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Nning Rail Info
Nning Rail Info
RUNNING
RAIL
GAUGE
Similar technique adopted as above over two consecutive sleepers - Actual end difference in gauges
noted.
When to take a reading using the multipurpose cage ensure that the gauge is placed on a centreline of
When taking the reading for the variation gauge between two consecutive sleepers, take your reading
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Running rail
Welded rail accounts for approximately 66% of the running rail in ballasted track, where
curvature restricts its use, short rails are installed. Two configurations of welded rail are
employed by LUL; long welded rail (LWR) and continuous welded rail (CWR). The long
welded rail sites are made up of either 95RBS bullhead rail or BS113A flat bottom rail, but
continuous welded rail is made up entirely of BS113A flat bottom rail.
Short rail
`locations where up to 91.4 m length welded strings of rail are tight jointed or welded together
to form a single rail length over 200 m but not exceeding 730 m. Long welded rail may
incorporate insulated joints"
`rail continuously welded together to form a single length over 200 m with no
maximum length. Continuous welded rail may incorporate insulated joints".
Rail wear
Apart from corrosion which affects the whole rail, the two areas affected by the passage of
traffic are the head and foot. The rail head suffers from head wear , sidecut , corrugation
and damage , the rail foot being affected by gall . Rail head wear takes place over a number of
years while sidecut and corrugation can occur over a short period of time, particularly if the
track mounted rail lubricators are not functioning correctly.
Head wear - when the rail head wears, there is a reduction in clearance between the
wheel flange and fishplates. If the permissible head wear is exceeded the wheel flange can
ride on top of the fishplate resulting wear and damage to both vehicle and track components
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When the head wear is within 3mm or gall exceeds 1mm of the limits stated in the
standards, monitor rail wear by taking measurements at no more than 100m
intervals every six months until the limit is reached.
Sidecut - on curved track, sidecut is normally caused by the action of the wheel flange riding hard
against the high rail on curves.
Intermittent sidecut can also occur because of local irregularities in alignment. This
is particularly noticeable on sections of short rails where intermittent sidecut is
reduced in the vicinity of the rail joints because the more rigid fishplates create a
flatter curvature. Where local irregularities are left unattended, eventually the small
sections of sidecut will overlap and become continuous. On straight track vehicle
'hunting' can also cause intermittent sidecut on alternate rails.
On curves where sidecut exists, the low rail mushrooms developing lipping,
particularly on the outside edge of the rail.
The wear on the gauge face of the rail cannot b e allowed to exceed an angle of
26 to the vertical. Using a sidecut gauge, where the angle is exceeded, the rail
needs to be replaced. Refer to Track Handbook 19, Managing the critical aspects of
track for details of measuring sidecut.
REMEMBER!
Different sidecut gauges are used when measuring bullhead and flat bottom rail.
Corrugation - there are two corrugation wave lengths, short wave which is visible
to the naked eye with an interval of between 30mm and 80mm and long wave which
is greater than 80mm.
They can only be removed by grinding (see TE -MTS-0304 the rail head and to
minimise component deterioration, the removal needs to be undertaken before the
depth of corrugation exceeds 0.04mm. Where the depth of corrugation is allowed to
exceed 0.08mm the increased vibrations and wheel noise will incur public complaints
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and if allowed to develop further, result in the premature failure of the track
components.
Where rail corrugation is allowed to develop uncontrolled, the fastenings used with
concrete sleepers are particularly susceptible to becoming life expired over a very
short time.
Corrugation has been found to occur on urban railways where the same type
of vehicles with the same running characteristics travel at the same speed
over a section of track.
Rail damage - under the passage of trains running rails roll out and the rail ends can
become lipped (see plate 1). Where this is allowed to continue unchecked, in short rails
the expansion gap is reduced and in insulated rail joints there is a possibility of a short
circuit, particularly when the rails expand.
If rail end lipping is not removed, it will eventually break off leaving an irregular
surface (see plate which can contribute to rail end batter (see table 25) or even flaking
of the running surface.
Plate 1 Lipped rail joint. Note the reduction5in expansion gap at the running edge.
RUNNING RAIL
Another problem, usually associated with bad rail joints is rail end batter where the
continual pounding of a poorly maintained rail joint causes the rail head to mushroom and
the potential for rail failure.
Gall - under the passage of trains, the continual rubbing between the rail and rail
support (fretting) causes wear on the rail foot (gall). Damp locations, such as
tunnels, are ideal for developing gall and if debris is allowed to accumulate around
the chairs or baseplates the situation becomes exacerbated by the production of a
very fine paste which grinds away the rail foot.
If gall goes unchecked, the stress concentrations created in the rail foot can cause
the rail to break.
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Rail Grinding
The head of the running rail can be reprofiled by grinding (see TE -MTS-0304) and can be
used to remove corrugation which is identified from the Track Recording Vehicle data on
normal track recording runs. As an alternative, corrugation can be measured using a 1m
straight edge and feeler gauges.
Before undertaking any reprofiling of the running rail, Track Managers need to consider
the rail life in terms of age, head wear and sidecut and where reprofiling is planned, the
track needs to be fettled with particular attention to top and line.
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Look for Measure / observe Decide: By the budget year .....?
Lateral wear: Rail head side cut using Will lateral wear of the running edge
combined running rail and reach or exceed 14mm?
Side cut (Plate 1B)
stock rail gauge (Plate 1A)
Will tolerances exceed + 3mm (wide
gauge) or -2mm (tight gauge)?
Remove all grease from rail
Concave wear edge before using gauge
Might concave wear develop to an
Check round curve in case
extent that causes risk of a wheel flange
sidecut is intermittent
riding the lip and unacceptable wheel
unloading?
Signs of "snowing"
(Plate 2A). Abnormal or
intermittent wear patterns
Track gauge widening Track gauge with inspector's Will the variation in gauge between
showing that wear is gauge or, if using tape, three consecutive sleepers exceed
nearing limit ensure measurement is 3mm?
taken at correct position on
gauge face of rails (13mm
below head of rail)
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Look for Measure / observe Decide: By the budget year .....?
Defects:
Rail end batter and Measure rail end batter by Will the batter or dip reach or exceed
dipped joints. using 1m straight edge. 3mm?
Measure dip by placing 1m
straight edge on top of rails
Breaking out of rail edge at a joint and measure Is the number / length of dipped joints
at joint. down from centre (500mm an issue?
mark) to rail end using
feeler gauge (Fig 1)
Will additional shimming be able to
rectify the condition?
Shimming of rail joints
where dips and/or batter
exist
Corrugations (Plate 2B) 'Roaring' or wheel noise Will there be a risk of premature failure
causing rail stress using noise meter of track components due to excessive
vibration?
Wear patterns Depth of corrugations using
straight edge and feeler
gauges
Scalloping, squats or Depth of scalloping, squats Will extent of these defects increase the
wheelburns (Plates 3B or wheelburns using dial risk of rail head fracture?
and 4A) gauge on straight edge or
feeler gauge Is their number / length an issue?
Gauge corner cracking Depth and extent of cracks Will cracks develop into squats or taches
ovales causing rails to fail or be at limit
Elongated arrow-shaped of wear?
cracks on gauge corner
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Maintenance
To control the effects of temperature stresses in the rails and ensure that track
stability is maintained, you need to take the following.
Before the start of the 'hot weather period', measure the rail lengths and expansion
gaps in cess and six foot rails and take the rail temperature. Record this data on
form TB1 (see attachment 2). When completed, this form needs to be forwarded to
the Track Manager.
Using the information on form TB1, calculate the total length of existing expansion
gaps.
If the total length of expansion gaps is the same as or more than the values shown in
tables 12 and 13 for the appropriate type of track, you need take no further action
except to ensure that expansion is evenly distributed.
If the total length of expansion gaps is less than the values shown in tables 12 and
13, you need to cut the rail or install an additional short rail to provide adequate
expansion.
During the annual assessment of short rails, if there are more than six consecutive
joints without expansion gaps you need to adjust the rails before the start of the
'hot weather period'.
If the rails are in 36.6m lengths, use the values shown in table 13 which assumes
that the middle section of each rail is secure against movement. If, however, the rails
are free to move over their whole length, the values in table 12 should be used
instead.
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When rerailing is carried out, the rail temperature needs to be taken and the rail
expansion gaps set, using expansion irons. To ensure the free expansion of rails,
grease needs to be applied to the fishing angles of both rails and fishplates before
assembly. During the 'hot weather period', the fishbolt torque (see table 13) needs to
be checked on the day following rerailing and corrected accordingly. When Rerailing,
ensure rails are left on site for a minimum of three weeks before installation to allow
them to attain the ambient temperature.
Rail joints
When fishplates are replaced, the fishbolts must be tighten ed progressively in the order 2,
3, 1, 4, using a torque spanner set to the correct torque (see figure 4, table 14. Six hole
glued insulated blockjoints and four hole Benkler insulated blockjoints are under evaluation
on certain sites on the network.
In March of each even-numbered year (e.g. 1996), remove the fishplates, clean
and examine the fishing angles of the fishplates and rails for fractures, then grease
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3.0 Track inspection Gauge Functions.
The gauge measures running rail, check rail, and conductor rail geometry
In addition some functions of the gauge can be locked and the gauge can then be used as a
fixed gauge (see 9.0)
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Refer to ‘diagram A’ to identify all the terms used in this text. Where references to the
diagram are included in the following text, the references have been printed in italics.
When not in use this gauge should be stored horizontally, If the gauge has to be propped in
a vertical position it should only be Carefully stood on its “sprung end”, with the gauge
locked.
When being transported, the positive rail arm should be set in the retracted position.
The shoulder strap must be removed prior to use, to prevent entanglement with any part of
the track.
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The positive rail height slide may be secured in the up position using the positive rail slide
lock screw, should its use not be required.
The gauge is balanced about its centre for carrying during use (with the strap removed).
Place the locating leg on the sprung end onto the running rail. Compress the gauge and
lower the unsprung end onto the other running rail. Release the pressure on the spring until
the locating leg on the unsprung end contracts the running edge.
The super elevation (in mm), is read directly from the cant scale using the mid-point of the
bubble. The scale allows 160mm super elevation at the positive rail arm end and 20mm at
the sprung end exceed 20mm - then the gauge must be turned around.
The scale can be illuminated by pressing the illumination button. Use this sparingly to
preserve the battery - which can only be changed during re-calibration (see 12.2 & 12.4).
Ensure that the sprung end lock is released. The track gauge can be read directly from the
track gauge scale.
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RUNNING RAIL
NB the measurement of track gauge recorded by this gauge takes no account or rail wear.
To obtain running rail gauge, the side wear on both rails needs to be establish, and added
to the track gauge measurement.
NB The check rail gauge measurement given by this gauge is between the worn flangeway
edge of the check rail and the unworn edge of the running rail. It must be noted that the
gauge takes into account wear on the check rail, but not on the high rail, which must be
established using the rail head and sidewear gauge.
To obtain the measurement, locate the upsprung end firmly against the high rail then pull
back the sprung end until the inner reference edge for check gauge scale.
Ensure that the sprung end locating leg is in contact with the running edge. Then pull the
flangeway trigger until the check rail is contacted. The flangeway width can be read directly
from the flangeway width scale.
Release the check rail height knob from the spring catch. Pivot the knob until a stop is
reached. Then press the check rail height knob vertically down until the rail head is
contacted. The check rail height above (max 30mm) or below (min 10mm) the running rail
can be read from the check rail height scale.
Re- secure the check rail height knob back in the spring catch after use.
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RUNNING RAIL
The negative rail height slide is fixed in the up position by a spring. To use, push the scale
down until the conductor rail blade contacts the conductor rail (it should align with the
centre of the rail). The height of the conductor rail above the running rail top (in mm) is
measured on the scale.
8.7 Negative Rail Lateral Position Measurement
With the negative rail lateral position scale set at zero (the spring locks as this point) the
conductor rail blade should contact the centre of the conductor rail. If the centre of the rail
does not align with the blade - reset the blade until it does - read the offset from the scale.
8.8 Use the positive rail lateral positioning knob to set zero on the positive rail lateral
position scale. Release the positive rail slide lock screw and the lower the positive rail slide
onto the head of the positive conductor rail above the running rail top (in mm) is measured
on the positive rail height scale.
8.9 Positive Rail Lateral Position Measurement
The positive rail slide when contacting the top of the rail should sit on the centre of the head
when the positive rail arm, (Using the positive rail lateral positioning knob), is set at zero on
the positive rail lateral position scale.
To obtain a more accurate measurement of the centre of the positive conductor rail from
the unworn running edge, use the following procedure. (NB not to done with live current
rail).
Withdraw the positive rail arm using the positive rail lateral positioning knob, until the
conductor rail blade drops down the side of the conductor rail. Ensure proper contact
without overtightening.
Read the measurement of the positive rail lateral position scale. Then calculate the position
of the conductor rail centre from the unworn running edge by subtracting the reading from
half the conductor rail width (measured separately).
Ex: 100mm width conductor rail
1/2 width =50mm
(Assume) 40mm reading on scale
Subtract 40mm from 50mm = 10mm
Therefore the centreline of the conductor rail is 10mm further from running rail than
required.
NB Remember that this gauge does not measure from the worn running edge of the
running rail.
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4 Rail condition
4.1 Running rail - side wear as measured with the head wear and side wear gauge
10
12
14
16
18
19
1
2
3
4
6
8
outside fishplate limits
9.5
10
11
9
8
7
6
5
3
2
1
0
Maximum permitted side ML Plan (1)
wear as measured 13mm replacement
depending
below the running surface of
on rate of
the rail head. The allowable wear
9
8
8
7
6
5
4
3
2
1
0
0
sidewear is a function of the
headwear with reference to
the profile of a new rail.
of a rail joint.
(1) These limits are to be applied to one side of the rail only. Application to both sides of the rail would
result from reversal of the rail’s flexure, which is not permitted in a high-rail situation.
(2) See S1157 for restrictions on turning or transposing rail.
Rate of change of sidewear. SS 6mm (over a distance of 1.5 metres the Consider
Maximum permitted maximum permitted decrease of side wear imposing a
shall be 3mm) speed
decrease of side wear over a
restriction
distance of 3 metres and grind to
provide
longer
transitions
within 1 week
Running rail -
side wear Head wear
New profile
13mm
Sidewear
Angle
Worn profile
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4.1 Running rail - side wear as measured with the head wear and side wear gauge
(cont/d)
> 11
11
10
1
8
or on track used by
TOC stock
11
0
below the running surface
of the rail head. The
allowable side wear is a
ML Plan (1)
function of the headwear
replacement
with reference to the depending on
8
0
profile of a new rail. rate of wear
Applies within fishplate
limits i.e. 1.5 metres of
the centreline of the joint, MT Monitor to (1)
or on track used by TOC determine rate
1.5
of wear
stock.
6
0
(1) These limits are to be applied to one side of the rail only. Application to both sides of the rail would
result from reversal of the rail’s flexure, which is not permitted in a high-rail situation.
(2) See S1157 for restrictions on turning or transposing rail.
Rate of change of SS 6mm (over a distance of 1.5 metres the Consider
sidewear. Maximum maximum permitted decrease of side wear imposing a
shall be 3mm) speed restriction
permitted decrease of
and grind to
side wear over a distance provide longer
of 3 metres transitions within
1 week
Running rail -
Head wear
side wear New profile
13mm
Sidewear
Angle
Worn profile
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4.2 Running rail – Side wear
4.4 Running rail – headwear as measured with the headwear and sidewear gauge
11
10
1
2
3
4
5
6
7
8
9
0
SS Replace
Maximum permitted head
within 4 weeks
wear allowable (excluding
19
18
16
14
13
12
10
of wear
joint.
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4.4.2 Running rail - Sidewear mm
headwear at fishplates
11
10
0
1
2
3
4
5
6
7
8
or on track used by
TOC stock
SS Replace
Maximum permitted head
within 4 weeks
wear allowable (excluding
10.5
1.5
11
14
10
8
6
4
3
2
1
rail gall) based on a
nominal rail depth of
145mm for 95RBH rail
and 159mm for 56E1 ML Plan to
(BS113A) FB rail. replace within
1.5
6 months
12
10
8
6
4
3
2
1
0
0
The allowable headwear
depending on
is a function of the
rate of wear
sidewear (see also 3.4
Table 4.1.2). MT Monitor every
6 months to
Applies within fishplate
establish rate
1.5
limits i.e. 1.5 metres of
10
8
4
3
2
1
0
0
0
0
of wear
the centreline of the joint,
or on track used by TOC
stock.
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Various rail defects
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