ISRAEL RAILWAYS LTD.

INFRASTRUCTURE DIVISION

Technical Specification
for
Manufacture and Supply of
FRICTION BUFFER-
STOPS,
FIXED BUFFER STOPS
and
BRAKING WHEEL STOP
SETS

No. E-01-0017.1
April 2020
ISRAEL RAILWAYS LTD

FRICTION BUFFER-STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

CONTENTS
1. SCOPE 2
2. REFERENCE DOCUMENTS 2
3. REFERENCE DOCUMENTS 3
4. GENERAL REQUIREMENTS 3
5. TECHNICAL DRAWINGS 7
6. CALCULATIONS AND TESTS 7
7. INSPECTION BY A REPRESENTATIVE OF ISR 7
8. MARKING 8
9. PACKING 9
10. LIST OF FILES (in PDF Format) TO BE SUBMITTED WITH BIDDER'S
PROPOSAL 9
11. LIST OF FILES (in PDF Format) TO BE SUBMITTED BEFORE SIGNING THE
AGREEMENT 11
12. LIST OF FILES (in PDF Format) TO BE SUBMITTED WITH EVERY ORDER 12
TECHNICAL APPENDIX A – DRAWING DSB 2A 17409 – DBS82-1 WHEEL PROFILE 13
TECHNICAL APPENDIX B – STOPING DISTANCE DEFINITION 14
TECHNICAL APPENDIX C - ISRAEL CLIMATE AND ENVIRONNEMENTAL
CONDITIONS 15
TECHNICAL APPENDIX D – EXAMPLE FOR RED AND WHITE REFLECTOR SIGN 16

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

1. SCOPE
1.1 These technical specifications describe the requirements for the
manufacture and supply of Friction Buffer Stops with different
working mechanism methods (friction, hydraulic), and different
amount of energy absorption for restrain Passenger Trains; Freight
Trains; locomitives; and Railbound Construction and Maintenance
Machines ("Railway Vehicles") in emergency cases without
serious injury to the driver and passengers and minimum impact to
the vehicle construction.
1.2 In additionally these technical specifications describe the
requirements for the manufacture and supply of Fixed Buffer Stops
to be installed on track ends.
1.3 In additionally these technical specifications describe the
requirements for manufacture and supply of Braking Wheel Stops
Sets (*), to be installed on rail heads to use on depot tracks and
marshalling yard tracks to stop track motor vehicles, locomotives
or light train. ISR using wheels of several diameters the wheel
profile types are in accordance with UIC510-2; EN13715 --- wheel
type S1002 : h=28, e=32.5, reverse slope 15%; and with DSB82-1
wheel profile type (IC3 trains) (see Technical Appendix A).
(*) Braking Wheel Stops Set - means two braking wheel stops, one
for each rail of the track.
2. REFERENCE DOCUMENTS
EN10204 Metallic products - Types of inspection
documents;
EN12899-1 Fixed, vertical road traffic signs - Part 1: Fixed
signs;
EN13481-2 Railway applications - Track - Performance
requirements for fastening systems - Part 2
Fastening systems for concrete sleepers;
EN13674-1 Track - Rail - Part 1: Vignole railway rails 46
kg/m and above;
EN13715 Railway applications - Wheelsets and bogies -
Wheels - Wheels tread;

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

EN15020 Railway applications – Automatic coupler –

Rescue coupler – Performance requirements,
specific interface geometry and test methods;
ISO1461 Hot dip galvanized coatings on fabricated iron
and steel articles — Specifications and test
methods;
ISO9001 Quality management systems – Requirements;
ISO10684 Fasteners — Hot dip galvanized coatings;
ISO12944 Paints and varnishes — Corrosion protection
of steel structures by protective paint systems;
UIC510-2 Trailing stock: wheels and wheelsets.
Conditions concerning the use of wheels of
various diameters.
Note – The latest edition of the referenced document should be
considered

3. REFERENCE DOCUMENTS
3.1 60E1 Rail Profile as defined in EN13674-1, Annex A,
figure A.23;
3.2 60E2 Rail Profile as defined in EN13674-1, Annex A,
figure A.24;
3.3 Automatic Coupler-Type 10 in accordance with EN15020

4. GENERAL REQUIREMENTS
4.1 The Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets shall be designed for used on railway track with 60E1
Rail Profile and/or 60E2 Rail Profile.
4.2 The Friction Buffer Stops and Fixed Buffer Stops, shall be
designed for use on ballasted track, with concrete sleepers (1667
sleepers per km) and on ballastless track (Slab track), on depot
track (non-ballasted track), with railway track nominal gauge of
1435 [mm], and with rail inclination of 1:30 on concrete bearers
of ballast track and 1:40 slab track.
4.3 The Braking Wheel Stop Sets shall be designed for use on rails in
depot and shunting area with rail inclination of 1:30; 1:40 and of
zero.

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BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

4.4 The Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets shall be designed for restrain Railway Vehicles having
axle load of up to 22.5 [ton].
4.5 The Friction Buffer Stops and Fixed Buffer Stops shall be designed
to enable safety stop of Railway Vehicles running at speed up to
10 [km/h] or at speed up to 15 [km/h], as detailed in the table in
section 4.12.
4.6 The Fixed Buffer Stops shall be designed to enable safely stop of
Railway Vehicles running at speed up to 5 [km/h], as detailed in
the table in section 4.12.
4.7 The Braking Wheel Stop Sets shall be designed with height above
the rail head of 85 or 90 [mm]; and 125 [mm] to enable safely stop
Railway Vehicles running at speed up to 5 [km/h], as detailed in
the table in section 4.12.
4.8 The Friction Buffer Stop and Fixed Buffer Stops shall be designed
to arrest the full range of Railway Vehicles between the heaviest
and lightest using a track without risk of serious injury to people
on the Railway Vehicle. Railway Vehicles shall be brought to a
controlled halt from the determined impact speed with an average
deceleration rate not exceeding 0.15g (1.47 m/s2). Where site
constrains make it unavoidable, lightweight trains may be
subjected to higher deceleration rates, but the average acceleration
rate for any train shall not exceed 0.25g (2.45 m/s 2), as detailed in
the table in section 4.12.
4.9 The Friction Buffer Stops, Fixed Buffer Stops design shall be taken
in consideration absorbing extra energy based on the following
energy coefficient factors - 1.5; 1.8; 2, as detailed in the table in
section 4.12.
4.10 The Friction Buffer Stops and Braking Wheel Stop Sets shall be
design with maximum stopping distance (Lw) (see Technical
Appendix B), as detailed in the table in section 4.12.
4.11 The Friction Buffer Stops and Fixed Buffer Stops shall be designed
with two large side strikes fit to absorb Railway Vehicles with
anticlimbers height of 1030+20
−20 [mm] above top of the rails and
with distance between the center of the two side strikes of 1650+8
−8
[mm], and at the same time to absorb Railway Vehicles with

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BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

buffers height of 1060+20

−20 [mm] above top of the rails, and distance
in between the center of the two side strikes shall be 1750+5
−5 [mm].
In additional to the two side strikes the Friction Buffer Stop shall
be design with center strike fit to absorb Railway Vehicle
Automatic Coupler - Type 10, with height of 1030+10 −10 above top
of the rails.
4.12 The Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets shall be designed in accordance with the following
parameters:
Parameter Friction Friction Friction Friction Friction Fixed Buffer Braking Wheel Braking Wheel
Buffer Buffer Stop Buffer Stop Buffer Stop Buffer hydraulic Stop Stop set Stop set
Stop Type Type Type Type Stop Type Type Type ISR301 Type ISR302
ISR101A ISR102A ISR103A ISR104A ISR105A ISR201A
Impact speed 10 km/h 10 km/h 15 km/h 15 km/h 15km/h 5km/h 5 km/h 5 km/h
Maximum mass 2200 ton 3500 ton 760 ton 760 ton 760 ton 116 ton 101 ton 180 ton
Minimum mass 120 ton 670 ton 410 ton 410 ton 670 ton 44.7 ton -
Rail profile 60E1 60E1 60E1 60E1 60E1 60E1 60E1 60E1
Track gradient -2.5‰ -2.5‰ -2.5‰ -2.5‰ -2.5‰ 0‰ 0‰ 0‰
Maximum
Stopping distance
9 meter 12 meter 7 meter 10 meter 12 meter 3 meter 3 meter
(Lw) (see Technical
Appendix B)
Plain Track
Distance in front of 20 meter 20 meter 20 meter 20 meter 20 meter 100 meter
stop device
Energy safety
1.8 2 1.5 1.8 2 1.8
factor
Average 0.25g 0.25g 0.15g 0.15g 0.15g 0.25g
deceleration (2.45 m/s2) (2.45 m/s2) (1.47 m/s2) (1.47 m/s2) (1.47 m/s2) (2.45 m/s2)
Wheel diameter 850[mm] 920[mm]
Not Not Not relevant trains with and 1010 mm
Not relevant Not relevant Not relevant
relevant relevant wheel type DSB (UIC510-2)
82-1
Center strike in
addition to side + + + + + - Not relevant Not relevant
strike
Braking wheel stop
Not Not
set -height above Not relevant Not relevant Not relevant Not relevant 125[mm] 85mm or 90mm
relevant relevant
the rail head
Sleepers type concrete concrete concrete concrete concrete concrete Not relevant Not relevant

4.13 The Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets life cycle shall not be less than 40 years. A signed
statement approving it shall be submitted.
4.14 The Friction Buffer Stops and Fixed Buffer Stops shall be installed
on electrified track with 25 [kV AC] and/or on non-electrified track
with electrical circuit and/or on track with electronic signaling
and/or on depot track. A signed statement approving it shall be
submitted.
4.15 All components – metallic and non-metallic shall be made of hot
weather resistant materials, suitable for use at ambient temperature
of up to 50 [ᵒC], and rail temperature of up to 70 [ᵒC], and under

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BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

high corrosion conditions. All metallic components shall be

painted or galvanized, and all non-metallic components shall be
UV protected. Israel climate condition shall be considered (see
Technical Appendix C). The certificates approving the
requirements above shall be submitted.
4.16 The components painting shall be done with two layers: the first
layer shall be premier layer, and second layer shall be pearl dark
grey paint (RAL 9023). The second paint layer shall have high
resistance to the environment condition including UV sun
radiation, and corrosion environment, and high resistance to wear,
to comply with ISO12944. Document describing the painting
process and a statement approving its compliance with ISO12944
and with quality control in accordance with ISO9001 shall be
submitted.
4.17 The components galvanizing shall be done with hot dip galvanized
process, to conform the requirements of ISO10684 and ISO1461,
all surfaces shall be thoroughly covered. Documents describing the
galvanizing process and a statement approving its compliance with
ISO10684 and ISO1461 and with quality control in accordance
with ISO9001 shall be submitted.
4.18 The Friction Buffer Stop and Fixed Buffer Stops shall be equipped
with 1[m] length red and white reflector sign in front of it, (see
Technical Appendix D). The reflector sign material shall be of a
material used for traffic reflector sign, with the highest
reflectibility (day and night) in accordance with EN12899.
Certificate of the complince with EN12899 shall be submitted.
In addition, the Friction Buffer Stops and the Fixed Buffer Stop
shall be equipped with affixation plate suitable to carry a red light
illuminator electric device, all to increase safety.
4.19 The Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets Components shall be manufactured in accordance to the
Manufacturer's quality management plan complying with ISO9001
and based on the relevant EN, UIC and ISO standards and these
Technical Specifications. A list of components and the referenced
standards and components test results shall be submitted.
4.20 Detailed List of Sub-Contractors, which are the components
manufacturers, shall be submitted (Name and Factory address, E-
mail, and its experience).

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

The components shall be manufactured only by the components

Manufacturers, which are listed in the Detailed List.
4.21 The Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets installation, maintenance and safety manuals shall be
submitted.

5. TECHNICAL DRAWINGS
5.1 The Technical Drawing, with dimensions and table of Components
with quantity and material main characteristics and coating
material, including relevant EN and/or ISO standards, for each type
of Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets, in accordance with the table in section 4.12 above, shall
be submitted and shall include the following:
 Assembled Friction Buffer Stops, including clamping
components to the track;
 Assembled Fixed Buffer Stops, including clamping
components to the track;
 Assembled Braking Wheel Stop Sets with installation
components, including blow up drawing.
5.2 ISR uses, SKL W14 fastening systems, and the fastening system
overall dimension are inside the envelope described in EN13481-
2 section 5.8. It shall be taken into consideration when the Friction
Buffer Stops, Fixed Buffer Stops and Braking Wheel Stop Sets will
be designed.

6. CALCULATIONS AND TESTS

6.1 For each type of Friction Buffer Stops, Fixed Buffer Stops and
Braking Wheel Stop Sets, as detailed in table 4.12., the energy
absorbing calculation results and limit cases, shall be submitted.
6.2 The test reports, done by the Bidder or in his behalf, and include at
least the following: documentation detailing test date; location and
which laboratory or facility performed the tests; the test procedure;
and test results, shall be submitted.

7. INSPECTION BY A REPRESENTATIVE OF ISR

7.1. The ISR technical team and/or an inspection body appointed by the
ISR ("The Inspector") shall have the privilege to inspect the

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

manufacture processes and/or the Friction Buffer Stops, Fixed

Buffer Stops and Braking Wheel Stop Sets, during and/or after
production.
7.2. It is the manufacturer’s responsibility to guarantee dimensional
accuracy and to ensure that the inspection is carried out with the
appropriate and calibrated measuring instruments.
7.3. The Manufacturer shall be responsible to coordinate inspection
process time table with The Inspector in accordance to the delivery
date defined in the purchase order.
7.4. The Manufacturer shall extend, to The Inspector, all necessary
assistance and cooperation, and shall give access to all test records,
calibrations and calculations that contribute to the results.
7.5. All the gauge/measuring instruments for manufacture verification
and inspection of Friction Buffer Stops, Fixed Buffer Stops and
Braking Wheel Stop Sets shall be made available by The
Manufacturer to The Inspector on request.
7.6. All Tests results shall be made available to The Inspector on
request.
7.7. The Calibration Certificates of the gauge/measuring instruments
signed and other relevant documents shall be made available to The
Inspector on request.

8. MARKING
8.1 Each Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets shall be inscribed with at least the following marks:
 The Manufacturer mark,
 The last two figures of the year of manufacturer,
 The product identification type.
 Drawing number.
 Item type (e.g. ISR101A)
8.2 Each Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets components shall be inscribed with at least the following
marks:
 The Manufacturer mark,
 The last two figures of the year of manufacturer,

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

 The product identification type.

9. PACKING
9.1 The Friction Buffer Stop, Fixed Buffer Stops and Braking Wheel
Stop Sets components shall be packed in wooden boxes and will
put in container.
The dimensions of the wooden shall be according to EN standard,
to enable maximum effective storage capacity in containers.
It shall be possible to put at least 3 wooden boxes one on the other.
wooden boxes will be tied to one another, and to wooden platform
by metal bands, and all shall be wrapped with Stretch wrap.
9.2 Each package shall include packing list with the following details:
o Components name and type;
o Production batch number;
o Date of manufacture;
o Component barcode;
o Component quantity in box;
o Gross and net weight;
o Manufacturer recognition number or name;
o ISR recognition number;
o ISR order number;
o Ordinal number on the packing list.
The labeling shall be with black letters and shall be on 3 spots on
the package (one on top of the package and the two others on the
sides).

9.3 Each type of Friction Buffer Stop, Fixed Buffer Stop and Braking
Wheel Stops Sets shall be delivered with 2 technical drawing and
packing list in the package.

10. LIST OF FILES (in PDF Format) TO BE SUBMITTED

WITH BIDDER'S PROPOSAL
10.1 A signed declaration signed by the manufacturer that the Friction
Buffer Stops, Fixed Buffer Stops and Braking Wheel Stop Sets
estimate life cycle (in years). (see section 4.13)
10.2 A signed declaration signed by the manufacturer that the Friction
Buffer Stops, Fixed Buffer Stops is approved for use on electrified
track with 25 [kV AC] and/or on non-electrified track with

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

electrical circuit and/or on track with electronic signaling and/or

on depot track. (see section 4.14)
10.3 Certificates approving that All components – metallic and non-
metallic shall be made of hot weather resistant materials, suitable
for use at ambient temperature of up to 50 [ᵒC], and rail
temperature of up to 70 [ᵒC], and under high corrosion conditions.
All metallic components shall be painted or galvanized, and all
non-metallic components shall be UV protected. (see section 4.15)
10.4 Document describing the painting process on the Components and
the certificates approving its compliance with ISO12944. (see
section 4.16)
10.5 Document describing the galvanizing process on the Components
and the certificates approving its compliance with ISO10684 and
ISO1461. (see section 4.17)
10.6 Certificate on the Red and White Reflector Sign, with the highest
reflectibility approving its complying with EN12899. (see section
4.18).
10.7 The Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets Components Manufacturer's quality management plan
complying with ISO9001 and based on the relevant EN, UIC and
ISO standards. (see section 4.19)
10.8 Detailed List of Sub-Contractors, which are the Components
manufacturers (Name and Factory address, E-mail, and its
experience). (see section 4.20)
10.9 A sample of Friction Buffer Stop Technical drawing. (see section
5.1)
10.10 A sample of Friction Buffer Stop technical descriptions. (see
section 5.1)
10.11 A sample of Friction Buffer Stop energy absorbing calculation
results. (see section 5.1)
10.12 A sample of Friction Buffer Stop installation, maintenance and
safety manuals. (see section 4.21)
10.13 For each type of Friction Buffer Stops, Fixed Buffer Stops and
Braking Wheel Stop Sets, as detailed in table 4.12., the energy
absorbing calculation results and limit cases. (see section 6.1)

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

10.14 The test reports, done by the Bidder or in his behalf, and include at
least the following: documentation detailing test date; location and
which laboratory or facility performed the tests; the test procedure;
and test results. (see section 6.2)
10.15 The manufacturer shall submit technical drawing of clamping
components dimension design in which envelope interface with
fastening system components is avoided in accordance with
EN13481-2 paragraph 5.8. (see section 5.2)

11. LIST OF FILES (in PDF Format) TO BE SUBMITTED

BEFORE SIGNING THE AGREEMENT
11.1 The manufacturer shall submit the relevant technical descriptions
for each type of the Friction Buffer Stops, Fixed Buffer Stops and
Braking Wheel Stop Sets, in the table, in section 4.12 including:
 The nature and main characteristics of the metallic and non-
metallic material including the mechanical properties and
chemical composite for every component.
 All components shall be conformed to the latest relevant ISO
or EN or UIC standards. A list of components and the
referenced standards shall be supplied.
11.2 The Technical Drawing, with dimensions and table of Components
with quantity and material main characteristics and coating
material, including relevant EN and/or ISO standards, for each type
of Friction Buffer Stops, Fixed Buffer Stops and Braking Wheel
Stop Sets, in accordance with the table in section 4.12 above, shall
be submitted and shall include the following:
 Assembled Friction Buffer Stops, including clamping
components to the track;
 Assembled Fixed Buffer Stops, including clamping
components to the track;
 Assembled Braking Wheel Stop Sets with installation
components, including blow up drawing.
(see section 5.1).
11.3 Material examination certificates of mechanical characteristics and
chemical composition shall be submitted by request.

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

11.4 The manufacturer shall submit signed and approved installing,

maintenance and safety manuals. The manufacturer in
maintenance manual shall specify what the needed instructions to
guaranty safe operation during the product life cycle, including
Spare Part List.

12. LIST OF FILES (in PDF Format) TO BE SUBMITTED

WITH EVERY ORDER
12.1 For every order - visual inspection, surface finish, geometry,
mechanical properties and chemical composition tests results,
which shall conform to the drawings, the quality management plan,
these technical specification and the relevant EN and/or ISO
standard, and in additional EN10204, Type 3.1; or Type 3.2, shall
be submitted.

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FRICTION BUFFER STOPS, FIXED BUFFER STOPS and

BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

TECHNICAL APPENDIX A – DRAWING DSB 2A 17409 – DBS82-1

WHEEL PROFILE

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BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

TECHNICAL APPENDIX B – STOPING DISTANCE DEFINITION

Lv – Track length for install Friction Buffer Stop and ensure efficient
stopping distance
Lb – Friction Buffer stop length
Lw - Maximum stopping distance

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BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

TECHNICAL APPENDIX C - ISRAEL CLIMATE AND

ENVIRONNEMENTAL CONDITIONS

C.1 Climate and Environmental Conditions

Max. ambient temperature 50 °C (shade)
Min. ambient temperature -5 °C
Relative humidity 10 to 90 %
Altitude -400 to +800 meter
Sunny 3300 hours per year
UV Radiation 360 to 600 MJ/m² per year
Rainfall 400 to 800 mm/year

C.2 Dust Conditions in the atmosphere

Maximum Half Hour Maximum Daily Average
Value* Value*
NOx 1064 560 71
SO2 780 260 21
O3 312 143 84
Suspended - 350 100
Dust
*(Microgram per m³ atmosphere)

C.3 Suspended Particulate Matter (SPM)

Particle size to 0.5-1 micron

C.4 Sea Salt Concentrations in the Atmosphere

Salt Element Na* Cl* SO4*
Position Dry Wet Dry Wet Dry Wet
Sea Air at Coast Line 7.3 16.0 12.0 22.0 5.3 7.0
600 m from Shore 3.1 4.8 4.2 7.9 1.9 2.0
6000 m from Shore 1.1 1.4 1.5 1.7 1.3 1.4
* (Micrograms per m³ atmosphere)

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BRAKING WHEEL STOP SETS No. E-01-0017.1 April 2020

TECHNICAL APPENDIX D – EXAMPLE FOR RED AND WHITE

REFLECTOR SIGN

(Dimensions in millimeters)
<200

100 100

1000

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