ESC 230 Traverse

Engineering Standard Track
ESC 230 SLEEPERS AND TRACK SUPPORT

Version 4.7 Issued June 2012
Owner: Approved by:
Chief Engineer, Track Andrew Wilson Technical Specialist Wheel/Rail Authorised by: Malcolm Kerr Chief Engineer Track
Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp 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 users sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp 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 RailCorp.
UNCONTROLLED WHEN PRINTED
Page 1 of 31
Engineering Standard
RailCorp Engineering Standard Track Sleepers and Track Support
ESC 230
Document control
Version 1 2 3 Date October, 2006 April, 2007 October, 2007 Summary of change First issue as a RailCorp document. Includes content from C 3108, C 3109, C 5200, BI 1126, TS 3101, TS 3306, TS 3341, TS 3397, CTN 04/06, CTN 04/17. Minor corrections; inclusion of spacing requirements at bridge ends; inclusion of polymer concrete half sleepers. Inclusion of requirement to keep concrete sleepers clear of points; addition of requirement for use of HD concrete sleepers adjacent to TT bridge ends; clarification of use of recycled timber sleepers; clarification of use of low profile clips; addition to approved products; clarification of use of fastening repair process. Section 5.1.4.4 Addition of boring requirements for timber sleepers, transoms and bearers; Section 5.7.2 Correction of caption on Table 14; Section 5.9.2 and 5.9.3 Clarification of application of fastening systems to bridge transoms; Section 5.9.3 Clarification of fastening requirements for timber bearers. Appendix 1 Updating of approved products. New Section 5.1.6 limits on short sleeper ends; Section 5.9.2 Inclusion of reference to threaded inserts. Format change; Section 4.9.6 - Resilient fastenings on bridges addition of requirements for use of resilient fastenings on concrete and masonry bridges; Appendix 1 Approved sleeper and fastening products Inclusion of Clouth alternative 1 sleeper plates. Section 4.9.5 additional requirements for Direct Fixation Track; New Section 4.9.7.4 ZLR assemblies; New section 8.2 Acceptance limits for direct fixation track systems; Section 8.3 renumbered; Section 9 - Damage limits added; Appendix 1 - Addition of approved Pandrol S series plates. Appendix 1 - Minor additions to description of approved products. Section 4.9.4 Table 19 Additional detail of approved Fastclip fastenings; Section 4.9.6.3 - addresses expansion of ballast top bridges; App 1- Additional approved components and suppliers. Section 4.9.4 - Addition of recommended use of elastomeric rail pads adjacent to timber sleepers or turnouts. Section 4.9.5 - Addition of requirement for thicker HDPE pads when used with resilient baseplates and epoxy grout Changes detailed in Summary table below.
May, 2008
4.1 4.2
December, 2008 May, 2009
4.3
December, 2009
4.4 4.5
July, 2010 February, 2011
4.6
August, 2011
4.7
June, 2012
Summary of changes from previous version

Summary of change Control Changes Reformatted to new template Section Document Control All
RailCorp Issued June 2012
Page 2 of 31 Version 4.7
ESC 230
Contents
1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5 6 7 8 8.1 8.2 8.3 9 10 10.1 10.2 10.3 Purpose, Scope and Application...........................................................................................4 References...............................................................................................................................4 Australian and International Standards.....................................................................................4 RailCorp Documents .................................................................................................................4 Other References......................................................................................................................4 Design & Performance Criteria..............................................................................................5 Track Configuration...................................................................................................................5 Sleepers and Bearers ...............................................................................................................5 Fastening Assembly Design .....................................................................................................5 Allowable Configurations.......................................................................................................6 Timber Sleepers........................................................................................................................6 Concrete Sleepers ....................................................................................................................9 Direct Fixation .........................................................................................................................10 Polymer Concrete Sleepers ....................................................................................................11 Concrete Guard Rail Sleepers ................................................................................................11 Timber Turnout Bearers ..........................................................................................................11 Concrete Turnout Bearers.......................................................................................................13 Steel Turnout Bearers .............................................................................................................13 Fastening Systems..................................................................................................................13 Prohibited Configurations....................................................................................................20 Mixed Configurations ...........................................................................................................20 Changing Configurations .....................................................................................................21 Acceptance Standards .........................................................................................................21 General....................................................................................................................................21 Direct Fixation Track System (slab track) ...............................................................................21 Sleeper Plates.........................................................................................................................22 Damage Limits.......................................................................................................................22 Repair Standards ..................................................................................................................23 Timber Sleepers and Bearers .................................................................................................23 Concrete Sleepers and Bearers..............................................................................................23 Fastenings...............................................................................................................................23 Approved Sleeper and Fastening Products........................................................24 Approved Repair Processes.................................................................................30 Sleeper Boring Patterns........................................................................................31
Appendix A Appendix B Appendix C
ESC 230
Purpose, Scope and Application

This Standard establishes functional and design requirements, approved configurations, acceptance and repair standards for sleepers, turnout bearers, and sleeper fastenings. It also includes requirements for concrete guard rail sleepers and fastening requirements for transoms. It is applicable to all Rail Corporation main line and siding tracks.
2
2.1
References
Australian and International Standards
AS 1085.3 (2002) - Railway Track Material Part 3: Sleeper plates AS 1085.8 (2002) - Railway Track Material Part 8: Dogspikes AS 1085.13 (2002) - Railway Track Material Part 13: Spring fastening spikes for sleeper plates AS 1085.14 (2003) Prestressed Concrete Sleepers AS 1085.18 (2003) - Railway Track Material Part 18: Screwspikes and threaded inserts AS 1085.19 (2003) - Railway Track Material Part 19: Resilient fastening assemblies AS 3818.2 (2002) - Timber - Heavy structural products - Visually graded - Railway track timbers
2.2
RailCorp Documents
ESC 200 - Track System ESC 220 - Rail and Rail Joints ESC 362 - Track Slabs SPC 231 - Timber Sleeper and Bearer Specification SPC 232 - Concrete Sleeper Specification SPC 233 - Concrete Bearer Specification SPC 234 Resilient Fastening Specification SPC 235 - Resilient Baseplate Specification
2.3
Other References
Nil
ESC 230
3
3.1
Design & Performance Criteria

Track Configuration
The configuration of track elements, including sleepers, turnout bearers, and sleeper fastenings is specified in ESC 200 Track System.
3.2
Sleepers and Bearers

This standard has been developed in consideration of the following criteria: Loading Service loads (and dynamic response) including effects of track alignment, maintenance standards, and traffic task. Resistance to impact loading (eg. wheel flats). Rail seat loads, sleeper bending moments, rail to sleeper pressure and sleeper to ballast pressure. Materials Sleeper material, type and spacing. Sleeper acceptance, inspection and testing requirements, and assessment of effectiveness prior to insertion in track. Sleeper life and treatment (eg. timber preservatives). Deterioration of the sleeper material (eg. rust, concrete reactivity, fungal rot, white ant attack). Interfaces with other rail infrastructure Track circuit requirements. Support of point switching equipment where necessary. Support Requirements Track support conditions and deflection criteria. Required track modulus. Performance requirements Need to provide resistance to the lateral buckling of the track. Need to provide effective support, positioning and restraint of the rail (in conjunction with the rail fastening system). Geometric requirements including the length and orientation of bearers in points and crossings structures.
3.3
Fastening Assembly Design

The factors to be considered in determining rail to sleeper fastening assembly design should include the following: Loading Service loads (and dynamic response) including effects of track alignment, maintenance standards, and traffic task. Attenuation of vertical impact loads and vibration. Pressure transmitted to the sleeper rail seat, for example the need for sleeper plates on timber sleepers.
ESC 230
Need to control damage to sleepers by rail seat abrasion. Interfaces with other rail infrastructure The need to provide electrical insulation where required to enable track circuits to work or to avoid current leakage. Support Requirements Required track modulus. Performance requirements The need to provide effective support, positioning and restraint of the rail (in conjunction with the sleepers and bearers). The need to hold rails to gauge and at the correct inclination when subjected to lateral forces caused by vehicle curving, track alignment irregularities and wheelset steering and hunting. The need to provide lateral and torsional restraint (in the horizontal track plane) to the rail against buckling in hot weather. The need to provide rail longitudinal creep resistance when the rail is subjected to thermal loads and vehicle braking and traction forces.
4
4.1
4.1.1
Allowable Configurations
Timber Sleepers
Selection
Sleeper type shall be selected in accordance with the existing or proposed track structure class detailed in RailCorp standard ESC 200. For the design of new lines, the beam on elastic foundation (BOEF) analysis may be used to determine sleeper size and spacing. For existing applications in ballasted plain track, detailed in ESC 200, sleeper size shall meet the requirements of Section 4.1.2 and the standard spacing shall be 600mm. All new timber sleepers shall meet the requirements of RailCorp Specification SPC 231.
4.1.2
4.1.2.1
Size
Standard Sleeper Size
Dimensions and acceptance tolerances for timber sleepers shall be in accordance with the requirements of Table 1. Length Width Depth Dimension (mm) 2 440 230 130 Acceptance Tolerance (mm) + 50 0 + 10 0 + 10 0
Table 1 Timber Sleeper Dimensions
ESC 230
4.1.2.2
Half Sleeper Size

Dimensions and acceptance tolerances for half sleepers for use in the City Tunnels shall be in accordance with the requirements of Table 2.
Length Width Depth Distance from the centre line of the rail to the end of the timber in either direction Distance from the end of the sleeper plate to the end of the sleeper
Dimension (mm) 800 230 130 Minimum 345 Minimum 90
Acceptance Tolerance (mm) + 50 0 + 10 0 + 10 0 NA NA
Table 2 - Timber half sleeper dimensions
4.1.3
4.1.3.1
Usage
New Timber Sleepers
Sleepers shall be cut from timber species nominated in Groups 1 and 2 of Table 3. Approval is required from the Chief Engineer Track to use species from Group 3. Treated sleepers are not approved for use. Group Group 1 Common Name Ironbark Grey Ironbark Grey Ironbark Grey Ironbark Red (Broad Leaved) Ironbark Red (Narrow Leaved) Ironbark Red Gum Slaty or Box Slaty Box White Box Grey Box Grey Tallow Wood Gum Grey Gum Grey Gum Forest Red Mahogany White Gum River Red Blackbutt Botanical Name E. Siderophloia E. Paniculata E. Drepanophylla E. Fibrosa E. Crebra E. Sideroxylon E. Dawsonii E. Albens E. Microcarpa E. Moluccana E. Microcorys E. Punctata E. Propinqua E. Tereticornis E. Acmeniodies E. Camaldulensis E. Pilularis
Group 2
Group 3
Table 3 - Approved timber species
4.1.3.2
Recycled Timber Sleepers

Recycled timber sleepers (ie sleepers that have previously been used in track) may not be used on main lines with the following exception: Sleepers are fitted with resilient plates, Sleepers have been assessed as having a minimum remaining life of 5 years at the new location, The connection between the plates and the sleeper is sound with no evidence of plate movement. Recycled sleepers may be used in crossing loops and in sidings.
ESC 230
4.1.4
4.1.4.1
Spacing
Spacing in Open Track
Timber sleeper spacing shall be in accordance with Table 4. Sleeper Acceptance Tolerance Spacing (spacing or skew) (mm) (mm) (Note 1, 2) ALL Track (mainline & sidings) All classes 600(Note 3) 20(Note 4) Operating Class Tolerance Limit/ m 10/6 (50mm)
Table 4 - Timber Sleeper spacing Note: 1. Installation tolerance for new or face resleepering of track sections 2. Skew is the variation from square from one side of the sleeper to the other 3. Except at rail joints (See Sect. 4.1.4.2) 4. Up to 50mm for spacing to allow for missing an aluminothermic weld (only over two sleepers)
4.1.4.2
Spacing at Rail Joints

Spacing of sleepers at rail joints in plain ballasted track shall be adjusted in accordance with Table 5. Rail (Kg/m) 60 Insulated 53 Insulated 53 Mechanical Glued Insulated Joints (any rail size) All Others Design Spacing (mm) 430 430 510 600 510 Acceptance Tolerance (mm) 20 20 20 20 20
Table 5 - Sleeper spacing at joints
4.1.4.3
Spacing at Bridge Ends

Spacing of rail support (sleepers, abutment and transoms) at transom topped bridge ends shall be adjusted in accordance with Table 6. Design Spacing (mm) Operating Class All classes New bridge structures All classes Existing bridge structures 600 600 preferred up to 900 subject to approval of Chief Engineer Track Acceptance Tolerance (mm) 20 20
Table 6 - Sleeper spacing at bridge ends
4.1.5
Boring Requirements in Timber Sleepers, Transoms and Bearers

Sleepers, transoms and bearers shall be bored to match the track plates used in the approved configuration. The patterns for DF 30 sleeper plates using dogspikes, lockspikes, dogscrews and lockscrews are detailed in Appendix C.
ESC 230
Hole sizes shall be as detailed in Table 7. Holes shall be bored completely through the timber. Fastening type Dogspikes Lockspikes Dogscrews Lockscrews Screwspikes Hole diameter (mm) 21 0.5 16 0.5 17 0.5 14 0.5 25 0.5 18 0.5 18 0.5
27 mm dia 24 mm dia 22 mm dia
Table 7 - Fastening hole diameters
4.1.6
Proximity of Plates to Sleeper and Bearer Ends in Turnouts

The outer end of sleeper plates shall, normally, be located no closer than 200mm to the end of timber sleepers or bearers. Civil Maintenance Engineers may approve a reduction to no less than 50mm in constrained situations at turnouts and special trackwork
4.2
4.2.1
Concrete Sleepers
Selection
There are two types of concrete sleepers 1. Heavy Duty - suitable for heavy freight tonnages and axle loads 30tonne or for providing greater lateral stability 2. Medium Duty -suitable for general use with axle loads 25 tonne. Only approved designs shall be used. Approved designs are detailed in Appendix A. For existing applications, detailed in ESC 200, all new concrete sleepers shall meet the requirements of RailCorp Specification SPC 232.
4.2.2
Size
The sleepers shall be designed to conform to the dimensions detailed in Table 8. Parameter Length Width (at base) depth ( centre of rail seat) Rail seat area (flat surface) Heavy Duty 2390 - 2500mm 220 - 255 mm 230mm maximum 28800mm2 Medium Duty 180mm maximum 25620mm2
Table 8 - Concrete sleeper dimensions
4.2.3
Use
Sleeper type shall be selected in accordance with the existing or proposed track structure class detailed in RailCorp standard ESC 200. On Mixed Passenger Freight Main Lines, the selection of heavy duty or medium duty concrete sleeper is governed by the following requirement:
ESC 230
On sharp curves <400m radius where Pandrol e2003 clips are installed, heavy duty insulators shall be used for new installations and for replacement of insulators. Heavy duty insulators are not required with 'Fastclip' installations. Where concrete sleepers are used as replacement sleepers within existing sections of concrete sleepers they shall reasonably match adjacent sleepers in dimensions and capacity. Concrete sleepers may only be interspersed with timber sleepers where they are in accordance with a specific strategy approved by the Chief Engineer Track. Where concrete sleepers are installed adjacent to turnouts with timber bearers, a transition zone of eight (8) timber bearers or sleepers is required between the concrete sleepers and the toe of the points. To improve the stability of track approaching transom top bridges, where concrete sleepers are installed adjacent to transom top bridges, twenty (20) Heavy Duty concrete sleepers shall be installed.
4.2.4
4.2.4.1
Spacing
Spacing in Open Track
Concrete sleepers shall be spaced in accordance with the requirements of Table 9. Operating Class Sleeper Spacing (mm) Tolerance (spacing or skew) (mm) (Note 1) 20(Note 2) 20 20 20 Tolerance Limit/ m 10/6 (50mm) 11/7.920 (60mm) 16/11 (80mm) 10/6 (50mm)
Design Spacing ALL Track 600 (mainline & sidings) Maximum spacing (Sidings ONLY) <25T Axle load 720 25T 650 30T 600
Table 9 - Concrete sleeper spacing Note: 1. Installation tolerance for new or face resleepering of track sections 2. Up to 50mm for spacing to allow for missing a thermit weld (only over two sleepers)
4.2.4.2
Spacing at Bonded Insulated Joints in Open Track

Spacing of concrete sleepers at glued insulated joints shall be 600mm ( 20mm).
4.3
Direct Fixation
Sleeper spacing >600mm may be designed for direct fixation track structures to a maximum of 700mm where axle loads are 25t (See Table 10). Operating Class Design Spacing ALL Track (mainline & sidings) Sleeper Spacing (mm) 700 Tolerance (spacing or skew) (mm) 10 Tolerance Limit/ m 10/7 (30mm)
Table 10 Sleeper spacing for direct fixation track

RailCorp Issued June 2012 Page 10 of 31 Version 4.7
ESC 230
Other requirements to be determined
4.4
4.4.1
Polymer Concrete Sleepers

Selection
Polymer concrete half sleepers are approved for use in areas where half timber sleepers have previously been installed. Current installations include City Underground, Church Street Underbridge (Parramatta), Pedestrian Subway Artarmon, Circular Quay Viaduct and ESR. Further installations shall be designed and approved on a case by case basis. Only approved designs shall be used. Approved designs are detailed in Appendix A.
4.5
4.5.1
Concrete Guard Rail Sleepers

Selection
Concrete Guard Rail Sleepers are concrete sleepers that have been designed to allow attachment of guard rails inside the running rails in accordance with site specific designs. Only approved designs shall be used. Approved designs are detailed in Appendix A. Selection, use and spacing shall be in accordance with Section 4.1.6.
4.6
4.6.1
Timber Turnout Bearers

Selection
Timber bearers for points and crossing structures may be designed using the beam on elastic foundation analysis (BOEF) similar to that used for sleepers, however some additional considerations may be necessary as follows: Allowance for additional length of timber bearers over standard sleepers. Allowance for centrifugal forces through curved pairs of rail. Allowance for forces and moment induced from points motors and other such equipment. For existing applications, detailed in ESC 200, all new timber turnout bearers shall meet the requirements of RailCorp Specification SPC 231.
4.6.2
Timber Bearer Size

Dimensions of timber turnout bearers shall be selected as follows: 250mm 180mm for general application 200mm for bearers on which points motors will be attached. Boxed heart timber bearers are only approved for use in depths of 180mm and 200mm. Length The minimum length of timber bearers shall be calculated as the measurement from the Outside gauge face to outside gauge face at the point at which the bearer is to be installed + 1.2m. The length shall be rounded up to match the next available size for the selected bearer depth in Table 11. Minimum dimensions for turnout switch and crossing timbers shall be in accordance with the requirements specified in Table 11. Width Depth
ESC 230
Width (mm) 250
Depth (mm) 180 200
Standard Timber Lengths Turnouts and Crossovers (m) 2.8, 3.0, 3.2, 3.4, 3.6, 3.8, 4.0, 4.2, 4.4, 4.6, 4.8, 5.0, 5.2, 5.4, 5.8, 6.0, 6.2, 6.4 2.8, 3.0, 3.2, 3.4, 3.6, 3.8, 4.0, 4.2, 4.8, 5.0, 5.2, Table 11 - Timber turnout bearer dimensions
The dimensional tolerances shall be in accordance with Table 12. Length Width Depth + 50 mm / - 0 mm + 15 mm - 0 mm + 10 mm / - 0 mm
Table 12 - Tolerances on timber bearer dimensions
4.6.3
4.6.3.1
Usage
New Timber Bearers
Bearers shall be cut from timber species nominated in Groups 1 and 2 of Table 13. Treated timber is not approved for use.
Group
Group 1
Common Name
Ironbark Grey Ironbark Grey Ironbark Grey Ironbark Red (Broad Leaved) Ironbark Red (Narrow Leaved) Ironbark Red Box Grey Box Grey Tallow Wood Gum Grey Gum Grey Mahogany White
Botanical Name
E. Siderophloia E. Paniculata E. Drepanophylla E. Fibrosa E. Crebra E. Sideroxylon E. Microcarpa E. Moluccana E. Microcorys E. Punctata E. Propinqua E. Acmeniodies
Group 2
Table 13 - Approved timber species
4.6.3.2
Recycled Timber Bearers

Recycled timber bearers (ie bearers that have previously been used in track) may not be used on main lines. Recycled bearers may be used in crossing loops and in sidings.
4.6.4
Spacing
Nominal design spacing of timber turnout bearers shall be 600mm. Variation of spacing to suit turnout requirements is permitted up to a maximum of 700mm (except at mechanical joints or mechanical insulated joints where the maximum is 600mm). Spacing shall not be less than 500mm.
ESC 230
4.7
4.7.1
Concrete Turnout Bearers

Selection
Only approved designs shall be used. Approved designs are detailed in Appendix A. For existing applications, detailed in ESC 200, all new concrete turnout bearers shall be designed and manufactured in accordance with the requirements of SPC 233.
4.7.2
Concrete Bearer Size

Limiting dimensions of concrete turnout bearers shall be selected as follows: Width Depth Length 240 300mm 220 300mm Varies 2.5m to 7.5m
The dimensional tolerances for approved designs shall be in accordance with Table 12. Length Width Depth + 10 mm / - 5 mm 3 mm 3 mm
Table 14 - Tolerances on concrete bearer dimensions
4.7.3
Spacing
Nominal design spacing of concrete turnout bearers shall be 600mm. Variation of spacing to suit turnout requirements is permitted up to a maximum of 700mm (except at mechanical joints or mechanical insulated joints where the maximum is 600mm). Spacing shall not be less than 500mm.
4.8
Steel Turnout Bearers

Steel turnout bearers are not approved for use in RailCorp.
4.9
Fastening Systems
Resilient or non-resilient fastening systems shall be selected in accordance with the existing or proposed track structure class detailed in RailCorp standard ESC 200.
4.9.1
Non-Resilient Fastening assemblies

The assembly generally consists of: 1. Sleeper plates - These shall be double shouldered and shall provide a nominal rail cant of 1 in 20 towards the centre of the track (except in special circumstances such as turnouts), and 2. Dogspikes - 2 (two) 22 mm round shank dogspikes (or approved equivalent) per sleeper plate, and 3. Spring fastening spikes - 2 (two) 16mm lockspikes (or approved equivalent) per sleeper plate. Non-resilient fastening assembly components shall be designed and manufactured to conform to the appropriate Australian Standard as detailed in Table 15.
ESC 230
Component Fastenings dogspikes (and equivalent fastenings) lockspikes (and equivalent fastenings) screw spikes Sleeper plates
Standard AS 1085.8 AS 1085.13 AS 1085.18 AS 1085.3
Table 15 - Australian standards for non resilient fastening assemblies Only approved fastenings and configurations shall be used. Approved non-resilient fastenings are detailed in Appendix A. Approved configurations are detailed in Table 17.
4.9.2
Resilient Fastening Assemblies

For timber sleepers, transoms and turnout bearers, the assembly generally consists of: 1. Sleeper plates - These shall be double shouldered and shall provide a nominal rail cant of 1 in 20 towards the centre of the track (except in special circumstances such as turnouts), and 2. Resilient rail clips - 2 (two) Pandrol clips (or approved equivalent) per sleeper plate, and 3. Spring fastening spikes - 4 (four) 16mm lockspikes (or approved equivalent) per sleeper plate. For concrete sleepers, the assembly generally consists of: 1. Cast in shoulders - These are integral to the design of the sleeper 2. Resilient rail clips - 2 (two) Pandrol clips (or approved equivalent) per sleeper plate, and 3. Insulators, and 4. rail seat pads. For concrete turnout bearers, the assembly generally consists of: 1. Base plates, and 2. Screwspikes - 4 (four) 24mm screwspikes (or approved equivalent) per plate, and 3. Resilient rail clips - 2 (two) Pandrol clips (or approved equivalent) per rail. For existing applications, detailed in ESC 200, all new resilient fastenings shall be designed and manufactured in accordance with the requirements of SPC 234. Resilient fastening assembly components shall be designed and manufactured to conform to the appropriate Australian Standard as detailed in Table 16.
ESC 230
Component Fastenings clips lockspikes screw spikes Sleeper plates Threaded Inserts Cast-in components
Standard AS 1085.19 AS 1085.13 AS 1085.18 AS 1085.3 round hole for transoms with larger screwspikes AS 1085.18 AS 1085.19
Table 16 - Australian standards for resilient fastening assemblies Only approved fastenings and configurations shall be used. Approved resilient fastenings are detailed in Appendix A. Approved fastening configurations for timber sleepers, transoms and turnout bearers are detailed in Section 4.9.3. Approved configurations for concrete sleepers are detailed in Section 4.9.4. Approved configurations for direct fixation are detailed in Section 4.9.5
4.9.3
Fastenings for Timber Sleepers, Transoms and Bearers

Standard configurations of fastening assemblies for timber sleepers, bridge transoms and turnout bearers are detailed in Table 17. Special arrangements apply for the fastening of chairs to A and B timber bearers in turnouts. These are detailed in Table 18.
ESC 230
Operating Class
Fastening Type No. per Plate/ Rail
Sleeper Plates Dwg. No.
Lockspikes (Note 2) No per Plate
Non Resilient (for existing installations ONLY) Main Lines (includes sleepers, transomsNote 5 and bearers) Passenger Main Line (Note 1) Mixed Passenger Freight Main Line 2 Dogspikes Light Line Sidings (includes sleepers, transoms and bearers) General Yard Passenger operations/ or 2 Dogspikes (Note 1) maintenance Passenger Siding Engineering Maintenance Siding 2 Dogspikes (Note 1) Resilient Main Lines ALL classes 2 Resilient E2003 ALL classes For existing installations ONLY CANNOT be reinstalled when sleeper is replaced Turnouts in ALL classes Transoms in ALL classes PREFERRED Insulated Joints in ALL classes Sidings ALL classes ALL classes
DF 30
DF 30 NIL
2 NIL
DF 62 & cast plates Reformed plates Appropriate baseplates DF 62 & cast plates Type ISP96486 S plates DF 62 DF 62
4 2 lockspikes + 2 Gauge lockspikes (or approved alternatives) (Note 3) 4 4 (.note 4) 4 X 24mm screw spikes (Note 4) 4 4 2 lockspikes + 2 Gauge lockspikes (or approved alternatives) (Note 3) 4
2 Resilient E1853 2 Resilient 2 Resilient E2003 2 Resilient Low profile clips e1627 (timber) 2 Resilient E2003
For existing installations ONLY CANNOT be reinstalled when sleeper is replaced
2 Resilient E1853
Reformed plates
Turnouts in ALL classes
2 Resilient
Table 17 - Timber sleeper fastening configuration Note: 1. Round shank dogspikes or approved alternative fastenings may be used. Approved alternatives are detailed in Section 4.9.6.2 and Appendix A 2. Lockspikes (L6) or approved alternative fastenings may be used. . alternatives are detailed in Section 4.9.6.2 and Appendix A Approved
3. Gauge lockspikes are approved for existing installations only and shall not be used in new installations. They CANNOT be re-installed when a sleeper is replaced. 4. In electrified or track circuited areas, where one of the spikes would cause shorting to the underframe of a steel underbridge, 3 (three) spikes per plate may be used on curves 300m radius, preferably with the two spikes on the gauge side of the rail. 5. Non resilient fastenings on transoms should be upgraded to resilient fastenings when transoms are renewed
ESC 230
A & B Timber Bearer Fastening Type New Installations 60kg/m steelwork Screwspikes 53kg/m steelwork Holding down bolts or approved equivalent swage fastenings For Repair/ Replacement 60kg/m steelwork If the screwpikes are no longer able to provide adequate grip or if timber quality is suspect use holding down bolts or approved equivalent swage fastenings 53kg/m steelwork Holding down bolts or approved equivalent swage fastenings Table 18 - A & B Timber Bearer fastening configuration
4.9.4
Fastenings for Concrete Sleepers and Bearers

Elastic fastening systems shall be used with concrete sleepers and bearers. Conforming fastening systems shall use Pandrol E-2003 clips, Fastclip or other approved alternatives. Rail pads of nominal 7.5mm thickness for E-clip fastenings and 10mm thickness for Fastclip fastenings shall be used. Fabreeka (or equivalent) 10mm elastomeric rail pads should be installed on the last 20 concrete sleepers to moderate the stiffness to an adjoining section of timber sleepers or timber turnout. Resilient fastenings are interchangeable for 53 and 60kg rail sections. Standard configurations of fastening assemblies for concrete sleepers and turnout bearers are detailed in Table 19. Sleeper Design Type 4 Type 5 Heavy Duty Medium Duty (Low Profile) Type 6M Heavy Duty Insulated Joints on all concrete sleepers/bearers with cast in shoulders and insulating material Insulated Joints on all concrete bearers with baseplates Fastening Type No. per Plate/ Rail 2 Resilient E2003 2 Resilient E2003 or 2 Fastclip FC1507 2 Resilient E2003 or 2 Fastclip FC1507 2 Resilient E2003 Low profile clips e1629 or Fastclip FC1507 Low profile clips e1627
Table 19 - Concrete sleeper fastening configuration
4.9.5
Fastenings for Slab Track

For Direct Fixation track systems (slab track) or wherever standard sleepers/ bearers are not used, the following requirements apply: Conforming fastening systems shall use Pandrol E-2003 clips, Fastclip or other approved alternatives. Resilience of the track system shall be considered. The default minimum resilient system shall be Type 1 as specified in SPC 235 (e.g. Delkor Alternative 1 or equivalent). Approved configurations of fastening assemblies for slab track are detailed in Table 20.
ESC 230
Slab Design ESR & City Railway
Fastening Type No. per Plate/ Rail 2 Resilient PR409
Base Plates Dwg. No. DF 62
Comments 2 Screwspikes minimum in curves 300m radius 4 Screwspikes in curves <300m radius
Table 20 - Slab track fastening configuration Where baseplates are used the minimum requirement is: curves < 300m radius curves 300m radius four screwspikes (two on each side) two screwspikes (one on each side)
On slab track where screwspikes are used they shall be fitted with helical spring washers. Where epoxy grout is used under resilient baseplates the minimum thickness of HDPE pads shall be at least 8mm to reduce the potential for warping of the pads (from thermal warping).
4.9.6
4.9.6.1
Resilient Fastenings on Bridges

Steel Openings
Transom top steel openings with spans < 18m On bridges where resilient fastenings are installed, normal elastic fastenings shall be installed on the entire length of each span. Transom top steel openings with spans 18m long but < 80m. On bridges where elastic fastenings are installed, normal elastic fastenings shall be installed on one third of the span from the fixed end and Zero Load Restraint (ZLR) fastenings installed on the remaining two thirds of the span. Where spans are located on curves <400m radius, advice on fastenings requirements shall be obtained from the Chief Engineer Track. Provision shall be made for play at the movable end of a bridge for the guard rail "V" to expand and contract (depending on length). This can be achieved when using MDFC concrete termination sleepers by setting the lock-in shoulders 6mm clear of the nose end rail. ZLR fastenings are used to secure the guardrail nose ends, allowing limited movement. Steel bridge spans >80m with expansion switches On bridges where elastic fastenings are installed, normal elastic fastenings are to be installed on the entire length of each span.
4.9.6.2
Concrete and Masonry Openings

For concrete and other track structures an assessment shall be made of the expansion requirements of the bridge structure as they affect rails. Concrete structures with spans < 25m On structures where resilient fastenings are installed, normal elastic fastenings shall be installed on the entire length of each span. Concrete structures with spans 25m
ESC 230
An assessment shall be made of the expansion needs and appropriate ZLR fastenings installed. Proposals shall be submitted to the Chief Engineer Track for approval. Note: whilst the expansion of concrete is similar to that of steel there is a difference in the temperature variation expected in concrete. For steel the minimum span to be considered is 18m.
4.9.6.3
Ballast Top Openings

Requirements for expansion of the rails and the ballast must be considered if the span is more than 40m in length otherwise standard fastening systems can be applied.
4.9.7
4.9.7.1
Alternative and Special Configurations

Pandrol Clips at Insulated Joints
Special low profile Pandrol clips shall be used at insulated joints in 53 & 60Kg rails to eliminate contact between clips and fishbolts. The clips are: For concrete sleepers and bearers - e1629 For timber sleepers and bearers - e1627 Clearances are compromised with the low profile clips in timber bearers with type PZ 147 and type 1 baseplates. Any clips that may become foul may be removed as long as sufficient fastenings remain in place to retain gauge security.
4.9.7.2
Approved Alternatives to Dogspikes and Lockspikes

The Pandrol (AJAX) Dogscrew and Lockscrew are approved alternatives to dogspikes and lockspikes respectively. They may be installed with the approval of the Civil Maintenance Engineer. The Dogscrew consists of a 19mm threaded shank with a 22mm shoulder below the flange. On top of the flange is a 6-lob head designed to fit an E24 drive socket. The Lockscrew consists of a 16mm threaded shank with a flange and 6 lob head, the same as the Dogscrew. There are two types of Lockscrew: Small flange for general use Large flange for use with the automatic magnet pickup machine used by production gangs. This type cannot be used on rolled Pandrol plates because of the flange interferes with the rolled shoulder and does not sit flush on the plate.
4.9.7.3
Resilient Baseplate Assemblies

Resilient baseplate assemblies may be used as an alternative to standard base plates on timber sleepers, transoms and bearers, concrete sleepers and bearers and for direct fixation track applications in the following applications: bridges where noise and / or vibration reduction is required, ballasted track where noise and / or vibration reduction is required, direct fixation track where noise and / or vibration reduction is required, and at interfaces between ballast and non-ballasted track where graded changes in track stiffness are required
ESC 230
Only approved designs shall be used. Approved designs are detailed in Appendix A. All new Resilient Baseplate assemblies shall be designed and manufactured in accordance with the requirements of RailCorp specification SPC 235.
4.9.7.4
Zero Load Restraint (ZLR) Assemblies

Zero Load Restraint assemblies allow longitudinal rail movement whilst retaining gauge and limiting upward movement of the rail. They shall be used in accordance with Section 4.9.6. Approved designs are listed in Table 21 and detailed in Appendix A. When used in conjunction with resilient baseplate assemblies, special configurations are required to fit the dimensional restrictions of the baseplate.
Configuration type Standard baseplates (with lockspikes or screwspikes) Alternative 1 resilient baseplates "Delkor Egg" resilient baseplates
Assembly Pandrol PMP 41027 for AS60kg rail Pandrol 12730 for AS60kg rail
Components ZLR Cap 41027 Clip e2079 ZLR Cap 12731 Clip e2079 Insulator IN55088 5 mm Rail Pad RP-65026
Table 21 - Zero Load Restraint assemblies
Prohibited Configurations
The following configurations are not permitted for permanent works on RailCorp trackwork: Steel sleepers Non-elastic fastening systems with 60kg/m rail Non-elastic fastening systems with concrete sleepers Elastic and non-elastic fastenings on the same sleeper Elastic fastenings on more than 1 in 3 sleepers in JWR track
Mixed Configurations
There are some limitations and special requirements when configurations are mixed. They are applicable to existing track ONLY. Concrete sleepers may be interspersed with timber sleepers in accordance with the following guidelines. Interspersing: shall be part of a line strategy, not random, may only be used with Medium Duty sleepers, and on line sections where medium duty sleepers may be used, shall lead eventually to 100% concrete, shall achieve the minimum ballast cleanliness standard, may be installed to a standard pattern of 1:2, 1:3 or 1:4 but with variation of one sleeper position permitted to suit local conditions, whole curves shall be resleepered and reasonable lengths of tangent track should be done to a consistent pattern, is not suitable for jointed track beyond the limits detailed in ESC 220 for standard welded track, may be used in patterns of 1:3 and 1:4 in poor ballast conditions, but more than this may only be used in ballast of good quality.
ESC 230
Timber sleepers with elastic fastenings may only be interspersed with timber sleepers with non elastic fastenings in CWR track where they are in accordance with a specific strategy and provided a consistent tie pattern is maintained (eg 1 in 2, 1 in 3 etc). Timber sleepers with elastic fastenings shall NOT be interspersed with timber sleepers with non elastic fastenings in LWR where this would result in them being more frequent than 1 in 3. A consistent tie pattern shall to be maintained. Where backcanting is evident in timber sleepers with non-elastic fastenings, replacement with elastic fastenings shall meet the minimum tie patterns detailed in Table 22 to avoid clip breakage: Tie Pattern 1 in 3 1 in 2 3 6 Limit of backcanting (mm) DS Plates Resilient Plates 5 10
Table 22 - Minimum Elastic fastening patterns in backcanted track When configuration changes are being undertaken by partial resleepering methods they shall be followed through in successive cycles until the changeout is complete. Mixed configurations are not permitted as a final product.
Changing Configurations
The following configurations are not desirable. Renewal strategies should be directed to their elimination: Timber sleepers on curves < 400m radius on mainline track Non-elastic fastenings in timber sleepers on mainline track Elastic fastened track on transom topped steel bridges with spans >18m that does not meet the requirements of Section 4.9.6.1 relating to the installation of Zero Load Restraint fastenings.
8
8.1
Acceptance Standards
General
Acceptance standards for condition and installation of sleepers, bearers and fastenings shall be as detailed in Sections 4, 5 and 6.
8.2
Direct Fixation Track System (slab track)

Track slabs shall be designed and constructed in accordance with the requirements of RailCorp Engineering standard ESC 362 "Track Slabs". In addition at the slab fastening system interface the following acceptance limits apply:
ESC 230
Item Finished surface of the slab Inward cant of rail Note need for cant transition over 2400mm Differential tilt of the rail seat in the direction of the rail Concavity or convexity of the rail seat in any direction
Limit Design level No voids Plain track Turnouts Turnout transition to plain track 0 0 1:20 0 0 to 1:20
Tolerance + 0mm - 5mm NA 1 in 400
1 in 100 0.5mm
Table 23 - Slab track acceptance limits
8.3
Sleeper Plates
Acceptance Standards for re-use of sleeper plates shall be as follows DO NOT use reformed pandrol plates, old pattern plates or single shoulder plates DO NOT use any sleeper plates with evidence of excessive corrosion, notch marks or oxyacetylene burn marks on the rail seat, shoulder or at spike holes. DO NOT use any sleeper plates with shoulders that are worn to a sharp edge. DO NOT use any sleeper plates with cracks DO NOT use any sleeper plates with plate underside concavity or convexity greater than 1mm. DO NOT use any sleeper plates with lockspike holes wider than 19mm at bottom surface. DO NOT use any sleeper plates with dogspike holes wider than 25.5mm at bottom surface. DO NOT use any sleeper plates with rail seat width greater than 150 (+1) mm.
Damage Limits
Normal (Note 1) Track Speed (Normal /XPT) km/hr 20/20 40/40 60/60 80/90 100/115 115/160 Nil Nil 900 700 2 1 5 years 0 0 5 2
Consecutive Missing Sleepers Not at joint Nil Nil Nil Nil Nil At a Joint Nil Nil Nil Nil Nil Spacing (mm) Not at joint 900 900 900 900 900 At a Joint 700 700 700 700 700 Clusters of Consecutive Ineffective Sleepers (only at isolated location) Tangents & Curves 2 2 2 2 2 R>1000m Curves R<1000m 1 1 1 1 1 General Condition Description Timber Sleepers Well tied 5 years 5 years 5 years 5 years 5 years Ineffective Timber Sleepers at Joints Tangents & Curves 0 0 0 0 0 R>1000m Curves R<1000m 0 0 0 0 0 Rail Movement relative to sleeper, including effect of rail roll (mm) Horizontal 8 8 8 5 5 Vertical 2 2 2 2 2 Note 1: The limit at or below which no response is required.
ESC 230
Table 24 - Normal limits for sleeper condition Maximum Limits(Note 2) Track Speed (Normal /XPT) km/hr 20/20 40/40 60/60 80/90 100/115 115/160 1 Nil 1200 900 4 3 28 days
Consecutive Missing Sleepers Not at joint 2 2 1 1 1 At a Joint 1 1 Nil Nil Nil Spacing (mm) Not at joint 1500 1500 1200 1200 1200 At a Joint 1200 1200 900 900 900 Clusters of Consecutive Ineffective Sleepers Tangents & Curves 5 5 4 4 4 R>1000m Curves R<1000m 4 4 3 3 3 General Condition Description Timber Sleepers Not Not Well tied securely securely 28 days 28 days 28 days tied tied Ineffective Timber Sleepers at Joints Tangents & Curves 1 1 1 1 1 R>1000m Curves R<1000m 1 1 1 1 1 Rail Movement relative to sleeper, including effect of rail roll (mm) Horizontal 12 12 12 12 12 Vertical 6 6 6 6 6 Note 2: The limit beyond which an emergency level response is required. Table 25 - Maximum limits for sleeper condition
1 1 12 6
10
10.1
Repair Standards
Timber Sleepers and Bearers
Timber sleepers and bearers may be crossbored (once only on each side of each rail) if they are otherwise sound.
10.2
Concrete Sleepers and Bearers

Cast in-situ shoulders may be replaced using an approved process. Approved processes are detailed in Appendix B.
10.3
Fastenings
Sleeper fastening components may be repaired using an approved process. Approved processes are detailed in Appendix B. Note: The Fastclip repair process is NOT approved for repair of consecutive sleepers.
ESC 230
Appendix A
Approved Sleeper and Fastening Products

Description Standard/ Drawing Manufacturer/ Supplier
Common Item Name Non Resilient Fastenings Dogspike Dogspike Dogspike Gauge Lockspike Lockspike Dogscrew Lockscrew Screw spike Screw spike
Spike, track; round shank; 22mm shank dia; 119mm long; forged; steel (dogspike) Spike, track; round shank; 22mm shank dia; 119mm long; forged; steel (dogspike) Spike, track; round shank; 22mm shank dia; 119mm long; forged; steel (dogspike) Spike, track, square shank lock type LG19, XS1070 Spike, track, square shank lock type L1, , XS1070 DogScrew 22mm Shouldered; 9mm Thick Flange; Galvanised LockScrew 16mm; Galvanised Spike, track Screw spike; 27mm dia 165mm long. For timber, galvanized
AS 1085.8 SRA Dwg CV0046205 AS 1085.8 Imported by SRA Dwg CV0046205 Westray Eng. AS 1085.8 Manufactured by SRA Dwg CV0046205 Greg Sewell Forgings AS 1085.13 Pandrol AS 1085.13 Pandrol
Spike, track Screw spike; 24mm dia; 122mm long; galv; For half polymer/concrete sleepers and 90mm nylon insert; galvanized Screw spike Spike, track Screw spike; 24mm dia; SRA W&W 205a-381b Delkor 165mm long; galv; For concrete or Delkor Dwg HSRsleepers; Galvanized 602d Screw spike Spike, track Screw spike; 24mm dia PRE Manufacturer Jinstar Fastener Co Ltd (Tekway) Washer, lock 25mm ID; 46mm OD; 6mm thick; high Delkor Dwg DSW - 01 Delkor tension double helical spring type;fe6; Galvanized to AS 1214 Screw spike Spike, track Screw spike; 22mm dia; RSA Consult. 150mm long; galv; For timber Dwg 885-066b sleepers; city underground; Galvanized to AS 1214 Resilient Fastenings Pandrol Clip E series Pandrol Clip E series Rail clip Type e2003; 20 mm dia; 106 mm l; 103 mm w; material XK 9261b; AS 1444; Rail clip e1600 series; timber sleeper insulated Joints; painted red; 16 mm dia; 100 mm l; 85 mm w; type e1627 Pandrol e-21027 AS 1085.19 Pandrol Dwg e1620002 Pandrol Pandrol
Ajax Fasteners Dwg Ajax / Pandrol No SRSG19.135 19/10/04 Ajax Fasteners Dwg Ajax / Pandrol No TLSB16.125 10/11/03 SRA Dwg 205A-374 (CV 0024139) AS 1085.18 SRA Dwg 885-067b or Delkor Delkor Dwg HSR-602e
ESC 230
Common Item Name Pandrol Clip E series Pandrol Clip E series
Description Rail clip e1600 series; concrete insulated Joints; painted blue; 16 mm dia; 100 mm l; 85 mm w; type e1629 Rail clip e1829 series;18mm dia;98mm lg;90mm w; 52.5mm 47mm heel;54mm toe; steel; black; (non insulated joints on timber sleepers); Rail clip e2079 series; 20mm dia; 106mm l; 102.5 mm w; material XK 9261b; AS 1444 Zero Longitudinal Restraint Plate 41027 to suit 60kg rolled steel sleeper plate and e2079clip. Plate, ZLR Cap 12731 to suit 60kg Delkor Cologne Egg Pandrol fastclip; type FC1507; silicomanganese spring steel XK9261b with plastic toe insulator Pandrol fastclip; type FC1509; silicomanganese spring steel XK9261b with toe insulator 10293 (white) and Sidepost Insulator 10292 (white) For concrete guard rail sleepers; eclip fastening (multilok system); to suit 47-60kg rail Track; tunnel clips; scheridised; A Clip for guardrails, SG Iron Serrated Type A Clip
Standard/ Drawing Pandrol Dwg e1620021 Pandrol e18-20002
Manufacturer/ Supplier Pandrol Pandrol
Pandrol Clip E series Pandrol Zero Longitudinal Restraint (ZLR) Plate Pandrol Zero Longitudinal Restraint (ZLR) Cap Fastclip type FC1507 Fastclip type FC1509 Sliding shoulder head Rail clip, railway Rail Clip, Railway Rail Clip, Railway
Pandrol e-21108 PMP-41027
Pandrol Pandrol
Pandrol 12730
Pandrol
Pandrol FC 1507 and Pandrol 8494 Dwg No 10291
Pandrol Pandrol
Amatek Rocla Dwg SSP 1456 Delkor S.85.745 Delkor RAC 02 and RAC-04, Rev A Pandrol In-55061
Pandrol Pandrol Delkor Delkor
Pads and Insulators Rail Insulator Insulator, rail 2 piece: composite insulator in-55058 with a slope of 1 in 45; including cover Plate in55057;125mm long x 54mm w; 53/60kg rail; Insulator, rail, Glass reinforced nylon insulator ;for concrete sleeper use with concrete sleeper having pandrol e-clip fastenings;to suit 53/60kg rails Rail Insulator Insulator, rail, concrete sleeper Dual function spacer/insulator for use with 47kg rail in 60kg rail seat;glass reinforced nylon; Rail Insulator G.R.H. Insulator to suit insulated joint Assemblies; 108mm long x 40mm w x 20mm h; 53/60kg rail; Rail Insulator side Pandrol side post insulator type 7551; post for use with concrete sleeper having Fastclip Pandrol Fastclip fastenings Rail Insulator toe Pandrol toe insulator type 8494;for Fastclip use with concrete sleeper having Pandrol Fastclip fastenings
Pandrol In-55088
Pandrol
Pandrol In-55186 Pandrol 7551 Pandrol 8494
Pandrol Pandrol Pandrol
ESC 230
Common Item Name Rail Insulator
Description
Standard/ Drawing Pandrol In-55185
Heavy duty insulator assembly type hda2; 8mm pad x 110mmw; Rail pad Rail pad, railway Fabreeka/rubber;190mm lg x 170mm w x 7mm thk Rail pad for use in Rail pad, railway NSR Studded;rubber;178mm lg x 160mm w x 9.75mm thk;164mm rail base/50kg rail; for concrete sleeper; (transfield product-NSR rail); Rail pad Grooved;HDPE plastic;180mm w x 186mm lg x 7.5mm thk; black; for 53/60kg rail/ concrete sleeper; Rail pad 163mm wide x 180mm long x 7.5mm thick; HDPE.; Used with 53kg and 60kg rails Rail pad 190mm wide x 190mm long x 5mm thick; H.D.P.E.; Used with 53kg and 60kg rails Rail pad Pandrol HDPE rail pad; type 8853; for use with concrete sleeper having pandrol e-clip fastenings Rail pad Pandrol HDPE rail pad;type 9154;for Fastclip use with concrete sleeper having pandrol fastclip fastenings Sleeper plates Sleeper Plate Screw spike; clip type; 148mm Rail Screwspike base; 1 in 20 cant; cat no 054 Sleeper Plate Screw spike; clip type; 146mm rail Screwspike base; 1 in 20 cant; cat no 086s; Sleeper Plate Clip type; 4hole; 146mm rail base; 1 Clip type in 20 cant; cat no 486; Sleeper Plate Double shoulder type; 127 mm rail dogspike base; 1 in 20 cant; Cat no 430; Sleeper Plate Screwspike clip type; 148mm rail Clip type base; 1 in 20 cant; cat no 098s; bridge type; Sleeper Plate Screwspike clip type; 148mm rail Clip type base; Zero cant Sleeper Plate Screwspike clip type; 148mm rail Clip type base; 1 in 20 cant Sleeper Plate Screwspike clip type; 148mm rail Clip type base; 1 : 30 cant Sleeper Plate Screwspike clip type; 148mm rail Clip type base; 1 : 40 cant Sleeper Plate Screwspike clip type; 148mm rail Clip type base; 1 in 80 cant Sleeper Plate Double shoulder type; 146mm rail dogspike base; 1 in 20 cant; cat no 420; Sleeper Plate Clip type; 6hole; 127mm rail base; 1 Clip type in 20 cant; Sleeper Plate Clouth alternative 1; 60kg rail; cast Clouth alternative Iron-rubber; sound damping, double 1 Shouldered 1:20 cant, end holes at 130mm centres
Manufacturer/ Supplier Pandrol
Pandrol RP-65184C Pandrol RP-65026 Pandrol 8853 Pandrol 9154
Pandrol Pandrol Pandrol Pandrol
Pandrol ISP95054 AS 1085.3 Pandrol isp95086 Pandrol ISP95486 BHP 2705 127dstb-df10 Pandrol ISP95098 Pandrol ISP96485 S Pandrol ISP96486 S Pandrol ISP96487 S Pandrol ISP96488 S Pandrol ISP96489 S BHP 2706 146dstb-df30 Pandrol isp-95064 Delkor RF 0. 02 192 CLA
Pandrol Pandrol Pandrol
Pandrol Pandrol Pandrol Pandrol Pandrol Pandrol
Pandrol Delkor
ESC 230
Common Item Name Sleeper Plate Clouth alternative 1 Sleeper Plate Clouth alternative 1 Timber Sleepers Timber Sleeper Timber Sleeper
Description
Clouth alternative 1; 60kg rail; cast Iron-rubber; sound dumping, double Shouldered 1:20 cant, end holes at 95mm centres Clouth alternative 1; 60kg rail; cast Delkor RF 0.29.092 Iron-rubber; sound damping, double CLA Shouldered 1:20 cant, side holes Sleeper, railway Timber; unbored; 230mm x 130mm x 2440mm ironbark or approved hardwood Sleeper, railway Timber; 230mm x 130mm x 2440mm lg; bored 47kg/80lb AS "A"; ironbark or approved hardwood Sleeper, railway Timber; 230mm x 130mm x 2440mm; Bored; 53kg new pattern; Ironbark or approved hardwood Sleeper, railway Timber; 230mm x 130mm x 2440mm; Bored for Pandrol fastenings Timber, Dog Screw, new pattern, 230mm x 130mm x 2440mm, Bored Timber, Dog Screw, Pandrol pattern, 230mm x 130mm x 2440mm, Bored AS 3818.2 AS 3818.2
Manufacturer/ Supplier Delkor RF 0.10.092 CL Delkor Standard/ Drawing
Delkor
Timber Sleeper
AS 3818.2
Timber Sleeper Timber Sleeper Timber Sleeper
AS 3818.2 AS 3818.2 AS 3818.2 AS 1085.14 Rocla
Concrete Sleepers Concrete Sleeper Concrete; Medium duty low profile 25t Medium Duty axle load; Pandrol Fastclip fastening Fastclip (MDFC), system; mass 232kg 25T Concrete Sleeper Concrete; Medium duty low profile 25t Medium Duty Eaxle load; Pandrol e2003 fastening clip (MDEC), 25T system; mass 232kg Concrete Sleeper Concrete;Heavy Duty Type 5 30t axle Heavy Duty E-clip load; Pandrol e-clip fastening system; (HDEC), 30T mass 285kg; Concrete Sleeper Concrete; Heavy Duty 30t axle load; Heavy Duty Pandrol Fastclip fastening system; Fastclip (HDFC), mass 285kg 30T Concrete Sleeper ARTC Concrete; Heavy Duty Heavy Duty Pandrol Fastclip fastening system; Fastclip (HDFCN) SG30/227 Restricted conditions of use requires approval from Chief Engineer Track Concrete Sleeper Concrete; Type 6M 30t axle load; 20 Type 6M 30t E-clip wire Pattern; Pandrol e2003 fastening system; (mass 275kg); Concrete Sleeper Concrete; track circuit sleeper; track circuit Medium duty 25t axle load; Pandrol Fastclip Fastclip fastening Concrete Guardrail Sleepers
AS 1085.14 AS 1085.14 AS 1085.14
Rocla Rocla Rocla
AS 1085.14 Rocla Dwg 90698 B dated 7/06/2006
Rocla
AS 1085.14 AS 1085.14
Rocla Rocla
ESC 230
Common Item Name Concrete Guardrail Sleeper Heavy Duty E-clip 30T No.1 Concrete Guardrail Sleeper Heavy Duty E-clip 30T No. 2 to No.6 Concrete Guardrail Sleeper Medium Duty Eclip 25T No. 1 Concrete Guardrail Sleeper Medium Duty Eclip 25T No. 2 to No.6 Concrete Guardrail Sleeper Heavy Duty Fastclip 30T No. 1 Concrete Guardrail Sleeper Heavy Duty Fastclip 30T No. 2 to No.6 Concrete Guardrail Sleeper Medium Duty Fastclip 25T No. 1 Concrete Guardrail Sleeper Medium Duty Fastclip 25T No. 2 to No.6 Concrete Guardrail Sleeper Heavy Duty Fastclip 30T
Description
Standard/ Drawing
Manufacturer/ Supplier
Concrete, Heavy Duty E-clip AS 1085.14 Guardrail sleeper, GR1, 30T axle load, Pandrol E-clip fastening system Concrete, Heavy Duty E-clip Guardrail sleeper, GR2 to GR6, 30T axle load, Pandrol E-clip fastening system AS 1085.14
Concrete, Medium Duty E-clip AS 1085.14 Guardrail sleeper, GR1, 25T axle load, Pandrol E-clip fastening system Concrete, Medium Duty E-clip Guardrail sleeper, GR2 to GR6, 25T axle load, Pandrol E-clip fastening system Concrete, Heavy Duty Fastclip Guardrail sleeper, GR1, 30T axle load, Pandrol E-clip fastening on guardrail and fastclip on running rail AS 1085.14
AS 1085.14
Concrete, Heavy Duty Fastclip AS 1085.14 Guardrail sleeper, GR2 to GR6, 30T axle load, Pandrol E-clip fastening on guardrail and fastclip on running rail Concrete, Medium Duty Fastclip Guardrail sleeper, GR1, 25T axle load, Pandrol E-clip fastening on guardrail and fastclip on running rail Concrete, Medium Duty Fastclip Guardrail sleeper, GR2, 25T axle load, Pandrol E-clip fastening on guardrail and fastclip on running rail AS 1085.14
AS 1085.14
Concrete, Heavy Duty Fastclip Guardrail sleeper, 30T axle load, Pandrol E-clip fastenings with cast in pandrol shoulders on guardrail and Fastclips on running rail Concrete Guardrail Concrete, Heavy Duty Fastclip Sleeper Guardrail sleeper, 30T axle load, Heavy Duty E-clip Pandrol E-clip fastenings with cast in 30T pandrol shoulders on guardrail and Pandrol E-clip fastenings on running rail Concrete bearer Concrete bearer, FLAT 1, 30T, 8 ferrules cast in for cant reducing sleeper plates
AS 1085.14 and drawing 785-568 & 785-569 AS 1085.14 and drawing 785-568 & 785-569
AS 1085.14 and drawing 785 576
ESC 230
Common Item Description Name Concrete Guardrail Concrete Guardrail Bearer, Type Bearer AGR1 for Alternative 1 sleeper plates under running rail, A clips hold the guardrail Ordinary AGR1 guardrail sleeper and no. 1 in termination set Concrete Guardrail Concrete Guardrail Bearer, Type Bearer AGR2 to AGR7 for Alternative 1 sleeper plates under running rail Polymer Concrete Half Sleepers Polymer Concrete Half Sleepers
Standard/ Drawing AS 1085.14 and drawings 785 030 and 785 031
Manufacturer/ Supplier
AS 1085.14 and drawings 785 030 and 785 031 RailCorp drawings ACO Polycrete Pty Ltd
ESC 230
Appendix B
Repair Item Pandrol Cast in shoulders Pandrol Fastclip shoulders
Approved Repair Processes

Description Epoxy concrete repair of damaged concrete shoulders Welded repair of Fastclip cast-in shoulder components Standard/ Drawing Manufacturer/ Supplier Pandrol Pandrol
ESC 230
Appendix C
Rail Section 53 kg
Sleeper Boring Patterns

Plate Cat No. DF 30 New Pattern A (mm) 1348 B (mm) 171 Comment Lockspike and dogspike arrangement is a mirrored and inverted image of Old Pattern
B Sleeper plate footprint
38 38 102 38 38 89 64 127
21mm dia dogspike hole OR 43 17mm dia dogscrew hole 16mm dia lockspike hole OR 14mm dia lockscrew hole
337
40
40
43
332
Figure 1 - 53 kg New pattern boring details

1184 337 Sleeper plate footprint
76 90
76 64
76 90
76 64
291
Figure 2 - Boring pattern for Pandrol for 53 & 60kg/m rail

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Engineering Standard Track

ESC 230 SLEEPERS AND TRACK SUPPORT

Owner: Approved by:

UNCONTROLLED WHEN PRINTED

RailCorp Engineering Standard Track Sleepers and Track Support

December, 2008 May, 2009

July, 2010 February, 2011

Summary of changes from previous version

RailCorp Issued June 2012

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Page 2 of 31 Version 4.7

RailCorp Engineering Standard Track Sleepers and Track Support

Appendix A Appendix B Appendix C

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RailCorp Engineering Standard Track Sleepers and Track Support

Purpose, Scope and Application

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RailCorp Engineering Standard Track Sleepers and Track Support

Design & Performance Criteria

Sleepers and Bearers

Fastening Assembly Design

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RailCorp Engineering Standard Track Sleepers and Track Support

Table 1 Timber Sleeper Dimensions

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Page 6 of 31 Version 4.7

RailCorp Engineering Standard Track Sleepers and Track Support

Half Sleeper Size

Dimension (mm) 800 230 130 Minimum 345 Minimum 90

Acceptance Tolerance (mm) + 50 0 + 10 0 + 10 0 NA NA

Table 2 - Timber half sleeper dimensions

Table 3 - Approved timber species

Recycled Timber Sleepers

RailCorp Issued June 2012

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RailCorp Engineering Standard Track Sleepers and Track Support

Spacing at Rail Joints

Table 5 - Sleeper spacing at joints

Spacing at Bridge Ends

Table 6 - Sleeper spacing at bridge ends

Boring Requirements in Timber Sleepers, Transoms and Bearers

RailCorp Issued June 2012

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RailCorp Engineering Standard Track Sleepers and Track Support

27 mm dia 24 mm dia 22 mm dia

Table 7 - Fastening hole diameters

Proximity of Plates to Sleeper and Bearer Ends in Turnouts

Table 8 - Concrete sleeper dimensions

RailCorp Issued June 2012

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