PM n IDEA D1.5 Image analysis - Component catalogue · D1.5 Image analysis - Component catalogue...

EC Contract No. FP7 - 234299

Instrument: Small or medium-scale focused research project

Thematic priority: Sustainable Surface Transport

PM n IDEA

D1.5 Image analysis - Component catalogue

Due date of deliverable: 31/5/2012 Actual submission date: 31/5/2012

Leader of this Deliverable: R Carroll, Stagecoach Reviewed: Y

Document status

Revision Date Description

0 31/5/2012 First issue

Project co-funded by the European Commission within the Seven Framework Programme (2007-2013)

Dissemination Level PU Public Y PP Restricted to other programme participants (including the Commission Services) RE Restricted to a group specified by the consortium (including the Commission Services) CO Confidential, only for members of the consortium (including the Commission Services)

Start date of project: 01/06/2009 Duration: 36 months


PMI–D-STA–009.1 Page 2 of 49 31/05/2012

EXECUTIVE SUMMARY

The partners in PM n IDEA include many measurement and sensor specialists with little

knowledge of the railway environment. This document has been written to give an overview of the

different components that can be found on tramways to allow the non-specialist to understand their

use. For each component a description, use and typical degradation mechanisms or maintenance

requirements are given along with images. The catalogue is not exhaustive but includes most of

the common features found on a typical tramway, other components and different designs are in

use on different tramways.


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1. INTRODUCTION

One of the aims of PM n IDEA was to carry out image capture and analysis of the track system of

metro and tram networks to reduce the need for manual inspection and increase the subjectivity of

the data reported. The research work has being carried out by image capture and analysis

specialists who have only a limited knowledge of the railway environment and the features that

can be observed. Therefore this document is a collection of photographs of different track

components to aid identification and explain their use. It also provides information on the

degradation mechanism of each component and the maintenance required to be carried out. The

information contained is also useful to other sensor and measurement specialists not previously

involved in railways or tramway who are developing inspection and monitoring technologies for

track components.

The information contained in the document has been provided by Warsaw Tram and Stagecoach

Supertram networks, additional images have been taken from mainline railways where

appropriate. The document includes the most common features found on these tramways but it

should be borne in mind that other tramways will use different designs of components not included

in this document. When carrying out work on other tramways, knowledge and images of the actual

components in use should be gained.


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2. COMPONENTS - BALLASTED AND SLAB TRACK

2.1 RAIL JOINTS

2.1.1 Standard Fishplated Rail Joint – 39E1 (BS80A) Rail

Use: Joining two rails together Description: Two fishplates on either side of rail web secured by 4 bolts. An electrical bond can often be found associated with them. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen. To allow expansion of the rails the fishplates require greasing, typically on a two yearly frequency. Cracks can occur in the fishplate or rail end Localised plastic deformation, “batter”, of rail ends, can lead to cracks

75mm

50mm

Traction Bond

Traction Bond


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2.1.2 Heavy Duty Fishplated Rail Joint - 39E1 (BS80A)

Use: Joining of two rails together Description: Two fishplates on either side of rail web secured by 4 bolts. An electrical bond can often be found associated with them. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen. To allow expansion of the rails the fishplates require greasing, typically on a two yearly frequency. Cracks can occur in the fishplate or rail end Localised plastic deformation, “batter”, of rail ends, can lead to cracks

2.1.3 Insulated Rail Joint

Use: Joining of two rails together while maintaining electric isolation of one rail from another Description: Similar to fishplated joint but with insulating material between rail and fishplates and between rail ends. Can be 4 or 6 hole and most commonly, in the UK, with the gap between rail ends at 90 although 45 versions are available. The only visible part of insulated joints in grooved rail is the gap between rail ends and the insulation between, not to be confused with a broken rail. No electrical connection between rails. Degradation Mechanisms/Maintenance Requirements: Degradation of insulating material leading to electrical breakdown Wear debris embedded in insulation can lead to short circuiting. A common problem for metros in tunnels. Plastic deformation of rail ends can reduce insulation gap leading to short circuiting.

420m

Traction Bond


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2.1.4 Aluminothermic (AT) Welded Rail

Use: Joining of two rails together Description: Joining of rails through use of filler material cast from above, ground prior to use. Degradation Mechanisms/Maintenance Requirements: Incorrect weld procedure can lead to failure. “Dipping” of welds (over several metres) can create dynamic forces in rail and can lead to failure “Cupping” (differential wear of surface) of weld can create dynamic forces and lead to corrugation

2.1.5 Flash Butt (FB) Welded Rail

Use: Joining of two rails together Description: Joining of rails through heating and forging two rails together with no filler material. The weld is narrow than aluminothermic welds. Rail surface ground prior to use. Degradation Mechanisms/Maintenance Requirements: “Dipping” of welds (over several metres) can create dynamic forces in rail and can lead to failure “Cupping” (differential wear of surface) of weld can create dynamic forces and lead to corrugation

Weld Metal

Heat Affected Zone (HAZ)

Original Rail

Original Rail


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2.1.6 39E1 (BS80A) Rail Expansion Joint (breather or adjustment switch)

Use: Joining of two rails together allowing expansion of the rails in hot temperatures Description: Joining of rails with two machine flanges alongside each other allowing movement caused by temperature variation but maintaining an unbroken running surface. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen To allow expansion the plates require greasing, typically a yearly frequency. Cracks can occur in machined rail ends Plastic deformation, “batter”, of rail ends. Electrical bonds can become detached or can be stolen If incorrectly set up and/or in extreme weather condition then expansion can be excessive or insufficient.

420mm


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2.1.7 Lateral Expansion Joint - 54E1A1(UIC54B) rail

Use: Joining of rails together allowing room for lateral movement of a structure. Description: Rails laid on a steel bed so that they can move to accommodate the movement of the structure. Tie bars hold the rails to gauge. Rails used are of an asymmetric type. Also incorporates standard rail expansion joints. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen. Tie bars may be subject to fatigue.

420mm

200mm


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2.1.8 Transition Rail

Use: Joining of flat bottom to grooved rail Description: A flat bottom rail joined to a grooved rail near the change from embedded track to ballast. The head width of the rail on both sides of the join will be different, the amount depends on the rail profiles. The groove is flared out at the end. Degradation Mechanisms/Maintenance Requirements: Similar to standard rail: wear, corrugation etc. Cracks around the end of the groove or near the weld (if applicable)

2.2 RAIL FASTENINGS

2.2.1 Pandrol e-clip with 1:40 (cast) base plate on timber sleeper

Use: Supports and fastens rail Description: Cast base plate, bolted (coach screw) to wooden sleeper on which rail sits fastened by Pandrol E-clips, no rail pad. Rail inclined at 1:40. Degradation Mechanisms/Maintenance Requirements: Bolts fastening base plate to sleeper can loosen Pandrol clips can move out of housing. Pandrol clips can corrode and/or break Timber sleepers can crack/degrade

200mm

140mm


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2.2.2 Pandrol e-clip with vertical (cast) base plate on timber sleeper

Use: Supports and fastens rail Description: Cast base plate (both vertical and 1:40 inclination plates used) coach bolted to wooden sleeper on which rail sits fastened by Pandrol E-clips. Vertical Rail. Degradation Mechanisms/Maintenance Requirements: Bolts fastening base plate to sleeper can loosen Pandrol clips can move out of housing. Pandrol clips can corrode and/or break Timber sleepers can crack/degrade

2.2.3 SB Rail Clip on Concrete Sleeper

Use: Supports and fastens rail Description: Rail is separated by separator (rail pad) from sleeper and fixed anchor on sleeper by spring clip Degradation Mechanisms/Maintenance Requirements:

Spring clip can move out of housing Spring clip can corrode and / or break Insulator can be damaged

420mm


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2.2.4 SKL - 12 Rail Fastenings on timber sleeper

Use: Supports and fastens rail Description: Base plate bolted to wooden sleeper on which rail is fastened by spring clip SKL – 12 which is fixed to base plate by coach screw Degradation Mechanisms/Maintenance Requirements:

Rail fastening bolt can loosen Bolts fastening base plate to sleeper can loosen Spring clip can move out of housing Spring clip can corrode and / or break Timber sleepers can crack/degrade

2.2.5 Type ”K” Fastening – concrete sleeper

Use: Supports and fastens rail Description: Base plate bolted to sleeper on which a U clip is bolted holding rail down Degradation Mechanisms/Maintenance Requirements: Rail fastening bolt can loosen Bolts fastening base plate to sleeper can loosen Spring clip can move out of housing Spring clip can corrode and / or break Timber sleepers can crack/degrade


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2.2.6 39E1 (BS80A) Rail with single Pandrol clip with U69 check rail on cast mountings

Use: Prevention of derailment on tight curves and S&C Description: Second rail fixed on inside of running rail. Requires a different form of rail fastening. Flange way increases at ends. Can also be fitted in conjunction with expansion joints (lower right) Degradation Mechanisms/Maintenance Requirements: Flange way clearance is maintained within a defined range. As running rail or check rail wears adjustment is necessary Bolts and fastening can become loose.

Flange way clearance

300mm


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2.2.7 39E1 (BS80A) rail on baseplate with flange-planed 56E1 (BS113A) guard rail

Use: Prevention/mitigation of derailment on structures Description: Second rail fixed on inside of running rail to prevent wheel derailing. In contrast to check rails, guard rails are fitted to both rails. Degradation Mechanisms/Maintenance Requirements: Unlike check rails, guard rails should not wear and therefore should not require adjustment Bolts and fastening can become loose.

420mm


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2.2.8 39E1 (BS80A) running rail with flange-planed 39E1 (BS80A) guard rail on fabricated steel baseplate

Use: Supports and fastens rail Description: Fabricated baseplate coach bolted to wooden sleeper on which rail and BS80A guard rail sits fastened by Pandrol E-clips. Associated with monoblock diamond crossings Degradation Mechanisms/Maintenance Requirements: Bolts fastening base plate to sleeper can loosen Pandrol clips can move out of housing. Pandrol clips can corrode and/or break Timber sleepers can crack/degrade

420mm


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2.2.10 Pandrol e-clip with (cast) base plate fixed by spring loaded bolt fastenings on concrete slab

Use: Support and fasten rail Description: Baseplates bolted to concrete slab. Rail fastened by Pandrol e clips Degradation Mechanisms/Maintenance Requirements: Pandrol clips can move out of housing. Pandrol clips can break Concrete slab can crack/degrade Bolts fastening base plate to slab can loosen

2.2.9 39E1 (BS80A) running rail with flange-planed 39E1 (BS80A) guard rail – Fishplated joint

Use: Prevention/mitigation of derailment on structures Description: Second rail fixed on inside of running rail to prevent wheel derailing. In contrast to check rails, guard rails are fitted to both rails. Can also be fitted in conjunction with expansion joints (lower right) Degradation Mechanisms/Maintenance Requirements: Unlike check rails, guard rails should not wear and therefore should not require adjustment Bolts and fastening can become loose.

190mm

190mm

420mm


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2.2.11 39E1 (BS80A) rail with Pandrol e-clips on Stanton Bonna twin (bi) block concrete sleepers

Use: Support and fasten rail on ballasted track Description: Sleeper consists of two concrete blocks on either end of a steel angle tie bar. Rail sits on a polymeric material pad and fastened to sleeper using Pandrol e-clips with a polymer insulator between them. Degradation Mechanisms/Maintenance Requirements: Pandrol clips can move out of housing. Pandrol clips can corrode and break Concrete sleepers can crack/degrade Steel tie bar can corrode Insulators can crack or break

2.2.12 39E1 (BS80A) with Pandrol E clip on Tiflex resilient base plate on concrete slab or plinth track

Use: Support and fasten rail Description: Support for rail incorporating resilient layer on which clip is fastened. On outside of both rails are walled concrete derailment guards. Degradation Mechanisms/Maintenance Requirements: Bolts fastening base plate to sleeper can loosen Pandrol clips can move out of housing. Pandrol clips can break Resilient layer can debond from base plate resulting in movement of rail

450mm

300mm

320mm

Pandrol E-clip

Insulator

Tie Bar


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2.2.13 Pandrol E clip with Lord resilient base plate on concrete slab or plinth track

Use: Support and fasten rail Description: Support for rail incorporating resilient layer on which clip is fastened. On outside of both rails are concrete derailment guards. Degradation Mechanisms/Maintenance Requirements: Bolts fastening base plate to sleeper can loosen Pandrol clips can move out of housing. Pandrol clips can break Resilient layer can debond from base plate resulting in movement of rail

2.2.14 39E1 (BS80A) rail on Lord base plate with machined U69 guard rail on fabricated mounting

Use: Support and fasten rail Description: Support for rail incorporating resilient layer on which clip is fastened. Guard rail prevents derailment on a structure Degradation Mechanisms/Maintenance Requirements: Bolts fastening base plate to sleeper can loosen Pandrol clips can move out of housing. Pandrol clips can break Resilient layer can debond from base plate resulting in movement of rail

420mm


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2.3 SWITCHES AND CROSSINGS (S&C)

2.3.1 Overview – Ballasted Track S&C

Stretcher Bar

Switch Blades

Crossing (frog)

Check Rail

Drive mechanism

Heel Block

Stock Rail

Stock Rail


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2.3.2 39E1 (BS80A) Switch blade on slide chair mountings – Ballasted Track

Open

Closed

Use: Provides alternative route for vehicle Description: Moveable piece of rail machined to provide tight fit to stock rail. Stretcher bars maintain distance between switch blades. Degradation Mechanisms/Maintenance Requirements: Fastening of switch and stock rail can loosen and/or break Fastenings of tie bar and drive mechanism can loosen/fatigue Switch blade can wear and the tip can plastically deform or break

Switch Blade

Stock Rail

Stretcher Bar

Switch Blade

Stock Rail

300mm

Slide Chair


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2.3.3 PR7 diamond mono-block crossings – Ballasted Track

Use: Provides alternative route for vehicle Description: A gap in the running rail to allow passing of wheels in different directions. PR7 machined rail and crossing from a solid block. Degradation Mechanisms/Maintenance Requirements: Crossing nose can wear or be plastically deformed. Fastenings can break or loosed

420mm

420mm


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2.3.4 Fabricated Crossing (also called a “Frog”) – Ballasted Track

Use: Provides alternative route for vehicle Description: A gap in the running rail to allow passing of wheels in different directions. Fabricated type made from individual rails machined and joined together. Degradation Mechanisms/Maintenance Requirements: Crossing nose can wear or be plastically deformed. Fastenings can break or loosed Weld between rails can break or spall

2.3.5 Heel Block

Use: Maintains spacing between stock rail and switch blade Description: Block of steel bolted to web of both rail

Degradation Mechanisms/Maintenance Requirements: Bolts may come lose

Splice rail

600mm

Separate machined rails

Wing rail

Wing rail

Crossing rail

420mm


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2.3.6 Stretcher bars, drive and detection mechanism

Use: Stretcher bar keeps switch blades to correct gauge. Drive mechanism moves switch blades allowing different routes to be set. Detection Mechanism ensure points are in correct place to allow movement of trams over them. Description: Bar or bracket connecting switch blades together with attachment for drive and detection mechanism from points motor. Many different types of stretcher bar and mechanism available. Degradation Mechanisms/Maintenance Requirements: Bolts can loosen. Bars can fatigue Correct flange way needs to be maintained Detection needs to be set so it fails if blades are incorrectly set Ballast can block movement

Stretcher Bar

Drive and Detection mechanism

1435mm

420mm

Anti trespass

Drive and Detection mechanism

Points motor


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2.4 OTHER FEATURES

2.4.1 Rail Lubricators

Use: Lubricate rail in tight curves Description: A supply of lubricant is stored in a drum to the side of track. A treadle actuated by tram forces grease onto gauge face and the check rail by an applicator fastened to rail. Degradation Mechanisms/Maintenance Requirements: Refilling with grease Cleaning

2.4.2 Cable attachments to rail

Use: Cables attached to rail for traction current return and for signalling system Description: Either drilled and bolted or CADWELD® studs to rail web Degradation Mechanisms/Maintenance Requirements: Cables can come loose and require refastening Cables can be stolen


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2.4.3 VIS Loop

Use: Part of signalling system Description: Plastic box in centre of track. Covering track detection loop of wire. Degradation Mechanisms/Maintenance Requirements: Electrical failure Failure of GRP cover

2.4.4 Signalling Apparatus

Use: Part of signalling system Description: Plastic or wood box in centre of track. Degradation Mechanisms/Maintenance Requirements: Electrical failure Equipment can become loose


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2.4.5 Distance “chainage” marker

Use: Mark distance on system from a known datum Description: Yellow plaque fastened towards sleeper end Degradation Mechanisms/Maintenance Requirements:

Clean to ensure visibility

2.4.6 Pedestrian Crossing

Use: Provide a level walk way for pedestrians Description: Wood or polymer on either side of flat bottom rail. Degradation Mechanisms/Maintenance Requirements:

Level of walking route needs to be maintained


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3. COMPONENTS - EMBEDDED TRACK

3.1 RAIL JOINTS

3.1.1 Aluminothermic (AT) Welded Rail

Use: Joining of two rails together Description: Joining of rails through use of filler material cast from above, ground prior to use. Degradation Mechanisms/Maintenance Requirements: Incorrect weld procedure can lead to failure. “Dipping” of welds (over several metres) can create dynamic forces in rail and can lead to failure “Cupping” (differential wear of surface) of weld can create dynamic forces and lead to corrugation

3.1.2 Insulated Rail Joint (IRJ) or Insulated block joint (IBJ)

Use: Joining of two rails together while maintain electrical insulation between rails Description: Joining of rails with an insulating material between them


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Degradation Mechanisms/Maintenance Requirements: Degradation of insulating material leading to electrical breakdown Wear debris embedded in insulation can lead to short circuiting. A common problem for metros in tunnels. Plastic deformation of rail ends can reduce insulation gap leading to short circuiting. Can also lead to cracks in rail.

3.2 RAIL FASTENINGS

3.2.1 SEI35G-TF Grooved Rail Embedded in Polymer

Use: Support grooved rail and maintain gauge Description: Grooved rail embed in polymer in a concrete trough. Trough may have cobbles or tarmac at the surface Degradation Mechanisms/Maintenance Requirements: Polymer can degrade and require replacement. Degradation of concrete


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3.2.2 LR55 Grooved Rail Embedded in Polymer

Use: Support grooved rail and maintain gauge Description: Grooved rail embed in polymer in a concrete trough. Trough may have cobbles or tarmac at the surface Degradation Mechanisms/Maintenance Requirements: Polymer can degrade and require replacement. Degradation of concrete

3.2.3 Twin 39E1 (BS80A) rail, flange-planed check/guard rail

Use: To provide a clear flange way on road crossing without the need for a small section of grooved rail with associated transition rails. Description: A second full section rail is fixed on the inside(4ft side) of the running rails. Flared at ends, usually by machining. Degradation Mechanisms/Maintenance Requirements: Grooves may be blocked with material Wear of rails including check rail


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3.2.4 BS80A rail with attached bulb-flat polymer support

Use: To provide a clear flange way on road crossing without the need for a small section of grooved rail with associated transition rails. Description: A bulb flat is fixed on the inside(4ft side) of the running rails. Flared at ends, usually by bending). Degradation Mechanisms/Maintenance Requirements: Grooves may be blocked with material Wear of rails including bulb flat on curves

Bulb Flat


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3.2.5 39E1 (BS80A) rail with adjacent flange-path ACO derailment channel

Use: To provide drainage on structures and channels to contain wheel in event of derailment Description: Plastic drain cover over channel Degradation Mechanisms/Maintenance Requirements: Plastic cover can be smashed by vandalism Drains can become blocked by leaves, soil etc and can require cleaning


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3.2.6 Embedded Rail Expansion Joint

Use: Joining of two rails together allowing expansion of the rails in hot temperatures Description: Joining of rails with two machine flanges alongside each other allowing movement caused by temperature variation but maintaining an unbroken running surface. Degradation Mechanisms/Maintenance Requirements: Bolts are set to a fixed torque requiring checking to ensure they do not loosen To allow expansion the plates require greasing, typically a yearly frequency. Cracks can occur in machined rail ends Plastic deformation, “batter”, of rail ends. Electrical bonds can become detached or can be stolen If incorrectly set up and/or in extreme weather condition then expansion can be excessive or

insufficient.

420m


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3.2.7 Embedded rail expansion joint

Use: Joining two rails together allowing expansion or contraction due to temperature change.

Description: Joining of rails with two machined faces allowing movement caused by temperature variation but maintaining an unbroken running surface. Degradation mechanisms / Maintenance requirements • Bolts are set to a fixed torque requiring checking to ensure they do not loosen • To allow expansion the plates require greasing, typically a yearly frequency. • Cracks can occur in machined rail ends • Plastic deformation, “batter”, of rail ends. • Electrical bonds can become detached or can be stolen • If incorrectly set up and/or in extreme weather condition then expansion can be excessive or insufficient.


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3.3 SWITCHES AND CROSSINGS (S&C)

3.3.1 Overview – Embedded Track S&C

Switch Blades

Crossing

Check Plate

Drive mechanism

Check Plate


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3.3.2 Switch Blades – Embedded Track

Use: Provides alternative route for vehicle Description: Moveable piece of rail machined to provide tight fit to stock rail. Stretcher bars maintain distance between switch blades, usually associated with drive or detection mechanism, all hidden under manhole. Degradation Mechanisms/Maintenance Requirements: Fastening of switch and stock rail can loosen and/or break Fastenings of tie bar and drive mechanism can loosen/fatigue Switch blade can wear and the tip can plastically deform or break


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3.3.3 Embedded Crossings - Cast AMS

Use: Provides alternative route for vehicle Description: A gap in running rail allowing vehicles to travel on separate routes. Example shown is cast from austenitic manganese steel (AMS). Crossings can be flange (bottom left) or tread(top left) running. Degradation Mechanisms/Maintenance Requirements: Inherent porosity revealed by wear, needing weld repair Damage to crossing by plastic deformation and wear

420mm


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3.3.4 Embedded Crossings – Flange Running Monoblock

Use: Provides alternative route for vehicle

Description: A gap in the running rail to allow passing of wheel in different directions. Across nose depth of flange way is shallow to allow flange running to occur. Degradation mechanisms / Maintenance requirements: Damage to crossing by plastic deformation and wear

3.3.5 Stretcher Bars and Drive Mechanism – Embedded Track

Use: Keeps switch blades to correct gauge and provides mechanism for moving blades into correct position Description: Bar or bracket connecting switch blades together sometimes with attachment to points motor or spring return. Various types in use, shown above is a spring return type with equipment hidden under the roadway, access by manhole covers. Sensors used to ensure that the blades are in correct position to allow signals to change, highlighted. Example shown is a spring return box, powered points are also common.


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Degradation Mechanisms/Maintenance Requirements: Bolts can loosen. Bars can fatigue

3.3.6 SEI35G-TF points – replaceable check plate

Use: Prevention of derailment at embedded S&C Description: Plate fixed to inside of rail opposite crossing nose to prevent derailment. Replaceable plate fixed by bolts. Degradation Mechanisms/Maintenance Requirements: Flange way clearance is maintained within a defined range. As running rail or check rail wears adjustment is necessary Bolts and fastening can become loose.

420mm


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3.4 OTHER FEATURES

3.4.1 SEI35G-TF Grooved Rail Drain Catch Pots

Use: Provide drainage for grooved rail Description: Square steel plate with hole is either bolted or welded down to drain pot. Section missing from keeper. Lower right is from interlaced (gauntleted) track Degradation Mechanisms/Maintenance Requirements:

Gully Pot drains collapse due to poor support and road vehicles Drains can be blocked leading to standing water on road

3.4.2 BS80A rail with attached Drain gulley catch pot

Use: Provide drainage for embedded BS80A rail Description: Square steel plate with hole is either bolted or welded down to drain pot. Keeper has to be cut away to accommodate.

420mm

420mm


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Degradation Mechanisms/Maintenance Requirements: Gully Pot drains collapse due to poor support and road vehicles Drains can be blocked leading to standing water on road

3.4.3 Embedded VIS Loop

Use: Part of signalling system Description: Loop in road surface Degradation Mechanisms/Maintenance Requirements: Damage from road traffic Electrical Failure

3.4.3 Embedded Magnetic Switch

Use: Part of signalling system Description: Aluminium cover over two electronic magnetic switch Degradation Mechanisms/Maintenance Requirements: Damage from road traffic Electrical Failure Water ingress

4. RAIL AND TRACK DEGRADATION

4.1 WEAR


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4.1.1 Flat Bottom (Vignole) Rails

Description: Loss of rail head material both vertically and from gauge face. Cause: Wear - Action of wheel removing metal from rail Measurements Required Wear measurements in relation to design profile - Vertical wear, W1 - Side wear, W2 – measured at a certain depth, L, below the rail head - 45 wear, W3 All the above require knowledge of the original rail profile

4.1.2 Grooved (girder) rails

Vertical Wear

Side Wear

45 Wear


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Description: Loss of rail head material both vertically and from gauge face, additionally wear can occur of the keeper. Cause: Wear - Action of wheel removing metal from rail Measurements Required as a function of location: Wear measurements in relation to design profile - Vertical wear, W1 - Side wear, W2 – measured at a certain depth below the rail head - Keeper or Keep wear All the above require knowledge of the original rail profile

4.1.3 Crossing wear

Vertical Wear

Side Wear

Keeper Wear


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Description: Wear of crossing nose

Cause: Wear - Action of wheel removing metal from rail

Measurements required: Flange way clearance Depth of groove Damage to crossing nose, deviation from original position


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4.2 OTHER RAIL DEFECTS

4.2.1 Corrugation

Description: longitudinal variation of the rail head profile often with a fixed wavelength Cause: Periodic wear and plastic deformation of running surface Measurements Required Location Amplitude – peak to trough Wavelength

4.2.2 Plastic Deformation

Description: Widening (“mushrooming”) of profile by plastic deformation of rail head material

Wavelength

Surface Profile Amplitude


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Cause: High contact stresses/low proof strength of rail Measurements Required Location Magnitude of widening Can also occur in conjunction rail wear

4.2.3 Rolling Contact Fatigue – Head Checks

Description: Cracks on the running surface of rail Cause: High contact stresses Measurements Required Location Surface crack length Angle of crack from gauge face Position of Initiation – distance from gauge corner to furthest end of crack Crack density – number of cracks per 100mm. If cracks are severe than spallation can occur the presence of which needs reporting.

4.2.4 Rolling Contact Fatigue – Squats

Description: Cracks in running surface of rail in association with a depression that results in deviation in running band

Surfac

e

Crack Density Angle

Position of Initiation


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Cause: High contact stresses Measurements Required Location Surface crack length Deviation in running band

4.2.5 Wheel Burns

Description: Depression in rail, widening of running band, highly polished region Cause: Spinning of wheel Measurements Required Location Length Deviation in running band Severity of spalling

4.2.6 Broken Rail

Description: Gap between ends of rail or large pieces missing from rail Cause: Loss of structural strength of rail.


PMI–D-STA–009.1 Page 46 of 49 31/05/2012

Measurements Required Location Distance between rail ends Not to be confused with a rail joint

4.2.7 Failure of weld repair

Description: Cracks and spalling of gauge corner weld restoration. Cause: Defective weld procedure Measurements Required Location Severity Possibility of turning into a broken rail

4.2.8 Fastening of embedded switch blade

Description: Gap between switch blade and grooved rail Cause: Loose attachment Measurements Required Location Distance between rail ends Not to be confused with a rail joint


PMI–D-STA–009.1 Page 47 of 49 31/05/2012

4.3 EMBEDDED RAIL SUPPORT DEFECTS

4.3.1 Defective Polymer

Description: Damaged, loose or missing polymer surrounding rail Cause: Heating of rail for welding, action of road vehicles etc. Measurements Required Location Length Depth Severity e.g. missing, loose etc.

4.3.2 Missing/Cracked Road Surface

Description: Uneven road surface Cause: Loss or damage to concrete, tarmac, cobbles etc. Measurements Required Location Length Depth Severity e.g. missing, loose etc.


PMI–D-STA–009.1 Page 48 of 49 31/05/2012

4.3.3 Collapsed/Missing Drain

Description: Uneven road surface around drain or lid missing from drain Cause: Action of road traffic on drain Measurements Required Location Severity e.g. missing, loose etc.

4.4 BALLASTED RAIL SUPPORT DEFECTS

4.4.1 Broken/Missing Clips


PMI–D-STA–009.1 Page 49 of 49 31/05/2012

Description: Missing/loose rail clip or broken clips Cause: Failure of clip, loosening of clip or poor maintenance Measurements Required Location Distance to next missing/broken clip

4.4.2 Defective Baseplate

Description: Cracks in baseplate from bolt hole or deboning of polymer cushion Cause: Defective design Measurements Required Location Number of defective baseplates in vicinity

4.4.3 Degraded Ballast

Description: Left: Contaminated Ballast “wet bed”; Right: Degradation of ballast due to voiding “white stone” Cause: Incorrect maintenance of ballast, poor drainage etc.

Measurements Required Location Severity

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