EN 16843:2024
(Main)Railway applications - Infrastructure - Mechanical requirements for joints in running rails
Railway applications - Infrastructure - Mechanical requirements for joints in running rails
This European Standard deals with mechanical rail joints for flat bottom rails 46 kg/m and over. The scope of this standard is: to
establish requirements for insulated and non-insulated rail joints, for stressed rail (continuous welded rail, CWR) and unstressed rail (jointed track); to define mechanical and electrical requirements for type approval and for acceptance of insulated rail joints which are manufactured in a factory (prefab construction) as well as assembled onsite (site construction). This standard specifies the minimum requirements. Special applications as for instance tram systems may require different demands in certain paragraphs and should be agreed between customer and supplier. The scope also excludes expansion joints (it is covered in EN 13232-8), and special joints in switch constructions.
Bahnanwendungen - Infrastruktur - Mechanische Anforderungen an Fahrschienenstöße
Dieses Dokument behandelt mechanische Schienenstöße für den dauerhaften Einbau an Vignolschienen von 46 kg/m und mehr.
Anwendungsbereich dieses Dokumentes:
Festlegung der Anforderungen für isolierte und nicht-isolierte Laschen der Schienenstöße, vorbelastete Schienen (zusammengeschweißte Langschiene (CWR, en: continuous welded rail)) und entspannte Schienen (verbundene Schienen);
Definition der mechanischen und elektrischen Anforderungen an die Bauartzulassung und Abnahme isolierter Schienenstöße, die in einem Werk hergestellt (vorgefertigt) und vor Ort montiert werden (Baustelle).
Dieses Dokument legt die Mindestanforderungen fest. Spezielle Anwendungen wie etwa für Straßenbahnsysteme können unterschiedliche Anforderungen in bestimmten Absätzen erfordern und werden zwischen dem Kunden und dem Lieferanten vereinbart.
Dieses Dokument ist anwendbar für Schienenverbindungen, die aus einem Schienenpaar mit rechtwinkligen oder abgewinkelten Schienenenden bestehen.
Der Anwendungsbereich dieses Dokumentes schließt alle Arten von temporären mechanischen Stößen in Gleisen aus wie beispielsweise während des Gleisbaus oder zur Sicherung gebrochener Schienen und Schweißverbindungen bis zur endgültigen Instandsetzung. Darüber hinaus schließt der Anwendungsbereich Auszugsvorrichtungen (behandelt in EN 13232 8) und Spezialstöße in Weichenkonstruktionen aus.
Applications ferroviaires - Infrastructure - Exigences mécaniques des joints dans les rails de roulement
Le présent document traite des joints mécaniques à usage permanent pour rails Vignole de masse supérieure ou égale à 46 kg/m.
Le domaine d'application du présent document est le suivant :
- établir les exigences relatives aux joints isolés et non isolés, pour les rails soumis à des contraintes de traction (voie en longs rails soudés, LRS) et les rails non soumis à des contraintes de traction (voie en rails éclissés) ;
- définir les exigences mécaniques et électriques relatives à l'homologation et à la réception des joints isolés fabriqués en usine (construction préfabriquée) et installés sur le terrain (construction sur site).
Le présent document définit les exigences minimales. Les applications spéciales, telles que les systèmes de tramway par exemple, peuvent exiger des demandes différentes dans certains paragraphes et il convient qu'elles fassent l'objet d'un accord entre le client et le fournisseur.
Le domaine d'application du présent document exclut tous les types de joints mécaniques destinés à être utilisés provisoirement en voie, par exemple pour la construction de voie ou la sécurisation des soudures et rails cassés avant réparation finale. Le domaine d'application exclut également les appareils de dilatation (voir EN 13232 8), ainsi que les joints spéciaux dans les constructions d'aiguillages.
Železniške naprave - Infrastruktura - Mehanske zahteve za spoje v voznih tirnicah
Ta evropski standard obravnava mehanske tirne spoje za tire z ravnim dnom 46 kg/m ali več. Področje uporabe tega standarda je:
določiti zahteve za izolirane in neizolirane tirne spoje, za napete tire (neprekinjeno zvarjene tirnice, CWR) in nenapete tire (stikovani tir); opredeliti mehanske in električne zahteve za homologacijo in potrditev izoliranih tirnih spojev, ki so izdelani v tovarni (montažna izdelava), in tistih, sestavljenih na kraju samem (izdelava na kraju samem). Ta standard določa minimalna zahteve. Za posebne načine uporabe kot na primer za sisteme tramvajev je morda treba uporabiti drugačne zahteve v določenih odstavkih; o tem naj se dogovorita odjemalec in dobavitelj. Področje uporabe vključuje tudi ekspanzijske spoje (zajete v standardu EN 13232-8) in posebne spoje v konstrukcijah kretnic.
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
01-april-2024
Železniške naprave - Infrastruktura - Mehanske zahteve za spoje v voznih tirnicah
Railway applications - Infrastructure - Mechanical requirements for joints in running rails
Bahnanwendungen - Infrastruktur - Mechanische Anforderungen an Fahrschienenstöße
Applications ferroviaires - Infrastructure - Exigences mécaniques des joints dans les rails
de roulement
Ta slovenski standard je istoveten z: EN 16843:2024
ICS:
45.080 Tračnice in železniški deli Rails and railway
components
93.100 Gradnja železnic Construction of railways
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
EN 16843
EUROPEAN STANDARD
NORME EUROPÉENNE
January 2024
EUROPÄISCHE NORM
ICS 93.100
English Version
Railway applications - Infrastructure - Mechanical
requirements for joints in running rails
Applications ferroviaires - Infrastructure - Exigences Bahnanwendungen - Infrastruktur - Mechanische
mécaniques des joints dans les rails de roulement Anforderungen an Fahrschienenstöße
This European Standard was approved by CEN on 16 July 2023.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this
European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2024 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 16843:2024 E
worldwide for CEN national Members.
Contents
European foreword . 4
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 6
4 Symbols and abbreviations . 8
5 Requirements . 11
5.1 General . 11
5.1.1 Design requirements . 11
5.1.2 Joint clearance capacity for jointed track . 11
5.1.3 Maximum rail length for jointed track . 11
5.1.4 Design approval . 12
5.2 Performance requirements for insulated rail joints . 12
5.2.1 Design requirements . 12
5.2.2 Mechanical requirements . 13
5.2.3 Electrical insulation requirements . 14
5.3 Field test requirements . 14
6 Type approval . 14
6.1 Overview . 14
6.2 Non-insulated rail joints . 14
6.3 Insulated rail joints for CWR . 14
6.4 Insulated rail joints for jointed track . 15
7 Test methods . 15
7.1 General . 15
7.1.1 Specimens . 15
7.1.2 Temperature . 15
7.2 Mechanical tests . 16
7.2.1 Mechanical strength test (longitudinal) . 16
7.2.2 Repeated bending test (vertical) . 19
7.3 Electrical insulation tests . 21
7.3.1 Test objective . 21
7.3.2 Test apparatus. 22
7.3.3 Test specimen . 22
7.3.4 Test procedure (dry) . 22
7.3.5 Test procedure (wet) . 23
7.3.6 Test report . 23
7.4 Field tests . 23
8 Acceptance tests for insulated rail joints . 24
8.1 General . 24
8.2 Geometrical and visual inspection . 24
8.3 Electrical insulation tests (only for prefab construction) . 24
8.4 Mechanical tests (only for prefab construction). 24
8.5 Electrical insulation and mechanical tests (only for site construction). 24
9 Identification and marking of insulated rail joints . 25
10 Documentation . 25
Annex A (normative) Fishplates for mechanical rail joints . 26
A.1 Material . 26
A.2 Approval . 26
A.3 Tolerances . 26
A.4 Surface requirements. 27
A.5 Identification . 28
Annex B (normative) Residual gap test . 29
B.1 Test objective . 29
B.2 Test apparatus and test specimen . 29
B.3 Test procedure . 29
B.4 Test report . 29
B.5 Relation to other tests . 30
Annex C (informative) Design of track with mechanical rail joints . 31
Annex D (informative) Static bending test . 34
D.1 Test objective . 34
D.2 Test apparatus and test specimen . 34
D.3 Test procedure . 34
D.4 Test report . 35
D.5 Relation to other tests . 35
Annex E (informative) Formula for bending moment . 36
Annex F (informative) Sample values for minimum tensile strength . 37
Annex G (informative) Sample values for bending moment . 38
Annex H (informative) Values for insulation resistance . 40
Bibliograpy . 41
European foreword
This document (EN 16843:2024) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by July 2024, and conflicting national standards shall be
withdrawn at the latest by July 2024.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
Any feedback and questions on this document should be directed to the users’ national standards body.
A complete listing of these bodies can be found on the CEN website.
According to the CEN-CENELEC Internal Regulations, the national standards organisations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia,
Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland,
Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North
Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and the United
Kingdom.
1 Scope
This document deals with mechanical rail joints for permanent installation with flat bottom rails 46 kg/m
and above.
The scope of this document is:
— to establish requirements for insulated and non-insulated fish-plated rail joints, for stressed rail
(continuous welded rail, CWR) and unstressed rail (jointed track);
— to define mechanical and electrical requirements for type approval and for acceptance of insulated
rail joints which are manufactured in a factory (prefab construction) as well as assembled on-site
(site construction).
This document specifies the minimum requirements. Special applications as for instance tram systems
can require different demands in certain paragraphs and are agreed between customer and supplier.
This document applies to rail joints formed of a pair of rails, with perpendicular or angled rails ends.
The scope of this document excludes all types of mechanical joints for temporary installation in track,
used for example during track construction or for securing broken rails and welds before final repair. The
scope also excludes expansion devices (covered in EN 13232-8), and special joints in switch
constructions.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
EN 10025-2:2019, Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-
alloy structural steels
EN 10204, Metallic products - Types of inspection documents
EN 13674 (series), Railway applications - Track – Rail
EN ISO 7500-1, Metallic materials - Calibration and verification of static uniaxial testing machines - Part 1:
Tension/compression testing machines - Calibration and verification of the force-measuring system (ISO
7500-1)
EN ISO 21920-2, Geometrical product specifications (GPS) - Surface texture: Profile - Part 2: Terms,
definitions and surface texture parameters (ISO 21920-2)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at http://www.electropedia.org/
3.1
customer
operator or user of the equipment, or the purchaser of the equipment on the user's behalf
3.2
supplier
body responsible for the use of the EN in response to the customer's requirements
3.3
mechanical rail joint
mechanical assembly, for example with fishplates to join two rail ends
3.4
standard mechanical rail joint
mechanical rail joint that connects two rails of the same profile
3.5
transition mechanical rail joint
mechanical rail joint that connects two rail profiles which are different or which compensate for railhead
wear
3.6
non-insulated rail joint
mechanical rail joint which does not separate the rail ends electrically
3.7
insulated rail joint
mechanical rail joint with the additional function to separate the rail ends electrically
3.8
insulated rail joint for jointed track with expansion
insulated rail joint with expansion capacity which can accommodate longitudinal displacement of the
jointed rail length
3.9
insulated rail joint for jointed track without expansion
insulated rail joint without expansion capacity which can only resist the longitudinal forces of a jointed
track
3.10
insulated rail joint for CWR
insulated rail joint without expansion capacity which can resist the forces in CWR
3.11
prefab construction
mechanical rail joints manufactured in a factory
3.12
site construction
mechanical rail joints manufactured in track (on-site) by an assembler
3.13
continuous welded rail
CWR
joint-free rail
rails welded together to form a single rail length longer than a defined length
3.14
rail with joints
rail in jointed track installed at lengths less than a defined length, with expansion gaps provided at
mechanical joints
3.15
fishplate
component applied in mechanical rail joints on each side of the rail on the fishing surfaces
3.16
fishplate bolts
bolts used in mechanical rail joints with special design to fit the fishplates
3.17
end post
insulating component between the two rail ends with the same profile as the rail ends
3.18
joint clearance
functionally required distance between the two rail ends of a jointed track
3.19
suspended joint
unsupported joint situated between two supports with regular spacing
3.20
supported joint
joint situated on top of one support, one sleeper or a double sleeper
3.21
rail bond
electrical connection for traction and/or signalling currents in jointed track
3.22
rail bolt for earthing
bolt connected to the rail for earth bond
3.23
insulating bush
insulating component between bolt and rail or fishplate
4 Symbols and abbreviations
Symbols and abbreviations used in this document are set out in Table 1.
Table 1 — Overview of symbols
Symbol Description Unit
A Cross-section area of the nominal rail profile m
rail
D Diameter of fishplate bolt m
b
D Diameter of holes in fishplate m
f
D External diameter of insulating bush m
ib
D Diameter of holes in rail end m
r
E Young’s modulus of rail steel N/m
F Force in repeated bending test N
F Minimum force in repeated bending test N
min
Fmax Maximum force in repeated bending test N
F Minimum tension strength in tension strength test N
t,min
F Tension strength in tension strength test N
t,s
H Height of rail section m
I Geometrical moment of inertia of rail section m
rail
J Joint clearance capacity m
c
J Minimum joint clearance m
min
J Maximum joint clearance m
max
Nominal joint clearance with rails, fishplates and fishplate bolts at
J m
n
nominal position
J Instantaneous joint clearance m
t
k Track index N/m
L Length of test specimen m
L Characteristic length m
char
L Maximum rail length for jointed track m
jt,max
L Total length of fishplate m
f
L Longitudinal distance between axes of centre holes of the fishplate m
f1
L Longitudinal distance between axes of fishplate holes 1 and 2 m
f2
Longitudinal distance between axes of fishplate holes 2 and 3
L m
f3
(optional)
Lh Longitudinal distance between clamps m
Longitudinal distance between rail end and axis of the nearest rail
L m
r1
hole 1
L Longitudinal distance between axes of rail holes 1 and 2 m
r2
Symbol Description Unit
L Longitudinal distance between axes of rail holes 2 and 3 (optional) m
r3
L Longitudinal distance between vertical supports m
s
L Longitudinal distance between load insertion points m
w
M Maximum bending moment Nm
max
M Required bending moment in repeated bending test Nm
r
M Bending moment in static bending test Nm
s
Nmax Maximum tension force in the rail due to temperature difference N
Q Nominal static wheel load N
d Average deflection of mechanical rail joint in static bending test m
d , d , d , d Deflections of mechanical rail joint in static bending test m
1 2 3 4
Maximum average deflection of mechanical rail joint in static bending
dmax m
test
e Thickness of end post (e = 0 if no end post is used) m
s, s , s Tolerances of fishplate in vertical deflection m
1 2
t, t , t Tolerances of fishplate in transverse deflection m
1 2
ws Residual gap in residual gap test m
w Maximum residual gap in residual gap test m
s,max
w Maximum rail deflection in adjoining track structure m
max
Rail temperature variation in jointed track (difference between
ΔT °C
minimum and maximum rail temperature)
Temperature difference between neutral (stress-free) and minimum
ΔT
1 °C
rail temperature
−1
α Linear thermal expansion coefficient of rail steel K
γ Safety and correction factor -
c
γ Safety factor for variable loads -
s
Figure 1 illustrates the parts of a mechanical rail joint.
a) rail ends
b) fishplate
c) insulating bush d) fishplate bolt
Key
x gap
NOTE 1 For insulated joint without expansion: gap x = e.
NOTE 2 For mechanical rail joints and insulated rail joints with expansion: gap x = J
n
NOTE 3 Figure 1 illustrates a typical configuration not a specific design.
Figure 1 — Definition of parts and design parameters of mechanical rail joints
5 Requirements
5.1 General
5.1.1 Design requirements
The general design shall satisfy the following requirements:
— to connect rail ends in such a way that the assembly behaves as a continuous beam in any direction;
— to limit relative displacements (vertical and lateral) of the rail ends while permitting longitudinal
displacement, if required, for thermal behaviour;
— to be compatible with the rail fastening system.
5.1.2 Joint clearance capacity for jointed track
The joint clearance capacity J is calculated as follows:
c
The nominal joint clearance J is:
n
Jn = Lf1 – 2Lr1 (1)
Assuming that L = L (4 bolts assembly) and that L = L (6 bolts assembly only), the maximum joint
r2 f2 r3 f3
clearance J is:
max
J = J + D + D – 2D (2)
max n r f b
with D ≥ D and D ≥ D .
r b f b
If insulating bushes are used then D shall be used instead of D .
ib b
The maximum joint clearance J shall be equal to the value defined by the customer.
max
The minimum joint clearance J is:
min
J = J – (D – D ) + (D – D ) (3)
min n r b f b
with D ≥ D and D ≥ D .
r b f b
If insulating bushes are used then D shall be used instead of D .
ib b
However, if this formula reveals that J > e then J = e, with e equal to the thickness of the end post, and
min min
e = 0 if no end post is used.
Finally the joint clearance capacity J is calculated as follows:
c
J = J – J (4)
c max min
5.1.3 Maximum rail length for jointed track
As a consequence of the joint clearance capacity, J , of a typical design of a mechanical rail joint for jointed
c
track, the rail length for jointed track is limited. The maximum rail length for jointed track L depends
jt,max
on the variation of rail temperature ΔT, which shall be defined by the customer.
For mechanical rail joints for jointed track, the customer, or the supplier with the approval of the
customer, shall define:
— a table of values for:
— the design temperature;
— the longitudinal distances between the centres of the holes in the rail ends L and in the
r1–3
fishplates L ;
f1-3
— joint clearances J , J , J and the joint clearance capacity J
n max min c;
— the diameter of the holes in the rail ends D and the fishplates D ;
r f
— the diameter of the fishplate bolts D ;
b
— the diameter of the insulating bushes D , if used;
ib
— the maximum number of joints
The fastenings used shall be agreed between the customer and supplier.
— a rule to give the maximum rail length for jointed track L depending on J , on the rail temperature
jt,max c
variation ΔT, and on the lateral and longitudinal resistance of the track.
NOTE See Annex C for an example for the design of a track with mechanical rail joints.
5.1.4 Design approval
The general design of a mechanical rail joint shall be described in technical documentation agreed
between the customer and the supplier including:
— the designation of the rail section according to the EN 13674 series of standards;
— overview drawing of the mechanical rail joint with the identification of the different components of
the rail joint;
— system drawing of track laying with the position of the rail joint axis and the distance between the
supports under the rail joint;
— technical specification for the parameters D , D , D , D , L L , L L and L ;
r f b ib r1 - r3 f1– f3 f
— technical specifications for fishplates, according to Annex A;
— technical specifications for components other than rail and fishplates (bolts, etc.);
— calculation of J in accordance with 5.1.2;
c
— L in accordance with 5.1.3;
jt,max
— installation and maintenance recommendations (including table of J for range of rail temperatures).
t
For transitional mechanical rail joints the technical documentation shall include additional information
for the rail profile on each side.
5.2 Performance requirements for insulated rail joints
5.2.1 Design requirements
The insulated rail joint shall satisfy the general design requirements of the mechanical rail joint as
specified in 5.1.2.
5.2.2 Mechanical requirements
5.2.2.1 Tensile strength test (longitudinal)
The mechanical performance under tension is determined by performing the tensile strength test as
described in 7.2.1. This test requires the minimum tensile strength F for stage 1, and reveals the tensile
t,min
strength F in stage 2.
t,s
The minimum tensile strength F is calculated as follows:
t,min
F = N · γ
t,min max s
= EA · α · ΔT · γ (5)
rail 1 s
9 2
E = 210·10 N/m
−5 −1
α = 1,2·10 K
ΔT to be defined by the customer
γ to be defined by the customer (recommended 1,5)
s
Annex F specifies sample values for a range of rail profiles and maximum temperature differences.
The tensile strength F of the mechanical rail joint shall be greater than the specified minimum tensile
t,s
strength F .
t,min
F > F (6)
t,s t,min
The mechanical performance of the mechanical rail joint is approved if Formula (6) is fulfilled, if no visual
damage is noticed in any of the components of the mechanical rail joint after stage 1 of the tensile strength
test and, if applicable, the electrical insulation requirements are fulfilled. Visual damage is observed
where there are signs of movement between the rails and plates, gaps emerging at the rail ends and/or
signs of physical damage to the components of the joint.
5.2.2.2 Repeated bending test (vertical)
The mechanical performance on bending is determined by performing the repeated bending test as
which shall be used for the repeated bending test, is calculated
described in 7.2.2. The bending moment Mr
as follows (see Annex E for the origin of this formula):
Q EI w
rail max
M = γ (7)
r c
9 2
E = 210·10 N/m
w to be defined by the customer.
max
γ = 1,5 for a suspended mechanical rail joint or 1,0 for a supported mechanical rail joint
c
NOTE See Annex E for alternative values of wheel load and Annex G for sample values for several rail profiles,
nominal wheel loads and maximum rail deflections.
The mechanical performance of the mechanical rail joint is approved if no visual damage is noticed in any
of the components of the mechanical rail joint after the repeated bending test and, if applicable, the
electrical insulation requirements are fulfilled.
5.2.3 Electrical insulation requirements
The electrical insulation performance of an insulated rail joint is established according to the test method
as described in 7.3. The insulation values to be achieved shall be agreed between customer and supplier.
Annex H provides a set of sample values. The insulation values shall not be affected by the range of
temperatures on the network.
The electrical performance of the insulated rail joint is approved if all the aforementioned electrical
insulation requirements are fulfilled.
5.3 Field test requirements
A field test, including a field test report, shall be done as specified in 7.4. The mechanical rail joint is
approved after a positive field test report.
6 Type approval
6.1 Overview
The assembly is designed to achieve the best continuity of the running surfaces and to reduce additional
vertical or lateral displacements due to the interruption in the rails. See Table 2.
Table 2 — Overview of mechanical rail joints
Mechanical rail joint
For continuous
For jointed track
welded rail (CWR)
Insulated with Insulated without
Non-insulated Insulated
expansion expansion
Type approval: Type approval: Type approval:
see 6.2 see 6.4 see 6.3
6.2 Non-insulated rail joints
The type approval shall consist of the following two stages:
— First stage:
— To fulfil design requirements in 5.1;
— For suspended rail joints, to fulfil the bending tests requirements in 5.2.2.2.
— Second stage:
— To fulfil field test requirements in 5.3.
6.3 Insulated rail joints for CWR
The type approval shall consist of the following two stages:
— First stage:
— To fulfil design requirements in 5.2.1;
— To fulfil mechanical requirements in 5.2.2;
— To fulfil electrical insulation requirements in 5.2.3.
— Second stage:
— To fulfil field test requirements in 5.3.
For manufacturing of prefab constructed insulated rail joints used type approval, the factory conditions
and procedures apply.
Where the Infrastructure Manager permits insulated rail joints for CWR to be assembled on-site, testing
shall be done on a site-assembled sample.
6.4 Insulated rail joints for jointed track
The type approval shall consist of the following two stages:
— First stage:
— To fulfil design requirements in 5.1;
— To fulfil mechanical requirements in 5.2.2, except 5.2.2.1;
— To fulfil electrical insulation requirements in 5.2.3.
— Second stage:
— To fulfil field test requirements in 5.3.
7 Test methods
7.1 General
7.1.1 Specimens
In this clause, three different test methods are described. Each of the tests requires its own test specimen.
Therefore, three test specimens are required. The details of the test specimens are given in the following
clauses:
— Tensile strength test – see 7.2.1.3;
— Repeated bending test – see 7.2.2.3;
— Electrical insulation test – see Repeated bending test, 7.2.2.3.
7.1.2 Temperature
The test apparatus shall be in a room where temperature is 23 °C ± 5 °C.
Test specimens shall be stored before the test at a temperature of 23 °C ± 5 °C for at least 24 h.
Tests shall be performed at a temperature of 23 °C ± 5 °C.
7.2 Mechanical tests
7.2.1 Mechanical strength test (longitudinal)
7.2.1.1 Test objective
This section describes a tensile strength test. The objective of the tensile strength test in the longitudinal
direction is to establish the ability of the mechanical rail joint to resist an extreme tension force which
might occur in track, while keeping its performance. Optionally a compression test may be substituted
for the tensile strength test.
7.2.1.2 Test apparatus
For this test, a test apparatus is required with a minimum load capacity of 20 % over the minimum
required value F , as defined in 5.2.2.1. Typically, a load capacity of 2 500 kN will be sufficient.
t,min
The test apparatus shall be able to apply a tension load at a rate (load-controlled). The tension load shall
be recorded and expressed in kN with an accuracy of Class 1 or Class 2 in accordance with EN ISO 7500-1.
The dimensions of the test apparatus shall be such that it can accommodate the test specimen.
7.2.1.3 Test specimen
For this test, a test specimen is required which is produced in accordance with the installation
instructions applicable to this type of mechanical rail joint. However, no coatings for prevention against
corrosion or pollution shall be applied on the test specimen.
The test specimen shall comply with the requirements for design and electrical insulation (if applicable).
The length of the test specimen shall be such that the tension load is introduced safely into the rail at a
distance of at least H/2 from the either end of the fishplates. The line of load application shall be parallel
to the neutral axis of the rail with no more than 5 mm offset (for details: see Figure 2).
No modifications are allowed to the rail and the fishplate within the area starting and ending at H/2 from
either end of the fishplate. Beyond this point, the rail sections can be modified by machining, welding or
drilling in order to accommodate the test apparatus facilities to introduce the tension load. If compression
test is carried out the end post shall be removed and rail ends cleaned to be free from glue.
Dimensions in millimetres
Figure 2 — Tensile strength test arrangement
NOTE Figure 2 shows the arrangement for pull apart test.
7.2.1.4 Test procedure
In case of an insulated rail joint, the electrical insulation test (dry) (see 7.3.4) shall be performed on the
test specimen.
Optionally the residual gap test (see Annex B) is performed. When correctly performed the residual gap
test has no effect on the result of the tension strength test.
Place the test specimen in the test apparatus checking that it is correctly aligned so that an axial tensile
force can be applied
The maximum test load is the required tension strength F , as defined in 5.2.2.1.It is very important
t,min
that the maximum test load is carefully selected. A test specimen can only be tested once in the tension
strength test.
In stage 1, the tension load is increased at a rate of maximum 20 kN/s until F is achieved. Then the
t,min
tension load is decreased at the same rate to 0 kN (see left diagram in Figure 3).
WARNING — This test bears the risk of unexpected collapse of the mechanical rail joint. Appropriate and
sufficient measures shall be taken by those who perform the test to avoid any possible damage.
After stage 1 of the tension strength test, the test specimen is observed for damage. Damage is defined as
follows:
— deformation of any element (bolt,, nut, fishplate, other parts of the mechanical rail joint);
— cracks in any part of the mechanical rail joint;
— cracking or debonding of adhesives (if applicable, debonding is sometimes audible during the test
process).
If none of the above type of damage is observed, then ‘no damage’ is reported.
Optionally the residual gap test (see Annex B) is performed again.
In case of an insulated rail joint, the electrical insulation test (dry) (see 7.3.4) shall be performed again
on the test specimen.
Stage 2 of the tension strength test is performed to determine the tension strength of the mechanical rail
joint F . The tension load is increased at a constant rate of maximum 20 kN/s until collapse of the
t,s
mechanical rail joint or until the maximum tension load of the test apparatus is reached. As soon as the
actual tension load decreases due to collapse of the mechanical rail joint, or as soon as the maximum
tension load of the test apparatus is reached, the tension load is reduced instantly to 0 kN (see right
diagrams in Figure 3). The maximum load, which is recorded during the test, is reported as F and
t,s
expressed in kN with an accuracy of 1 % of the loading capacity.
(a) Maximum tension reached (b) Full and partial collapse
Key
F Force
t Time
x Maximum force F
t,s
1 Loading and unloading speed 20 kN/s maximum
2 Full collapse
3 Partial collapse
Figure 3 — Tensile strength test procedure
7.2.1.5 Test report
The test report shall include, as a minimum, the following information:
— Number, title and date of this European Standard;
— Name and address of the laboratory performing this test, not being the supplier;
— Date test performed;
— Name, type and description of the mechanical rail joint tested;
— Origin and date of manufacturing of the test specimen(s);
— Configuration of the test specimen in the test apparatus;
— Temperature at which the test was performed;
— Value of the maximum tension load F ;
t,min
— A load-diagram of stage 1 of the test (load in kN versus time in s);
— The result of the visual inspection of damage of the mechanical rail joint after the test;
— The results of the electrical insulation test (dry) before and after the test;
— Optionally: the result of the residual gap test before and after the test;
— Value of the tension strength F ;
t,s
— A load-diagram of stage 2 of the test (load in kN versus time in s);
— The result of visual inspection of damage on the mechanical rail joint after stage 2.
7.2.2 Repeated bending test (vertical)
7.2.2.1 Test objective
The objective of the bending test is to establish the ability of the mechanical rail joint to resist the vertical
forces of passing wheels, while keeping its performance.
7.2.2.2 Test apparatus
For this test, a test apparatus is required for 4-point bending tests. An actuator is vertically positioned
over the centre of the test specimen. The load capacity of the actuator shall be sufficient to provide the
required bending moment M (see 7.2.2.4). The load generated by the actuator shall be recorded and
r
expressed in kN with an accuracy of Class 1 or Class 2 in accordance with EN ISO 7500-1. The test
apparatus shall be able to apply a force at a constant rate and a harmonic sinusoidal load at a frequency
of 3 to 10 Hz. Test apparatus shall be in a room where the temperature is 23 °C ± 5 °C.
A load distribution plate with two load application rolls and another two support rolls form the rest of
the test arrangement. The radius of the load application rolls and the support rolls is 25 mm to 75 mm.
The rolls are all fixed, i.e. to the load distribution plate and to the base of the test apparatus (for details
see Figure 4 which illustrates the case for a 4 hole joint).
The centre-to-centre distance of the load application points L is 120 mm to 175 mm, and the centre-to-
w
centre distance of the support points L shall be the length of the fishplate L plus minimum two times the
s f
height of the rail H.
(8)
LH+ 2 ≤L ≤ LH+ 4
( ) ( )
f sf
Figure 4 – Arrangement for static and dynamic bend test
7.2.2.3 Test specimen
For this test, a test specimen is necessary which is produced in accordance with the installation
instructions applicable to this type of mechanical rail joint. However, no coatings for prevention against
corrosion or pollution shall be applied on the test specimen.
The test specimen shall comply with the requirements for design and electrical insulation (if applicable).
The length of the test specimen L shall be at least 150 mm longer than the distance between the support
points L .
s
7.2.2.4 Test procedure
In case of an insulated rail joint, the electrical insulation test (dry) (see 7.3.4) shall be performed first on
the test specimen.
Optionally the static bending test (see Annex D) is performed. When correctly performed the static
bending test has no effect on the result of the repeated bending test.
The test arrangement shall be placed on a horizontal surface under a vertically aligned actuator. The test
specimen shall be aligned horizontally (longitudinally and laterally), so that the centre of the mechanical
rail joint is in line with the centre of the actuator.
Then a maximum test load F is defined, which shall be calculated from the required bending moment
max
M (see 5.2.2.2) and the dimensions of the test arrangement L and L :
r s w
M
r
F = 4 (9)
max
LL−
( )
sw
The loading is between a minimum value F of 5 kN and the maximum value F at a frequency of (3 to
min max
10) Hz. The number of load cycles is 3 million. During this test the maximum temperature of any
component shall not exceed 50 °C. Cooling by fan or a slight reduction in frequency within (3 to 10) Hz,
or a temporary stop in loading can be used to avoid overheating.
After the test, the test specimen is visually inspected for damage. Damage is defined as follows:
— shall be located in the mechanical rail joint area;
— shall be visible with the naked eye;
— can be deformation of any element (bolt, insulating bush, nut, fishplate, other parts of the mechanical
rail joint);
— can be cracks in any part of the mechanical rail joint;
— can be cracking or debonding of adhesives (if applicable).
If none of the above type of damage is observed, then ‘no damage’ is reported.
Optionally the static bending test (see Annex D) is performed again.
In case of an insulated rail joint, the electrical insulation test (dry) (see 7.3.4) shall be performed again
on the test specimen.
7.2.2.5 Test report
The test report shall include at least the following information:
— Number, title and date of this European Standard;
— Name and address of the laboratory performing this test, if not the supplier or manufacturer;
— Date test performed;
— Name, type and description of the mechanical rail joint tested;
— Origin and date of manufacturing of the test specimen(s);
— Configuration of t
...
Questions, Comments and Discussion
Ask us and Technical Secretary will try to provide an answer. You can facilitate discussion about the standard in here.
Loading comments...