RUBBER RAIL PADS Scope The Rubber Rail Pads, hereinafter referred to as pad(s), shall be manufactured in accordance with this Specification. General Requirements (@) The pads shall be compatible with the approved fastening system and the sleeper. (>) The pad manufacturer shall be ISO 9001:2015 accredited and shall adhere to a quality assurance protocol and evaluation in accordance with the relevant quality standard. (©) The pad shall have minimum installed working thickness of 10 mm and high attenuation type as defined in Sub-Clause 5.3 of EN 13481-2:2012. (d)__ The Contractor shall ensure that the manufacturer has a calibration system consistent with the recrenrens THSCrSabh SoH for alt mspectton-andest extn hr contractor after compteting is teview, stat submit manttactarersquatity assurcaice pa to the Engineer and obtain the approval of the Engineer prior to commencement of manufacture of pads. The quality assurance plan shall, include checks on raw material, manufacturing process and finished pads, sampling plans and acceptable quality levels. (e) The Contractor shall also submit Inspection and Test Plan (ITP) to the Engineer and obtain the approval of the Engineer prior to commencement of manufacture of the pads Material The base polymer for the rail pad shali be natural rubber. The pad may be manufactured with composite rubber provided the design and performance requirements are satisfied@ (b) © ‘Manufacturing Process Drawings The Contractor shall submit fastening drawings and obtain approval of the Engineer prior to ‘commencement of manufacture of the pads. Process ‘The pad shall be produced using compression molding technique. Dimensions: The pads shall be menufactured to the dimensions and tolerances given_on the approved ' __ drawings. = @ (b) © @ © oO “Testing for Physical and Mechanical Propecties Raw Materi Contractor and manufacturer shall ensure that the raw material used for manufacturing the pads meets the requirements of this Specificati ‘Surface Finish Pads shall be visvally inspected. The area of the pad studs/grooves shall be clean and free from any blemish, Minor blemistes are allowed on all other areas of the pad. Dimensional Accuracy Pads shall be inspected with calibrated inspection equipment. The pads shall conform to the dimensions detailed on the appropriate drawing. Hardness Pads shall be tested for hardness in accordance with BS ISO 48 Method M or equivalent Standard, Test shall be taken on flat strips cut from the length of each pad. Three hardness values shall te measured equally spaced along the length of each strip and the median value recorded, ‘The hardness shall be inthe range of 70-4/- 5 IRHD. Tensile Strength and Elongation ads shall be tested for ultimate tensile strength and pereentage-clongation in-accordance-with- “Test Method BS 180 37, sample type:2 or equivalent standard. shall be removed from the pads to allow a tensile test specimen to be removed from the resultant membrane, The tensile test specimen from rubber pads may be cut ot punched out ‘Three test pieces per pad shall be cut in the longitudinal ditection (rail seat length). The median value shall be recorded as the value for etch property Minimum average tensile strength shall be [5 MPa and minimum average elongation 300%. Electrical Resistivity (Volume Resistivity) Pads shall be tested in accordance with Test Method BS 903: Part C2 or equivalent. | Pads shall be unconditioned and uncoated. The central portion of the pad shall be used for the electrical resistance test. The testis to be undertaken with studs/grooves in place.‘Test voltage shall be {00 volts DC, duration of voltage 60 seconds, minimum electrode diameter 5Omm and minimum guard gap 5 mm. Minimum electrical resistivity shall be tx10* ohm em. (2) Compression set Pads shall be tested in accordance with Test Method BS ISO 815-1 or equivalent. The tests and results shall conform @ Test Compression set: 30 per cent maximum; Duration of test: 22 hours; ‘Temperature: 70 degrees Celsius; ‘Straln-constant:25 per cent; and (il) Test 2 © Compression set: 20 percent maximum; © Duration of test: 70 hours; © Temperature: 23 degrees Celsius; ‘Strain constant: 25 percent; and + Recovery period 30 minutes at 23 degrees Celsius. (h) Load deflection Pads shall be tested in accordance with EN 13146-9 and the pad stiffness shall be between 100 and 150 kN/mn. ‘Tests Prior to Bulk Manufacture Before commencing bulk manufacture of the pads, the Contractor/manufacturer shall conduct the tests listed in Table C 5.6, in accordance with Sub-Clause C 5.4.5 on sample pads. Such samples shall not be specially prepared and shall have been manufactared in the same manner and with same equipment with which regular bulk manufacture will be carried out. The samples shall meet the requirements of Sub-Clause C 5.4.5. The Contractor shall submit the results to the Engineer in an approved format and ‘obtain approval of the Engineer prior to commencement of bulk manufacture of the pads. Table Tests Prior to Bulk Manufacture of Rubber Pads Property I Number of Sampes Raw Material Quality | Contractor shall submit--Certificate of Conformance of raw} ‘Surface Finish Eight sample pads shall be visually inspected ‘Dimensional Accuracy Eight sample pads shall be checked Hardness Five sample pads shall be tested for Rockwell hardness Tensile Strength and Elongation _| Five sample pads shall be tested Electrical Resistivity (Volume | Three sample pads shall be tested Resistivity) Compression Set ‘Three sample pads shall be tested Load Deflection ‘Two sample pads shall be tested