PUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6306 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 4.1 ‘WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE SPECIFICATION WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS [issued by | Track Engineering Department L4, 589 Collins Street, Melbourne, Vic. 3001 Signature Tel: (03) 9619 4498 or Fax: (03) 9619 4440 Prepared by __| G G Bell, Standards and Development Engineer Checked by _ |G G Bell, Standards and Development Engineer [Approved by _ | 8. Held, Department Manager [Authorised by _[D. Patterson, Group Manager ‘© Copyright Public Transport Corporation, Engineering Services 24) AS 2A at bali Division, 1998 o “Track Engineering 24/11/88 Page 119PUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6306 a ENGINEERING SERVICES DIVISION a Infrastructure Engineering Services Group VERSION 1.1 WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS RECORD OF AMENDMENT/CHANGE ‘The amendments noted in the undermentioned amendment list have been incorporated in this copy of the publication: "ANENDHENT | VERSION | VERSION SUMMARY OF CHANGE ‘DOCUMENT USTNO, DATE AUTHORITY 7 TO [oe — [reese Wy Tack Erg z Ti [ Nov 98 | Retormated to confomnTo ENGIWS0B VIO tI | 3 a 5 3 7 = 5 Track Engneeing 24711108 PagezorsPUBLIC TRANSPORT CORPORATION ENG-TE-SPE-6306 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS CLAUSE 1 GENERAL ry 12 13 14 15 16 WELDING OF RAIL USING LONG MODULE LENGTHS. 24 22 23 24 WELDING OF RAIL USING THE ROLLING ANCHOR BLOCK TECHNIQUE ‘TABLE OF CONTENTS PURPOSE ‘SCOPE. es REFERENCE DOCUMENTS DEFINITIONS. RESPONSIBILITIES, RECORDS. GENERAL RESTRICTIONS TO WELDING TRACK WITH LONG MODULE LENGTHS. ADDITIONAL PRECAUTIONS. 2.3.1 Ambient Temperature 2.3.2 Binding of Rail on Curves and Crests 23.3. Tensing of Track in Cold Weather. WELDING PROCEDURE USING LONG MODULE LENGTHS. 2.4.1 Module Length 2.4.2 Rail Anchor Blocks. PAGE Raa R eRe 5 5 5 5 5 5 5 6 6 6 3.1. GENERAL 7 3.2 RESTRICTIONS ON USING THE ROLLING ANCHOR BLOCK TECHNIQUE. 7 3.3 ADDITIONAL PRECAUTIONS. 7 3.3.1 Ambient Temperature 7 3.3.2 Binding of Rail on Curves and Crests 7 3.4 WELDING PROCEDURE USING ROLLING ANCHOR BLOCKS 8 34.1 Rall Foot Marks 8 342 Rail Stability 9 3.4.3 Removing Intermediate Anchor Blocks. 9 3.44 — Reuse of Released Rail Anchors 8 - - Track Engineetng 247798 Pape 3 ofPUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6306 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 ‘WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS. 4._ GENERAL 4.4 PURPOSE ‘This specification sets limits for rail tensing using the technique of rolling anchor blocks. This specification also sets standards for the welding and tensing of CWR with module lengths between 330m and a maximum of 440m, 4.2 SCOPE This specification applies to all mainline rail tracks controlled by the Public Transport Corporation, VicTrack, Viine Infrastructure, Bayside Trains, Hillside Trains and all successors. 4.3. REFERENCE DOCUMENTS. CEC 3187 Instructions Relating to the Laying, Welding, Destressing and Maintenance of Welded Rail Track 1.4 DEFINITIONS Track definitions are as specified in ENG-TE-STD-2101 Rail and Tram Track Definitions cwR Continuously welded rail. Rails welded into a continuous string. Rolling Anchor Blocks The method of rong anchor blocks utilises the rail anchor block of the previous module to secure the next module rather than the Practice of installing a new rail anchor block especially for this purpose as required by CEC 3/87, 1.5 RESPONSIBILITIES This specification applies to all Track Maintenance Managers, Track Engineers, District Engineers, Road Masters, Road Foremen, Track Supervising Officers, Special Gangers, Track Gangers, Track Inspectors and Contractors responsible for, or involved in, the construction, maintenance and inspection of CWR tracks. {tis the responsibilty of the Track Maintenance Manager or Track and District Engineer to nominate those sections of track suitable for tensing using the rolling anchor block technique. Itis the responsibilty of the above officers to ensure that rail welding on mainlines is performed, maintained and monitored in accordance with this specification. 1.6 RECORDS The Track Maintenance Managers, Track and District Engineers or Infrastructure Owner as ‘appropriate shall maintain records of the lengths of track containing sections that have been tensed using rolling anchor block technique. Track Engineering 24711188 Page dof| PUBLIC TRANSPORT CORPORATION ENG-TE-SPE-6306 — ihe ENGINEERING SERVICES DIVISION c Infrastructure Engineering Services Group VERSION 1.1 WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS Weld records shall be prepared in accordance with the “weld repair permission form’ from CEC 3187. 2__ WELDING OF RAIL USING LONG MODULE LENGTHS 24 GENERAL The current instructions for the welding of rail as described in CEC 3/87 permits the welding of ral into CWR using module lengths of up to 330m. This specification allows the welding of rail into CWR using long module lengths of up to 440m, 2.2 RESTRICTIONS TO WELDING TRACK WITH LONG MODULE LENGTHS. The welding and tensing of track using long module lengths is restricted to those sections of track which conform to BOTH the following criteria; a. Restricted to tangents and large radius curves in accordance with CEC3/87 and shall NOT be carried out on curves of less than 520m radius. b. Restricted to tracks of a Class 3 Track quality standard or better. 2.3 ADDITIONAL PRECAUTIONS 2.3.4 Ambient Temperature If possible, welding and tensing of the rail should be performed when the rail temperature of the bulk of the module length is close to but does not exceed 35 degrees Celsius. This will minimise the ‘amount of tensing that is performed during the welding process, 2.3.2 Binding of Rail on Curves and Crests ‘Care must be taken when using this procedure as problems relating to binding of the rail against the rail plates may occur when tensing the rail on curves and crests 2.3.3 Tensing of Track in Cold Weather Due to the increase in the module length, the presence of crests and curves, the possible jamming of the rail on the sleeper plates etc., it may not be possible with the current tensor equipment to adequately tense the rail at low rail temperatures, If itis found that the tensor is unable to stress the rail adequately in accordance with CEC 3/87, the following could be considered; @. — Ashorter module length could be selected b. Rail tensing equipment with more power could be used c. The welding could be delayed to allow the rail temperature to rise to approx. 8 degrees Celsius. ‘Track Engineering 24/11/98 Page SofPUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6306 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS 24 WELDING PROCEDURE USING LONG MODULE LENGTHS ‘The welding and tensing of track using long module lengths shall be performed in accordance with CEC 3/87 with the following alterations and additions; 2.4.1 Module Length ‘Welding of rail modules up to a maximum length of 440m in length is permitted. A Revised Rail Stress Adjustment Table is provided for calculating the correct rail adjustment gaps for the longer rail modules. Refer Appendix 1 2.4.2 — Rall Anchor Blocks ‘The required rail anchor block for modules between 330m and 440m is: a. Track (dogspike fastenings). Full box anchor every second sleeper for 50m. b. Track (resilient fastenings). Resilient rail fastenings on every sleeper for 50m. ‘The rail anchor block for modules of 330m and less shall remain in accordance with CEC3I87. ‘Track Engineering 24/11/98 Page 6 of 8ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 a PUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6306 wv WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS 3__WELDING OF RAIL USING THE ROLLING ANCHOR BLOCK TECHNIQUE 3.4 GENERAL ‘The current instructions for the welding of rail as described in CEC 3/87 demands that each rail ‘module is restrained with a discreet set of rail anchors especially installed for this purpose at each end of each module. ‘The following specification permits the welder to use of the rail anchor block of the previous module to secure the next module rather than the practice of installing a new rail anchor block especially for this purpose. This procedure shall be referred to as the method of roling anchor blocks. 3.2 RESTRICTIONS ON USING THE ROLLING ANCHOR BLOCK TECHNIQUE ‘The welding and tensing of track using the rolling anchor block technique is restricted to those sections of track which conform to BOTH the following criteria; a. Track modules must be longer than 330m. Modules of less than 330m in length should be welded into CWR in accordance with CEC3/67 b. The technique is restricted for use on curves of 520m radii or greater. Modules on curves less than 520m radii should be welded into CWR in accordance with CEC3/87. 3.3 ADDITIONAL PRECAUTIONS 3.3.1 Ambient Temperature {f possible, rail welding and tensing of the rail should be performed when the rail temperature of the bulk of the module length is close to but does not exceed 36 degrees Celsius. This will minimise the amount of tensing that is performed during the welding process 3.3.2. Binding of Rail on Curves and Crests Care must be taken when using this procedure as problems relating to binding of the rail against the fail plates may occur when tensing the rail on curves and crests. Track Engineering 24/1198 Page 7 of9PUBLIC TRANSPORT CORPORATION ay fe ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group ENG-TE-SPE-6306 VERSION 1.1 WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS 3.4 WELDING PROCEDURE USING ROLLING ANCHOR BLOCKS Rail anchors are applied to the module in the same way as describe in CEC 3/87 with the following additions and alterations; a The last anchor block of the previous module shall be used as the first anchor block of the next module. The rail module layout when using the rolling anchor block technique is shown in Diagram 1, Layout for Rail Anchor Blocks. b. The method of determining the length of the modules is shown in Diagram 1, Layout for Rail Anchor Blocks. cc. _ The length of the anchor block is increased as described in Section 2.4. ‘Care must be taken to ensure that each module is properly anchored prior to moving and working ‘on the next module. The use of rail foot marks (refer section 3.4.1) and light tapping of the rail with the rail tensor applied (refer section 3.4.2) is used is used to determine if the rail is stable and anchored property. Diagram 1 Layout of Rolling Anchor Blocks ‘Module Length 1 ‘Module Length 3 330m min 330m min 44om max 440m max +—____—_—___»> A 8 c Module Length 2 330m min 4aom max ‘Anchor blocks are shown as al ——_— ei D 3.4.1 Rail Foot Marks Make a rail foot mark on the field side of the rail wth crayon/chalk by drawing a single continuous line accurately across the rail foot and onto the sleeper plate, ‘Aral footmark shall be made at the mid point of each anchor block prior to tensing ‘The relative movement between the line on the rail foot and the line on the sleeper plate when the rail tensor is applied will indicate the effectiveness of the rail anchors and will be used as a check to ensure the correct final tensing of the track has been achieved. Track Engineering Page bofPUBLIC TRANSPORT CORPORATION | ENG-TE-SPE-6306 ENGINEERING SERVICES DIVISION Infrastructure Engineering Services Group VERSION 1.1 WELDING OF RAILS INTO CWR USING ROLLING ANCHOR BLOCKS 3.4.2 Rail Stability ‘The rail shall be lightly tapped along the full ength of the module whilst watching the rail foot marks. ‘The rail in track is considered stable only f there is NO relative movement between the mark on the rail foot and the mark on the sleeper plate when the rails lightly tapped. Additional rail anchors may be required to achieve adequate rail stability. ‘Welding MUST only proceed ifthe ral is stable and the anchor block of the previous module has resisted the tensile force applied from tensing the adjacent module. 3.4.3 Removing Intermediate Anchor Blocks Following the completion of several modules using the rolling anchor block technique the intermediate anchor blocks may be removed. For example (refer Diagram 1}, following the completion of the tensing of Module 2, the intermediate anchor "B" may be removed. The rail anchors between anchor blocks “A” and °C’ can be redistributed to the 1:4 pattern Following the completion of the tensing of Module 3, the intermediate anchor block "C", may be removed, Refer Diagram 1. The rail anchors between anchor blocks *C* and "D" can be redistributed to the 1:4 pattern. The removal if intermediate anchor blocks can be repeated for all subsequent and intermediate modules. ‘The rail anchor blocks at either end of the total section of CWR track must remain in place and cannot be removed (ie. anchor block "A" and *D”, cannot be removed, refer Diagram 1) 3.44 Reuse of Released Rail Anchors Rall anchors released by the rolling anchor block technique may be reused provided they conform to the appropriate serviceable rail anchor gauge and Engineering Services Drawing No. 102-95. ‘rack Engineering 24711798 Page 9 ofRall Temp (Deg C) APPENDIX 1. RAIL STRESS ADJUSTMENT TABLE 330 170 166 162 158 154 151 147 143 139 135, 131 127 426 120 16 12 108 104 coo (GAP IN MM) 356 183 179 175 m1 167 162 158 184 150 148 142 137 133, 129 125 121 1W7 412 108 104 100 98 92 a7 83 79 5 1 67 62 58 84 50 48 42. a7 33 29 25 24 7 12 coone Rail Length (m) 984 198 193 189 184 180 175 71 166 162 187 153 148 144 139 138 130 126 121 17 112 108 103 99 ed $0 85 81 76 72 67 63 58 54 49 45 49 31 27 22 16 13, ooo ant 212 207 202 197 192 188 183 178 173 168 163 159 156 149 144 139 135 130 125 120 15 aT 101 coon 440 227 221 216 att 208 201 186 190 185, 180 175 170 165 160 184 149 144 139 134 129 124 118 113 108 103