Engineering Standard Track

ESC 230 SLEEPERS AND TRACK SUPPORT
Version 4.7 Issued June 2012

Owner: Approved by:

Chief Engineer, Track Andrew Wilson Technical Specialist Wheel/Rail Authorised by: Malcolm Kerr Chief Engineer Track

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

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Engineering Standard

RailCorp Engineering Standard — Track Sleepers and Track Support

ESC 230

Document control
Version 1 2 3 Date October, 2006 April, 2007 October, 2007 Summary of change First issue as a RailCorp document. Includes content from C 3108, C 3109, C 5200, BI 1126, TS 3101, TS 3306, TS 3341, TS 3397, CTN 04/06, CTN 04/17. Minor corrections; inclusion of spacing requirements at bridge ends; inclusion of polymer concrete half sleepers. Inclusion of requirement to keep concrete sleepers clear of points; addition of requirement for use of HD concrete sleepers adjacent to TT bridge ends; clarification of use of recycled timber sleepers; clarification of use of low profile clips; addition to approved products; clarification of use of fastening repair process. Section 5.1.4.4 – Addition of boring requirements for timber sleepers, transoms and bearers; Section 5.7.2 – Correction of caption on Table 14; Section 5.9.2 and 5.9.3 – Clarification of application of fastening systems to bridge transoms; Section 5.9.3 – Clarification of fastening requirements for timber bearers. Appendix 1 – Updating of approved products. New Section 5.1.6 – limits on short sleeper ends; Section 5.9.2 – Inclusion of reference to threaded inserts. Format change; Section 4.9.6 - Resilient fastenings on bridges – addition of requirements for use of resilient fastenings on concrete and masonry bridges; Appendix 1 Approved sleeper and fastening products – Inclusion of Clouth alternative 1 sleeper plates. Section 4.9.5 – additional requirements for Direct Fixation Track; New Section 4.9.7.4 ZLR assemblies; New section 8.2 Acceptance limits for direct fixation track systems; Section 8.3 renumbered; Section 9 - Damage limits added; Appendix 1 - Addition of approved Pandrol S series plates. Appendix 1 - Minor additions to description of approved products. Section 4.9.4 – Table 19 Additional detail of approved Fastclip fastenings; Section 4.9.6.3 - addresses expansion of ballast top bridges; App 1- Additional approved components and suppliers. Section 4.9.4 - Addition of recommended use of elastomeric rail pads adjacent to timber sleepers or turnouts. Section 4.9.5 - Addition of requirement for thicker HDPE pads when used with resilient baseplates and epoxy grout Changes detailed in Summary table below.

4

May, 2008

4.1 4.2

December, 2008 May, 2009

4.3

December, 2009

4.4 4.5

July, 2010 February, 2011

4.6

August, 2011

4.7

June, 2012

Summary of changes from previous version
Summary of change Control Changes Reformatted to new template Section Document Control All

© RailCorp Issued June 2012

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RailCorp Engineering Standard — Track Sleepers and Track Support

ESC 230

Contents
1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5 6 7 8 8.1 8.2 8.3 9 10 10.1 10.2 10.3 Purpose, Scope and Application...........................................................................................4 References...............................................................................................................................4 Australian and International Standards.....................................................................................4 RailCorp Documents .................................................................................................................4 Other References......................................................................................................................4 Design & Performance Criteria..............................................................................................5 Track Configuration...................................................................................................................5 Sleepers and Bearers ...............................................................................................................5 Fastening Assembly Design .....................................................................................................5 Allowable Configurations.......................................................................................................6 Timber Sleepers........................................................................................................................6 Concrete Sleepers ....................................................................................................................9 Direct Fixation .........................................................................................................................10 Polymer Concrete Sleepers ....................................................................................................11 Concrete Guard Rail Sleepers ................................................................................................11 Timber Turnout Bearers ..........................................................................................................11 Concrete Turnout Bearers.......................................................................................................13 Steel Turnout Bearers .............................................................................................................13 Fastening Systems..................................................................................................................13 Prohibited Configurations....................................................................................................20 Mixed Configurations ...........................................................................................................20 Changing Configurations .....................................................................................................21 Acceptance Standards .........................................................................................................21 General....................................................................................................................................21 Direct Fixation Track System (slab track) ...............................................................................21 Sleeper Plates.........................................................................................................................22 Damage Limits.......................................................................................................................22 Repair Standards ..................................................................................................................23 Timber Sleepers and Bearers .................................................................................................23 Concrete Sleepers and Bearers..............................................................................................23 Fastenings...............................................................................................................................23 Approved Sleeper and Fastening Products........................................................24 Approved Repair Processes.................................................................................30 Sleeper Boring Patterns........................................................................................31

Appendix A Appendix B Appendix C

© RailCorp Issued June 2012

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2 (2002) .2 RailCorp Documents ESC 200 .Railway Track Material Part 18: Screwspikes and threaded inserts AS 1085.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 1 Purpose.3 Other References Nil © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 4 of 31 Version 4.Concrete Sleeper Specification SPC 233 . turnout bearers.14 (2003) – Prestressed Concrete Sleepers AS 1085.Railway Track Material Part 8: Dogspikes AS 1085. 2 2.Visually graded .Railway Track Material Part 13: Spring fastening spikes for sleeper plates AS 1085.19 (2003) .1 References Australian and International Standards AS 1085.Railway track timbers 2.Timber .8 (2002) .Railway Track Material Part 3: Sleeper plates AS 1085. acceptance and repair standards for sleepers.13 (2002) .Railway Track Material Part 19: Resilient fastening assemblies AS 3818.18 (2003) .Track Slabs SPC 231 .3 (2002) .Track System ESC 220 . approved configurations. Scope and Application This Standard establishes functional and design requirements. It is applicable to all Rail Corporation main line and siding tracks. and sleeper fastenings.Rail and Rail Joints ESC 362 .Timber Sleeper and Bearer Specification SPC 232 .Resilient Baseplate Specification 2.Concrete Bearer Specification SPC 234 – Resilient Fastening Specification SPC 235 .7 .Heavy structural products . It also includes requirements for concrete guard rail sleepers and fastening requirements for transoms.

for example the need for sleeper plates on timber sleepers.7 . Support Requirements • Track support conditions and deflection criteria. • Geometric requirements including the length and orientation of bearers in points and crossings structures. and traffic task. sleeper bending moments. including sleepers. and sleeper fastenings is specified in ESC 200 Track System. type and spacing. Performance requirements • Need to provide resistance to the lateral buckling of the track. • Need to provide effective support. and traffic task. 3. wheel flats). © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 5 of 31 Version 4. rust. • Sleeper life and treatment (eg.2 Sleepers and Bearers This standard has been developed in consideration of the following criteria: Loading • Service loads (and dynamic response) including effects of track alignment. • Attenuation of vertical impact loads and vibration. Interfaces with other rail infrastructure • Track circuit requirements. fungal rot. inspection and testing requirements. maintenance standards. • Deterioration of the sleeper material (eg. • Rail seat loads. • Sleeper acceptance. • Support of point switching equipment where necessary. • Pressure transmitted to the sleeper rail seat. rail to sleeper pressure and sleeper to ballast pressure.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 3 3. maintenance standards. concrete reactivity.1 Design & Performance Criteria Track Configuration The configuration of track elements. timber preservatives). • Required track modulus.3 Fastening Assembly Design The factors to be considered in determining rail to sleeper fastening assembly design should include the following: Loading • Service loads (and dynamic response) including effects of track alignment. Materials • Sleeper material. and assessment of effectiveness prior to insertion in track. • Resistance to impact loading (eg. 3. turnout bearers. positioning and restraint of the rail (in conjunction with the rail fastening system). white ant attack).

detailed in ESC 200. track alignment irregularities and wheelset steering and hunting. sleeper size shall meet the requirements of Section 4.2 and the standard spacing shall be 600mm. Performance requirements • The need to provide effective support.1 Allowable Configurations Timber Sleepers Selection Sleeper type shall be selected in accordance with the existing or proposed track structure class detailed in RailCorp standard ESC 200. 4 4. Length Width Depth Dimension (mm) 2 440 230 130 Acceptance Tolerance (mm) + 50 − 0 + 10 − 0 + 10 − 0 Table 1 – Timber Sleeper Dimensions © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 6 of 31 Version 4. • The need to provide lateral and torsional restraint (in the horizontal track plane) to the rail against buckling in hot weather.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 • Need to control damage to sleepers by rail seat abrasion.1.1 4. positioning and restraint of the rail (in conjunction with the sleepers and bearers).1. For existing applications in ballasted plain track.1. Support Requirements • Required track modulus.1 Size Standard Sleeper Size Dimensions and acceptance tolerances for timber sleepers shall be in accordance with the requirements of Table 1. • The need to provide rail longitudinal creep resistance when the rail is subjected to thermal loads and vehicle braking and traction forces.7 .2.2 4.1. For the design of new lines. 4. the beam on elastic foundation (BOEF) analysis may be used to determine sleeper size and spacing. • The need to hold rails to gauge and at the correct inclination when subjected to lateral forces caused by vehicle curving. Interfaces with other rail infrastructure • The need to provide electrical insulation where required to enable track circuits to work or to avoid current leakage. All new timber sleepers shall meet the requirements of RailCorp Specification SPC 231.

Length Width Depth Distance from the centre line of the rail to the end of the timber in either direction Distance from the end of the sleeper plate to the end of the sleeper Dimension (mm) 800 230 130 Minimum 345 Minimum 90 Acceptance Tolerance (mm) + 50 − 0 + 10 − 0 + 10 − 0 NA NA Table 2 .2 Recycled Timber Sleepers Recycled timber sleepers (ie sleepers that have previously been used in track) may not be used on main lines with the following exception: • Sleepers are fitted with resilient plates.2 Half Sleeper Size Dimensions and acceptance tolerances for half sleepers for use in the City Tunnels shall be in accordance with the requirements of Table 2.1. Siderophloia E. Dawsonii E. Albens E.1.7 .1.3. Microcorys E. Fibrosa E. Microcarpa E.1 Usage New Timber Sleepers Sleepers shall be cut from timber species nominated in Groups 1 and 2 of Table 3. Propinqua E.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 4. Moluccana E. Treated sleepers are not approved for use. Paniculata E. Crebra E. Acmeniodies E. Camaldulensis E. • Sleepers have been assessed as having a minimum remaining life of 5 years at the new location. • The connection between the plates and the sleeper is sound with no evidence of plate movement. • Recycled sleepers may be used in crossing loops and in sidings. Punctata E.2. Pilularis Group 2 Group 3 Table 3 . Tereticornis E.Timber half sleeper dimensions 4. Approval is required from the Chief Engineer Track to use species from Group 3. Sideroxylon E.Approved timber species 4.3.1.3 4. © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 7 of 31 Version 4. Drepanophylla E. Group Group 1 Common Name Ironbark Grey Ironbark Grey Ironbark Grey Ironbark Red (Broad Leaved) Ironbark Red (Narrow Leaved) Ironbark Red Gum Slaty or Box Slaty Box White Box Grey Box Grey Tallow Wood Gum Grey Gum Grey Gum Forest Red Mahogany White Gum River Red Blackbutt Botanical Name E.

1. dogscrews and lockscrews are detailed in Appendix C.4 4.4. Except at rail joints (See Sect.1. Installation tolerance for new or face resleepering of track sections 2.Sleeper spacing at joints 4.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 4. Skew is the variation from square from one side of the sleeper to the other 3.Sleeper spacing at bridge ends 4.4.3 Spacing at Bridge Ends Spacing of rail support (sleepers. Design Spacing (mm) Operating Class All classes – New bridge structures All classes – Existing bridge structures 600 600 preferred up to 900 subject to approval of Chief Engineer Track Acceptance Tolerance (mm) ± 20 ± 20 Table 6 . © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 8 of 31 Version 4.1. Transoms and Bearers Sleepers.2 Spacing at Rail Joints Spacing of sleepers at rail joints in plain ballasted track shall be adjusted in accordance with Table 5.1.5 Boring Requirements in Timber Sleepers.2) 4.4. Rail (Kg/m) 60 Insulated 53 Insulated 53 Mechanical Glued Insulated Joints (any rail size) All Others Design Spacing (mm) 430 430 510 600 510 Acceptance Tolerance (mm) ± 20 ± 20 ± 20 ± 20 ± 20 Table 5 . lockspikes.7 .1 Spacing Spacing in Open Track Timber sleeper spacing shall be in accordance with Table 4. The patterns for DF 30 sleeper plates using dogspikes.1. Up to 50mm for spacing to allow for missing an aluminothermic weld (only over two sleepers) 4. Sleeper Acceptance Tolerance Spacing (spacing or skew) (mm) (mm) (Note 1. abutment and transoms) at transom topped bridge ends shall be adjusted in accordance with Table 6.4. 4. transoms and bearers shall be bored to match the track plates used in the approved configuration.Timber Sleeper spacing Note: 1.1. 2) ALL Track (mainline & sidings) All classes 600(Note 3) ± 20(Note 4) Operating Class Tolerance Limit/ m 10/6 (±50mm) Table 4 .

be located no closer than 200mm to the end of timber sleepers or bearers.7 .2 4.1. detailed in ESC 200. 4. On Mixed Passenger Freight Main Lines. the selection of heavy duty or medium duty concrete sleeper is governed by the following requirement: © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 9 of 31 Version 4.2500mm 220 .6 Proximity of Plates to Sleeper and Bearer Ends in Turnouts The outer end of sleeper plates shall. Approved designs are detailed in Appendix A.5 25 ± 0.1 Concrete Sleepers Selection There are two types of concrete sleepers 1. Parameter Length Width (at base) depth ( centre of rail seat) Rail seat area (flat surface) Heavy Duty 2390 . normally.2.Fastening hole diameters 4.5 17 ± 0.2 Size The sleepers shall be designed to conform to the dimensions detailed in Table 8. Holes shall be bored completely through the timber.5 14 ± 0.Concrete sleeper dimensions 4.5 18 ± 0.suitable for heavy freight tonnages and axle loads ≤ 30tonne or for providing greater lateral stability 2.5 18 ± 0. Fastening type Dogspikes Lockspikes Dogscrews Lockscrews Screwspikes Hole diameter (mm) 21 ± 0. Only approved designs shall be used.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Hole sizes shall be as detailed in Table 7. Heavy Duty . For existing applications. Medium Duty -suitable for general use with axle loads ≤ 25 tonne.2.2.5 27 mm dia 24 mm dia 22 mm dia Table 7 . all new concrete sleepers shall meet the requirements of RailCorp Specification SPC 232.255 mm 230mm maximum 28800mm2 Medium Duty 180mm maximum 25620mm2 Table 8 . Civil Maintenance Engineers may approve a reduction to no less than 50mm in constrained situations at turnouts and special trackwork 4.3 Use Sleeper type shall be selected in accordance with the existing or proposed track structure class detailed in RailCorp standard ESC 200.5 16 ± 0.

920 (±60mm) 16/11 (±80mm) 10/6 (±50mm) Design Spacing ALL Track 600 (mainline & sidings) Maximum spacing (Sidings ONLY) <25T Axle load 720 25T 650 30T 600 Table 9 . Where concrete sleepers are used as replacement sleepers within existing sections of concrete sleepers they shall reasonably match adjacent sleepers in dimensions and capacity. Heavy duty insulators are not required with 'Fastclip' installations. Operating Class Sleeper Spacing (mm) Tolerance (spacing or skew) (mm) (Note 1) ± 20(Note 2) ± 20 ± 20 ± 20 Tolerance Limit/ m 10/6 (±50mm) 11/7.2. where concrete sleepers are installed adjacent to transom top bridges. heavy duty insulators shall be used for new installations and for replacement of insulators. Up to 50mm for spacing to allow for missing a thermit weld (only over two sleepers) 4.3 Direct Fixation Sleeper spacing >600mm may be designed for direct fixation track structures to a maximum of 700mm where axle loads are ≤ 25t (See Table 10).1 Spacing Spacing in Open Track Concrete sleepers shall be spaced in accordance with the requirements of Table 9.4 4.2.4. a transition zone of eight (8) timber bearers or sleepers is required between the concrete sleepers and the toe of the points. 4.Concrete sleeper spacing Note: 1. twenty (20) Heavy Duty concrete sleepers shall be installed.4. Where concrete sleepers are installed adjacent to turnouts with timber bearers. Concrete sleepers may only be interspersed with timber sleepers where they are in accordance with a specific strategy approved by the Chief Engineer Track. 4.2 Spacing at Bonded Insulated Joints in Open Track Spacing of concrete sleepers at glued insulated joints shall be 600mm (± 20mm).RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 • On sharp curves <400m radius where Pandrol e2003 clips are installed.2. Installation tolerance for new or face resleepering of track sections 2.7 UNCONTROLLED WHEN PRINTED . Operating Class Design Spacing ALL Track (mainline & sidings) Sleeper Spacing (mm) 700 Tolerance (spacing or skew) (mm) ± 10 Tolerance Limit/ m 10/7 (±30mm) Table 10 – Sleeper spacing for direct fixation track © RailCorp Issued June 2012 Page 10 of 31 Version 4. To improve the stability of track approaching transom top bridges.

7 .6. Pedestrian Subway Artarmon. use and spacing shall be in accordance with Section 4. 4. • Allowance for forces and moment induced from points motors and other such equipment. • Allowance for centrifugal forces through curved pairs of rail. Width – Depth – © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 11 of 31 Version 4.6. however some additional considerations may be necessary as follows: • Allowance for additional length of timber bearers over standard sleepers. For existing applications. Circular Quay Viaduct and ESR.4 4.2 Timber Bearer Size Dimensions of timber turnout bearers shall be selected as follows: 250mm 180mm for general application 200mm for bearers on which points motors will be attached. Only approved designs shall be used.6. 4. 4. detailed in ESC 200. Boxed heart timber bearers are only approved for use in depths of 180mm and 200mm. Minimum dimensions for turnout switch and crossing timbers shall be in accordance with the requirements specified in Table 11. Selection. The length shall be rounded up to match the next available size for the selected bearer depth in Table 11. Church Street Underbridge (Parramatta). Further installations shall be designed and approved on a case by case basis.1 Concrete Guard Rail Sleepers Selection Concrete Guard Rail Sleepers are concrete sleepers that have been designed to allow attachment of guard rails inside the running rails in accordance with site specific designs. Current installations include City Underground. Approved designs are detailed in Appendix A.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Other requirements to be determined 4.5.5 4. Approved designs are detailed in Appendix A. Only approved designs shall be used.1 Timber Turnout Bearers Selection Timber bearers for points and crossing structures may be designed using the beam on elastic foundation analysis (BOEF) similar to that used for sleepers.1 Polymer Concrete Sleepers Selection Polymer concrete half sleepers are approved for use in areas where half timber sleepers have previously been installed. all new timber turnout bearers shall meet the requirements of RailCorp Specification SPC 231.6 4.4.1. Length – The minimum length of timber bearers shall be calculated as the measurement from the “Outside” gauge face to “outside” gauge face at the point at which the bearer is to be installed + 1.2m.

6.3.0.4.0.0. Table 11 . 3.8.2 Recycled Timber Bearers Recycled timber bearers (ie bearers that have previously been used in track) may not be used on main lines. 4. Treated timber is not approved for use. Length Width Depth + 50 mm / .8.0.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Width (mm) 250 Depth (mm) 180 200 Standard Timber Lengths Turnouts and Crossovers (m) 2.0. Recycled bearers may be used in crossing loops and in sidings.7 . © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 12 of 31 Version 4.4. 4. 5.2. 3. 6.3 4. 4.0 mm + 10 mm / . Variation of spacing to suit turnout requirements is permitted up to a maximum of 700mm (except at mechanical joints or mechanical insulated joints where the maximum is 600mm).2.4. 3. Punctata E.8.6. Sideroxylon E.2.6.6.8. Moluccana E.4 Spacing Nominal design spacing of timber turnout bearers shall be 600mm. 3. 3.6. 3.Tolerances on timber bearer dimensions 4. Paniculata E. 4. 4.2.1 Usage New Timber Bearers Bearers shall be cut from timber species nominated in Groups 1 and 2 of Table 13. 5.8. 5. 3.3. Microcorys E. 3. Propinqua E. 4.0 mm Table 12 . Drepanophylla E.8. 3. Spacing shall not be less than 500mm. 4.0. Siderophloia E.6.4 2. 4. 6. 5.8.4. Fibrosa E. Acmeniodies Group 2 Table 13 . Microcarpa E. 5.6. 4.2.2. Group Group 1 Common Name Ironbark Grey Ironbark Grey Ironbark Grey Ironbark Red (Broad Leaved) Ironbark Red (Narrow Leaved) Ironbark Red Box Grey Box Grey Tallow Wood Gum Grey Gum Grey Mahogany White Botanical Name E. 5.0 mm + 15 mm . 3.Approved timber species 4.0.2. Crebra E.Timber turnout bearer dimensions The dimensional tolerances shall be in accordance with Table 12. 6.

Spring fastening spikes .7 . detailed in ESC 200. 4. Length Width Depth + 10 mm / .RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 4.8 Steel Turnout Bearers Steel turnout bearers are not approved for use in RailCorp.9. Spacing shall not be less than 500mm. 4.1 Concrete Turnout Bearers Selection Only approved designs shall be used.1 Non-Resilient Fastening assemblies The assembly generally consists of: 1.2 Concrete Bearer Size Limiting dimensions of concrete turnout bearers shall be selected as follows: Width – Depth – Length – 240 – 300mm 220 – 300mm Varies 2. Non-resilient fastening assembly components shall be designed and manufactured to conform to the appropriate Australian Standard as detailed in Table 15. Dogspikes . Sleeper plates .7.2 (two) 16mm lockspikes (or approved equivalent) per sleeper plate.7. 4. all new concrete turnout bearers shall be designed and manufactured in accordance with the requirements of SPC 233.2 (two) 22 mm round shank dogspikes (or approved equivalent) per sleeper plate. 4.3 Spacing Nominal design spacing of concrete turnout bearers shall be 600mm.5 mm ± 3 mm ± 3 mm Table 14 . For existing applications. and 3. and 2.9 Fastening Systems Resilient or non-resilient fastening systems shall be selected in accordance with the existing or proposed track structure class detailed in RailCorp standard ESC 200.Tolerances on concrete bearer dimensions 4.These shall be double shouldered and shall provide a nominal rail cant of 1 in 20 towards the centre of the track (except in special circumstances such as turnouts). Variation of spacing to suit turnout requirements is permitted up to a maximum of 700mm (except at mechanical joints or mechanical insulated joints where the maximum is 600mm). Approved designs are detailed in Appendix A.7 4.7. © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 13 of 31 Version 4.5m to 7.5m The dimensional tolerances for approved designs shall be in accordance with Table 12.

and 3. Base plates.13 AS 1085. Approved non-resilient fastenings are detailed in Appendix A. Screwspikes .9.7 . the assembly generally consists of: 1. and 3. Cast in shoulders . all new resilient fastenings shall be designed and manufactured in accordance with the requirements of SPC 234. and 4.2 (two) Pandrol clips (or approved equivalent) per rail. 4. and 2.18 AS 1085. Sleeper plates . Insulators. © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 14 of 31 Version 4.4 (four) 16mm lockspikes (or approved equivalent) per sleeper plate.2 (two) Pandrol clips (or approved equivalent) per sleeper plate. For concrete sleepers. transoms and turnout bearers. Resilient rail clips . detailed in ESC 200. Resilient fastening assembly components shall be designed and manufactured to conform to the appropriate Australian Standard as detailed in Table 16.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Component Fastenings⎯ dogspikes (and equivalent fastenings) lockspikes (and equivalent fastenings) screw spikes Sleeper plates Standard AS 1085.These are integral to the design of the sleeper 2.2 (two) Pandrol clips (or approved equivalent) per sleeper plate. the assembly generally consists of: 1.4 (four) 24mm screwspikes (or approved equivalent) per plate.2 Resilient Fastening Assemblies For timber sleepers. rail seat pads. For concrete turnout bearers. the assembly generally consists of: 1.8 AS 1085. For existing applications.These shall be double shouldered and shall provide a nominal rail cant of 1 in 20 towards the centre of the track (except in special circumstances such as turnouts). Resilient rail clips . Resilient rail clips . Approved configurations are detailed in Table 17.3 Table 15 . and 3.Australian standards for non resilient fastening assemblies Only approved fastenings and configurations shall be used. and 2. Spring fastening spikes .

Approved configurations for concrete sleepers are detailed in Section 4.9.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Component Fastenings⎯ clips lockspikes screw spikes Sleeper plates Threaded Inserts Cast-in components Standard AS 1085.7 . Approved resilient fastenings are detailed in Appendix A.19 Table 16 . bridge transoms and turnout bearers are detailed in Table 17. © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 15 of 31 Version 4.9. Approved configurations for direct fixation are detailed in Section 4.18 AS 1085.9. Special arrangements apply for the fastening of chairs to A and B timber bearers in turnouts.3 Fastenings for Timber Sleepers.3 round hole for transoms with larger screwspikes AS 1085.Australian standards for resilient fastening assemblies Only approved fastenings and configurations shall be used. transoms and turnout bearers are detailed in Section 4.3.4.13 AS 1085. Approved fastening configurations for timber sleepers. These are detailed in Table 18.5 4.18 AS 1085.9.19 AS 1085. Transoms and Bearers Standard configurations of fastening assemblies for timber sleepers.

Non resilient fastenings on transoms should be upgraded to resilient fastenings when transoms are renewed © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 16 of 31 Version 4.9. 5. . transoms and bearers) General Yard Passenger operations/ or 2 Dogspikes (Note 1) maintenance Passenger Siding Engineering Maintenance Siding 2 Dogspikes (Note 1) Resilient Main Lines ALL classes 2 Resilient E2003 ALL classes For existing installations ONLY CANNOT be reinstalled when sleeper is replaced Turnouts in ALL classes Transoms in ALL classes PREFERRED Insulated Joints in ALL classes Sidings ALL classes ALL classes DF 30 2 DF 30 NIL 2 NIL DF 62 & cast plates Reformed plates Appropriate baseplates DF 62 & cast plates Type ISP96486 S plates DF 62 DF 62 4 2 lockspikes + 2 Gauge lockspikes (or approved alternatives) (Note 3) 4 4 (. Lockspikes (Note 2) No per Plate Non Resilient (for existing installations ONLY) Main Lines (includes sleepers.6.6. Round shank dogspikes or approved alternative fastenings may be used. In electrified or track circuited areas. transomsNote 5 and bearers) Passenger Main Line (Note 1) Mixed Passenger Freight Main Line 2 Dogspikes Light Line Sidings (includes sleepers. 4. Gauge lockspikes are approved for existing installations only and shall not be used in new installations.Timber sleeper fastening configuration Note: 1.note 4) 4 X 24mm screw spikes (Note 4) 4 4 2 lockspikes + 2 Gauge lockspikes (or approved alternatives) (Note 3) 4 2 Resilient E1853 2 Resilient 2 Resilient E2003 2 Resilient Low profile clips e1627 (timber) 2 Resilient E2003 For existing installations ONLY CANNOT be reinstalled when sleeper is replaced 2 Resilient E1853 Reformed plates Turnouts in ALL classes 2 Resilient Table 17 . alternatives are detailed in Section 4.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Operating Class Fastening Type No. where one of the spikes would cause shorting to the underframe of a steel underbridge.9. Lockspikes (L6) or approved alternative fastenings may be used. No. per Plate/ Rail Sleeper Plates Dwg. 3 (three) spikes per plate may be used on curves ≥300m radius. preferably with the two spikes on the gauge side of the rail. They CANNOT be re-installed when a sleeper is replaced. Approved alternatives are detailed in Section 4.2 and Appendix A 2.2 and Appendix A Approved 3.7 .

7 . © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 17 of 31 Version 4. Fastclip or other approved alternatives.9. The default minimum resilient system shall be Type 1 as specified in SPC 235 (e. per Plate/ Rail 2 Resilient E2003 2 Resilient E2003 or 2 Fastclip FC1507 2 Resilient E2003 or 2 Fastclip FC1507 2 Resilient E2003 Low profile clips e1629 or Fastclip FC1507 Low profile clips e1627 Table 19 . the following requirements apply: • Conforming fastening systems shall use Pandrol E-2003 clips.4 Fastenings for Concrete Sleepers and Bearers Elastic fastening systems shall be used with concrete sleepers and bearers.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 A & B Timber Bearer Fastening Type New Installations 60kg/m steelwork Screwspikes 53kg/m steelwork Holding down bolts or approved equivalent swage fastenings For Repair/ Replacement 60kg/m steelwork If the screwpikes are no longer able to provide adequate grip or if timber quality is suspect use holding down bolts or approved equivalent swage fastenings 53kg/m steelwork Holding down bolts or approved equivalent swage fastenings Table 18 .g. Delkor Alternative 1 or equivalent). • Resilience of the track system shall be considered. Rail pads of nominal 7. Fabreeka (or equivalent) 10mm elastomeric rail pads should be installed on the last 20 concrete sleepers to moderate the stiffness to an adjoining section of timber sleepers or timber turnout. Approved configurations of fastening assemblies for slab track are detailed in Table 20. Standard configurations of fastening assemblies for concrete sleepers and turnout bearers are detailed in Table 19.5mm thickness for E-clip fastenings and 10mm thickness for Fastclip fastenings shall be used. Conforming fastening systems shall use Pandrol E-2003 clips.9. Fastclip or other approved alternatives.5 Fastenings for Slab Track For Direct Fixation track systems (slab track) or wherever standard sleepers/ bearers are not used. Resilient fastenings are interchangeable for 53 and 60kg rail sections.A & B Timber Bearer fastening configuration 4.Concrete sleeper fastening configuration 4. Sleeper Design Type 4 Type 5 Heavy Duty Medium Duty (Low Profile) Type 6M Heavy Duty Insulated Joints on all concrete sleepers/bearers with cast in shoulders and insulating material Insulated Joints on all concrete bearers with baseplates Fastening Type No.

Slab track fastening configuration Where baseplates are used the minimum requirement is:• curves < 300m radius• curves ≥ 300m radius four screwspikes (two on each side) two screwspikes (one on each side) On slab track where screwspikes are used they shall be fitted with helical spring washers.1 Resilient Fastenings on Bridges Steel Openings Transom top steel openings with spans < 18m • On bridges where resilient fastenings are installed.9. • On bridges where elastic fastenings are installed.6. This can be achieved when using MDFC concrete termination sleepers by setting the lock-in shoulders 6mm clear of the nose end rail. No.9.2 Concrete and Masonry Openings For concrete and other track structures an assessment shall be made of the expansion requirements of the bridge structure as they affect rails. 4. Transom top steel openings with spans ≥ 18m long but < 80m. advice on fastenings requirements shall be obtained from the Chief Engineer Track. Where epoxy grout is used under resilient baseplates the minimum thickness of HDPE pads shall be at least 8mm to reduce the potential for warping of the pads (from thermal warping).6 4. • Provision shall be made for play at the movable end of a bridge for the guard rail "V" to expand and contract (depending on length).6. DF 62 Comments 2 Screwspikes minimum in curves ≥ 300m radius 4 Screwspikes in curves <300m radius Table 20 . Where spans are located on curves <400m radius. Concrete structures with spans ≥ 25m © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 18 of 31 Version 4. 4. allowing limited movement.7 . per Plate/ Rail 2 Resilient PR409 Base Plates Dwg. normal elastic fastenings shall be installed on one third of the span from the fixed end and Zero Load Restraint (ZLR) fastenings installed on the remaining two thirds of the span. Steel bridge spans >80m with expansion switches • On bridges where elastic fastenings are installed. Concrete structures with spans < 25m • On structures where resilient fastenings are installed.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Slab Design ESR & City Railway Fastening Type No. normal elastic fastenings shall be installed on the entire length of each span. normal elastic fastenings shall be installed on the entire length of each span. normal elastic fastenings are to be installed on the entire length of each span.9. ZLR fastenings are used to secure the guardrail nose ends.

9.9. 4.1 Alternative and Special Configurations Pandrol Clips at Insulated Joints Special low profile Pandrol clips shall be used at insulated joints in 53 & 60Kg rails to eliminate contact between clips and fishbolts.9.7. 4. 4. direct fixation track where noise and / or vibration reduction is required. For steel the minimum span to be considered is 18m. 4.2 Approved Alternatives to Dogspikes and Lockspikes The Pandrol (AJAX) Dogscrew and Lockscrew are approved alternatives to dogspikes and lockspikes respectively. transoms and bearers.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 • An assessment shall be made of the expansion needs and appropriate ZLR fastenings installed. There are two types of Lockscrew: Small flange – for general use Large flange – for use with the automatic magnet pickup machine used by production gangs.9. They may be installed with the approval of the Civil Maintenance Engineer. This type cannot be used on rolled Pandrol plates because of the flange interferes with the rolled shoulder and does not sit flush on the plate. ballasted track where noise and / or vibration reduction is required.7. Note: whilst the expansion of concrete is similar to that of steel there is a difference in the temperature variation expected in concrete.7.3 Ballast Top Openings Requirements for expansion of the rails and the ballast must be considered if the span is more than 40m in length otherwise standard fastening systems can be applied. The clips are: • For concrete sleepers and bearers .7 © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED .‘e’1629 • For timber sleepers and bearers . Proposals shall be submitted to the Chief Engineer Track for approval. Any clips that may become foul may be removed as long as sufficient fastenings remain in place to retain gauge security. and at interfaces between ballast and non-ballasted track where graded changes in track stiffness are required Page 19 of 31 Version 4. The Lockscrew consists of a 16mm threaded shank with a flange and 6 lob head.6. The Dogscrew consists of a 19mm threaded shank with a 22mm shoulder below the flange. the same as the Dogscrew.9.‘e’1627 Clearances are compromised with the low profile clips in timber bearers with type PZ 147 and type 1 baseplates. On top of the flange is a 6-lob head designed to fit an E24 drive socket.3 Resilient Baseplate Assemblies Resilient baseplate assemblies may be used as an alternative to standard base plates on timber sleepers.7 4. concrete sleepers and bearers and for direct fixation track applications in the following applications: • • • • bridges where noise and / or vibration reduction is required.

Approved designs are detailed in Appendix A.6. – shall achieve the minimum ballast cleanliness standard. special configurations are required to fit the dimensional restrictions of the baseplate. not random. They are applicable to existing track ONLY. They shall be used in accordance with Section 4. – may only be used with Medium Duty sleepers. 4. All new Resilient Baseplate assemblies shall be designed and manufactured in accordance with the requirements of RailCorp specification SPC 235. • Concrete sleepers may be interspersed with timber sleepers in accordance with the following guidelines.9. 1:3 or 1:4 but with variation of one sleeper position permitted to suit local conditions. – may be used in patterns of 1:3 and 1:4 in poor ballast conditions. – is not suitable for jointed track beyond the limits detailed in ESC 220 for standard welded track. and on line sections where medium duty sleepers may be used. Interspersing: – shall be part of a line strategy. – shall lead eventually to 100% concrete. When used in conjunction with resilient baseplate assemblies. © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 20 of 31 Version 4. – may be installed to a standard pattern of 1:2.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Only approved designs shall be used.7 .7. Configuration type Standard baseplates (with lockspikes or screwspikes) Alternative 1 resilient baseplates "Delkor Egg" resilient baseplates Assembly Pandrol PMP 41027 for AS60kg rail Pandrol 12730 for AS60kg rail Components ZLR Cap 41027 Clip e2079 ZLR Cap 12731 Clip e2079 Insulator IN55088 5 mm Rail Pad RP-65026 Table 21 . – whole curves shall be resleepered and reasonable lengths of tangent track should be done to a consistent pattern.4 Zero Load Restraint (ZLR) Assemblies Zero Load Restraint assemblies allow longitudinal rail movement whilst retaining gauge and limiting upward movement of the rail. but more than this may only be used in ballast of good quality.9. Approved designs are listed in Table 21 and detailed in Appendix A.Zero Load Restraint assemblies 5 Prohibited Configurations The following configurations are not permitted for permanent works on RailCorp trackwork: • • • • • Steel sleepers Non-elastic fastening systems with 60kg/m rail Non-elastic fastening systems with concrete sleepers Elastic and non-elastic fastenings on the same sleeper Elastic fastenings on more than 1 in 3 sleepers in JWR track 6 Mixed Configurations There are some limitations and special requirements when configurations are mixed.

Renewal strategies should be directed to their elimination: • Timber sleepers on curves < 400m radius on mainline track • Non-elastic fastenings in timber sleepers on mainline track • Elastic fastened track on transom topped steel bridges with spans >18m that does not meet the requirements of Section 4. 8. 1 in 3 etc). bearers and fastenings shall be as detailed in Sections 4.Minimum Elastic fastening patterns in backcanted track • When configuration changes are being undertaken by partial resleepering methods they shall be followed through in successive cycles until the changeout is complete. 7 Changing Configurations The following configurations are not desirable.6. 8 8.1 relating to the installation of Zero Load Restraint fastenings.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 • Timber sleepers with elastic fastenings may only be interspersed with timber sleepers with non elastic fastenings in CWR track where they are in accordance with a specific strategy and provided a consistent tie pattern is maintained (eg 1 in 2. • Where backcanting is evident in timber sleepers with non-elastic fastenings. Mixed configurations are not permitted as a final product.2 Direct Fixation Track System (slab track) Track slabs shall be designed and constructed in accordance with the requirements of RailCorp Engineering standard ESC 362 – "Track Slabs". replacement with elastic fastenings shall meet the minimum tie patterns detailed in Table 22 to avoid clip breakage: Tie Pattern 1 in 3 1 in 2 3 6 Limit of backcanting (mm) DS Plates Resilient Plates 5 10 Table 22 .9.1 Acceptance Standards General Acceptance standards for condition and installation of sleepers. In addition at the slab fastening system interface the following acceptance limits apply: © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 21 of 31 Version 4. A consistent tie pattern shall to be maintained. • Timber sleepers with elastic fastenings shall NOT be interspersed with timber sleepers with non elastic fastenings in LWR where this would result in them being more frequent than 1 in 3. 5 and 6.7 .

Slab track acceptance limits 8.5mm NA ± 1 in 400 1 in 100 ± 0. notch marks or oxyacetylene burn marks on the rail seat.5mm at bottom surface.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Item Finished surface of the slab Inward cant of rail Note need for cant transition over 2400mm Differential tilt of the rail seat in the direction of the rail Concavity or convexity of the rail seat in any direction Limit Design level No voids Plain track Turnouts Turnout transition to plain track 0 0 1:20 0 0 to 1:20 Tolerance + 0mm . • DO NOT use any sleeper plates with dogspike holes wider than 25. 9 Damage Limits Normal (Note 1) Track Speed (Normal /XPT) km/hr 20/20 40/40 60/60 80/90 100/115 115/160 Nil Nil 900 700 2 1 5 years 0 0 5 2 Consecutive Missing Sleepers Not at joint Nil Nil Nil Nil Nil At a Joint Nil Nil Nil Nil Nil Spacing (mm) Not at joint 900 900 900 900 900 At a Joint 700 700 700 700 700 Clusters of Consecutive Ineffective Sleepers (only at isolated location) Tangents & Curves 2 2 2 2 2 R>1000m Curves R<1000m 1 1 1 1 1 General Condition Description – Timber Sleepers Well tied 5 years 5 years 5 years 5 years 5 years Ineffective Timber Sleepers at Joints Tangents & Curves 0 0 0 0 0 R>1000m Curves R<1000m 0 0 0 0 0 Rail Movement relative to sleeper.7 . • DO NOT use any sleeper plates with shoulders that are worn to a sharp edge. • DO NOT use any sleeper plates with cracks • DO NOT use any sleeper plates with plate underside concavity or convexity greater than 1mm.5mm Table 23 . • DO NOT use any sleeper plates with lockspike holes wider than 19mm at bottom surface. • DO NOT use any sleeper plates with rail seat width greater than 150 (+1) mm. including effect of rail roll (mm) Horizontal 8 8 8 5 5 Vertical 2 2 2 2 2 Note 1: The limit at or below which no response is required. shoulder or at spike holes.3 Sleeper Plates Acceptance Standards for re-use of sleeper plates shall be as follows • DO NOT use reformed pandrol plates. old pattern plates or single shoulder plates • DO NOT use any sleeper plates with evidence of excessive corrosion. © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 22 of 31 Version 4.

Normal limits for sleeper condition Maximum Limits(Note 2) Track Speed (Normal /XPT) km/hr 20/20 40/40 60/60 80/90 100/115 115/160 1 Nil 1200 900 4 3 28 days Consecutive Missing Sleepers Not at joint 2 2 1 1 1 At a Joint 1 1 Nil Nil Nil Spacing (mm) Not at joint 1500 1500 1200 1200 1200 At a Joint 1200 1200 900 900 900 Clusters of Consecutive Ineffective Sleepers Tangents & Curves 5 5 4 4 4 R>1000m Curves R<1000m 4 4 3 3 3 General Condition Description – Timber Sleepers Not Not Well tied securely securely 28 days 28 days 28 days tied tied Ineffective Timber Sleepers at Joints Tangents & Curves 1 1 1 1 1 R>1000m Curves R<1000m 1 1 1 1 1 Rail Movement relative to sleeper. Note: The Fastclip repair process is NOT approved for repair of consecutive sleepers. Table 25 . including effect of rail roll (mm) Horizontal 12 12 12 12 12 Vertical 6 6 6 6 6 Note 2: The limit beyond which an emergency level response is required.Maximum limits for sleeper condition 1 1 12 6 10 10.2 Concrete Sleepers and Bearers Cast in-situ shoulders may be replaced using an approved process.7 . Approved processes are detailed in Appendix B. 10. 10.1 Repair Standards Timber Sleepers and Bearers Timber sleepers and bearers may be crossbored (once only on each side of each rail) if they are otherwise sound. © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 23 of 31 Version 4.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Table 24 . Approved processes are detailed in Appendix B.3 Fastenings Sleeper fastening components may be repaired using an approved process.

galv. 122mm long.8 Imported by SRA Dwg CV0046205 Westray Eng. painted red. For half polymer/concrete sleepers and 90mm nylon insert.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Appendix A Approved Sleeper and Fastening Products Description Standard/ Drawing Manufacturer/ Supplier Common Item Name Non Resilient Fastenings Dogspike Dogspike Dogspike Gauge Lockspike Lockspike Dogscrew Lockscrew Screw spike Screw spike Spike. RSA Consult. galv. . 6mm thick. AS 1444. high Delkor Dwg DSW . timber sleeper insulated Joints. square shank lock type LG19. 119mm long. 46mm OD.18 SRA Dwg 885-067b or Delkor Delkor Dwg HSR-602e © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 24 of 31 Version 4. track. 27mm dia 165mm long. track. For concrete or Delkor Dwg HSRsleepers. material XK 9261b. forged. round shank.13 Pandrol AS 1085. 106 mm l. track. 16 mm dia.8 Manufactured by SRA Dwg CV0046205 Greg Sewell Forgings AS 1085. 85 mm w. 22mm shank dia. forged. forged. Galvanised Spike. round shank.8 SRA Dwg CV0046205 AS 1085. steel (dogspike) Spike. city underground.13 Pandrol Spike.125 10/11/03 SRA Dwg 205A-374 (CV 0024139) AS 1085. square shank lock type L1. steel (dogspike) Spike. 20 mm dia. For timber. 24mm dia PRE Manufacturer Jinstar Fastener Co Ltd (Tekway) Washer. type e1627 Pandrol e-21027 AS 1085. 24mm dia. 100 mm l.19 Pandrol Dwg e1620002 Pandrol Pandrol Ajax Fasteners Dwg Ajax / Pandrol No SRSG19. 22mm shank dia. track Screw spike. track. Galvanized to AS 1214 Resilient Fastenings Pandrol Clip E series Pandrol Clip E series Rail clip Type e2003. XS1070 Spike. 22mm shank dia.135 19/10/04 Ajax Fasteners Dwg Ajax / Pandrol No TLSB16.01 Delkor tension double helical spring type. 103 mm w. round shank. 119mm long. track Screw spike. Galvanized to AS 1214 Screw spike Spike.7 . Rail clip e1600 series. galvanized AS 1085. 24mm dia. steel (dogspike) Spike. 119mm long. 150mm long. Galvanized 602d Screw spike Spike. lock 25mm ID. track Screw spike. galvanized Screw spike Spike. 9mm Thick Flange. XS1070 DogScrew 22mm Shouldered. 22mm dia. track Screw spike. track. For timber Dwg 885-066b sleepers. track Screw spike. galv.fe6. SRA W&W 205a-381b Delkor 165mm long. AS 1085. Galvanised LockScrew 16mm.

5 mm w. Insulator.for Fastclip use with concrete sleeper having Pandrol Fastclip fastenings Pandrol In-55088 Pandrol Pandrol In-55186 Pandrol 7551 Pandrol 8494 Pandrol Pandrol Pandrol © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 25 of 31 Version 4. concrete insulated Joints. 85 mm w. type FC1509. silicomanganese spring steel XK9261b with plastic toe insulator Pandrol fastclip. 102. 53/60kg rail.for concrete sleeper use with concrete sleeper having pandrol e-clip fastenings.R.H. 108mm long x 40mm w x 20mm h. Rail clip e2079 series. painted blue. concrete sleeper Dual function spacer/insulator for use with 47kg rail in 60kg rail seat. Insulator to suit insulated joint Assemblies. 20mm dia.85. Rail Insulator G. to suit 47-60kg rail Track. eclip fastening (multilok system). 52. 16 mm dia.745 Delkor RAC 02 and RAC-04. steel. Glass reinforced nylon insulator . 53/60kg rail. Plate. 100 mm l. Rail Insulator side Pandrol side post insulator type 7551.54mm toe. (non insulated joints on timber sleepers). SG Iron Serrated Type ‘A’ Clip Standard/ Drawing Pandrol Dwg e1620021 Pandrol e18-20002 Manufacturer/ Supplier Pandrol Pandrol Pandrol Clip E series Pandrol Zero Longitudinal Restraint (ZLR) Plate Pandrol Zero Longitudinal Restraint (ZLR) Cap Fastclip type FC1507 Fastclip type FC1509 Sliding shoulder head Rail clip. including cover Plate in55057. post for use with concrete sleeper having Fastclip Pandrol Fastclip fastenings Rail Insulator toe Pandrol toe insulator type 8494. type FC1507. 106mm l. ‘A’ Clip for guardrails. rail. AS 1444 Zero Longitudinal Restraint Plate 41027 to suit 60kg rolled steel sleeper plate and e2079clip.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Common Item Name Pandrol Clip E series Pandrol Clip E series Description Rail clip e1600 series.125mm long x 54mm w. rail.7 . Railway Rail Clip.18mm dia. material XK 9261b. tunnel clips. Rev A Pandrol In-55061 Pandrol Pandrol Delkor Delkor Pads and Insulators Rail Insulator Insulator. railway Rail Clip. silicomanganese spring steel XK9261b with toe insulator 10293 (white) and Sidepost Insulator 10292 (white) For concrete guard rail sleepers. scheridised. Railway Pandrol e-21108 PMP-41027 Pandrol Pandrol Pandrol 12730 Pandrol Pandrol FC 1507 and Pandrol 8494 Dwg No 10291 Pandrol Pandrol Amatek Rocla Dwg SSP 1456 Delkor S. type e1629 Rail clip e1829 series. black.5mm 47mm heel.glass reinforced nylon.90mm w.98mm lg. ZLR Cap 12731 to suit 60kg Delkor Cologne Egg Pandrol fastclip. rail 2 piece: composite insulator in-55058 with a slope of 1 in 45.to suit 53/60kg rails Rail Insulator Insulator.

Rail pad 163mm wide x 180mm long x 7. cat no 486. 1 in 20 cant. 1 in 20 cant. 1 in 20 cant. 148mm rail Clip type base. 148mm rail Clip type base. railway NSR Studded. double 1 Shouldered 1:20 cant.P.190mm lg x 170mm w x 7mm thk Rail pad for use in Rail pad. 1 : 40 cant Sleeper Plate Screwspike clip type.D. bridge type. Rail pad Grooved. Sleeper Plate Screwspike clip type. Sleeper Plate Screwspike clip type. 1 : 30 cant Sleeper Plate Screwspike clip type. 146mm rail dogspike base.type 9154. Used with 53kg and 60kg rails Rail pad 190mm wide x 190mm long x 5mm thick. H.for Fastclip use with concrete sleeper having pandrol fastclip fastenings Sleeper plates Sleeper Plate Screw spike. Used with 53kg and 60kg rails Rail pad Pandrol HDPE rail pad. HDPE. 148mm rail Clip type base. for concrete sleeper. 4hole. Cat no 430. cat no 420. for use with concrete sleeper having pandrol e-clip fastenings Rail pad Pandrol HDPE rail pad. Zero cant Sleeper Plate Screwspike clip type. 148mm rail Clip type base. for 53/60kg rail/ concrete sleeper.7 . cat no 054 Sleeper Plate Screw spike.3 Pandrol isp95086 Pandrol ISP95486 BHP 2705 127dstb-df10 Pandrol ISP95098 Pandrol ISP96485 S Pandrol ISP96486 S Pandrol ISP96487 S Pandrol ISP96488 S Pandrol ISP96489 S BHP 2706 146dstb-df30 Pandrol isp-95064 Delkor RF 0. cast Clouth alternative Iron-rubber. Sleeper Plate Clip type. cat no 098s. 6hole. Sleeper Plate Double shoulder type.5mm thk. 148mm rail Clip type base. 146mm rail Screwspike base. 02 192 CLA Pandrol Pandrol Pandrol Pandrol Pandrol Pandrol Pandrol Pandrol Pandrol Pandrol Delkor © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 26 of 31 Version 4.rubber. 1 in 20 cant. end holes at 130mm centres Manufacturer/ Supplier Pandrol Pandrol RP-65184C Pandrol RP-65026 Pandrol 8853 Pandrol 9154 Pandrol Pandrol Pandrol Pandrol Pandrol ISP95054 AS 1085. 1 Clip type in 20 cant. Sleeper Plate Clip type. 127mm rail base.178mm lg x 160mm w x 9. clip type. 1 in 80 cant Sleeper Plate Double shoulder type.E. 1 in 20 cant. 148mm Rail Screwspike base. 8mm pad x 110mmw. 146mm rail base. black.HDPE plastic.5mm thick. 1 Clip type in 20 cant. sound damping.. type 8853. cat no 086s. 148mm rail Clip type base.180mm w x 186mm lg x 7. (transfield product-NSR rail). railway Fabreeka/rubber. Rail pad Rail pad. Sleeper Plate Clouth alternative 1.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Common Item Name Rail Insulator Description Standard/ Drawing Pandrol In-55185 Heavy duty insulator assembly type hda2.164mm rail base/50kg rail.. 127 mm rail dogspike base. 1 in 20 cant Sleeper Plate Screwspike clip type. clip type.75mm thk. 60kg rail.

track circuit sleeper. 230mm x 130mm x 2440mm. Type 6M 30t axle load. 20 Type 6M 30t E-clip wire Pattern.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Common Item Name Sleeper Plate Clouth alternative 1 Sleeper Plate Clouth alternative 1 Timber Sleepers Timber Sleeper Timber Sleeper Description Clouth alternative 1. unbored. Bored for Pandrol fastenings Timber.2 Manufacturer/ Supplier Delkor RF 0. system. mass 285kg 30T Concrete Sleeper ARTC Concrete. Pandrol e2003 fastening clip (MDEC). Dog Screw. 60kg rail. Ironbark or approved hardwood Sleeper. mass 232kg 25T Concrete Sleeper Concrete.2 AS 3818. Concrete Sleeper Concrete. ironbark or approved hardwood Sleeper. Bored. double Shouldered 1:20 cant. track circuit Medium duty 25t axle load. 60kg rail. Medium duty low profile 25t Medium Duty axle load. railway Timber.14 Rocla Dwg 90698 B dated 7/06/2006 Rocla AS 1085.7 .2 AS 3818. side holes Sleeper. 230mm x 130mm x 2440mm. Fastclip (HDFCN) SG30/227 Restricted conditions of use – requires approval from Chief Engineer Track Concrete Sleeper Concrete. railway Timber. 230mm x 130mm x 2440mm. Pandrol e-clip fastening system.14 Rocla Rocla © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 27 of 31 Version 4. Heavy Duty Pandrol Fastclip fastening system.14 AS 1085. Dog Screw. double CLA Shouldered 1:20 cant. end holes at 95mm centres Clouth alternative 1. mass 232kg Concrete Sleeper Concrete. (HDEC). Pandrol e2003 fastening system.10.2 AS 3818. 230mm x 130mm x 2440mm lg.2 Timber Sleeper Timber Sleeper Timber Sleeper AS 3818. Heavy Duty 30t axle load. 25T system. Fastclip (HDFC).14 Rocla Concrete Sleepers Concrete Sleeper Concrete. Bored AS 3818. (mass 275kg).14 AS 1085. Pandrol pattern. 30T mass 285kg. Heavy Duty Heavy Duty Pandrol Fastclip fastening system. 53kg new pattern. Pandrol Fastclip fastening Fastclip (MDFC).092 Iron-rubber. Bored Timber. cast Delkor RF 0.14 Rocla Rocla Rocla AS 1085.29. Medium duty low profile 25t Medium Duty Eaxle load. railway Timber. Concrete Sleeper Concrete. 230mm x 130mm x 2440mm ironbark or approved hardwood Sleeper. 230mm x 130mm x 2440mm. Pandrol Fastclip Fastclip fastening Concrete Guardrail Sleepers AS 1085. railway Timber. bored 47kg/80lb AS "A".14 AS 1085.2 AS 1085.092 CL Delkor Standard/ Drawing Delkor Timber Sleeper AS 3818. sound dumping. new pattern. sound damping.Heavy Duty Type 5 30t axle Heavy Duty E-clip load. cast Iron-rubber.

2 to No. Pandrol E-clip fastenings with cast in pandrol shoulders on guardrail and Fastclips on running rail Concrete Guardrail Concrete. 25T axle load.14 Concrete. Pandrol E-clip fastening system Concrete. Pandrol E-clip fastening on guardrail and fastclip on running rail Concrete. Medium Duty Fastclip Guardrail sleeper. Heavy Duty Fastclip Guardrail sleeper. 1 Concrete Guardrail Sleeper Medium Duty Eclip 25T No. Heavy Duty Fastclip Guardrail sleeper. Pandrol E-clip fastening system Concrete. 30T axle load. GR2 to GR6. Medium Duty E-clip Guardrail sleeper. Medium Duty E-clip AS 1085.14 AS 1085. 2 to No. 1 Concrete Guardrail Sleeper Heavy Duty Fastclip 30T No. 30T axle load.1 Concrete Guardrail Sleeper Heavy Duty E-clip 30T No. GR2 to GR6.6 Concrete Guardrail Sleeper Heavy Duty Fastclip 30T Description Standard/ Drawing Manufacturer/ Supplier Concrete. Heavy Duty E-clip Guardrail sleeper. 25T axle load. 30T axle load. Pandrol E-clip fastening on guardrail and fastclip on running rail Concrete.14 Guardrail sleeper. GR1. 30T axle load. 1 Concrete Guardrail Sleeper Medium Duty Fastclip 25T No. 30T. 8 ferrules cast in for cant reducing sleeper plates AS 1085. Pandrol E-clip fastening system Concrete. Heavy Duty Fastclip AS 1085. Medium Duty Fastclip Guardrail sleeper. 25T axle load.14 Guardrail sleeper. Heavy Duty Fastclip Sleeper Guardrail sleeper.14 Concrete.14 Concrete.14 and drawing 785-568 & 785-569 AS 1085. 2 to No. 2 to No.14 and drawing 785 576 © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 28 of 31 Version 4. GR1. FLAT 1.14 AS 1085.14 Guardrail sleeper.6 Concrete Guardrail Sleeper Medium Duty Eclip 25T No. GR1. Pandrol E-clip fastening on guardrail and fastclip on running rail AS 1085. Heavy Duty E-clip AS 1085.14 and drawing 785-568 & 785-569 AS 1085. Pandrol E-clip fastening system AS 1085.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Common Item Name Concrete Guardrail Sleeper Heavy Duty E-clip 30T No.7 .6 Concrete Guardrail Sleeper Heavy Duty Fastclip 30T No. GR1. Heavy Duty E-clip Pandrol E-clip fastenings with cast in 30T pandrol shoulders on guardrail and Pandrol E-clip fastenings on running rail Concrete bearer Concrete bearer. Pandrol E-clip fastening on guardrail and fastclip on running rail AS 1085. GR2 to GR6. 30T axle load.6 Concrete Guardrail Sleeper Medium Duty Fastclip 25T No. 30T axle load. GR2. 25T axle load.

7 .14 and drawings 785 030 and 785 031 RailCorp drawings ACO Polycrete Pty Ltd © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 29 of 31 Version 4.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Common Item Description Name Concrete Guardrail Concrete Guardrail Bearer. Type Bearer AGR1 for “Alternative 1” sleeper plates under running rail. ‘A’ clips hold the guardrail Ordinary AGR1 guardrail sleeper and no. Type Bearer AGR2 to AGR7 for “Alternative 1” sleeper plates under running rail Polymer Concrete Half Sleepers Polymer Concrete Half Sleepers Standard/ Drawing AS 1085.14 and drawings 785 030 and 785 031 Manufacturer/ Supplier AS 1085. 1 in termination set Concrete Guardrail Concrete Guardrail Bearer.

RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Appendix B Repair Item Pandrol Cast in shoulders Pandrol Fastclip shoulders Approved Repair Processes Description Epoxy concrete repair of damaged concrete shoulders Welded repair of Fastclip cast-in shoulder components Standard/ Drawing Manufacturer/ Supplier Pandrol Pandrol © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 30 of 31 Version 4.7 .

7 .53 kg New pattern boring details 1184 337 Sleeper plate footprint 76 90 76 64 76 90 76 64 291 Figure 2 . DF 30 New Pattern A (mm) 1348 B (mm) 171 Comment Lockspike and dogspike arrangement is a mirrored and inverted image of Old Pattern B A B Sleeper plate footprint 38 38 102 38 38 89 64 127 21mm dia dogspike hole OR 43 17mm dia dogscrew hole 16mm dia lockspike hole OR 14mm dia lockscrew hole 337 40 40 43 332 Figure 1 .Boring pattern for Pandrol for 53 & 60kg/m rail © RailCorp Issued June 2012 UNCONTROLLED WHEN PRINTED Page 31 of 31 Version 4.RailCorp Engineering Standard — Track Sleepers and Track Support ESC 230 Appendix C Rail Section 53 kg Sleeper Boring Patterns Plate Cat No.