Engineering Manual Track CRN CM 231 SLEEPERS AND FASTENINGS Version 1.1 Issued January, 2012 CRN DMS REFERENCE: CRN-EMN-AMS-017 Owner: Asset Management & Engineering Services Manager Approved by: C Francis, Principal Civil Engineer Authorised by: G Dewberry, Asset Management & Engineering Services Manager Disclaimer. This document was prepared for use on the CRN Network only. John Holland Rail Pty Ltd makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user‟s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by JHR. JHR accepts no liability whatsoever in relation to the use of this document by any party, and JHR excludes any liability which arises in any manner by the use of this document. Copyright. The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of JHG. UNCONTROLLED WHEN PRINTED Page 1 of 76 CRN Engineering Manual - Track CRN CM 231 Sleepers and Fastenings Document control Revision Date of Approval Summary of change 1.0 November, 2011 First Issue. Includes content from the following former RIC standards: TS 3341, TS 3397, RTS 3648, CTN 01/06, CTN 02/04, CTN 04/06, CTN 04/17, CTN 04/28, TS 20 540 3 01. 1.1 January, 2012 Additions and Correction of errors (See Summary of changes below) Summary of changes from previous version Section Summary of change C1-4.1 Additional reference for steel sleepers C4-1 Deletion of duplicated sentence C4-2 Table 11 – Correction of missing heading C5-2 Correction of Table 16 “clumping of steel sleepers” to match CRN CS 230. Refinement of definition of “track length” Appendix 1 Addition of steel sleepers and steel sleeper components to approved products © JHR UNCONTROLLED WHEN PRINTED Page 2 of 76 Issued January, 2012 Version 1.1 CRN Engineering Manual - Track CRN CM 231 Sleepers and Fastenings Contents Chapter 1 Introduction .................................................................................................................................. 4 C1-1 Purpose ......................................................................................................................................... 4 C1-2 Context .......................................................................................................................................... 4 C1-3 How to read the Manual ................................................................................................................ 4 C1-4 References .................................................................................................................................... 5 Chapter 2 Management requirements ......................................................................................................... 6 C2-1 Proximity of plates to sleeper and bearer ends in turnouts ........................................................... 6 C2-2 Restriction on resleepering in summer months ............................................................................. 6 C2-3 Variation of acceptance limits ........................................................................................................ 6 C2-4 Anchoring requirements ................................................................................................................ 6 C2-5 Sleeper installation strategy .......................................................................................................... 6 C2-6 Re-use of steel sleepers ................................................................................................................ 6 Chapter 3 Competencies .............................................................................................................................. 7 Chapter 4 Manual timber resleepering ........................................................................................................ 8 C4-1 Planning ......................................................................................................................................... 8 C4-2 Lift method ................................................................................................................................... 10 C4-3 The “NO lift” method (Boodling)................................................................................................... 18 Chapter 5 Installing steel sleepers ............................................................................................................ 20 C5-1 Introduction .................................................................................................................................. 20 C5-2 Planning ....................................................................................................................................... 20 C5-3 Installing sleepers ........................................................................................................................ 24 Chapter 6 Replacing defective fastenings on timber sleepers............................................................... 28 C6-1 Planning ....................................................................................................................................... 28 C6-2 Replacing fastenings ................................................................................................................... 28 Chapter 7 Use of "Pandrol" type resilient fastenings ............................................................................. 31 C7-1 Selection of fastenings ................................................................................................................ 31 C7-2 Identification of fastenings ........................................................................................................... 32 C7-3 Installation procedure .................................................................................................................. 33 Chapter 8 Installing Pandrol E clips at insulated joints .......................................................................... 34 Chapter 9 Installing resilient fastenings on bridges ............................................................................... 36 Chapter 10 Installing 'Fastclip' fastenings ................................................................................................. 37 C10-1 Identification of fastenings ........................................................................................................... 37 C10-2 Installation .................................................................................................................................... 38 Chapter 11 Installing and removing dogscrews and lockscrews ............................................................ 39 C11-1 Identifying dogscrews and lockscrews ........................................................................................ 39 C11-2 Installation .................................................................................................................................... 40 C11-3 Removal ....................................................................................................................................... 40 Chapter 12 Use of reclaimed sleeper plates ............................................................................................... 41 C12-1 Sleeper plates with dogspike holes ............................................................................................. 41 C12-2 Sleeper plates for Pandrol fastenings ......................................................................................... 41 Chapter 13 Assessment of damaged steel sleepers for use .................................................................... 43 C13-1 Criteria for reuse of damaged steel sleepers .............................................................................. 43 Chapter 14 Assessment of fatigue life ........................................................................................................ 44 Chapter 15 Storing timber sleepers ............................................................................................................ 45 Chapter 16 Replacing Fastclip cast-in shoulders ...................................................................................... 46 Chapter 17 Installing Fastclip Weld-on shoulders ..................................................................................... 68 Appendix 1 Approved sleeper and fastening products ............................................................................. 71 © JHR UNCONTROLLED WHEN PRINTED Page 3 of 76 Issued January, 2012 Version 1.1 CRN Engineering Manual - Track CRN CM 231 Sleepers and Fastenings Chapter 1 Introduction C1-1 Purpose This manual provides requirements, processes and guidelines for the installation and maintenance of sleepers and sleeper fastenings. It applies to timber, steel and concrete sleepers installed on the Country Regional Network (CRN). C1-2 Context The manual is part of CRN's engineering standards and procedures publications. More specifically, it is part of the Civil Engineering suite that comprises standards, installation and maintenance manuals and specifications. Manuals contain requirements, processes and guidelines for the management of track assets and for carrying out examination, construction,