
4.2 Rails, fishplates and sleeper plates crossings 4.2.1 Rail New rail shall comply with AS 1085.1 or other standard approved by the purchaser.and The use of head hardened rail shall be specified by the purchaser. Where a head hardened section is available for a particular rail size its use is recommended. The straightness tolerance shall conform to the rail straightness for un-machined surfaces in accordance with AS 1085.1. In addition, the straightness shall not vary by more than 1mm over a length of 2 m. switches New or part worn rail may be used for turnouts, switches and crossings manufacture. Part worn rail shall only be used with approval of the purchaser. The rail should: (a) be free from surface defects greater than 1 mm deep; (b) be straight, with a maximum1085.21 allowable deviationComment of 3 mm over any 3 m length; (c) have gauge faces that are smoothTurnouts, and free of metal flow; AS (d) not have excessive top wear21: and side wear; top wear not to exceed 3 mm and side wear not to exceed 5mm. Public Flame cutting of rails may also be permitted for ease of handling purposes. After flame cutting, the rails should be saw cut a minimumPart distance for of 150mm from the flame cut edge. Any reduction from the rolled section shall be by machining. The surface roughness value of machined or planed surfaces shall be better than 12.5 m.
4.2.2 Fishplates Draft Fishplates shall complymaterial with AS 1085.2 or other standard approved by the purchaser. Flame cutting of holes in rails and fishplates is not permitted. 4.2.3 trackSleeper plates Cast reforged or fabricated steel plates may be used as an alternative to the standard rolled sleeper plates specified as AS 1085.3 or other standard approved by the purchaser. Cast iron plates shall be made from AS 1831 minimum Grade 500-7 ductile iron or equivalent material. Railway 4.3 Castings All castings shall be: (a) clean and smooth on the surface; (b) free from surface defects;
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(c) compatible with interfacing rail components; (d) dimensions shown on the drawings; (e) neatly dressed and cleaned; (f) machined to accurately fit the rails. Machined steel shall be smooth on the surface and sharp to the form and dimensions shown on the drawings. All blocks shall be machined to accurately fit the rails.
4.4 Steel and iron castings crossings All steel and iron castings shall comply with the following standards: (a) AS 1830 for cast iron. and (b) AS 1831 for ductile iron. (c) AS 2074 for cast steel. (d) Other equivalent standard approved by the rail infrastructure manager. switches 4.5 Manganese steel castings
4.5.1 General All manganese steel castings shall comply with section 4.3. 1085.21 Comment Castings shall be manufactured so as to conformTurnouts, to the tolerances listed in Table 4-3. Manganese steel castings, include: AS (a) rail-bound manganese (RBM)21: crossing inserts; (b) solid cast crossings; Public (c) manganese steelPart switch tipsfor; and (d) any special component part used for turnouts, switches and crossings. 4.5.2 Material Draft Cast manganese steel shall be in accordance with AS 2074 minimum Grade H1A. material 4.5.3 Heat treatment Heat treatment shall be in accordance with AS 2074 minimum Grade H1A.
4.5.4 trackMachining allowance Machining allowance may be specified, this is designed to remove surface defects from the critical regions of the casting and to reduce the amount of weld repairs performed. The machining allowance shall be removed by a metal cutting process.
Railway4.5.5 Surface hardening Unless indicated otherwise manganese steel crossings shall be explosively hardened to have hardness within the range 350 to 415 HBW, on all top surfaces and 20 mm down the flangeways. Hardness testing shall be in accordance with AS 1816. Castings which fail to meet the hardness specifications may be accepted only where agreed by the purchaser.
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Machining of hardened surfaces shall not be undertaken unless approved. Distortion resulting from the depth hardening process shall be rectified before the final assembly Hardness testing locations shall be taken on each hardened area as per Figure 4-1.
crossings
and
switches
Legend: Hardness test locations All top running1085.21 surfaces and flangewaysComment to a depth of 35 mm, and Critical area the junction of the Turnouts,tang and the casting on the top and bottom surface. All ASareas that are not critical such as other flangeway areas, the base of the Non-critical area casting, outside21: w alls, webs, flanges and ribs. NOTE: For other types of castings Hardness testing to be agreedPublic with purchaser.
PartFigure 4-for1 Hardness testing locations 4.5.6 Surface defects 4.5.6.1 General Draft All castings shall bematerial inspected visually for the presence of the following surface defects: (a) Scale. (b) Lack of metal. track(c) C racks. (d) Sand holes. (e) Adherent sand. (f) Surface porosity. Railway (g) Gas pockets. (h) Cold shots. (i) Cold shuts. Surface imperfections shall not exceed the criteria given in see table 4.1.
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Table 4-1 Allowable imperfections
Maximum allowable dimensions or number of Imperfections imperfections
Crack Not permitted
Lack of fusion Not permitted
Surface pore Not more than 3mm diameter
Slag inclusion Not permitted
Loss of cross-sectional area (including porosity) >5% crossings Surface imperfections shall be measured using dye penetrant testing. and Surface imperfections will not be classed as defects if dye penetrant testing verifies that they are less than 1 mm deep in critical areas and less than 3 mm deep in sub-critical areas. All surface defects identified during visual inspections shall be prepared for weld repairs. After weld preparation, the defect shall be re-measured for size using non-destructive testing. 4.5.6.2 Additional testing switches Radiographic testing should be carried out to ensure the integrity of the casting in the following situations: (a) There are 8 or more defects within any one critical area. (b) The size of the defect is 1085.21greater than 5 mmComment deep or 10 mm wide. Turnouts, (c) The clear distanceAS betw een weld preparations is less than 15 mm. 4.5.6.3 Permissible repairs 21: Manufacturing defects may be repaired if the defectPublic sizes are in accordance with Table 4-2. TablePart 4- 2 forSurface defect approval Manufacturing defect size Area after weld preparation
Draft < 5 mm deep and <10 mm wide Critical area material < 7 defects of any size
Non-critical area < 10 mm deep and <15 mm wide NOTE: Adjacenttrack weld preparations with less than 15 mm separation are considered as single defect for assessment purposes. Where defect sizes exceed the tolerances outlined in Table 4.2 repair may be undertaken when approved by the rail infrastructure manager.
Railway
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4.5.7 Repairing defects 4.5.7.1 General Defects shall not be repaired by peening, plugging or impregnating. Weld repairs shall not be performed on a casting following the explosive hardening process. If any defect is found in a region that has been explosively hardened, the casting shall not be accepted. Casting defects in new manganese steel inserts that have not been explosively hardened may be repaired by welding. The complete removal of defects shall be verified by dye penetrant testing. Welding repairs shall be performed in accordance AS 1988. crossings All weld repairs shall be performed in accordance with a qualified weld procedure endorsed by the rail infrastructure manager. and When weld repair is undertaken, all preparatory work, welding and non-destructive testing shall be undertaken by a competent person experienced in the qualified weld procedure. 4.5.7.2 Qualifying a weld procedure A procedure will be deemed qualified when a test sample is welded under similar conditions to that encountered in production and destructively tested by preparing twoswitches macro-specimens in accordance with AS 2205.1. The two macro-specimens should not be opposing surfaces of the same cut. Both the weld and heat affected zone (HAZ) shall be examined. The qualified welding procedure must contain all of the information necessary for the welder to perform the repair and may take the form of a work instruction. 1085.21 Comment Turnouts, The test sample shall consist of manganese steel complying with this specification of final dimensions not less than 25 mm × 60AS mm × 200 mm. Surface decarburization shall be removed from the surface to be welded. Four layers21: of weld metal shall be deposited to within 5 mm of all edges. The heat input shall not exceed 1.0 kJ/mm.Public The interpass temperature shall not exceed 260°C. The test piece can be tack welded to a backing plate to prevent distortion and shall be welded in the flat position. Unless Partotherwise for approve by the rail infrastructure manager, electrodes shall be equivalent to AWS A5.13 EFeMn-A/B/C/D/E or AWS A5.21 ERFEMn-C/F/G/H. Welders shall be qualified by welding the same test sample as detailed above using a qualified welding procedure and tested in accordanceDraft with the above. 4.5.7.3 Explosivematerial hardening Explosive hardening, if required by the purchaser, shall be carried out following weld repair and reheat treatment. Following trackthe explosive hardening, hardness testing in line with section 4.5.5 shall be carried out at the locations shown in Figure 4.1. Manufacturers shall maintain suitable quality records of the hardness test report. 4.5.7.4 Straightening of castings RailwayFollowing explosive hardening, the casting shall be straightened and machined in non-critical areas so as to conform to the tolerances listed in tolerance Table 4-3. 4.5.7.5 Epoxy gluing of RBM castings All blocks and RBM crossings may be epoxy glued using an air curing epoxy. Surface preparation should be in accordance with the recommendations of the epoxy glue manufacturer. As a minimum, surface preparation shall include sand blasting or an equivalent surface preparation and degreasing.
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The fitting surfaces shall comply with section 4.1 and in no circumstances shall epoxy be used in lieu of a proper fit.
4.5.8 Theoretical point The theoretical point shall be marked on the cast crossings, after final machining and assembly as appropriate.
4.5.9 Identification All crossings shall be designated with an embossed stamp or glued on plate on the body of the casting. The marking shall be in a visible place that will not undergo any wear. The marking should include the following details: crossings (a) Name or symbol of manufacturer. (b) Manufacturer’s serial/work order number. and (c) Year of manufacture. (d) Angle of crossing. (e) Size of rail. (f) Heat number. switches 4.5.10 Weld maps A weld map shall be prepared for all castings produced. Weld maps shall show the location of each weld. If the casting has no defects the weld map is to be clearly marked with ‘No defects’. 1085.21 Comment Weld maps shall also include: Turnouts, AS (a) the heat number, 21: (b) manufacturer’s name, and Public (c) crossing rate. Part for 4.6 Fastening 4.6.1 Bolts Draft Fishbolts shall complymaterial with Australian Standard for fishbolts and nuts, AS 1085.4. High strength (HS) steel bolts and associated nuts and washers shall comply with AS/NZS 1252 or equivalent grade. All bolts shalltrack be of the forms and sizes nominated in the design and of a length to provide 3 mm minimum to 12 mm maximum projection of the end of the bolt beyond the nut when finally screwed into position. The head of all bolts shall be formed by forging. Tapered washers shall be used with bolts when the angle between the head of the fastener and the Railwayrail exceeds 3 degrees. Tapered washers shall be manufactured from either cast steel, AS 2074 Grade C6, or steel in accordance with AS/NZS 3679 minimum grade 250.
4.6.2 Swaged fastenings Swaged fastenings shall be used with flanged or non-flanged collars. Non-flanged collars may be used in conjunction with either a flat or tapered hardened washer.
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The first washer under the head of any swaged fastener shall have clearance for the head to shank radius. Tapered washers shall be used with swaged fasteners when the angle between the head of the fastener and the rail exceeds 3 degrees. Tapered washers shall be manufactured from either cast steel, AS 2074 Grade C6, or steel in accordance with AS/NZS 3679 minimum grade 250. Flat hardened washers shall be used to pack the swaged fasteners to obtain the correct grip length and shall be equally distributed under the head and collar. The maximum clearance between the inside diameter of the washer and pin shall be 3mm. Up to a maximum total of four washers shall be used to provide grip length. crossings The total number of washer combinations shall consist of either: (a) four 4 mm washers, or and (b) two 4 mm washers and two 10 mm washers. Washers shall be equally distributed under the head and collar. The number of washers should be kept to a minimum.
4.6.3 Retaining compound Where high strength steel bolts are approved for use in crossings,switches a high strength anaerobic retaining compound shall be applied to the threads of the bolts and their nuts during the final assembly. The threads shall be clean and dry and any rust, grease, oil, etc. shall be removed from the threads by a wire brush as far as possible. Solvents1085.21 such as petrol andComment kerosene shall not be used to clean oil or grease. Turnouts, AS 4.7 Flame cutting 21: Rails shall not be flame cut. Public
4.8 Welding Part for Unless approved by the purchaser, welding shall only be permitted where shown on the drawings and shall be in accordance with AS/NZSDraft 1554.1. 4.9 Hardeningmaterial Certain wearing surfaces of components manufactured from plain carbon rail may be hardened in the critical areas indicated in Figure 4-2 and Figure 4-3. The hardeningtrack method employed by the manufacturer shall produce a minimum hardness of 300 HBW.
Railway
Figure 4-2 - K-crossing - critical areas
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Figure 4-3 V-crossing - critical areas
4.10 Rail drilling All drilled holes shall be accurately drilled in accordance with tolerance specified in Table 4-3. All holes shall be finished by machining a 1 mm chamfer on each side of the rail web. Rolling brands shall be removed from rails prior to drilling. Holes shall not be hot or cold punched in rail sections.
4.11 Sawing and machining crossings Rails shall only be cold sawn. Out-of-square cut of rail ends over the maximum width and/or height of the rail shall not exceed 1 mm. and Sawn and machined rails shall be free of sharp edges and burrs. All mating surfaces are to be machined or ground to provide uniform bearing throughout.
4.12 Riveting Rivet material shall conform to the requirements specified in AS/NZSswitches 3679, Grade 250. Rivets shall be heated uniformly and shall be perfectly driven to ensure a firm bond between riveted components. No rivets shall be over heated. All loose rivets and rivets with mis-shaped heads shall be cut out and replaced by sound rivets. 1085.21 Comment 4.13 Fitting Turnouts, All components shall be to the correctAS form, dimensions and angles. They shall be fitted with accuracy to the dimensions and within the21: tolerances shown in Table 4-3. All blocks shall be finished to fit the rail profile overPublic 80% of their fitting surfaces. The manufacturer shall make-duePart allowances for for variations in rail rolling tolerances, for the machining and fitting of rail components and blocks.
4.14 Forgings Draft All forgings shall bematerial free from distortion, excessive scale and other imperfections. Allowance shall be made in the dies to prevent excessive drawing of the metal or distortion of the holes and rail surfaces. track 4.15 Cast iron blocks All cast iron blocks shall comply with section 4.3 and section 4.4. All grey iron castings shall conform to AS 1830 grade T260. RailwayAll ductile iron castings shall conform to AS 1831 grade 500-7.
4.16 Cast steel blocks
4.16.1 General All cast steel blocks shall comply with section 4.3 and section 4.4.
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4.16.2 Steel blocks, and steel packing blocks Steel filler blocks, steel distance blocks and steel packing blocks may be manufactured from one of the following: (a) Cast steel, the class and quality of which shall comply AS 2074 grade L1. (b) Machined from AS/NZS 3679 minimum grade 250.
4.17 Special heel bolt ferrules Special heel bolt ferrules shall be machined from AS 1442 grades S1040 or S1045 steel bar, case hardened and tempered to 480 HBW. crossings 4.18 Nylon bushes and Bushes shall be injection moulded from type 11 nylon impregnated with graphite or molybdenum disulphide or an approved equivalent.
4.19 Epoxy gluing of crossings Epoxy gluing shall not be used in lieu of a proper fit. switches When specified, blocks and rail mating surfaces used in turnouts, switches and crossings shall be epoxy glued using air curing epoxy or purchaser approved equivalent. Surface preparation should be in accordance with the recommendations of the epoxy glue manufacturer. 1085.21 Comment As a minimum, surface preparation shall includeTurnouts, sand blasting or an equivalent surface preparation and degreasing. AS 21: 4.20 Switch assembly Public Switch assemblies comprise of a switch,Part stockrail and associated components. Switch and stockrails shall be machined accuratelyfor to the dimensions and sections shown on the manufacturing drawings. Distortion of parts caused by machining or other operations shall be corrected before the switch and stockrail is assembled. Draft All arises and sharpmaterial edges on switches created by the machining process shall be ground off. Switch assemblies for the turnout shall have the appropriate set in the stockrails for the nominated turnout type. The assemblytrack shall have plates, switch stops, heel blocks or anti-creep device attached. Each switch assembly shall be fitted together as a complete set on a strong level platform, or other surface, and measured for compliance to the relevant drawings. All sliding surfaces of switch chair plates shall be coated with an approved lubricant or provided with Railwayan engineered surface which does not require the use of lubricant.
4.21 Crossing assembly A crossing assembly may be a solid casting or be manufactured from rail, manganese steel or other approved material.
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Crossing components shall be machined accurately to the dimensions and sections shown on the manufacturing drawings. Distortion of parts caused by machining or other operations shall be corrected prior to assembly of crossings. All arises and sharp edges on crossings created by the machining process shall be ground off. All rails for the crossings shall have the appropriate sets and curves to meet required angles and radii. Consideration should be given during pressing operations to ensure excessive stress in the rail does not occur. The assembly shall have plates, blocks and stops attached. crossings Each crossing assembly shall be fitted together on a strong level platform, or other surface, and measured for compliance to the relevant drawings. All sliding surfaces shall be coated with an approved lubricant or provided with anand engineered surface which does not require the use of lubricant. Swing nose crossing assemblies may be provided with a sliding joint with an approved lubricant.
4.22 Tolerances switches Unless shown otherwise on the drawings the tolerances on manufacture set out in Table 4-3 shall apply. Table 4-3 Manufacturing tolerances Component 1085.21 CommentTolerance a. Rails Turnouts, AS Length of switches 21: ± 3 mm Length of stockrail Public ± 5 mm Straightness of switchblade and stockrailPart for ± 2 mm Switch and stockrail mating surfaces +0, +1 mm
Length of point rails ± 3 mm Draft Length of check rails ± 5 mm
Length of wing rails material ± 5 mm
Length of closure rails ± 5 mm b. Crossingtrack lengths Fabricated and R.B.M crossing leg lengths to theoretical point ± 3 mm
Fabricated and R.B.M. crossing, overall length ± 6 mm Railwayc. Width of flangeways Fabricated crossings +0, −2 mm
Solid cast crossings +0, −2 mm
d. Manganese steel castings R.B.M. crossings
Overall length ±6 mm
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Component Tolerance
Theoretical point to end of casting ±3 mm
Toe and heel spread ±2 mm
Running surface flatness from theoretical top ±1 mm over a 2-metre length
Machined surfaces ±0.5 mm
Flangeway width +1, −2 mm Flangeway depth and vertical dimensions (except as specified otherwise) ±2 mm crossings Gauge face alignment from theoretical line ±2 mm Maximum twist of casting from end to end ±5 mm and Hole vertical position and diameter ±1 mm
All running surfaces, both top and flangeway edge, and fishing surfaces are to be machined or ground smooth and true prior to hardening to achieve the tolerances. Relative height of casting to running rails at throat area and tang: switches For non-machined surfaces ±1 mm
For machined surfaces ±0.5 mm
Gauge face alignment, casting to abutting tang rails ±1 mm Crossings (all crossings) 1085.21 Comment Turnouts, Relative height of crossing nose to wingAS rails ±1 mm Solid cast manganese crossings 21: Relative height of casting to top running surface of abuttingPublic rails ±1 mm
Rail ends shall be cut square to thePart axis of for the rail unless otherwise required. Flangeway widths shall be measured at the gauge point. Unless shown otherwise on the drawings the gauge point shall be defined as 16 mm below the top of the head of the rail. Draft material
track
Railway
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4.23 Stamping Each switch assembly and crossing shall have an identification tag attached as per the typical stamping details shown in Figure 4-4.
crossings and
switches
1085.21 Comment Turnouts, AS 21: Public Part for
Draft material
track
Railway
Figure 4-4 Typical turnout identification tags
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4.24 Match marking Each turnout shall be match marked to facilitate re-assembly in the field. The match marking may be either colour coding, lettering or numbering.
4.25 Painting and coating If requested by the purchaser all components except bolts, pins and sliding surfaces of plates may be coated with one coat of an approved ‘environmentally friendly’ protective coating. Prior to dispatch the sliding surfaces of plates shall be coated with an approved plate lubricant. The coating may be applied by brushing, spraying or dipping. All bolts and pins may be dipped in an approved protective coating. crossings Surfaces shall not be painted or oiled before final inspection. All loose rust and mill scale shall be removed before painting. and
4.26 Final assembly and inspection The purchaser may nominate the whole item, or any portion thereof, to be completely assembled prior to delivery. The assembly shall comply with all the specifications in Section 3 of this Standard. switches The purchaser may require an inspection of the track assemblies and components at their discretion. If an inspection is required, the sub-contractor shall demonstrate compliance to the purchaser’s specifications through the use of an approved quality assurance plan or system. 1085.21 Comment Turnouts, 4.27 Preparation for dispatchAS All components shall be prepared for dispatch21: into sub-assemblies, as individual rails or packed components. Public Sub-assemblies (e.g. switches) shall be securely held together with an approved method and stiffened if necessary, so no damagePart can occurfor during transport or handling. Individual rails (e.g. check rails/closure rails) shall be securely held together with an approved method or loaded individually, so no damage can occur during transport or handling. All packaged components, includingDraft bundles or bags of items, shall be packed into suitable crates or boxes andmaterial securely bound so no damage can occur during transport or handling. All components, individual rails or packaged items shall be clearly labelled for identification in an approved manner so to be easily distinguished by the purchaser. track
Railway
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5 Product acceptance
5.1 General This section covers product acceptance of new and existing turnouts, switches and crossings design and manufacture.
5.2 Type approval The type approval process should typically include sections on determination of need, safety, performance, reliability, suitability, previous use of similar designs on other systems, crossings maintainability and cost benefits. Networks and asset owners may have varying type approval process, which should be applied when introducing a new product into a system. and 5.3 Certificate of compliance Manufacturers shall provide a certificate of compliance that details the conformance with this Standard and any further specific requirements when requested.
5.4 Trial assembly switches Trial assemblies may be requested by the purchaser for initial proving and validation of product.
5.5 Assembly maintenance manuals and drawings 1085.21 Comment 5.5.1 Assembly Turnouts, The Manufacturer shall provide instructionsAS for the assembly of turnouts, switches and crossing when requested by the purchaser. 21: 5.5.2 Maintenance Public Manufacturers shall provide recommendationsPart for for the maintenance of turnouts, switches and crossings when requested by the purchaser.
5.5.3 Manuals and drawings Manufacturers shall provide assemblyDraft manuals particularly where new equipment or methods are introduced. The manual may include recommended lifting points, maximum length and mass of individual componentmaterials.
track
Railway
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Appendix A Hazard register
(Informative)
Hazard number Hazard 6.8.1.9 Poor specifications, manufacture and QA (Quality Assurance) of material 6.9.1.36 Poor design and manufacture 6.14 Derailment 6.15 Track failure crossings 6.28 Track and civil infrastructure design failure 5.2.1.2 Track failure causing collisions with a wayside structures and
switches
1085.21 Comment Turnouts, AS 21: Public Part for
Draft material
track
Railway
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Appendix B Terminology and drawings
(Informative)
B.1 General This appendix provides additional terms, definitions and drawings used in relation to turnouts, switches and crossings. B.2 Bearer crossings A type of sleeper used under turnouts and special trackwork. Bearers are generally larger in dimension than standard sleepers to provide support for both tracks as well as the increased loading experienced under such track structures. Generally manufactured from eitherand steel, concrete or timber.
B.3 Catchpoint Provides a level of protection against train collision by derailing the train prior to the junction of rail lines. See Figure B 1. switches Generally, catchpoints comprise the following: (a) One switch and stockrail assembly. (b) Closure rails. (c) Throw off rails (where required)1085.21. Comment Turnouts, (d) Ramp (where required)AS . (e) Bearers. 21: (f) Plates, fasteners and rail jointsPublic. (g) Point operating equipment.Part for Stockrail Draft
Switch material
track Bearers
Figure B 1 - Typical catchpoint RailwayB.4 Switch chair plate A flat plate with a fixed raised section that is fastened to the web of either the stockrail, in the case of a switch assembly, or the checkrail carrier, in the case of a checkrail assembly. The types of chairs are identified by marking on the end of the plate by stamping.
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B.5 Checkrail A steel section (can be manufactured from rail) placed inside the running rail which comes into contact with the back of the wheel flange, along the checking face. It is used to provide steering of the wheel set, such that the crossing nose or switch point is not contacted and is protected by the opposite wheel. A checkrail can be raised above the level of the running rail (i.e. the top of the checkrail is above the running rail). B.6 Checkrail effectiveness crossings Distance from the checking face of checkrail to the gauge face of the crossing nose. Measured square to the running rail at the nose of the crossing (see Figure B 2). and
switches
1085.21 Comment Figure B 2 CheckrailTurnouts, effectiveness B.7 Crossing types and termsAS 21: B.7.1 General Public A track component that enables a wheel travelling along one rail to pass through the rail of a track which crosses its path. The mostPart common for types are ‘V’ and ‘K’.
B.7.2 End opening The opening between the gauge faceDraft of rails at each end of a crossing. B.7.3 Housedmaterial (spliced) rail The rail in a fabricated ‘V’ or ‘K’ crossing that takes the minimum traffic or speed. This rail is machined and attached to the point rail to complete a ‘V’ assembly. track B.7.4 Point rail The rail in a fabricated ‘V’ crossing that takes the maximum traffic or speed. It is mechanically attached to the housed rail to complete the ‘V’ assembly. Refer to Figure B 8. RailwayB.7.5 Practical point The location of the tip of the crossing nose. Refer to Figure B 3.
B.7.6 Crossing rate A measure of the angle made by the rail gauge faces at the theoretical point. It is defined by one of three methods, either:
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(a) centre-line, (b) right angle, or (c) isosceles. Refer Figure 1.3, in which a 1- in- 8 crossing is shown as measured by each method. The preferred method is the right-angle method. Angle of crossing is ‘A’ in the equations in Figure B 3. Rate of crossing is ‘B’ in the equations in Figure B 3, i.e. 1 in 8. crossings
1 and 퐴 = 2 푇푎푛−1 2퐵 퐴 = 7.15266875° switches
1085.21 Comment Turnouts, 1 퐴 = 푇푎푛−1 AS 퐵 21: Public 퐴 = 7.12501635° Part for
Draft material
track 1 퐴 = 2 푆𝑖푛−1 2퐵 퐴 = 7.1666433° Railway
Figure B 3 Crossing - rate
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B.7.7 Special crossing A non-standard crossing designed for a specific site. The crossing may be of an uncommon angle and may have varying leg lengths or curved legs.
B.7.8 Tang The cast extension at the ‘V’ end of a rail bound manganese crossing to which the heel rails are fastened. B.7.9 Theoretical point crossings The intersection of the gauge lines of the two running rails forming the crossing.
B.7.10 Throat and Where the minimum distance occurs between the inside edges of the wing rails at a position ahead of the nose(s) of a crossing.
B.7.11 Wing rail Wing rails form part of the construction of all crossings. They are switcheseither of the two outside rails of a permanent way crossing of which both are rigid in a fixed nose and swing nose crossing and one hinged in a spring wing crossing.
B.7.12 ‘K’ type crossings A crossing comprising two opposing ‘V’s, 1085.21a running wing railComment and a wing checkrail. ‘K’ crossings are used in diamond and slip assemblies. Turnouts, AS 21: Public Part for
Draft material
track Figure B 4 ‘K’ Crossing B.7.12.1 Fabricated The noses, wing rails and checkrails are fabricated from sections of rail, set, machined and Railwayfitted together with blocks/chocks and bolts (refer to Figure B 4). B.7.12.2 Solid cast manganese A one piece solid cast manganese steel crossing with the four legs joined to standard rail sections through a welding process or by bolts and plates (see Figure B 5).
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Figure B 5 ‘K’ Crossing types – Solid cast manganese
crossings and
switches
1085.21 Comment Turnouts, AS 21: Public Part for
Draft material
track
Railway
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B.7.12.3 Switchable The two opposing switches of the ‘K’ crossing that move to allow a continuous surface for the wheel to run through the crossing (see Figure B 6).
Heel block Theoretical point Heel block
Switch throw Toe of switch
Figure B 6 ‘K’ crossing types – switchable crossings B.7.13 ‘V’ type crossings and A crossing comprising a ‘V’ and two wing rails fixed by blocks/chocks and bolting to a specified geometric configuration (See Figure B 7).
switches
1085.21 Comment Figure B 7 ‘V’Turnouts, crossing AS B.7.13.1 Fabricated 21: A fabricated ‘V’ crossing comprises a ‘V’ which isPublic manufactured from a point rail and a housed rail which are machined to match, assembled with two wing rails, fitted with spacer blocks and bolted or swage fastened togetherPart at the requiredfor angle (see Figure B 8). The point rail may be right hand or left hand and is generally laid along the rail carrying the predominant traffic. Draft material
track
Railway Figure B 8 ‘V’ crossing types - fabricated
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B.7.13.2 Compound A compound crossing comprises a single piece ‘V’ and two wing rails which form the front legs of the crossing. See Figure B 9. The ‘V’ point is manufactured from a special material (e.g. cast manganese, billet steel or forged material) which is welded to rails to complete the ‘V’. This assembly in the wheel transfer area replaces the point/housed rails in a fabricated crossing. Spacer blocks may be epoxy-glued or welded to the ‘V’ and are fastened together using high-tensile bolts or high tensile swage fasteners. crossings and
switches Figure B 9 ‘V’ crossing types – compounds 5.5.3.1 Rail bound manganese Rail-bound manganese (RBM) crossings are crossings which include two specially machined and set wing rails which form the front legs1085.21 of the crossing andComment which then enclose the insert casting and provide guarding of the transfer fromTurnouts, the casting to the heel rails. (see Figure B 10) Additional spacer blocks are providedAS between the rails and insert to provide flangeway clearance and strength to the crossing assembly.21: The insert, wing rails, heel rails and spacer blocksPublic are usually set with an epoxy glue and secured with high tensile swage fasteners. The manganese steel insert castingPart is usually for machined and explosively hardened prior to its assembly into the crossing. Draft material
track Figure B 10 ’V’ crossing types – rail bound manganese
Railway
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B.7.13.3 Solid cast manganese Cast manganese steel monoblock crossings, or cast solid crossings are manufactured from a single austenitic manganese steel casting (see Figure B 11). The running surfaces may be machined and explosively pre-hardened prior to installation into track. Short closure rails may be welded to each leg of the casting to facilitate welding into track or by bolts and fishplates.
crossings and
Figure B 11 Crossing types – solid cast manganese
B.7.13.4 Spring wing switches A modified ‘V’ crossing with both a fixed and spring wing leg (see Figure B 12). The spring wing effectively eliminates the flangeway gap when using the main line thus reducing the wheel generated impact in the crossing. The wheel flange forces the spring wing open when taking the siding track. 1085.21 Comment Turnouts, AS 21: Public Part for
Figure B 12 ‘V’ Crossing types – spring wing B.7.13.5 Swing nose Draft The ‘V’ which formsmaterial a moveable point, a moveable ‘V’ or a swing-nose crossing may be moved horizontally so that it may fit flush against one wing-rail or the other (see Figure B 13) The operation of the swing- nose is controlled by a motor or operating equipment which is interlockedtrack with the motor or equipment used to operate the switches of the same turnout. Because the swing-nose is fitted against the relevant wing-rail, there is no gap when wheels transfer between the running rails and the ‘V’. No checkrails are required with this crossing type.
Railway
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Figure B 13 ‘V’ Crossing types – swing nose crossings B.7.14 Crossover B.7.14.1 General and A means by which trains pass from one track to an adjacent track (see Figure B 14). A crossover is constructed from two turnouts, one on each track facing opposite directions. Turnout
switches
Turnout 1085.21 Comment Figure B 14Turnouts, Crossover AS 5.5.3.2 Scissors type 21: Two crossovers, in opposite directions, that intersectPublic between the same two tracks being connected. This intersection formsPart a diamond for ( see Figure B 15)
Turnout Turnout Draft material Diamond track
Turnout Turnout
Figure B 15 Crossover – scissors type Railway
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B.8 Diamond Diamonds provide for one track to cross another whilst maintaining continuous support and direction. See Figure B 16. They are an assembly of rail or cast components comprising the following: (a) ‘V’ crossings; (b) ‘K’ crossings; (c) checkrails closure rails; crossings (d) bearers; (e) plates, fasteners and rail joints. and
‘K’ crossing
‘V’ crossing switches‘V’ crossing
Checkrails Gauge 1085.21 Comment Gauge ‘K’Turnouts, crossing AS 21: Figure B 16Public Diamond B.8.1 Diamond crossing typesPart - fabricated for A diamond comprising fabricated ‘V’ and ‘K’ crossings.
B.8.2 Fully cast manganeseDraft A diamond comprising of fully cast ‘V’ and ‘K’ crossings. B.8.2.1 Switchablematerial ‘K’s A diamond comprising two ‘V’ crossings and two switchable ‘K’ crossings.
B.8.3 trackDiamond types Diamond types can be flange bearing or rail running. B.8.3.1 Flange bearing Where the depth of flangeway is reduced so that the wheels of the rolling stock run on the Railwaysurface of the component separating the running rails. This operation occurs through the flangeway gap of the crossings. B.8.3.2 Rail running Where the tread of the rolling stock wheel runs on the crown (head) surface of the running rails.
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B.9 Dual gauge turnouts Turnouts that are constructed with a mixture of both Standard Gauge (1435 mm) and Broad Gauge (1600 mm) widths, or Standard and Narrow Gauge (1067 mm) widths utilizing a common rail.
B.10 Expansion switch An assembly comprising two rails appropriately matched and fastened at the longitudinal interface to provide virtual continuity of the running rail and gauge faces while allowing controlled longitudinal slip (see Figure B 17).. crossings Expansion switches provide a level of control for rail stresses when tracks are attached to sub- structures (e.g. steel underbridges) which are also subject to temperature related expansion and contraction. and Expansion switches comprise: (a) switch and stockrail assemblies; (b) bearers; (c) plates, fasteners and rail joints. switches
1085.21 Comment Turnouts, AS 21: Public Part Figure B 17for Typical expansion switch
B.11 Fastening system A combination of base plates, andDraft fasteners used to attach the rail to the bearer. The system may include spikes,material pads, clips, insulators and anchors. B.12 Fishplate A metal jointtrack bar used to connect adjacent rails. Refer to AS 1085.2.
Railway
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B.13 Flangeway
B.13.1 General The space adjacent to the running rail to allow for the passage of wheel flanges (see Figure B 18).
crossings and
switches
Figure B 18 Flangeway 1085.21 Comment B.13.2 Flangeway depth Turnouts, The vertical distance between the topAS running surface and the top of the blocks/chocks separating the running and guarding surfaces21: to ensure wheel flange clearance. B.13.3 Flangeway width Public The distance between the runningPart and checking for surfaces to ensure wheel flange clearance or guidance.
B.13.4 Flangeway running Where the toe of the wheel runs onDraft a raised flangeway block. Used in crossings in urban environments for noisematerial abatement or in light rail where there is risk the wheelset width is too small to transfer from the wing rail to the crossing nose with larger angle crossings.
B.13.5 Flare The taperedtrack opening at the ends of flangeways to gradually engage wheel flanges and position them to pass through flangeways.
B.14 Heel block RailwayB.14.1 General Single or multiple blocks, depending on switch type, that rigidly fix the switch rail to the adjacent rail in the correct geometric configuration.
B.14.2 Heel fishplate The special or set fishplate at the heel of pivot heel switches which supports the switch.
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B.14.3 Heel joint The joint around which a pivot heeled switch rotates. The joint is made up of a steel block with fishplates and bolts which are designed to allow this movement.
B.14.4 Heel point Actual heel joint, for pivot heeled switches, or theoretical point, for flexible switches, that is used for turnout/switch design. B.15 In-bearer crossings A bearer of specific shape that is used at a set of switches or swing nose crossing (see section B.7.13.4) to house the switch operating rodding. This eliminates the rodding being located in a bay between bearers. and
B.16 Asymmetric rail Asymmetric rail is used primarily for the manufacture of switches. The short height of the switch rail permits resilient fastening of the gauge side of the stockrail. Refer to AS 1085.1 for rail profile. switches B.17 Rail brace A cast or fabricated component that supports the rail in a fixed position. The rail brace is attached to the stockrail. 1085.21 Comment B.18 Rail brace plates Turnouts, Rail brace plates are used under theAS switch assembly to which a rail brace is attached and this in turn is attached to the stockrail. The plates21: are distinguishable by a number stamped at the end. Public B.19 Resilient / elastic fasteningsPart for Resilient fastening assemblies provide a flexible restraint that holds the rail in position on the sleeper or other support structures by providing a spring force of known magnitude. The assembly may, if required, also provide load spreading, impact attenuation and electrical isolation. Draft NOTE: Refer to AS 1085.19.material B.20 Slip
B.20.1 trackGeneral Also known as a ‘compound’. Allows two tracks to cross each other or diverge, but unlike a diamond, contain sets of switches to allow movement from one line to the other (see Figure B 19). RailwayA slip comprises the following: (a) Switch and stockrail assemblies. (b) ‘V’ crossings; (c) ‘K’ crossings; (d) checkrails;
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(e) closure rails; (f) bearers; (g) plates, fasteners and rail joints.
B.20.2 Double A slip with four sets of switch assemblies (see Figure B 19(b)).
B.20.3 Single A slip with two sets of switch assemblies (see Figure B 19 (a)). crossings and
switches
1085.21 Comment Turnouts, AS 21: Public Part for
Draft material
track
Railway
Figure B 19 Slip type – single/double
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B.21 Switch assembly
B.21.1 General A switch assembly consists of either a right and left hand switch and stockrail, complete with associated plating and fastenings. Also known as ‘points’.
B.21.2 Operating equipment The switch machine or lever, rodding, detectors, brackets and fastenings that control the movement of the switch. crossings B.21.3 Switch assembly types B.21.3.1 Heavy duty and A switch with a thickened tip that must be used with a joggled stockrail to ensure the running face of the running rail is co-linear(see Figure B 20) .
switches
1085.21 Comment Turnouts, AS 21: Public FigurePart B 20 forSwitch type – heady duty B.21.3.2 Housed A heavy duty switch and joggled stockrail equipped with a ‘housing’ (see Figure B 21). The housing is a specially machinedDraft component with a hardened checking face fitting above the switch to act as a checkrail for the opposite switch and joggle. Where both switches are required to be heavy duty a housingmaterial is required on one of the switches.
track
Railway
Figure B 21 Switch type - housed switches
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B.21.3.3 Pivot heeled A switch that pivots about a pivot joint between the switch rail and adjoining closure rail (see Figure B 22. The heel assembly is bolted to the switch, stockrail and adjoining closure rail to allow for movement. The switch length is the total length of the switch rail.
crossings and
Figure B 22 Switch type – pivot heeled
B.21.4 Switchblade B.21.4.1 Switchblade angle switches The included angle between the gauge lines of the switch and the stockrail. B.21.4.2 Switchblade length On pivot heeled switches, the length of the switch from the switch tip to the heel joint. On flexible switches, the length from the switch1085.21 tip to the heel point.Comment Turnouts, B.21.5 Switchblade types AS B.21.5.1 Asymmetric 21: A switch manufactured from an asymmetric rail sectionPublic. Refer to AS 1085.1 or other approved standard. Part for B.21.5.2 Symmetric A switch manufactured from a symmetric rail section. There are generally two types of these switches—overriding and non-overriding.Draft Refer to AS 1085.1 or other approved standard. B.21.5.3 Tangentialmaterial A switch type with a continuous curve through the full length of the switch. The curved gauge line of the switch is tangent to the gauge line of the attached stockrail at a distance in front of the switch tip (see Figure B 23). track
Railway Figure B 23 Switch type - tangential B.21.5.4 Manganese tipped A switch where a section of the switch rail has a manganese steel insert fitted.
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B.21.5.5 Flexible, fixed heeled A switchblade machined from longer rails and fixed towards the end with blocks/chocks to the adjacent stockrail (see Figure B 24). The switch movement is provided by the flexibility of the longer switch rail.
crossings and
Figure B 24 Flexible switch B.21.6 Switch rollers switches Rollers that support and assist the operation of the switchblade or moveable nose on a swing nose crossing, during the opening and closing operation. They can be located in the bay between bearers, bolted to the stockrail or switch blade, or as part of the plate assembly under the switch. They reduce the need to lubricate the switch plate/switch interface.
B.21.7 Switch stops 1085.21 Comment Turnouts, Stops that are bolted to the web of the stockrail and make contact with the web of the switch when the switch is in the closed positionAS to provide lateral support. They may be manufactured from castings, rolled angle sections or extended21: bolts. Public B.22 Turnout Part for B.22.1 General A turnout is a complete track assembly that allows rolling stock to converge or diverge into or from a single track (respectively).Draft A turnout consists of the following: (a) switchmaterial assembly; (b) ‘V’ crossing; (c) checkrails; track(d) closure rails; (e) bearers; (f) plates, fasteners and rail joints; Railway (g) switch operating equipment. Turnouts are identified by the track geometry and componentry comprising the completed configuration. Turnout handing is determined when looking from the toe end of a turnout, as defined by the direction of the diverge track. Refer to Figure B 25.
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crossings and
switches
1085.21 Comment Turnouts, AS 21: Public Part for
DraftFigure B 25 Turnout B.22.2 Lead lengthmaterial The distance from the toe of the switch to the theoretical point of the crossing measured along the main line running rail containing the crossing.
B.22.3 track Turnout rate The angle of the turnout expressed as a ratio. For example, turnout rate 1 in 8 is calculated as follows:
1 Railway = 푡푎푛−1 ( ) 8
= 7.125°
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Turnout rate is measured at the end of the turnout arc. Refer to dimension F in Figure 2-11 Tangential turnout geometry (with straight crossing). The turnout rate may vary from the crossing rate in some geometric turnout configurations.
B.22.4 Flexure types B.22.4.1 Similar A turnout on a curve where the curve direction of the turnout diverging track is similar (see Figure B 26 Turnout similar flexureFigure B 26). crossings and
switches
Figure B 26 Turnout similar flexure B.22.4.2 Contraflexure A turnout on a curve where the direction of1085.21 the turnout diverging Comment track is opposite to the curve (see Figure B 27). Turnouts, AS 21: Public Part for
Draft material Figure B 27 Turnout contraflexure
track
Railway
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Appendix C Information to be supplied by the purchaser
(Informative) Provided over page is an example form to assist purchasers when ordering and/or seeking quotations for the supply of turnouts, switches and crossings.
crossings and
switches
1085.21 Comment Turnouts, AS 21: Public Part for
Draft material
track
Railway
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Request for service – supply of turnouts, switches and crossings
Customer information
Purchaser Name Quote No
Contact Name Line item(s)
Project
Ref No Date: crossings Rail infrastructure manager
Specification/Drawing and References
Product data
Design life MGT, or Years Annual Grossswitches Tonnes Mtpa Axle Load t (max) Structure Gauge Std
Main Line Speed Km/h Diverge Speed Km/h
Rate of cant deficiency Allowable cant deficiency 1085.21mm (max) mm/s Comment Flangeway width mmTurnouts, Flangeway depth mm AS Crossover track centres 21: mm Other Rolling stock Public Design Criteria Wheel back to back mm Wheel profile Part for Axle centres m Bogie Centres m
Comments Draft material
Crossover- Crossover – Single Double Turnout Diamond Single Scissor type Slip Slip Producttrack Crossing Catchpoint Switch only Switch Assembly Other- only
Rail 31kg 41kg 50kg 53kg 60kg 68kg General RailwayFlexing Straight Similar Contrary Special Other - Hand Right Left Unhanded Unknown
Gauge Narrow – 1067 Std – 1435 Broad – 1600 Dual 0 B/S or N/S Other -
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Comments:
Switch panel Cast in Shoulders Screw spikes Other -
Crossing panel Cast in shoulders Screw spikes Other -
Closure panel Plated Un-plated Other -
tenings crossings Cast in Shoulders Screw spikes
Comments and Plating & Fas
Slip RBM Mono-block Type switches SNX Spring wing Fabricated V Other-
Angle 1 in Or °
Extended Legs mm Long legs Short legs Both legs
Crossing Comments 1085.21 Comment Turnouts, AS 21: Public Product Full set Half set Blades only Other - Part for Type Tangential Fixed heel Pivot heel
Asymmetric rail Standard rail Other -
Radius Draft m RH LH
s Openings materialToe mm Throat mm (min) Extended legs Stockrail m Front, back or both Switche track Switch rail m Comments:
Railway Lever Required Not required Location RH/LH side
Type -
Switch Required Not required Location RH/LH side operation Machine Other - Trailable operation Yes / No
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Required Not required Rodding Back drive Yes / No
Switch rodding type Locking Type - Detection type -
Other -
Comments:
crossings
Bearers Required Not required and Type Timber Concrete Steel Composite
Other -
In bearer Steel Other - Points Yes / No Frontswitches & rear Front only
Bearers SNX Yes / No
Comments:
1085.21 Comment Turnouts,
Closure Rails GIRJ andAS location Resilient Plating Cant plates 21:fasteners Public Junction rails Check rails SNX rollers Switch rollers Insulation pads Manuals Other - Part for
Comments: Draft Other items
material Delivery date to site Yes / No
Locationtrack Trial assembly Yes / No
Comments: Deliverydetails Railway
NOTE: Indicate product identification parameters and provide additional description and comments where necessary to ensure quotations are correct. Manufacturer to provide purchaser with documentation supporting the acceptance/type approval of the product by the rail infrastructure manager - Yes or No.
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Appendix D Bibliography
AS 1085.19 Railway track materials, Part 19: Resilient fastening assemblies AS 7633 – Railway infrastructure clearances
crossings and
switches
1085.21 Comment Turnouts, AS 21: Public Part for
Draft material
track
Railway
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RISSB Australian Standards Development Process The Standards development process is rigorous and transparent. Authors work with RISSB's Standards Development Managers and Development Groups to ensure that products are acceptable to industry. Standing Committees oversee this work and ensure that proper governance and process is followed. The products are exposed to the public and industry for comment and validated by an independent validator. Once agreed by the Development Groups, Standing Committees and Validator, the drafts are passed to the RISSB Board for approval. The same process is used in developing other RISSB products, although Guidelines are not exposed to the public for comment or validated, given their non-binding nature. crossings
Standards Development and Accreditation Committee and RISSB is accredited by the Standards Development and Accreditation Committee (SDAC), and all Standards produced by RISSB since 31 July 2007 are published as Australian Standards. The Standards Development and Accreditation Committee audits RISSB annually to ensure that RISSB’s processes are in accordance with SDAC accreditation requirements. switches
Sales and distribution Australian Standards developed by RISSB are sold1085.21 and marketed through Comment SAI Global. For further information, please visit www.saiglobal.com. Turnouts, Financial members of RISSB are granted accessAS with membership. 21: Public Part for
Draft
material
About Railtrack Industry Safety and Standards Board The Rail Industry Safety and Standards Board is a not for profit company limited by guarantee. Wholly owned by its funding members, RISSB is required to apply the whole of its income and assets to achieving the objects listed in its constitution. RISSB is responsible for the development and management of Standards, Rules, Codes of Practice and Guidelines Railwayfor the Australian rail industry. For further information, visit www.rissb.com.au
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