prEN 16843
(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 noninsulated 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 132328), and special joints in switch constructions.
Bahnanwendungen - Infrastruktur - Mechanische Anforderungen an Fahrschienenstöße
Diese Europäische Norm behandelt mechanische Schienenstöße für Vignolschienen ab 46 kg/m.
Diese Norm hat folgenden Anwendungsbereich:
- Festlegung der Anforderungen an Isolierstöße und unisolierte Schienenstöße von belasteten Schienen (durchgehend verschweißte Schienen (CWR)) und unbelasteten Schienen (verschraubte Schienen);
- Festlegung der mechanischen und elektrischen Anforderungen an die Typprüfung und Annahme von Isolierstößen, die in einem Werk hergestellt werden (vorgefertigte Herstellung) und von Isolierstößen, die vor Ort zusammengebaut werden (Vor-Ort-Herstellung).
Diese Norm legt die Mindestanforderungen fest. Für besondere Anwendungen, wie z. B. Straßenbahnsysteme, können bezüglich bestimmter Abschnitte andere Anforderungen gelten, die zwischen Verbraucher und Lieferant zu vereinbaren sind.
Vom Anwendungsbereich ausgenommen sind auch Auszugsvorichtungen (die in EN 13232-8 behandelt werden) und besondere Stöße in Weichenkonstruktionen.
Applications ferroviaires - Infrastructures - Exigences mécaniques des joints dans les rails de roulement
La présente Norme européenne traite des joints mécaniques pour rails Vignole de masse supérieure ou égale à 46 kg/m.
Le domaine d’application de la présente Norme est le suivant :
- établir les exigences relatives aux joints isolés et non isolés, pour les rails avec contraintes (longs rails soudés, LRS) et les rails sans contraintes (voie avec joints) ;
- définir les exigences mécaniques et électriques relatives à l’homologation et à l’acceptation des joints isolés fabriqués en usine (construction préfabriquée) et installés sur le chantier (construction sur site).
La présente norme définit les exigences minimales. Les applications spéciales telles, par exemple, que les systèmes de tramway peuvent exiger des demandes différentes dans certains paragraphes et doivent être convenues entre le client et le fournisseur.
Le domaine d’application exclut également les joints de dilatation (ce point est couvert par l’EN 13232-8), ainsi que les joints spéciaux dans les constructions d’aiguillages.
Železniške naprave - Infrastruktura - Mehanske zahteve za spoje v voznih tirnicah
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
01-februar-2020
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 - Infrastructures - Exigences mécaniques des joints dans les
rails de roulement
Ta slovenski standard je istoveten z: prEN 16843
ICS:
45.080 Tračnice in železniški deli Rails and railway
components
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
DRAFT
EUROPEAN STANDARD
NORME EUROPÉENNE
EUROPÄISCHE NORM
December 2019
ICS
English Version
Railway applications - Infrastructure - Mechanical
requirements for joints in running rails
Applications ferroviaires - Infrastructures - Exigences Bahnanwendungen - Infrastruktur - Mechanische
mécaniques des joints dans les rails de roulement Anforderungen an Fahrschienenstöße
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/TC 256.
If this draft becomes a European Standard, 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.
This draft European Standard was established by CEN 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, Turkey and
United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2019 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 16843:2019 E
worldwide for CEN national Members.
Contents Page
European foreword . 4
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 5
4 Symbols and abbreviations . 8
5 Requirements . 10
5.1 General . 10
5.1.1 Design requirements for mechanical rail joints . 10
5.1.2 Joint clearance capacity for jointed track . 10
5.1.3 Maximum rail length for jointed track . 11
5.1.4 Design approval . 11
5.2 Performance requirements for insulated rail joints . 12
5.2.1 Design requirements . 12
5.2.2 Mechanical requirements . 12
5.2.3 Electrical insulation requirements . 13
5.3 Field test requirements . 13
6 Type approval . 13
6.1 Overview . 13
6.2 Non-insulated rail joints . 13
6.3 Insulated rail joints for CWR . 14
6.4 Insulated rail joints for jointed track . 14
7 Test methods . 14
7.1 General . 14
7.1.1 Specimens . 14
7.1.2 Temperature . 14
7.2 Mechanical tests . 15
7.2.1 Mechanical strength test (longitudinal) . 15
7.2.2 Repeated bending test (vertical) . 18
7.3 Electrical insulation tests . 20
7.3.1 Test objective . 20
7.3.2 Test apparatus. 21
7.3.3 Test specimen . 21
7.3.4 Test procedure (dry) . 21
7.3.5 Test procedure (wet) . 22
7.3.6 Test report . 22
7.4 Field tests . 22
8 Acceptance tests for insulated rail joints . 22
8.1 General . 22
8.2 Geometrical and visual inspection . 23
8.3 Electrical insulation tests (only for prefab construction) . 23
8.4 Mechanical tests (only for prefab construction). 23
8.5 Electrical insulation and mechanical tests (only for site construction). 23
9 Identification and marking of insulated rail joints . 23
10 Documentation . 23
Annex A (normative) Fishplates for mechanical rail joints . 24
A.1 Material . 24
A.2 Approval . 24
A.3 Tolerances . 24
A.4 Surface requirements. 25
A.5 Identification . 25
Annex B (normative) Residual gap test . 26
B.1 Test objective . 26
B.2 Test apparatus and test specimen . 26
B.3 Test procedure . 26
B.4 Test report . 26
B.5 Relation to other tests . 27
Annex C (informative) Design of track with mechanical rail joints . 28
Annex D (informative) Static bending test . 31
D.1 Test objective . 31
D.2 Test apparatus and test specimen . 31
D.3 Test procedure . 31
D.4 Test report . 32
D.5 Relation to other tests . 32
Annex E (informative) Formula for bending moment . 33
Annex F (informative) Sample values for minimum tensile strength . 34
Annex G (informative) Sample values for bending moment . 35
Annex H (informative) Values for insulation resistance . 36
Bibliography . 37
European foreword
This document (prEN 16843:2019) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.
The following terms are used within to define the parties involved in using the EN as the technical basis
for a transaction:
— Customer: the Operator or User of the equipment, or the Purchaser of the equipment on the User's
behalf;
— Supplier: the body responsible for the use of the EN in response to the Customer's requirements.
1 Scope
This document deals with mechanical rail joints for permanent use with flat bottom rails 46 kg/m and
above.
The scope of this document 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 on-site
(site construction).
This document 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 of this document excludes all types of mechanical joints for temporary use 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
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
mechanical rail joint
mechanical assembly, for example with fishplates to join two rail ends
3.2
standard mechanical rail joint
mechanical rail joint that connects two rails of the same profile
3.3
transition mechanical rail joint
mechanical rail joint that connects two rail profiles which are different or which compensate for
railhead wear
3.4
non-insulated rail joint
mechanical rail joint which does not separate the rail ends electrically
3.5
insulated rail joint
mechanical rail joint with the additional function to separate the rail ends electrically
3.6
insulated rail joint for jointed track with expansion
insulated rail joint with expansion capacity which can accommodate longitudinal displacement of the
jointed rail length
3.7
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
3.8
insulated rail joint for CWR
insulated rail joint without expansion capacity which can resist the forces in CWR
3.9
prefab construction
manufactured in a factory
3.10
site construction
manufactured in track (on-site) by an assembler
3.11
continuous welded rail
CWR
joint-free rail
rails welded together to form a single rail length longer than a defined length
3.12
rail with joints
rail in jointed track installed at lengths less than a defined length, with expansion gaps provided at
mechanical joints
3.13
fishplate
component applied in mechanical rail joints on each side of the rail on the fishing surfaces
3.14
fishplate bolts
bolts used in mechanical rail joints with special design to fit the fishplates
3.15
end post
insulating component between the two rail ends
3.16
joint clearance
functionally required distance between the two rail ends of a jointed track
3.17
suspended joint
unsupported joint situated between two supports with regular spacing
3.18
supported joint
joint situated on top of one support, one sleeper or a double sleeper
3.19
rail bond
electrical connection for traction currents in jointed track
3.20
rail bolt for earthing
bolt connected to the rail for earth bond
3.21
insulating bush
insulating component between bolt and rail or fishplate
Key
Top: rail ends
Middle: fishplate
Bottom left: insulating bush
Bottom right: fishplate bolt
For insulated joint without expansion: x = e
For mechanical rail joints and insulated rail joints with x = J
n
expansion:
Figure 1 – Definition of parts and design parameters of mechanical rail joints
4 Symbols and abbreviations
Table 1 – Overview of symbols
Symbol Description Unit
A Cross-section area of rail m
rail
D Diameter of fishplate bolt m
b
Df Diameter of holes in fishplate m
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
F Maximum force in repeated bending test N
max
F Minimum tension strength in tension strength test N
s,min
Symbol Description Unit
F Tension strength in tension strength test N
s,t
H Height of rail section m
I Rail moment of inertia 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 nominal
J m
n
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
Lf2 Longitudinal distance between axes of fishplate holes 1 and 2 m
L Longitudinal distance between axes of fishplate holes 2 and 3 (optional) m
f3
L Longitudinal distance between clamps m
h
L Longitudinal distance between rail end and axis of the nearest rail hole 1 m
r1
L Longitudinal distance between axes of rail holes 1 and 2 m
r2
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
N Maximum tension force in the rail due to temperature difference N
max
Q Nominal 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
dmax Maximum average deflection of mechanical rail joint in static bending test m
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
Symbol Description Unit
w Residual gap in residual gap test m
s
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 minimum and
ΔT K
maximum rail temperature)
Temperature difference between neutral (stress-free) and minimum rail
ΔT K
temperature
−1
α Linear thermal expansion coefficient of rail steel K
γ Safety and correction factor -
c
γ Safety factor for variable loads -
s
5 Requirements
5.1 General
5.1.1 Design requirements for mechanical rail joints
The general design shall satisfy the following requirements:
— to connect rail ends in such a way that the assembly may behave 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
J = L – 2L (1)
n f1 r1
Assuming that L = L (4 bolts assembly) and that L = L (6 bolts assembly only), the maximum joint
r2 f2 r3 f3
clearance Jmax is:
J = J + 2.(D – D ) (2)
max n r 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,
min min
and 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
c
jointed track, the rail length for jointed track is limited. The maximum rail length for jointed track L
jt,max
depends 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
— a rule to give the maximum rail length for jointed track L depending on J , on the rail
jt,max c
temperature 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 B;
— 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
t
temperatures).
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
s,min
tensile strength F in stage 2.
s,t
The minimum tensile strength F is calculated as follows:
s,min
F = N · γ
s,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
NOTE Difference between neutral (stress-free) and minimum rail temperature
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
s,t
strength F .
s,min
F > F (6)
s,t s,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.
5.2.2.2 Repeated bending test (vertical)
The mechanical performance on bending is determined by performing the repeated bending test as
described in 7.2.2. The bending moment M which shall be used for the repeated bending test, is
r
calculated 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
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 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 consists of the following two stages, in which it is required:
— 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 consists of the following two stages, in which it is required:
— 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.
For site constructed insulated rail joints it is required to assemble the joints under factory conditions
with the same material, except for the rail, and procedure as per the site design.
6.4 Insulated rail joints for jointed track
The type approval consists of the following two stages, in which it is required:
— 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 ± 5 °C.
Test specimens shall be stored before the test at a temperature of 23 ± 5 °C for at least 24 h.
Tests shall be performed at a temperature of 23 ± 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. If agreed between Customer and
Supplier, an alternative compression test may be substituted.
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.
s,min
The test apparatus shall be able to apply a tension load at a constant rate (load-controlled). The tension
load shall be recorded and expressed in kN with an accuracy of 1 % of the load capacity.
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 produce
...
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