Professional Documents
Culture Documents
Rail Track Material Catalogue A5
Rail Track Material Catalogue A5
OneSteel Whyalla has significant experience and expertise in the production of steel rail and steel sleeper systems in service to the Australian railway industry. A series of major investments in our facilities has resulted in the consistent manufacture of high quality steel products. OneSteel is proud to claim our steel rail and steel sleeper systems as Australian Made. OneSteel Whyalla gained accreditation to ISO 9001 for its manufacturing operations in 1990. Our Quality Management System supports our core values of Safety and Customer and is designed to allow us to deliver quality products in line with our Promise to Customers whilst not compromising on Safety.
Contents
STEEL RAILS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 68kg Rail Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 60kg Rail Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 53kg Rail Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 50kg Rail Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 NZR50kg Rail Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 41kg Rail Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Standard Rail Drilling Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drilling Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Selection of Steel Sleepers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Steel Sleeper Selection Items for Consideration . . . . . . . . . . . . . 12 Steel Sleeper Typical Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rolled Steel Sleeper Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Dimensional Tolerances For Steel Sleepers . . . . . . . . . . . . . . . . . . 15
TRAK-LOK 2 CLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TURNOUT bEARERS AND SPECIAL TRACKwORK . . . . . . . 30 TRAK-LOK INSTALLATION AND REMOVAL TOOLS . . . . . . 30
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Motorised Application Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Sleeper Plate Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hole Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table of Sleeper Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 34 34 34
steeL RAILs
Rails are manufactured and supplied by the OneSteel Whyalla steelworks in South Australia. OneSteel produces both Plain Carbon and Head Hardened rails in a range of sizes suitable for the Australasian rail market. OneSteel manufacture steel rails in accordance with the following OneSteel Rail Technical Agreement specifications. RT19 68kg AS profile RT23 41kg, 50kg and 60kg AS profile RT25 53kg AS profile RT24 50kg NZ profile These specifications detail production of rails in accordance with Australian Standard AS 1085.12002 with clarifications and enhancements contained therein. A copy of these specifications are available on request.
Chemical Composition
As Rolled Rail Product 41kg Rail 50kg Rail NZR50kg Rail 53kg Rail 60kg Rail 68kg Rail Carbon % 0 .53 to 0 .69 0 .65 to 0 .82 0 .72 to 0 .82 0 .65 to 0 .82 0 .65 to 0 .82 0 .65 to 0 .82 Manganese % 0 .60 to 0 .95 0 .70 to 1 .25 1 .00 to 1 .25 0 .70 to 1 .25 0 .70 to 1 .25 0 .70 to 1 .25 Silicon % 0 .15 to 0 .58 0 .15 to 0 .58 0 .15 to 0 .58 0 .15 to 0 .58 0 .15 to 0 .58 0 .15 to 0 .58 Element Phosphorous % 0 .025 max 0 .025 max 0 .025 max 0 .025 max 0 .025 max 0 .025 max Sulfur % 0 .025 max 0 .025 max 0 .025 max 0 .025 max 0 .025 max 0 .025 max Aluminium % 0 .005 max 0 .005 max 0 .005 max 0 .005 max 0 .005 max 0 .005 max Nitrogen % 0 .010 max 0 .010 max 0 .010 max 0 .010 max 0 .010 max 0 .010 max
Head Hardened Rail Carbon % 50kg Rail 0 .65 to 0 .82 NZR50kg Rail 0 .65 to 0 .82 53kg Rail 0 .65 to 0 .82 60kg Rail 0 .65 to 0 .82 68kg Rail 0 .65 to 0 .82 Product Manganese % 0 .70 to 1 .25 0 .70 to 1 .25 0 .70 to 1 .25 0 .70 to 1 .25 0 .70 to 1 .25 Silicon % 0 .15 to 0 .58 0 .15 to 0 .58 0 .15 to 0 .58 0 .15 to 0 .58 0 .15 to 0 .58 Element Phosphorous % 0 .025 max 0 .025 max 0 .025 max 0 .025 max 0 .025 max Sulfur % 0 .025 max 0 .025 max 0 .025 max 0 .025 max 0 .025 max Aluminium % 0 .005 max 0 .005 max 0 .005 max 0 .005 max 0 .005 max Nitrogen % 0 .010 max 0 .010 max 0 .010 max 0 .010 max 0 .010 max
Mechanical Properties
As Rolled Rail Product 41kg Rail 50kg Rail NZR50kg Rail 53kg Rail 60kg Rail 68kg Rail Head Hardened Rail Product 50kg Rail NZR50kg Rail 53kg Rail 60kg Rail 68kg Rail 0.2% Proof Stress MPa (min) 780 780 780 780 780 Tensile Strength MPa (min) 1130 1130 1130 1130 1130 Elongation Min (%) 9 9 9 9 9 Surface Hardness Min (Hb) 340 340 340 340 340 0.2% Proof Stress MPa (min) 420 420 420 420 420 Tensile Strength MPa (min) 700 880 940 880 880 880 Elongation % (min) 8 8 8 8 8 8 Surface Hardness Hb (min) 260 260 260 260 260
Page 2
Page 3
70 20.2
1 IN 20
R254.0 R31.8
R 190 49
R 80
R 15.5
R 10 R 35
16 17
GAUGE POINT
1 IN
R7.9 R7.9 7.1
1 in 4
R5
17.5 R19.1
R203.0
R 20
CENTRELINE OF 203 AND 508 RADII 185.7 CENTRELINE BOLT HOLES R508.0 NEUTRAL AXIS
170 REF 93
79.3
R 20 74.5
80
1 IN
28
1 in 4
R3
R2
152.4
146
68kg Rail
Area of Head Area of Web Area of Foot Total Area Calculated Mass Maximum Rail Length 3,117 mm2 2,349 mm2 3,147 mm2 8,614 mm2 67 .7 kg/m 25 .0 m Horizontal Axis Second Moment of Area Section Modulus Head Section Modulus Foot Vertical Axis Second Moment of Area 39 .3 10 mm 390 .7 103mm3 462 .9 103mm3
6 4
60kg Rail
Area of Head Area of Web Area of Foot Total Area Calculated Mass Maximum Rail Length 2,999 mm2 1,974 mm2 2,752 mm2 7,725 mm2 60 .6 kg/m 27 .5 m Horizontal Axis Second Moment of Area Section Modulus Head Section Modulus Foot Vertical Axis Second Moment of Area 29 .3 106mm4 322 .4 103mm3 369 .3 103mm3 4 .90 106mm4
6 .03 106mm4
Page 4
Page 5
70 20.2
70.0
R11.0
R 80
R 10 R 15.5 R 35
16
1 IN 20
R190
17
45
GAUGE POINT R5
3 1 IN
IN 4
R 15
R9.5 14.7 CENTRELINE 406 RADIUS NEUTRAL AXIS 86.5 CENTRELINE BOLT HOLES
157.1
R406.0
R12.7
1 IN 5
67.9
73.0
77.4
74.7
R 15
67
75
R3.0
1 IN
25
24.6
R3
R2
146.0 R2.0
127
53kg Rail
Area of Head Area of Web Area of Foot Total Area Calculated Mass Maximum Rail Length 2,721 mm2 1,520 mm2 2,522 mm2 6,763 mm2 53 .1 kg/m 27 .5 m Horizontal Axis Second Moment of Area Section Modulus Head Section Modulus Foot Vertical Axis Second Moment of Area 22 .8 10 mm 271 .6 103mm3 312 .8 103mm3
6 4
50kg Rail
Area of Head Area of Web Area of Foot Total Area Calculated Mass Maximum Rail Length 2,710 mm2 1,578 mm2 2,163 mm2 6,451 mm2 50 .6 kg/m 27 .5 m Horizontal Axis Second Moment of Area Section Modulus Head Section Modulus Foot Vertical Axis Second Moment of Area 20 .1 106mm4 253 .5 103mm3 269 .1 103mm3 3 .26 106mm4
4 .54 106mm4
Page 6
Page 7
63.5
R13.0
R11.0
R300.0
16.0
R305.0 40.5
16.0
1 IN 20
45.0
4 1 IN
R2.0
1 IN
R3.0
GAUGE POINT
15.0
13.1
R9.5
NEUTRAL AXIS
136.5 74.6
NEUTRAL AXIS
71.3
76.0
64.5
R9.5
1 IN
60.3
67.5
30.0
R2.0
21.4
1 IN 5
25.5
1 IN
R3.0
R2.0
R2.0
132.0
127.0
nZR50kg Rail
Area of Head Area of Web Area of Foot Total Area Calculated Mass Maximum Rail Length 2,536 mm2 1,416 mm2 2,453 mm2 6,405 mm2 50 .1 kg/m 27 .5 m Horizontal Axis Second Moment of Area Section Modulus Head Section Modulus Foot Vertical Axis Second Moment of Area 19 .7 10 mm 240 .9 103mm3 276 .0 103mm3
6 4
41kg Rail
Area of Head Area of Web Area of Foot Total Area Calculated Mass Maximum Rail Length 2,162 mm2 1,132 mm2 1,907 mm2 5,193 mm2 40 .8 kg/m 27 .5 m Horizontal Axis Second Moment of Area Section Modulus Head Section Modulus Foot Vertical Axis Second Moment of Area 13 .25 106mm4 184 .3 103mm3 205 .7 103mm3 2 .67 106mm4
3 .40 106mm4
Page 8
Page 9
H A
Section 41kg Rail NZR50kg Rail 50kg Rail 53kg Rail 60kg Rail 68kg Rail H (mm) 60 .3 63 .0 67 .0 67 .9 74 .5 78 .6
Trak-Lok Steel Sleeper Systems are manufactured from OneSteels rolled M sleeper sections and incorporates the Trak-Lok resilient fastening system that has been developed specifically for use with steel sleepers.
B
A (mm) 62 .0 54 .0 88 .0 62 .0 88 .0 88 .9 b (mm) 127 .0 114 .3 130 .0 127 .0 130 .0 152 .0 Hole Diameter 30 .0 30 .0 30 .0 30 .0 30 .0 30 .0
Steel sleepers are support members that form part of the structure of the railway track. The steel sleepers are embedded into ballast and provide support to the rails above. The steel sleepers tie the rails together maintaining gauge and rail position whilst resisting lateral and longitudinal movement of the rail. The Trak-Lok 2 resilient clip secures the rail to the sleeper in conjunction with the appropriate Trak-Lok Lock In Shoulder. The Trak-Lok fastening system also includes an optional range of Insulation Pads for various rail sizes that provide electrical insulation between rail and steel sleeper which ensures the correct operation of track signalling and traction current return systems. The Trak-Lok fastening system also has a large range of Spacers available to enable the use of smaller rail in rail seats designed for larger rail sizes that may be employed in the future.
Australian Standards AS 1085 Part 17 - Steel Sleepers and AS 1085 Part 19 - Resilient Fastening Assemblies have been developed as a means for the selection of steel sleepers and their associated resilient fastenings. The procedures specified in these standards have two main parts: 1. Firstly a design procedure that enables the calculation of design vertical and lateral rail seat loadings for the proposed sleeper (if actual loading conditions are not known); and
2. Secondly the standards specify a series of laboratory test procedures, some of which utilise the calculated design or actual loadings, to determine the performance of the proposed sleeper systems against critical performance requirements. These critical performance requirements include sleeper fatigue, overload strength, rail fastening capability and rail insulation. In addition to the critical performance requirements specified above, other factors should also be considered, including how they are to be installed in track, assembly and disassembly of components, compatibility with common track maintenance activities and track stability. For the first time user, in-track trials are recommended so that experience may be gained regarding installation procedure, general track performance, maintenance techniques required and general overall costs. By both in-track testing and testing in the laboratory to criteria as determined in accordance with the Australian Standards, confidence may be gained as to whether any particular sleeper system is suitable for an intended purpose.
Page 10
Page 11
4. 5.
The details presented hereafter detail the commonly used components and configurations for Trak-Lok Steel Sleeper Systems, however other specific requirements may also be able to be accommodated. Please contact a OneSteel Trak-Lok representative for further details.
Page 12
Page 13
Characteristic Overall length of sleeper Individual cross-sectional dimensions of sleepers other than those specified in Items (c), (d) and (e) Internal width of sleeper at the section toe, B Overall depth of sleeper section, D Thickness of the sleeper top, T Inward cant of rail seats: (i) hot-pressed (ii) cold-pressed Rail seat flatness (flatness tolerance shall be measured in accordance with AS/ NZS 1100 .101) (no convexity allowed) Note: Where this tolerance is not met by special sleepers such as turnout and splay bearers, the flatness may be agreed with the purchaser . Differential tilt angle of rail seats in the direction of rail Track gauge, measured between gauge points of rails with the rail placed hard against the outer shoulder Distance between inside walls of inner and outer shoulders of each rail measured 2mm above the rail seat Inside walls of inner and outer housings of each rail seat to be parallel to longitudinal axis of each rail Sleeper longitudinal straightness (over the nominally straight portion in plan view) Distance between outer edges of external fixing holes Distance between outer edges of fixing holes of the same rail seat
Tolerance (mm) as per AS1085.17 +/- 10 +/- 3 +/- 5 +/- 2 +0 .5, -0 .3 +/- 0 .50 +/- 0 .20 0 .0 to 1 .0
(b)
54
R10 R15
25
(c) (d)
X
(e)
DEPTH 'D'
184,6
0 R8
(f)
't' (R
EF)
70
R8 232,7 R5 10 (REF)
(g)
'd'
7244" (REF)
R5
Designation
Mass kg/m
T mm 7 .5 8 .5 10
D mm 98 .0 99 .0 100 .5
d mm 19 .5 20 .5 22 .0
About x -x I 106mm4 2 .943 3 .217 3 .639 Z top 103mm3 92 .81 102 .35 116 .41 Z bottom 103mm3 44 .4 47 .61 52 .56 (k) (l) (m) (n)
M7 .5 M8 .5 M10
Chemical Composition Product Steel Sleeper Section Mechanical Properties Product Steel Sleeper Section Yield Strength MPa, min 250 Carbon %, max 0 .24 Manganese %, max 1 .5 Element Silicon %, max 0 .5 Phosphorous %, max 0 .04 Sulfur %, max 0 .04
Page 14
Page 15
Queensland
Sleeper Section M7 .5 Gauge Narrow (1067mm) Narrow (1067mm) Narrow + 7mm or +13 (1074mm and 1080mm) Narrow (1067mm) Narrow (1067mm) Part No Sleeper Centreline Length 2060mm 2060mm Flat or Cant Flat Flat Insulation Requirements Ins or Ins Part NI No NI NI Clip No LIS No Spacer Major Rail Size AS41 AS41 & AS50 Sleeper Drawing Number 2065 2068
tasmania
Sleeper Section M7 .5 M7 .5 Gauge Narrow (1067mm) Narrow + 6mm (1073mm) Narrow + 12mm (1079mm) Narrow (1067mm) Narrow (1067mm) Narrow + 6mm (1073mm) Narrow + 12mm (1079mm) Part No Sleeper Centreline Length 2010mm 2010mm Flat or Cant Cant Cant Insulation Requirements Ins or Ins Part NI No NI NI Clip No LIS No Spacer Major Rail Size AS41 AS41 Sleeper Drawing Number 12207 12235 M8 .5 7 .5SN12236TSS 8 .5NG12136TSS 8 .5NG12180TSS 8 .5NG12405TSS 2010mm 2060mm 2060mm 2060mm Cant Cant Cant Cant NI Ins NI Ins 2213 2213 B296 B296 B296 B296 2411 2409 2410 2409 AS41 AS41 AS41 AS41 12236 M8 .5 12136 12180 12405 M7 .5
7 .5NG2065TSS 7 .5NG2068TSS
B296 B296
2411 2411
2529
7 .5SN12207TSS 7 .5SN12235TSS
B296 B296
2411 2411
M8 .5
8 .5NG12393TSS
2060mm
Flat
NI
B296
2410
2529
AS41
12393
8 .5NG2074TSS 8 .5NG2089TSS
2060mm 2060mm
Flat Cant
Ins Ins
2214 2214
B296 B296
2409 2409
M7 .5 M8 .5 M8 .5 M8 .5
2074 2089
south Australia
Sleeper Section M10 M7 .5 Gauge Narrow (1067mm) Standard (1435mm) Standard (1435mm) Narrow (1067mm) Narrow (1067mm) Part No Sleeper Centreline Length 2060mm 2430mm 2430mm 2010mm 2010mm Flat or Cant Cant Cant Cant Flat Cant Insulation Requirements Ins or Ins Part NI No Ins NI NI NI NI 2213 Clip No LIS No Spacer Major Rail Size AS41 AS60 AS60 AS31 AS53 Sleeper Drawing Number 12152 12402 12126 12129 12391
M8 .5
8 .5NG12406TSS
2060mm
Cant
Ins
2213
B296
2409
AS41
12406
M10 M7 .5 M7 .5
Page 16
Page 17
Western Australia
Sleeper Section M7 .5 M7 .5 M7 .5 M7 .5 M7 .5 M8 .5 M8 .5 M8 .5 M8 .5 M10 Gauge Narrow (1067mm) Narrow (1067mm) Narrow (1067mm) Narrow (1067mm) Narrow + 6mm (1073mm) Narrow (1067mm) Narrow (1067mm) Narrow (1067mm) Narrow + 6mm (1073mm) Narrow (1067mm) Standard (1435mm) (1434mm with AS50) Standard (1435mm) Standard (1435mm) Standard + 6mm (1441mm) Standard (1435mm) Standard (1435mm) Standard (1435mm) Standard (1435mm) Standard + 6mm (1441mm) Part No Sleeper Centreline Length 2010mm 2010mm 2010mm 2010mm 2010mm 2060mm 2060mm 2060mm 2060mm 2060mm Flat or Cant Cant Cant Cant Cant Cant Cant Cant Cant Cant Cant Insulation Requirements Ins or Ins Part NI No NI NI NI NI NI Ins Ins Ins Ins Ins 2213 2213 2212 2213 2213 Clip No LIS No Spacer Major Rail Size AS41 AS50 AS47/50 RE66 AS50 AS41 AS50 AS60 AS50 AS41 AS41 & AS47/50 AS41 AS50 AS50 AS41 AS50 AS60 AS41 & AS47/50 AS50 Sleeper Drawing Number 12185 12187 12410
tRAK-LoK 2 CLIPs
Trak-Lok Steel Sleeper Systems supplied by OneSteel incorporate the Trak-Lok Fastening System which has been specifically developed for use with steel sleepers. The Trak-Lok B296 clip is most commonly used. A lower toe load version, the Trak-Lok B286 clip, is also used in some applications. Trak-Lok clips are manufactured from a high silicon spring steel and are hot formed, quenched and tempered in a semi-automatic process. OneSteel Whyalla also manufacture and supply as spares the superseded Trak-Lok 1 clips that were used on the Trak-Lok 1 Steel Sleepers (now obsolete).
7 .5SN12185TSS 7 .5SN12187TSS 7 .5SN12410TSS 7 .5SN12260TSS 7 .5SN12202TSS 8 .5NG2095TSS 8 .5NG12120TSS 8 .5NG12369TSS 8 .5NG12160TSS 10NG12152TSS
B286 B286 B286 B286 B286 B296 B296 B296 B296 B296
2411 2411 2411 2411 2411 2409 2409 2409 2409 2408
trak-Lok 2 Clips
12260 12202 2095 12120 12369
Designation where Used Note 1 For use with Insulated and B286 Non-Insulated M7 .5, M8 .5 and M10 Steel Sleepers . Material thickness = 8mm Nominal Toe Load = 9kN Nominal Deflection = 16mm B296 Note 1 For use with Insulated and Non-Insulated M7 .5, M8 .5 and M10 Steel Sleepers . Material thickness = 9mm Nominal Toe Load = 10kN Nominal Deflection = 16mm
Drawing
12160 12152
M7 .5
7 .5SG12231TSS
2430mm
Cant
NI
B286
2411
2529
12231
M7 .5 M7 .5 M7 .5 M8 .5 M8 .5 M8 .5 M8 .5 M8 .5
JB296 Note 1
For use with Insulated and Non-Insulated M7 .5, M8 .5 and M10 Steel Sleepers at Insulated Joints . Material thickness = 9mm
Zip9 Note 2
For use with Insulated and Non-Insulated M7 .5, M8 .5 and M10 Steel Sleepers . Material thickness = 9mm Nominal Toe Load = 10kN Nominal Deflection = 16mm
Note 1 Australian Design No . 142843 . All rights reserved . Note 2 Australian Patent No . 774152 . All rights reserved .
Page 18
Page 19
trak-Lok 1 Clips
Designation where Used S187L Used with Non-Insulated M7 .5 and M8 .5 Trak-Lok 1 Steel Sleepers . Material thickness = 8mm Nominal Toe Load = 9kN Nominal Deflection = 10 .5mm S193L Used with Insulated M7 .5, M8 .5 and M10 Trak-Lok 1 Steel Sleepers . Material thickness = 9mm Nominal Toe Load = 10kN Nominal Deflection = 13 .5mm Used with Non-Insulated M6 .5 Note: Use S187L Clip as replacement . Trak-Lok 1 Steel Sleepers . Material thickness = 7mm Nominal Toe Load = 8kN Nominal Deflection = 10 .5mm Used with Non-INsulated M7 .5 and M8 .5 Trak-Lok 1 Steel Sleepers . Material thickness = 9mm Nominal Toe Load = 10kN Nominal Deflection = 10 .5mm Drawing
S195L
2408 Note 2
S197L
2425 Note 2
Note 1 Australian Design No . 129140 . All rights reserved . Note 2 Australian Design No . 129139 . All rights reserved .
Page 20
Page 21
Designation 2217 Not adjustable used at Insulated Joints 2218 Not adjustable used at Insulated Joints 2219 Not adjustable used at Insulated Joints 2220 Gauge adjustable used at Insulated Joints
Drawing
AS53kg, AS60kg
146mm
Drawing
127mm
NZR50kg
132mm
WHITE IDENTIFICATION BUTTON PART No. 2210 (IN THICK SIDED PAD ONLY)
127mm
127mm
Page 22
Page 23
tRAK-LoK sPACeRs
The Trak-Lok Fastening System includes a range of both insulated and non-insulated spacers to allow the use of various rail sizes in the one seat.
non-Insulated spacers
Part Number 2517 where Used This Spacer located on the Field side of DKA42 rails in an AS41 rail seat in conjunction with Spacer Part No 2252 .
SPACER PART No. 2517
Drawings
DKA42 Rail
Insulated spacers
Part Number 2509 where Used This Spacer (2 off required per rail seat) locates AS47 or AS50 rails in 146mm Insulated Rail Seat in association with Insulated Pad Part No 2212 . This Spacer (2 off per rail seat) also locates AS31 rails in an AS41 Insulated rail seat in association with Insulated Pad Part Nos 2213 & 2214 .
SPACER PART No. 2509 TRAK-LOK LOCK-IN SHOULDER TRAK-LOK 2 CLIP
SPACER PART No. 2552 NON-INSULATED LOCK-IN SHOULDER TRAK-LOK B296 CLIP FIELD SIDE GAUGE SIDE
Drawings
SPACER PART No. 2509
2521
2518
This Spacer located on the Field side of DKA42 rails in 127mm Insulated Rails Seat in association with Insulation Pad Part No 2213 and Spacer Part No 2518 This Spacer located on the Gauge side of DKA42 rails in 127mm Insulated Rails Seat in association with Insulation Pad Part No 2213 and Spacer Part No 2518 This Spacer located on the Field side of WA60lb rails in 127mm Insulated Rail Seat in association with Insulated Pad Part No 2213 and Spacer Part No 2509 .
2522
TRAK-LOK LOCK-IN SHOULDER GAUGE SIDE SPACER PART No. 2519 DKA42 RAIL FIELD SIDE SPACER PART No. 2518 TRAK-LOK 2 CLIP
2519
2528
This Spacer located on the Field side in conjunction with Spacer Part No 2522 located on the Gauge side used to locate WA60lb rails in rail seats designed for AS41 rails . This Spacer located on the Gauge side in conjunction with Spacer Part No 2521 located on the Field side used to locate WA60lb rails in rail seats designed for AS41 rails . This Spacer (2 off per rail seat) used to locate AS31 rails in rails seats designed for AS41 rails . This Spacer (one per sleeper used to maintain gauge when used with AS41 or AS47/50 rails in rail adjustable steel sleepers .
WA 60lb. RAIL
TRAK-LOK 2 CLIP
2529
AS50 RAIL
AS50 RAIL
TRAK-LOK SPACER
2557
FIELD SIDE SPACER PART No. 2557 WA 60lb RAIL GAUGE SIDE SPACER PART No. 2509 TRAK-LOK 2 CLIP
AS41 RAIL
2530
TRAK-LOK INSULATION PAD PART No. 2213
This Spacer (2 off per rail seat) used to locate AS47 / AS50 rails in rails seats designed for AS53 / AS60 rails . This Spacer (2 off per rail seat) used to locate AS31 rails in rails seats designed for AS41 rails at Fishplated Joints .
2534
This Spacer locates AS47 or AS50 rails at joints in 146mm Insulated Rail Seat in association with Joint Insulation Pad Part No 2218 .
2535
Page 24
Page 25
where Used This Spacer (2 off per rail seat) used to locate AS47 / AS50 rails in rails seats designed for AS53 / AS60 rails at Fishplated Joints . This Spacer located on the Field side in conjunction with Spacer Part No 2554 located on the Gauge side used to locate NSW60B (1896) rails in rail seats designed for AS53 rails .
Drawings
where Used This Spacer located on the Field side in conjunction with Spacer Part No 2556 located on the Gauge side used to locate QR41 .25lb or NSW71 .5D rails in rail seats designed for AS53 rails . This Spacer located on the Gauge side in conjunction with Spacer Part No 2555 located on the Field side used to locate QR41 .25lb or NSW71 .5D rails in rail seats designed for AS53 rails . This Spacer (2 off per rail seat) used to locate AS50 rails in rail seats designed for AS60 rails .
FIELD SIDE SPACER PART No. 2555 TRAK-LOK LOCK-IN SHOULDER TRAK-LOK 2 CLIP
Drawings
41.25 lb. RAIL
2545
2556
SPACER PART No. 2554 NON-INSULATED LOCK-IN SHOULDER TRAK-LOK B296 CLIP
FIELD SIDE
GAUGE SIDE
2570
AS50 RAIL TRAK-LOK LOCK-IN SHOULDER NON-INSULATED SPACERS PART NO. 2570 TRAK-LOK CLIP
2551
2552
2553
2554
This Spacer located on the Field side in conjunction with Spacer Part No 2552 located on the Gauge side used to locate 80A and 80AA rails in rail seats designed for AS53 rails . This Spacer located on the Gauge side in conjunction with Spacer Part No 2551 located on the Field side used to locate 80A and 80AA rails in rail seats designed for AS53 rails . This Spacer located on the Field side in conjunction with Spacer Part No 2554 located on the Gauge side used to locate AS31 (60lb) rails in rail seats designed for AS53 rails . This Spacer located on the Gauge side in conjunction with Spacer Part No 2553 located on the Field side used to locate AS31 (60lb) rails in rail seats designed for AS53 rails .
SPACER PART No. 2552 NON-INSULATED LOCK-IN SHOULDER TRAK-LOK B296 CLIP
FIELD SIDE
GAUGE SIDE
NOTE: Other Spacer configurations can be designed to suit special specific installation requirements . Customers to check Spacer availability prior to ordering as tooling for Spacers may be life expired and require replacement .
SPACER PART No. 2554 NON-INSULATED LOCK-IN SHOULDER TRAK-LOK B296 CLIP
FIELD SIDE
GAUGE SIDE
Page 26
Page 27
spacer Dimensions
Spacer width Dist Tolerance (mm) (mm) +/- 0 .1 +/- 0 .1 +/- 0 .1 +/- 0 .1 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 +/- 0 .5 Angle F/Plate Joint Spacer width Dist Tolerance (mm) (mm) Angle
50kg rail steel sleeper system Rail to be Fitted Rail Size WA 60lb 2534 9 .5 +/- 0 .1 12 .5deg 47kg rail steel sleeper system Rail to be Fitted 13 deg 0 5 deg 43 13 deg 12 11deg 18 11deg 18 11deg 18 13 deg 30 13 deg 0 13 deg 0 11deg 18 11deg 18 6 deg 0 6 deg 0 14 deg 0 Rail Size 2535 2537 9 .5 9 .5 +/- 0 .5 +/- 0 .5 11deg 18 11deg 18 WA 60lb Head width 53 .9 Rail Height 115 Rail Foot width 101 .6 Ins or NI Ins Head width 53 .9 Rail Height 115 Rail Foot width 101 .6 Ins or NI Ins
Insulated Spacers 2509 9 .5 2518 5 .0 2519 12 .0 2557 16 .5 Non-Insulated Spacers 2517 11 .1 2521 17 .5 2522 9 .0 2528 9 .5 2529 6 .5 2530 9 .5 2545 30 .0 2551 14 .0 2552 5 .0 2553 24 .0 2554 14 .0 2555 20 .5 2556 4 .8 2570 9 .5
Rail Design Rail Head width Size Height 50kg 70 154 Gauge Side Field Side Gauge Spacer No. Spacer No. achieved 2509 2557 nom
Design Rail Rail Head width Size Height 47kg 70 141 .3 Gauge Side Field Side Gauge Spacer No. Spacer No. achieved 2509 2557 nom
41kg rail steel sleeper system Rail to be Fitted Head Rail Rail Foot Ins or width Height width NI 31kg 63 .5 117 .5 108 NI DKA 42kg 68 .5 138 110 NI 60B or 63lb 63 .5 117 .5 108 NI 75lb 61 .9 122 .2 122 .2 NI WA 60lb 53 .9 115 101 .6 NI 31kg 63 .5 117 .5 108 Ins DKA 42kg 68 .5 138 110 Ins 60B or 63lb 63 .5 117 .5 108 Ins 75lb 61 .9 122 .2 122 .2 Ins * Tooling not available for this Spacer at the present time . Rail Size
Rail Design Rail Head width Size Height 41kg 63 .5 136 .5 Gauge Side Field Side Gauge Spacer No. Spacer No. achieved 2528 2528 nom 2517* 2552 -1mm 2528 2528 nom Nil 2556 -2mm 2522 2521 nom 2509 2509 nom 2519 2518 nom 2509 2509 nom Nil 2518 -1mm
Rail Foot width 127 where Commonly Used Common Tasmania Tasmania Tasmania WA Common Tasmania Tasmania Tasmania
60lb rail steel sleeper system Rail to be Fitted Rail Size 41 .25lb Head width 47 .6 Rail Height 93 .7 Rail Foot width 82 .6 Ins or NI NI
Design Rail Rail Head width Size Height 60lb 63 .5 117 .5 Gauge Side Field Side Gauge Spacer No. Spacer No. achieved 2556 2555 nom
Page 28
Page 29
Part where Used Number 2809 Installation of B296, B286 and Zip9 Trak-Lok Clips . Supplied with angled handle .
Drawings
Trak-Lok steel sleeper systems come complete with a full range of tools to enable the safe application and removal of Trak-Lok Resilient Fastening Clips. Part where Used Number 2802 Installation of B296, B286 and Zip9 Trak-Lok Clips . Supplied with straight handle . Drawings
2902
2803
Installation of B296, B286 and Zip9 Trak-Lok Clips . For use in dual gauge track .
Page 30
Page 31
Drawings
Part where Used Number 2912 Removal of S187L and S195L Trak-Lok Clips on flat Trak-Lok steel sleepers using ballast inspection holes .
Drawings
2904
Removal of S195L TrakLok Clips on rails with a 108mm rail foot . Removal of JS195L TrakLok Clips on rails with a 108mm rail foot . Removal of S195L TrakLok Clips on rails with a 127mm rail foot . Removal of JS195L TrakLok Clips on rails with a 127mm rail foot . Removal of S187L TrakLok Clips on rails with a 127mm rail foot .
spare Parts
Part where Used Number 2806 MK Hook Assembly as A replacement on Part Nos 2802, 2803 and 2809 . Drawings
2905
2913
2914
2906
Page 32
Page 33
= = 50.8 = = 12.7
A 92
18.0 TYP
2701-1
25.4
standards
AS1085 Part 3 Sleeper Plates.
82.8 295
Hole sizes
All holes are located in accordance with OneSteel drawings. Holes are provided in varying configurations to suit the Customers fastening requirements. Each sleeper plate has a designated DF number that is used to identify the sleeper plate. When ordering sleeper plates it is only the abbreviated designation as per the drawing heading that is required to be quoted eg. 127 DSTB DF27.
9.5 12.7
129.4
= 7.9 TYP
182
10
DATUM
= = 51 = = 13 21 TYP DATUM C 13 51
A 95
A 1 25 203
25
21 TYP
DATUM
2702-1
83 295 = 129.4 = 8 TYP
Page 34
14
17.5
Page 35
11.9
25.4
= = 50.8 ==
17.5
50.8
A 92
A 1
00
18.0 TYP
DATUM
2721-0
DATUM
129.4
= 129.4 = 7.9 TYP
7.9
14.3
17.5
18.3
182 139 55
10
DATUM
51
21 TYP.
2700-1
83
= =
24.0 TYP
24.0 TYP
R12.0
TYP
20.6 = =
==
20.6
83
295
295
DATUM
129.4
129.4
7.9
DATUM
A 92
A 1 295
13 21 TYP.
A 98
2704-1
82.8
2719-0
83 295
Page 36
18.3
Page 37
12
10
= 51 ==
25.4
18.0 TYP
21 TYP DATUM C
DATUM
148.4
129.4
7.9
(1 IN 20) 2.86
19.0
201.7
200.0
11.9
11.9
92
DATUM
18.0 TYP
92
25.4
203 12.7
==
2703-1
= =
R12.0 TYP
24.0 TYP
82.8 314
DATUM
148.4
= 148.4 = 7.9 TYP
7.9
2706-1
A 92
= =
92
13
203
25 13 51 A DIM
12.7 50.8
25
21 TYP
2707/1
2705-1
146 DSLB DF69
R12 TYP
84
82.8
315
50.8
12.7 50.8
DATUM
18.0 TYP
= =
25.4
24.0 TYP
Page 38
9.5
19.1
Page 39
notes
Page 40
www.onesteel.com
This publication has been prepared by OneSteel (OneSteel Manufacturing Pty Limited ABN 42 004 651 325) . Please note that the specifications and technical data are subject to change without notice and to ensure accuracy, users of this publication are requested to check the information to satisfy themselves and not to rely on the information without first doing so . Unless required by law the company cannot accept any responsibility for any loss, damage or consequence resulting from the use of this publication . Photographs shown are representative only of typical applications, current at October 2011 . This brochure is not an offer to trade and shall not form any part of the trading terms in any transaction . Trak-Lok is a registered trade mark of OneSteel Manufacturing Pty Limited ABN 42004651 325 . Copyright 2011 . October 2011 . TS0756