IRS TRACK MANUAL RFa Brief notes on rails & fastenings Rails : The UIC 60 kg/m rail wetion appearing in UIC code she and the following British Standard flat footed, rai] sections appearing in BSS 11-1936 and reproduced in Indian Railway Standards Specification T-12, have been adopted for use on Indian Railways. These include the 52 kg per metre section but exclude 115 1b section whichis now obsolete. S2kg ForBroad Gauge having the same foot- width as BS No. 90R and facilitating the use of the same bearing plates & sleepers. BSNo. 90R For Broad Gauge BSNo.90R&75R_ For Metre Gauge BSNo. 60R For Metre Gauge BSNo. 50R This rail section has been in use over an appreciable kilometrage of Metre Gauge; but it is not being adopted in current designs. This will however be used for Narrow Gauge. Due to the introduction of the metric system of weights and measures, the BS rails namely 90R, 75R, 60R, and 50R have not been redesigned but merely reproduced in the IRS Specification T-12 by indicating their dimensions and weight in metric equivalent upto two decimal places. The tables on pages RF 1 in 6 sheets give the main dimensions, calculated weights and properties of rail sections relevant to the two principal axes. Fishplates: The rolled profile of fishplate for UIC 60 kg/m rai) and its properties are given on page RF 3 in six sheets. The requirements as to their manufacture are governed by UIC code 864-4 and 864-8 (Appendix 2). Wheareas “Revised 0 0 British Standard” rail sections have been adopted for use on Indian Railways, the British Standard fishplates designed for these sections have not been considered sufficiently strong for adoption as Standard in India. For this reason stroneer and heavier fich='IRS TRACK MANUAL RFb The fishplate designs as adopted and subsequently metricised appear in IRS Specification T-1. These metricised fishplates have been designed, keeping in view the requirement of free interchangeability with the corresponding FPS fishplates The details and tables on pages RF 3 in 5 sheets show their main dimensions, sections, properties, weights and part numbers. Fishbolts : For reasons similar to those mentioned under fishplates, the fishbolts adopted on Indian Railways and shown on page RF2 are of larger diameter than the corresponding British Standard fishbolts. The metric fishbolts too have a free interchangeability with their FPS counter-parts. However metric fishbolts can not be used with FPS nuts and FPS fishbolts can not be used with metric nuts due to different threads. The main design dimensions adopted for these fishbolts and nuts as also the other requirements relating to their manufacture and procurement appear in IRS Specification T-23. Spring washers : Single and double coiled spring washers are shown on page RF2A sheet 1, for 25 mm dia. and 20. mm dia. bolts respectively. Combination fishplates : The IRS designs shown on pages RF4 in 6 sheets comprise two main groups of sections : Group I having the IL and OR or OL and IR asidentical combination fishplates. Group II having all IL, OR, OL and IR asdifferent combination fishplates. The different combinations falling under either of the above two groups have been prepared and the main dimensions and part numbers of the fishplates as well as those of the special fishbolts have been tabulated. The IRS combination fishplates have been designed, with an adequate thickening up of the section in the middleIRS TRACK MANUAL. RFe portion where the change in section takes place. Another feature of these designs is the elimination of the expansion joint, i.e. the rail ends are made to butt, which helps in making the joints considerably stronger than would be the case with ordinary joints. A uniform system of marking the right or left hand and the inner or outer fishplates has been adopted. This is illustrated in the key plans on the drawings. The combination fishplates have to be procured as per IRS Specification T-6. Insulated rai] joints: There are a variety of designs of insulated rail joints in use on the various Railway systems in the world. Some of these designs have proved to be very efficient in service, but the object of the IRS designs shown on pages RF 5 in 8 sheets is to provide a satisfactory joint without introducing specially rolled fishplates. For such insulated rail joints, standard fishplates have to be planed on the fishing planes to accommodate channel type insulation between the rails and the fishplates. Other insulating features are an end-post between the rail ends and bushes around the fishbolts. The drawings for insulated rail joints for 60kg UIC, 52kg, BS Nos. 90R, 75R, 60R and SOR rails have been issued. The part numbers and their main dimensions are tabulated for reference. Besides the above and in order to effect efficiency and economy, glued insulated rail joints have been adopted on Indian Railways. The glued joints have been included in IRS Track Manual Vol. II. Rail expansion joints for bridges ; Two types of expansion joints have been designed :— (a) With the rail end mitred. (b) With the rail ends mitred but with a central rail piece in between.IRS TRACK MANUAL RFd | Type (a) is for use on short span bridges upto 30.5 metres and type (b) on long spans above 30.5 metres and upto 76.2 metres. In both the types the outer fishplate is of a special section, the top face of which is level with the rail table, so as to support the wheet tread over the expansion gaps. This gap is a maximum of 26 mm in type (a) and 33 mm between thé rail end and the central rail piece making a total of 66 mm in type (b); alternative types have been prepared to suit canted or uncanted rails. The part numbers and the main dimensions for expansion joints and for the special fishplates are tabulated on pages RF 6 in 8 sheets. Atable showing gaps between rails at various temperatures for type (a) and another showing range of temperature for various spans with maximum expansion gap of 66 mm for type (b) have also been included. For welded track, expansion joints have been included in IRS Track Manual, Vol II. Rail anchors : Spring steel rail anchors for UIC 60 kg, 52kg, 90R, 75R, 60R, 5OR and SONS rail sections are detailed on pages RF6A. They have to be procured as per IRS Specification T-24. Table showing weights and quantities of rails and fastenings : Estimates of quantities and weights of rails, fishplates and fishbolts for track projects are often required to be made by the permanent way staff. To facilitate this work, the tables on pages RF7 in 4 sheets give the weight of each component, the number of components of each type per tonne and the weight of each component per track kilometre for the various rail lengths (full and shorts) of standard sections in common use. 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