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Scanned Document 1 REPORT NO. FRA/ORD-77 /19 PB I U.S. - U.S.S.R. TRACK AND RAIL METALLURGY INFORMATION EXCHANGE \ MARCH 1977 FINAL REPORT This document is available to the public through The National Technical Information Service, Springfield, Virginia 22161 .. Prepared for: U.S. DEPARTMENT OF TRANSPORTATION FEDERAL RAILROAD ADMINISTRATION Office of Research and Development Washington, D.C. 20590 NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Govern­ ment assumes no liability for its contents or use thereof. I 1 ~ Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. FRA/ORD-77 /19 4. Title and Subtitle 5. Report Date U.S. - U.S.S.R. March 1977 Track and Rail Metallurgy Information Exchange 6. Performing Organization Code ~7~.~A~u~th-or~l.~)----------------------------------------------~ 8. Performing Organi zotion Report No. Richard F. Beck 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Elgin, Joliet and Eastern Railway Company P. 0. Box 880 11. Contract or Grant No. Joliet, Illinois 60434 P o __No_ ..11±2 7n 13. Type of Report and Period Covered 12. Sponsoring Agency Name and Address Department of Transportation Final Report Federal Railroad Administration (OR&D) 2100 Second Street, Southwest 14. Sponso~ng Agency Code Washington, D. C. 20590 15. Supp I ementary Notes 16. Abstract The report covers track research and development activities, rail metallurgy and the technology of laying welded rail, assembly and disassembly of track panels and wood tie reclamation. It draws upon the experiences, observations and discussions of a seven-man team of engineers, researchers, and metallurgists who visited the Soviet Union during an 11-day period in 1976. The basic goals were to expand upon the knowledge obtained by previous delegations and to learn as much as possible for application or modification to US research and development activities and track maintenance procedures. 17. KeyWords 18. Distribution Statement Track Research and Development, Document is available to the oublic Standards, Maintenance, Track through the National Technical Equipment, Rail Metallurgy, Information Service, Springfield, Concrete Ties, Welded Rail, Track Virginia 22161 Production & Reclamation Techniqu~s 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 140 Form DOT F 1700.7 (B-72} Reproduction of completed page outhori zed i TABLE OF CONTENTS PAGE INTRODUCTION 1-1 CONDUCT OF THE INFORMATION EXCHANGE 2-1 BACKGROUND INFORMATION ON USSR RAILROADS 3-1 General Discussion 3-1 Operating Environment and Traffic Density 3-1 Physical Plant 3-3 Organization 3-7 Dissemination of Technical Information 3-11 RESEARCH AND DEVELOPMENT 4-1 General Discussion 4-1 Track Buckling Facility 4-2 Shcherbinka Experimental Test Ring and Laboratories 4-11 General Discussion 4-11 Facilities 4-11 Train Operation 4-14 Track Maintenance Procedures 4-18 Laboratory and Field Testing 4-19 General 4-19 Instrumentation 4-19 Laboratory Testing of Rail 4-20 Field Testing of Rail 4-21 Laboratory and Field Testing of Concrete Ties 4-22 Laboratory and Field Testing of Rail Fasteners 4-23 Track-Train Dynamic Testing and Track Loadings 4-23 Rail Metallurgy, Production and Properties 4-28 Rail Service Life, Defects and Wear 4-35 Ties, Fastenings and Concrete Panels 4-43 LAYING OF WELDED RAIL 5-1 SUPPORT FACILITIES 6-1 General Discussion 6-1 Disassembly of Wood Track Panels· 6-1 Tie Reclamation 6-2 Assembly of Track Panels 6-7 WELDING AND JOINING RAIL 7-1 MAINTENANCE COMMENTS AND GENERAL OBSERVATIONS 8-1 SUMMARY OF FINDINGS 9-1 APPENDIX A 10-1 APPENDIX B 11-1 APPENDIX C 12-1 iii INDEX OF FIGURES PAGE 1. US Delegation in Bryansk with Officials of Moscow Railroad 1-6 2. USSR Diesel Locomotive 3-6 3. USSR Train Consist on South Western Railroad 3-6 4. Tank Car with Four Two-Axle Trucks 3-8 5. Track Buckling Test made During a Downpour 4-6 6. Displacement Dial Gauges Used in Test 4-6 7. Track Buckle Observed 4-7 8. Soviet Track Buckling Test Data 4-8 9. Range of Temperatures within which Continuously Welded Rail may be Laid and Welded 4-10 10. Shcherbinka Test Rings 4-13 11. Static Load Test 4-13 12. Rail Rolling Load Test 4-15 13. Static Testing of Car Wheel 4-15 14. Static Bolster Test Showing Failure 4-16 15. Ultrasonic Rail Flaw Profiling Device 4-16 16. Bridge of New Design under Construction 4-17 17. Track Fastening BL65 4-24 18. Track Fastening K2S 4-25 19. Track Fastening BS3 4-26 20. RE 132 lb. Rail Section with US and USSR Dimensions 4-30 21. Oil Quenching Equipment for Heat-Treated Rails 4-33 22. Fatigue Defects and Tonnage 4-38 23. Wear Criteria for Rail Removal 4-42 24. Type of Fastenings Tested 4-46 25. Type of Fastenings Tested 4-47 26. Type of Fastenings Tested 4-48 27. Present Standard Concrete Tie and KB Fastening 4-49 28. Cross Section of Soviet and US Main Line Tie 4-51 29. Various Types of Concrete Slab Trackage 4-52 30. Welded Rail Laying Crane 5-2 31. Welded Rail Laying Crane 5-2 32. Welded Rail Threader Sled 5-4 33. Remote, Self-Propelled Cars 5-4 34. Tightening Rail Fastenings 5-5 35. Continuous Vibrating Power Tamper 5-5 36. Epoxy Bonded Insulated Joint in Welded Rail String 5-7 37. Track Panels to be Disassembled 6-3 38. Ties Being Removed by Hydraulic Equipment 6-3 39. Usable Ties Leaving Dismantling Station 6-4 40. Soviet Tie Refurbishment 6-5 41. Production Line in Tie Reconditiong Plant 6-6 42. Drilling Tie for New Spiking Pattern 6-7 iv INDEX OF FIGURES PAGE 43. Placement of New Wood Dowels after Adzing 6-9 44. Wood Dowels Used at Both Ends of Tie 6-9 45. Tie Creosoting Station 6-10 46. Ties Entering Tie Plate, Gauging and Spiking Machine 6-12 47. Rail Hold Down Spikes Being Set 6-12 48. Gantry Crane Handling Rail 6-13 49. Rail Resting on Steel Supports Before Ties are Raised 6-13 for Spiking 50. Hydraulic Spiker Driving Rail Hold Down Spikes 6-14 51. Gantry Crane Moving Completed Panel to Storage Area 6-14 52. Tie Plates, Pads and Fittings for Concrete Ties 6-15 53. Tie Plates Attached to Concrete Ties 6-15 54. Gantry Crane Handling Ties to Prefabricating Bed 6-16 55. Automatic Spacing of Ties 6-18 56. Rail Hold Down Devices Hydraulically Torqued 6-19 57. Gantry Crane Moving Completed Panel 6-19 58. Track Panel Storage Area 6-20 59. Rehabilitated Panel for Main Line Use 6-22 60. PRSM-3 Mobile In-Track Welder 7-2 61. Welder in Operation 7-2 62. Upset Being Removed 7-3 63. Typical Main Line Trackage 8-4 INDEX OF TABLE 1. Properties and Composition of US and USSR Rails 4-36 2. USSR Rail Defect Statistics for Conventional and 4-40 Heat-Treated Rail APPENDICES A. Itinerary 10-1 B. USSR Table of Organization 11-1 C. Documents 12-1 v INTRODUCTION This report covers the track and metallurgical information exchange of the United States (US) Delegation to the USSR, which took place between June 14 and 25, 1976. The meetings were carried out under the US-USSR Agreement on Cooperation in the Field of Transportation, under the direction of Assistant Secretary for Policy, Plans and International Affairs, Mr. R. H. Binder, of the U. S. Department of Transportation and Mr. G. U. Aleksenko, Deputy Chairman of the Soviet State Committee for Science and Technology. The railroad technology exchange is under the direction of a joint, US-USSR, Railroad Working Group with co-chairmen, Mr. R. E. Parsons, Associate Administrator, Office of Research and Development, Department of Transportation/Federal Railroad Administration, and Mr. N. V. Kolodyazhnyi, Vice Chairman, Council of Science and Technology, USSR Railroad Transport Ministry. The basic goals were to expand upon the knowledge obtained by previous Delegations and to learn as much as possible for application or modification to US track maintenance practices. The specific goals were to obtain as much information as possible in the following areas: 1-1 1. Economic considerations controlling the overall utilization, selection, and use of rail steel and related track components. 2. The design, operation, field and laboratory testing and experience of the Shcherbinka Test Ring and the Track Buckling Facility in relation to the new US Facility for Accelerated Service Testing (FAST) at Pueblo, Colorado. 3. The analysis of data obtained from the test facilities as related to the Soviet's develop­ ment and modification of track standards and maintenance practices. 4. The metallurgy and strength of rail steel, including its microstructure, chemical composition, heat treatment, service life, reliability prediction, wear, strength, and the initiation, growth, location ,and type of defects. 5. The manufacture of rail,including production control, hydrogen embrittlement, 25 meter (82 ft.) length rails, heat tre~ting techniques, microstructure, standards, residual stresses and a visit to a rail and axle mill. 6. The technology of laying and surfacing welded rail. 1-2 7. The various technologies of joining rails, including the operation of a mobile in-track welding machine with an automatic shear and a reduced welding cycle. 8. The reclamation and reuse of welded and conventional rail, concrete and wood ties and fastenings. Previous delegations to the Soviet Union dealt with track maintenance procedures, electrification technology and rail flaw defect technology. Our discussions with the Soviets were characterized by a spirit of cooperation and openness, but were influenced to a considerable degree by the language barrier and time spent in interpretation.
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