Technical Specification Turnouts and Expansion Switches - 0 (ISRAEEL SWITCH)

ISRAEL RAILWAYS LTD
INFRASTRUCTURE DIVISION
TRACK AND RIGHT OF WAY DEPARTMENT
Technical Specification
for
Manufacture and Supply of
Turnouts and
Expansion Switches
for Use in Israel Railways
Conventional Track Network
No. E-01-0022
June 2015
ISRAEL RAILWAYS LTD
Turnouts and Expansion Switches

for Use in Israel Railways Conventional Track Network
No. E-01-0022 June 2015
CONTENTS
1. SCOPE 4
2. STANDARDS REFERENCES 5
3. RELATED ISR TECHNICAL SPECIFICATION REFERENCE 8
4. DEFINITIONS 8
5. GENERAL REQUIREMENTS 11
6. TURNOUTS DESIGN CRITERIA 13
7. IN-CURVE TURNOUTS 15
8. EXPANSION SWITCHS 16
9. TURNOUT PARTS 16
9.1 SWITCH PANELS 16
9.2 CROSSING PANELS 17
9.3 ACTUATION SYSTEM, LOCKING AND DETECTION DEVICES 18
10. TURNOUT COMPONENTS 20
10.1 RAILS 20
10.2 GROOVED RAILS 20
10.3 CHEAK RAILS 21
10.4 PRE-HARDENED MONOBLOCK CAST AUSTENITIC MANGANESE CROSSING 21
PART FABRICATED CROSSING WITH CENTRAL MONOBLOCK CROSSING
10.5 NOSE 24
10.6 GLUED INSULATING RAIL JOINTS 28
10.7 CONCRETE BEARERS WITH USP 29
10.8 WOOD BEARERS 31
10.9 STEEL HOLLOW BEARERS 31
10.10 FASTENING SYSTEMS 32
10.11 MANUAL SWITCH STAND 33
10.12 SWITCH RAIL ROLLERS DEVICE 33
10.13 OTHER COMPONENTS IN THE TURNOUTS 33
11. FLASH-BUTT WELDING 34
12. DRAWINGS 36
QUALITY CONTROL AND QUALITY ASSURANCE PROCEDURES
13. PLAN 37
14. QUALIFICATION TESTS 37

14.1 TURNOUTS TYPE and PROTOTYPE QUALIFICATION TESTS 37
14.2 EXPANSION SWITCH QUALIFICATION TESTS 37
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14.3 TURNOUT COMPONENTS QUALIFICATION TESTS 38

15. QUALITY TESTS 38
15.1 TURNOUTS QUALITY TESTS 38
15.2 EXPANSION SWITCHES QUALITY TESTS 39
15.3 TURNOUT COMPONENTS AND SUB-COMPONENTS QUALITY TESTS 40
16. TURNOUTS AND EXPANSION SWITCH INSPECTION 40
17. ACCEPTANCE TESTS 41
18. TURNOUT AND EXPANSION SWITCH BOM LIST 41
19. OTHER TURNOUTS DESIGN REQUIREMENTS 42
20. MARKING AND LABLING 42
21. PACKING LOADING TRANSPORTING AND STORING 45
LAYING, MAINTENANCE, REPLACE AND INSPECTION
22. INSTRUCTION MANUALS 46
LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S
23. PROPOSAL 46
LIST OF DOCUMENTS TO BE SUBMITTED BEFORE SIGNING THE
24. AGREEMENT (Precedent Documentation) 51
25. LIST OF DOCUMENTS TO BE SUBMITTED WITH EVERY ORDER 52
TECHNICAL APPENDIX A - THE TURNOUTS TO BE SUPPLIED LIST 54

TECHNICAL APPENDIX B – THE TURNOUTS TO BE SUPPLIED
60
GEOMETRY SCHEMES
TECHNICAL APPENDIX C - ISRR OF TURNOUT SAFETY GEOMETRY
65
CRITERIA
TECHNICAL APPENDIX D - WHEEL PROFILE DRAWING: DSB_2A_17409
68
– DBS82-1
TECHNICAL APPENDIX E - WHEELS - PERMITTED WEAR BEFORE
69
USING OF LATHE
TECHNICAL APPENDIX F - FISHPLATE BOLT HOLES POSITION IN
70
RAIL WEB
TECHNICAL APPENDIX G – COLOR MARKING GUIDE FOR TURNOUTS 72
TECHNICAL APPENDIX H – STANDARD TURNOUTS WITH GLUED
74
INSULATING JOINTS POSITION SCHEMES
TECHNICAL APPENDIX I – SWITCH AND STOCK RAILS CLOSING
76
MEASUREMENT PRINCIPLE SCHEME
TECHNICAL APPENDIX J – ISRAEL CLIMATE AND 77
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ENVIRONNEMENTAL CONDITIONS
TECHNICAL ATTACHMENT A - Technical specification for manufacture

and supply of 54E1 and 60E2 Rails R260 and 78
R350HT Grades No. E-01-0004.T_June_2015
TECHNICAL ATTACHMENT B - Technical specification for manufacture and
supply of Glued Insulating Rail Joints for 83
Turnouts No. E-01-0023.T_June_2015
TECHNICAL ATTACHMENT C - Technical specification for manufacture
and supply Fastening Systems for Turnouts No. 96
E-01-0026.T_June_2015
TECHNICAL ATTACHMENT D - Technical specification for manufacture
and supply of Wood Bearers No. E-01- 114
321A.2.T_June_2015
TECHNICAL ATTACHMENT E - Technical specification for manufacture and
supply of Steel Hollow Bearers for ALD
(Actuation System, Locking Device and
120
Detection Device) integration No. E-01-
0025.T_June_2015
TECHNICAL ATTACHMENT F - Technical specification for manufacture and

supply of Concrete Bearers Screws Protective 130
Coating Wax No. E-01-0027.T_June_2015
TECHNICAL ATTACHMENT G - Technical specification for manufacture
and supply of Manual switch Stand No.E-01- 133
0028.T_June_2015
1. SCOPE
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1.1 This technical specification prescribe the technical requirements for

manufacturing and supply of turnouts and Diamonds ("Turnout(s)") and
Expansion Switches of various types and dimensions, for use in ISR
conventional track network, insuring the rolling-stock, freight trains and
railbound vehicles safe and comfort passage.
1.2 The Turnouts will include the following Turnout Parts:
 Switch Panels;
 Closure Panels;
 Crossing Panels;
 Actuation System;
 Locking Device;
 Detection Device.
And shall include the following Turnout Components:
 Rails;
 Check Rails;
 Crossing Component (Frog) –
o Pre-Hardened Monoblock Cast Austenitic Crossing;
o Central Monoblock Crossing Nose;
 Glued Insulating Rail Joints;
 Concrete with USP Bearers/ Wood Bearers/ Steel Hollow Bearers
 Fastening Systems;
 Manual Switch Stand;
 Switch Rail Roller Device;
 And any other Components.
1.3 Unless otherwise specified hereafter the Turnouts and Expansion Switch
requirements shall conform in every aspect with EN13232 parts 1-9,
exclude part 7.
1.4 The Turnouts on Wood Bearers shall be designed for a minimum service
life of 20 years.
1.5 The Turnouts on Concrete Bearers and Slab Track shall be designed for a
minimum service life of 30 years.
1.6 The design of Switch Panels, Closure Panels and Crossing Panels and their
components and Sub-components for turnouts on Wood Bearers shall be
the same as for turnouts on Concrete Bearers and for turnouts for Slab
Track (exclude Fastening Systems).
1.7 The Common Crossing of turnout shall be identical to the Common
Crossing of Diamond.
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1.8 Each and every Turnouts and Expansion Switches Component or Sub-
component shall be manufactured in accordance with the Turnouts and
Expansion Switches manufacturer's layout design and its quality
management plan complying to ISO 9001 and based on the relevant EN,
UIC and ISO standards conforming with this technical specification
(including related ISR technical specifications, see section 3. hereinafter).
All in reference to the technical requirements and the Quality Tests in
particularly, or by their mechanical and chemical characteristics, only in
the non-existence of ISO or EN or UIC standards.
1.9 List of all Components and Sub-component and the reference to the
relevant EN, UIC and ISO standards shall be submitted.
1.10 This technical specification shall also be applied for manufacture and
supply of replacements Parts, Components and Sub-components for
maintenance of Turnouts and Expansion Switches, based on ISR order
details.
1.11 Please note remarks - "(*)" in section 2. ; and remark "(**)" in section
9.3.13.2
2. STANDARDS REFERENCES (*)
EN 13232-1 Railway applications - Track - Switches and crossings -
Part 1: Definitions;
Part 2: Requirements for geometric design;
Part 3: Requirements for wheel rail interaction;
Part 4: Actuation locking and detection;
Part 5: Switches;
Part 6: Fixed common and obtuse crossings;
Part 8: Expansion devices;
Part 9: Layouts;
EN 13674-1 Railway applications - Track - Rail - Part 1: Vignole
railway rails 46 kg/m and above;
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EN 13674-2 Railway applications - Track - Rail - Part 2: Switch and

crossing rails used in conjunction with Vignole railway
rails 46 kgm and above;
EN 13674-3 Railway applications - Track - Rail - Part 3: Check rails;
EN 14811 Railway applications – Track – Special purpose rail –
Grooved and associated construction
EN 15689 Railway applications - Track - Switches and crossing -
Crossing components made of cast austenitic manganese
steel;
EN 16273 Railway application - Track - Froged rail transitions
EN 13481-2 Railway applications - Track - Performance requirements
for fastening systems - Part 2: Fastening systems for
concrete sleepers;
for fastening systems - Part 3: Fastening systems for
wood sleepers;
for fastening systems - Part 5 Fastening systems for slab
track;
for fastening systems - Part 7 Special fastening systems
for switches and crossings and check rails;
EN 13146-1 Railway applications - Track - Test methods for fastening
systems - Part 1: Determination of longitudinal rail
restraint;
systems - Part 2: Determination torsional resistance;
systems - Part 3: Determination of attenuation of impact
loads;
systems - Part 4: Effect of repeated loading;
systems - Part 5: Determination of electrical resistance;
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systems - Part 6: Effect of severe environmental
conditions;
systems - Part 7: Determination of clamping force;
systems - Part 9: Determination of stiffness;
EN 13145 Railway applications - Track - Wood sleepers and
bearers;
EN 13230-4 Railway applications - Track - Concrete sleepers and
bearers - Part 4: Prestressed bearers for switches and
crossings;
EN 16431 Railway applications – Track – Hollow sleepers and
bearers;
EN 14587-3 Railway applications - Track - Flash butt welding of rails
- Part 3: Welding in association with crossing
construction;
prEN16730 Railway applications - Track - Concrete sleepers and
bearers with under sleeper pads
EN 15313 Railway applications - In-service wheelset operation
requirements - In service and off-vehicle wheelset
maintenance
EN 13715 Railway applications – Wheelsets and bogies – Wheels –
Wheels thread;
EN 206-1 Concrete - Part 1: Specification, performance, production
and conformity
UIC 866 Technical specification for the supply of cast manganese
steel crossing for switch and crossing work;
UIC 713 Design of monoblock concrete sleepers
UIC 864-2 Technical specification for the supply of steel track bolts;
UIC 510-2 Trailing stock: wheels and wheelsets - Conditions
concerning the use of wheels of various diameters;
ISO 9001 Quality management systems – Requirements;
ISO/IEC 17025 General requirements for the competence of testing and
calibration laboratories.
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(*) latest edition of the referenced standard.
3. RELATED ISR TECHNICAL SPECIFICATIONS REFERENCE

3.1 ISR related technical specifications (see list in section 3.3 hereinafter)
which are attached at the end of this technical specification, shall be
associated as part of this technical specification.
3.2 Each and every Turnouts Component or Sub-component which is not on
the ISR related technical specification reference list shall be manufactured
in accordance to the Turnouts and Expansion Switch manufacturer's layout
design its quality management plan follows by ISO9001:2008 and based on
the relevant EN, UIC and ISO standards conforming with this technical
specification and relevant ISO or EN or UIC standards.
3.3 ISR related technical specification reference list
 Technical specification for manufacture and supply of 54E1 and 60E2
Rails R260 and R350HT Grades No. E-01-0004.T_June_2015;
 Technical specification for manufacture and supply of Glued
Insulating Rail Joints for Turnouts No. E-01-0023.T_June_2015;
 Technical specification for manufacture and supply Fastening Systems
for Turnouts No. E-01-0026.T_June_2015;
 Technical specification for manufacture and supply of Wood Bearers
No. E-01-321A.2.T_June_2015;
 Technical specification for manufacture and supply of Steel Hollow
Bearers for ALD (Actuation System, Locking Device and Detection
Device) integration No. E-01-0025.T_June_2015;
 Technical specification for manufacture and supply of Concrete
Bearers Screws Protective Coating Wax No. E-01-0027.T_June_2015;
 Technical specification for manufacture and supply of Manual switch
Stand No.E-01-0028.T_June_2015;
4. DEFINITIONS
turnout as defined in EN 13232-1, section 3.2;
Diamond as defined in EN 13232-1, sections 4.3.1-4.3.10
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Expansion Switch as defined in EN 13232-8, section 3.2.2

Part a constituent of the Turnout and Expansion
Switches;
Component any constituent of the Part;
Sub-component any constituent of the Component;
Half set of Switch as defined in EN 13232-5, sections 3.1.1-3.1.2
Crossing Legs rails welded to the crossing;
Under Concrete
Sleeper/Bearer Pad (USP) as defined in prEN16730, sections 3.9
ISR Israel Railways Ltd;
ISR Order detailed purchasing request of Turnouts and/or
Expansion Switches and/or parts and/or
Components and/or Sub-components based on
the agreement between ISR and the Turnouts
and Expansion Switches Manufacturer;
ISRR Israel Railways Ltd Regulation;
ISRTS Israel Railways technical specifications;
ISRR of Turnout Safety
Geometry Criteria permissible safety geometric dimensions for
Turnouts laying and maintenance;
The Laboratory the laboratory performing the Components
Qualification Tests, which shall have the
following certificate:
 A laboratory certified in accordance with
ISO/IEC17025 in the field of relevant
Component testing
and/or
 A laboratory accredited by national
laboratory accreditation authority in the
field of relevant Component quality testing;
and/or
 Prüfamt für Bau von
Landverkehrswegen, Technische
Universität, München
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BOM (Bill of materials) list of the Turnouts, Expansion Switches , Parts,

Components, Sub-components including the
manufacturer ID number, the drawing number
and the quantities of each item needed to be in
a manufactured Turnout or Expansion Switch;
The Inspector ISR technical team and/or an inspecting body
appointed by the ISR;
Turnout Qualification Test test to be carried out by the Turnout
manufacturer in accordance with EN13232-9
section 5-7 on each Turnout type, in accordance
to technical appendix A - the Turnouts to be
supplied list, hereinafter, and Turnout
prototype;
Expansion Switch
Qualification Tests test to be carried out by the Turnout
manufacturer in accordance with EN13232-8
sections 6 and 7 on each Expansion Switch
type, in accordance to technical appendix A -
the Turnouts to be supplied list, hereinafter;
Component
Qualification Test test to be carried out by The Laboratory for the
Turnout and Expansion Switch Components
manufacturer and/or for the Turnout and
Expansion Switch manufacturer on a specific
type before mass production in accordance with
the relevant ISO or EN or UIC standards;
Turnout Quality test test to be perform by the Turnout manufacturer
on each Turnout to be supplied in accordance
with EN13232-9 section 8;
Component/
Sub-component
Quality Test test to be performed by the Component/ Sub-
component manufacturer on its product during
manufacturing and before supplying to Turnout
and Expansion Switch manufacturer in
accordance with the relevant ISO or EN or UIC
standards and this technical specification;
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Acceptance Test tests carrying out in Israel on the delivered

Turnout and/or Expansion switches and/or the
delivered Parts and/or Components and/or Sub-
components
Track category TC3 as defined in prEN16730, section 3.3;
GBP Geometric Ballast Plate, as defined in
prEN16730, section 3.16
NDT non destructive testing.
5. GENERAL REQUIREMENTS
5.1 The manufacturing and supplying of Turnouts shall be in accordance with
technical appendix A - The Turnouts to be supplied list, hereinafter
5.2 The Turnouts shall be designed to be integrated in continuous welded rails
track with rail profile 54E1 or 60E2, rail grade R260 or R350HT, based on
ISR order.
5.2.1 The turnout with grooved rail with rail profile 68G1 and rail grade R260
shall be designed based on ISR order.
5.3 The Crossing Component shall be with zero inclination in reference to the
Bearers, and Crossing Legs shall be transitioned from zero to 1/30 on
Wood and Concrete Bearers, and from zero to 1/40 on Slab Track.
5.4 The Expansion Switch shall be designed to be integrated in continuous
welded rails track with rail profile 60E2 with rail inclination of 1/30.
5.5 The Turnout shall be manufactured and supplied with Wood or Concrete
Bearers, based on ISR order details.
5.6 All Concrete Bearers shall be equipped with elastic Under Bearers Pads, in
accordance with the requirement prescribed in section 10.6.
5.7 The Rails in Turnouts shall be fastened to the Bearers with elastic rail
Fastening System including with tension clamp:
 SKL-W12 for Wood Bearers;
 SKL-W14 or other equivalent SKL-W for Concrete Bearers;
 SKL-W15 for Bogl System and/or SKL-W15 for RHEDA2000 System
and/or SKL-W14 for LVT System for Slab Track.
in accordance with ISRTS No. E-01-0026.T_June_2015 (Technical
Attachment C).
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5.8 The Rails in Expansion Switch shall be fastened to the Concrete Bearers
with Fastening System including with tension clamp SKL-W14 or other
equivalent SKL-W, in accordance with ISRTS No. E-01-
0026.T_June_2015 (Technical Attachment C).
5.9 The Fastening System sets and their suitable Sub-components shall be
designed in accordance with EN 13481 - parts: 2, 3 ,5 , 7 and EN 13146 -
parts 1-7 and 9 requirements; and EN 13232-8 section 4.2.1.2 and 4.2.1.3
requirements (specific requirements for Expansion Switches).
5.10 A complete set of Turnouts, Expansion Switches, Parts, Components and
Sub-components manufacturing drawings with dimensions, critical
dimensions, tolerances, material type, coating and heat treatment
description, etc., shall be submit.
5.11 A complete set of Parts, Components and Sub-components technical
specifications with material types, technical characteristics, chemical
composition, standards number to be complied with, coating and heat
treatment process details, etc., shall be submitted.
5.12 All materials shall be conformed to the latest relevant ISO or EN or UIC
standards. Material examination certificates of mechanical and chemical
characteristics shall be submitted.
5.13 Turnouts and Expansion Switches design shall conform to the:
 Components and Sub-components tolerances requirements. Each
Component and Sub-components in accordance to the latest relevant
ISO or EN or UIC standards;
 Parts critical dimensions. In accordance with EN 13232-5, section 6.3;
EN 13232-6, section 6.3; and EN 13232-8, section 5.3;
 Welding geometry and dimension in accordance with EN14587-3,
section 8. The tolerances for alignment and flatness of flash-butt
welds shall be CLASS 1 (EN14587-3, section 8.1 - Table 1).
 Turnouts laying and maintenance safety dimensions. In accordance
with technical appendix C - ISRR of Turnout safety geometry criteria,
hereinafter.
5.14 Turnouts shall be manufactured and supplied with and without fishplate
bolt holes based on ISR order details.
Fishplate bolt holes shall be drilled in the rail web at the end of each panel,
and shall have a 1 mm chamfer. (Switch, Closure and Crossing Panels).
 Bolt holes diameter: 28 [mm];
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 Distance from the end of the panel: 230 [mm];

 Height from the bottom of the rail:
- for rail profile 60E2: 76.25 [mm];
- for rail profile 54E1: 69.90 [mm].
See technical appendix F – Fishplate bolt holes position in rail web,
hereinafter.
5.15 The drawings shall include welding point to assemble the Turnouts panels.
ISR could request to change their position without extra cost.
5.16 Israel climate condition should be considered (see technical appendix I).
All parts which are non-metallic shall be made of hot weather resistant
materials, suitable for use at temperature of up to 67°C (maximum rail
temperature) and under high corrosion conditions. Plastic parts shall be UV
protected.
5.17 Any technical changes in the design, specifications, manufacture, etc. of
the Turnouts and Expansion Switches and their Parts, Components and
Sub-components shall not be permitted, without ISR approval.
5.18 Forged rails, if incorporated in the Turnouts shall conform to EN 16273.
6. TURNOUTS DESIGN CRITERIA
6.1 Type of rail profiles: 54E1, 60E2.
6.2 Nominal track gauge: 1435 mm.
6.3 Maximum axle load: 22.5 ton.
6.4 Maximum permissible speed: in accordance with technical appendix A -
The Turnouts to be supplied list, hereinafter.
6.5 Switch Rail toe opening: , exclude in Double Slip .
6.6 Locking Device opening with Actuation System (Minimum switch

flangeway): mm at maximum force of 200 kg, at the interface
between actuator and the Locking Device.
6.7 Opening with Manual Switch Stand: .
6.8 Switch and Stock Rails adjacent (proper closing): at least 3 [m] from the
Switch Rail toe.
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6.9 Gap between switch rail and stock rail (GAP J1) plus Gap between locking
component and clamp component (GAP J2) (see technical appendix I –
Switch and Stock Rails closing measurement principle): max 1 [mm].
6.10 Gap between locking part and the foot of stock rail (GAP J3) (see technical
appendix I – Switch and Stock Rails closing measurement principle): max
1[mm];
6.11 Gap between the foot of switch rail and the slide chair (GAP J4) (see
technical appendix I – Switch and Stock Rails closing measurement
principle): max 1[mm].
6.12 Foot clearance: in accordance with the Turnouts manufacturer's layout

design. The foot clearance value and tolerance shall be submitted.
6.13 Neutral position: in accordance with the Turnouts manufacturer's layout
design; the neutral position value and tolerance shall be submitted.
6.14 Negative force: in accordance with the Turnouts manufacturer's layout

design; the negative force value and tolerance shall be submitted.
6.15 Maximum cant deficiency:
Speed [km/h] Vmax ≤100 100< Vmax ≤160 160< Vmax ≤ 200
Maximum cant
≤ 110 ≤ 100 ≤ 60
deficiency [mm]
6.16 Maximum design limiting values of abrupt change of cant deficiency on
diverging track for Turnouts shall be:
(a) 120 mm for switches allowing Turnout speeds of 30≤V≤70 [km/h];
(b) 105 mm for switches allowing Turnout speeds of 70<V≤160 [km/h].
6.17 Turnouts' geometry: in accordance with technical appendix B – The

Turnouts to be supplied geometry schemes, hereinafter.
6.18 Wheels back to back dimension: as defined in EN15313, section 6.2.1.5.
6.19 Wheel dimensions:
The Turnouts shall be designed to ensure safe and comfort wheel passage
with the following ISR wheel profiles:
 According to EN 13715 S1002, h=28, e=32.5, reverse slope 15% ;
 According to UIC 510-2, appendix B1;
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 Wheels of Ø850 with profile DSB 82-1 in accordance with technical

appendix D - Drawing DSB 2A 17409 – DBS82-1 wheel profile,
hereinafter.
6.20 Axle bogies

The Turnouts shall be designed to ensure safe and comfort passage for
rolling stocks, freight trains and other railbourn vehicles with 2-axle bogie
and with 3-axle bogies. The Turnout geometry design shall ensure safe and
comfort passage in reference to the speeds and safety geometric dimensions
prescribed in technical appendix C – ISRR of Turnout safety geometry
criteria, hereinafter.
6.21 Maximum permissible Check Rail tolerance height above running table
during laying: -2, +5 [mm].
6.22 Check Rail design basic scheme:
1,3803 1,39532 1,39532 1,3803
3
1,370 1,3703
1,3703
1,39532 1,3703
 Free wheel passage at check rail entry 1370 mm [±3];

 Nose protection in fixed common crossing 1395 mm [-2; +3].
6.23 The depth of the flangeway shall be sufficient to prevent flanges from
running on the floor of the flangeway. This shall be verified considering the
increased depth of flange of a maximum worn wheel (see technical
appendix E – Wheels – Permitted wear before using of lathe, hereinafter)
and with the shallow flangeway of a maximum worn running surface of a
rail. It shall be wide enough to allow the flanges of the wheels to pass
without being trapped or being forced to climb and derail.
6.24 The Turnouts designed shall ensure that each 2 close Bearers shall be with
a distance no smaller than 500 [mm].
6.25 The Turnouts designed shall ensure that all welds central axis shall be in
the middle of 2 close Bearers.
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7. IN-CURVE TURNOUTS
7.1 The manufacturer shall design and manufacture In-curve turnouts based on
technical information which will be submitted by ISR in its order.
7.2 Based on this information, a complete set of manufacturing drawings with
dimensions, critical dimensions, tolerances, material type, coating and heat
treatment description, including documentary instruction set for laying,
maintenance and period inspections shall be submit for ISR approval
before manufacturing.
7.3 Maximum cant deficiency for CURVE TURNOUTS:
Speed [km/h] Vmax ≤120 100< Vmax ≤160 160< Vmax ≤ 200
Maximum cant
≤ 110 ≤ 100 ≤ 60
deficiency [mm]
8. EXPANSION SWITCHES
8.1 The maximum expansion capacity of the expansion switch (maximum
permissible relative longitudinal movement between two rails) shall be one
of the following: 500, 800, 1200 mm.
8.2 The Expansion Switches shall be designed for installation in horizontal
curves radius not less than 400 meter, and vertical curves radius not less
than 10000 meter.
8.3 The Expansion Switches shall be designed with rail inclination of 1/30 in
the entire length of the expansion switch without transition.
8.4 The Expansion Switches are designed to be incorporated in continuous
welded 60E2 rails track.
8.5 The Expansion Switch critical dimensions shall be in accordance to EN
13232-8, section 5.5.
8.6 Other technical information, in reference to the structure the Expansion
Switch should be laying on, will be submitted by ISR in its order.
8.7 Based on this information, a complete set of manufacturing drawings with
dimensions, critical dimensions, tolerances, material type, coating and heat
treatment description, including documentary instruction set for laying,
maintenance and period inspections shall be submit for ISR approval
before manufacturing.
9. TURNOUT PARTS
9.1 SWITCH PANEL
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9.1.1 The Switch Panel shall be supplied fully assembled.

Half Set of Switch can be ordered separately.
9.1.2 The grade, specifications and requirements of the rails to be used in the
Switch Panel shall be as specified in section 10.1 hereafter.
9.1.3 All bolts and other fixing instruments in the Switch Panel shall be
minimum grade 5.6, exclude bolts in Glued Insulation Rail Joints which
shall be minimum grade 10.9, other specifications and requirements shall
be in accordance with UIC 864-2. Blocks and fittings shall be
manufactured to minimum steel grade R200.
9.1.4 The Switch Panel shall be designed with flexible Switch Rail in accordance
with EN13232-5 section 3.2.2.
9.1.5 The Switch Panel shall be manufactured and supplied with full depth
Switch Rails or shallow depth Switch Rails based on ISR order details.
9.1.6 The wheel transfer between switch and Stock rail shall be designed to give
the greatest support and smallest lateral jerk within the transfer region.
9.1.7 The Switch Panel shall be manufactured and supplied with or without
Switch Rail Rollers Device based on ISR order details.
9.1.8 The Switch Rail Rollers Device shall be manufactured and design in
accordance to the requirements in section 10.12 hereinafter.
9.1.9 The location of the toe of the point rail shall be punch marked on the stock
rail.
9.1.10 All Switch Rails and Stock Rails shall be examined by the Turnout
manufacturer in accordance with EN 13232-5, section 6.5.
9.1.11 The Half Set of Switch could be ordered with stock rails with extra length
on each side and switch rails on the heel side of: 80 mm or 600 mm based
on ISR order details.
9.2 CROSSING PANELS
9.2.1 Crossings Panel shall be supplied with one of the following types:
 Pre-Hardness Monoblock Cast Austenitic Manganese Crossing with
flash-butt welded Crossing Legs;
or
 Part Fabricated Crossing with Central Monoblock Crossing Nose
with flash-butt welded Crossing Legs and screwed wing rails.
9.2.2 Pre-Hardness Monoblock Cast Austenitic Manganese Crossing with flash-
butt welded Crossing Legs
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9.2.2.1 The Pre-Hardness Monoblock Cast Austenitic Manganese specifications

and requirements to be used are prescribed in section 10.3 hereafter.
9.2.2.2 The Crossing Legs shall be flash-butt welded to the Crossing Component
employing with austenitic material elements.
9.2.3 Part Fabricated Crossing with Central Monoblock Crossing Nose with
flash-butt welded Crossing Legs and installed wing rails
9.2.3.1 The Central monoblock Crossing Nose shall be flash-butt welded to the
machined and longitudinally welded (on the rail head and foot) Crossing
Legs, and screwed with wing rails on at least 6 points with two bolts per
point. These bolts shall have minimum grade of 10.9, other specifications
and requirements in accordance with UIC864-2.
9.2.3.2 The Part Fabricated Crossing with Central Monoblock Crossing Nose
specifications and requirements to be used is prescribed in section 10.4
hereafter.
9.2.4 All bolts and other fixing instruments in the Crossing Panel to the bearers
shall have minimum grade of 5.6, other specifications and requirements in
accordance with UIC864-2. Blocks and fittings shall be manufactured to
minimum steel grade R200.
9.2.5 The Crossing Panels could be ordered with Crossing Legs with extra length
on each side of: 80 mm or 600 mm, based on ISR order details).
9.3 ACTUATION SYSTEM, LOCKING AND DETECTION DEVICES
9.3.1 The Actuation System, Locking and Detection Devices shall be designed in
accordance to EN 13232-4. Their design shall ensure safe and comfort
passage at the speeds and geometry and safety dimensions prescribed in
technical appendixes A, B and C.
9.3.2 ISR is using only the following Actuation system motors types,
manufactured by ALCATEL SEL AG:
 L700H - to be installed on the left or right side of the turnout;
 L826H – to be installed on the left or right or in the Steel Hollow Bearer.
Actuation system motors are being purchases separately by ISR. (**)
9.3.3 The Turnout manufacturer shall supply the Turnout with the Actuation
system rods and fastener components, the Locking Device and the
Detection Devices. The Detection Device shall be supplied based on ISR
order details.
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9.3.4 The Turnout manufacturer shall ensure the full integration and the Turnouts
operation with the Actuation System, Locking Device, Detection Devices
and Manual Switch Stand.
9.3.5 The Turnouts shall be designed to enable the installation of the Actuation
System motor on the left, right or in the Steel Hollow Bearer.
9.3.6 The Turnout shall be designed to enable installing the Locking Device on
the opposite side of the Actuation System or on the same side.
9.3.7 The Locking and Detection Devices shall be insulated from both rails with
not less than 5 M / 500 V DC.
9.3.8 Each turnout shall have holes in for the installation of the Locking and
Detection Devices (the turnout shall have holes for the Detection Devices
even if the turnout is ordered without it).
9.3.9 The Actuation System mechanical components technical data shall be
submitted and include: drawing with dimension and tolerances, including
tolerances for installing; materials mechanical and chemical characteristics;
coating and heat treatment process details; design rod non-buckling
calculations; etc..
9.3.10 The Locking Device mechanical components technical data shall be
submitted and include: mechanical and chemical characteristics; drawing
with dimension and tolerances, including tolerances for installing; materials
mechanical and chemical characteristics; coating and heat treatment
process details; design rod non-buckling calculations; etc..
9.3.11 The Detection Device mechanical components technical data shall be
submitted and include: mechanical and chemical characteristics; drawing
with dimension and tolerances, including tolerances for installing; materials
mechanical and chemical characteristics; coating and heat treatment
process details; design rod non-buckling calculations; etc..
9.3.12 Actuation System, Locking And Detection Device and Manual Switch
Stand qualification tests
For new Turnout prototype, and when there is a change in the Switch Panel
design or if the actuator and locking system changes, the following tests to
ensure the safe and efficient operation shall carried out by The Laboratory:
 Locking Device opening with Actuation System (Minimum switch
flangeway); (see section 6.6)
 Switch and Stock Rails adjacent (proper closing); (see section 6.8)
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No. E-01-0022 June 2015
 Gap between switch rail and stock rail (GAP J1) plus Gap between
locking component and clamp component (GAP J2) (see section 6.9)
 Gap between locking part and the foot of stock rail (GAP J3) (see
section 6.10)
 Gap between the foot of switch rail and the slide chair (GAP J4) (see
section 6.11)
 Foot clearance; (see section 6.12)
 Neutral position; (see section 6.13)
 Negative force; (see section 6.14)
9.3.13 Actuation System, Locking And Detection Device and Manual switch
Stand Quality Tests
9.3.13.1 The same tests prescribed in section 9.3.12 aforementioned shall be carried
out by the Turnout manufacturer on every Turnout, ordered by ISR.
9.3.13.2 The Locking and Detection Devices shall be insulated from both rails with
not less than 5 M / 500 V DC.
(**) to perform the qualification and Quality Tests the Turnout
manufacturer shall be equipped with the Actuation System motors types
prescribed aforementioned, and Manual Switch Stand.
10. TURNOUT COMPONENTS
10.1 RAILS
10.1.1 The Rails – Switch Rails; Closure Rails; Stock Rails; Crossing Legs and
rails in Glued Insulating Rail Joints, to be used in Turnouts and Expansion
Switches shall be made of steel grade R260 or R350HT, based on ISR
order details and manufactured in accordance with EN13674-1, EN13674-2
and ISRTS No. E-01-0004.T_June_2015 (Technical Attachment A).
10.1.2 Rails qualification test
10.1.2.1 The qualification tests shall be carried out in accordance to ISRTS No. E-
01-0004.T_June_2015 (Technical Attachment A). The Qualification Tests
report shall be submitted.
10.1.3 Rails Quality Test
10.1.3.1 The Quality Test shall be carried out in accordance to ISRTS No. E-01-
0004.T_June_2015 (Technical Attachment A). The Quality Test report
shall be submitted.
10.2 GROOVED RAILS
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10.2.1 The Grooved Rails – Switch Rails; Closure Rails; Stock Rails; Crossing
Legs and rails in Glued Insulating Rail Joints, to be used in Turnouts shall
be made of steel grade R260, profile G70, based on ISR order details and
manufactured in accordance with EN14811.
10.2.2 Grooved Rails Quality Test

10.2.2.1 The Quality Test including Electric conductivity shall be carried out in
accordance to EN14811 section 8. The Quality Test report shall be
submitted.
10.3 CHECK RAILS
10.3.1 Check Rails to be used in Turnouts shall be made of steel grade R320cr
manufactured in accordance with EN 13674-3.
10.3.2 The manufacturing process shall be continuous casting and no other
process shall be allowed.
10.3.3 Technical drawings for each type of check rails for each Turnout and speed
shall be submitted.
10.3.4 Check rails without bolt holes shall be manufactured and supplied based on
ISR order details.
10.3.5 The bolts fasten the check rails shall be designed with applicable length for
installation of different adjustment plates with thickness up to 9 mm.
10.3.6 The bolts fasten the Check Rails shall be protected against the loosening of
bolted joints with NORD LOCK washers.
10.3.7 Check Rails Quality Test
The Quality Test shall be carried out in accordance to EN 13674-3, section
8. The Quality Test report shall be submitted.
10.4 PRE-HARDENED MONOBLOCK CAST AUSTENITIC MANGANESE
CROSSING
10.4.1 Pre-hardened monoblock crossing shall be manufactured from cast
austenitic higher manganese steel in accordance with EN15689 and this
technical specification.
10.4.2 The manufacturer shall provide design details with regards to the nose
profile, wheel transfer to nose, flange-ways and rail hardness. The
monoblock cast austenitic manganese crossing shall be designed
asymmetrical.
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No. E-01-0022 June 2015
10.4.3 The suitability of the pattern design, mould preparation procedures, casting
conditions and heat treatment procedures shall be demonstrated by
producing prototype casting for every new pattern.
10.4.4 The Pre-Hardened Monoblock Cast Austenitic Manganese Crossing
chemical composite in accordance with EN 15689, section 6.1.
10.4.5 The necessary pre-heating prior to quenching shall be carried out in a
furnace equipped with proper [calibrated] temperature control and
recording equipment. The required pre-heating procedure shall be
submitted. Temperature recording from the control equipment shall be
available to ISR or it's representative at all times.
10.4.6 Appearance and finish
10.4.6.1 All casting shall be carefully cleaned of sand and all loose oxide; casting
gates, air-holes and sink-heads must be removed. The casting shall be free
of the following defects: shrinkage cavities, scabs, cold shuts, flakes,
cracks, blisters, lack of metal, porosity and inclusions.
All casting shall have clean surfaces; any irregularities, traces of joints,
casting fins, etc. shall be carefully ground off.
10.4.6.2 Running surfaces and their connecting fillets, fishing surfaces and all
surfaces which make contact on assembly, together with end, shall be
contently shaped.
10.4.7 The Pre-hardened monoblock cast austenitic manganese crossing machined
surfaces shall have less than the maximum levels of arithmetical roughness
as prescribed in EN 15689, section 6.3.3.
10.4.8 The Pre-Hardened Monoblock Cast Austenitic Manganese Crossing shall
be manufactured with the tolerance ranges as prescribed in UIC 866,
section 1.7.
10.4.9 Weld rectification of surface discontinuities shall be carried out, when
needed, in accordance with EN 15689, section 9, including welds
rectification testing and recording.
Larger excavations then the defined in EN15689, section 9.2 are forbidden.
10.4.10 Pre-Hardened Monoblock Cast Austenitic Manganese Crossing
Qualification Test
10.4.10.1 The test report for sample approval in accordance with EN 15689, section 5
of the following Turnouts types of: 1/8; 1/9; 1/12; 1/20; Double Slip;
Scissor Crossover, and for the following rail profiles: 54E1 (UIC54); 60E2,
shall be submitted.
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No. E-01-0022 June 2015
Test method Test frequency (*) Test requirements

chemical analyze for new pattern and EN 15689 section 7.1
for Turnouts types in
this section
impact bend for new pattern and EN 15689 section 7.2
this section
Metallographic for new pattern and EN 15689 sections 7.3
examination for Turnouts types in and 6.2 (to be carried
this section out before the bend test
on the same piece)
Visual inspection for new pattern and EN 15689 sections 7.4
for Turnouts types in and 6.3
this section
Dye penetrate testing 1 for new pattern and EN 15689 section 7.5
this section
Radiography for new pattern and EN 15689 section 7.6
this section
Hardness test for new pattern and EN 15689 section 8.1.3
this section
Dye penetrate testing 2 for new pattern and EN 15689 section 8.1.2
this section
Hardness test pre-hardened crossing EN 15689 sections 8.3
every 2 years and 8.1.3
Dye penetrate testing pre-hardened crossing EN 15689 sections 8.3
every 2 years and 8.1.2
10.4.10.2 Pre-hardened monoblock cast austenitic crossing qualification test report

from the last 2 years shall be submitted.
10.4.10.3 During the agreement period Pre-hardened monoblock cast austenitic
crossing qualification test report shall be submitted every 2 years.
10.4.11 Pre-Hardened Monoblock Cast Austenitic Crossing Quality Tests
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No. E-01-0022 June 2015
10.4.11.1 The following Quality Tests shall be carried out on the Pre-Hardened
Monoblock Cast Austenitic Crossing by its manufacturer during the
manufacturing process:
Test method Test frequency Test requirements
chemical analyze each cast or batch of EN 15689 section 7.1
liquid steel
impact bend each melt EN 15689 section 7.2
and heat treatment
charge.
Metallographic each melt EN 15689 sections 7.3
examination and heat treatment and 6.2 (to be carried
charge. out before the bend test
on the same piece)
Visual inspection each casting EN 15689 sections 7.4
and 6.3
Dye penetrate testing 1 each monoblock EN 15689 section 7.5
crossing before pre-
harding
Radiography 1 in 50 castings from EN 15689 section 7.6
the same pattern
Hardness test every pre-hardened EN 15689 sections 8.2
crossing and 8.1.3
Dye penetrate testing 2 after pre-hardening EN 15689 sections 8.2
and 8.1.2
10.4.11.2 The Quality Test reports shall be submitted, while the NDT tests and
results shall be signed by certified NDT operators (accordance to EN473 or
equivalent standard).
10.5 CENTRAL MONOBLOCK CROSSING NOSE
10.5.1 The Central Monoblock Crossing Nose shall be heat treated steel with:
 tensile strength - at least 1000 N/mm2;
 elongation - at least 9%;
 material hardness - running surface at least 350 HBW
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No. E-01-0022 June 2015
- at depth of 10 mm underneath the running

surface at least 340 HBW
10.5.2 The microstructure shall be fully pearlitic with no martensite, bainite or
grain boundary cementite.
10.5.3 Technical description of the central monoblock crossing nose with the
following information: mechanical properties, chemical composite,
metallurgical structure (micro and macro structure), manufacturing
technology procedure, NDT testing procedure include ultrasonic testing
shall be submitted.
10.5.4 Appearance and finish
10.5.4.1 All casting shall be carefully cleaned of sand and all loose oxide; casting
gates, air-holes and sink-heads must be removed. The casting shall be free
of the following defects: shrinkage cavities, scabs, cold shuts, flakes,
cracks, blisters, lack of metal, porosity and inclusions.
All casting shall have clean surfaces; any irregularities, traces of joints,
casting fins, etc. shall be carefully ground off.
10.5.4.2 Running surfaces and their connecting fillets, fishing surfaces and all
surfaces which make contact on assembly, together with end, shall be
contently shaped.
10.5.5 The Central Monoblock Crossing Nose shall be manufactured with the
relevant tolerance ranges as prescribed in UIC 866, section 1.7.
10.5.6 Central Monoblock Crossing Nose Qualification Test
10.5.6.1 The test results for sample approval in accordance with EN 15689, section
5 of the following turnouts types of: 1/8, 1/9 with the following rail
profiles: 54E1 (UIC54); 60E2, shall be submitted.
Test method Test frequency (*) Test requirements
chemical analyze for new pattern and for comply the chemical
the Turnouts in this composition
section requirements of the
central monoblock
crossing nose
manufacturer
impact bend for new pattern and for test procedure in
the Turnouts in this accordance EN 15689
section section 7.2, mechanical
properties in
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No. E-01-0022 June 2015
accordance with section

9.4.1 aforementioned
Metallographic for new pattern and for test procedure in
examination the Turnouts in this accordance EN 15689
section sections 7.3 and 6.2 (to
be carried out before
the impact bend test on
the same piece),
microstructure in
Visual inspection for new pattern and for EN 15689 sections 7.4
the Turnouts in this and 6.3 on the surface
section of the central
monoblock crossing
nose
Dye penetrant testing for new pattern and for The surface of the
the Turnouts in this central monoblock
section crossing nose shall be
checked in accordance
with EN 571-1.
Acceptance shall be in
accordance with
EN 1371-1 - quality
level SP1. No linear
indication shall be
allowed.
Radiography for new pattern and for EN 15689 section 7.6
the Turnouts in this
section
Hardness test for new pattern and for test procedure in
the Turnouts in this accordance EN 15689
section section 8.1.3, hardness
in accordance with
section 10.4.1
aforementioned
10.5.7 Central Monoblock Crossing Nose Quality Tests
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No. E-01-0022 June 2015
10.5.7.1 The following Quality Tests shall be carried out on the Central Monoblock
Crossing Nose by its manufacturer:
Test method Test frequency Test requirements
chemical analyze each cast or batch of comply the chemical
liquid steel composition
requirements of the
central monoblock
crossing nose
manufacturer
impact bend each melt test procedure in
accordance EN 15689
section 7.2, mechanical
properties in
Metallographic each melt test procedure in
examination accordance EN 15689
sections 7.3 and 6.2 (to
be carried out before
the impact bend test on
the same piece),
microstructure in
Visual inspection each central EN 15689 sections 7.4
monoblock crossing and 6.3 on the surface
nose of the central
monoblock crossing
nose
Dye penetrant testing each central The surface of the
monoblock crossing central monoblock
nose crossing nose shall be
checked in accordance
with EN 571-1.
Acceptance shall be in
accordance with
EN 1371-1 - quality
level SP1. No linear
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No. E-01-0022 June 2015
indication shall be
allowed.
Radiography 1 in 50 central EN 15689 section 7.6
monoblock crossing
nose from the same
pattern
Hardness test each central test procedure in
monoblock crossing accordance EN 15689
nose section 8.1.3, hardness
in accordance with
section 10.4.1
aforementioned
10.5.7.2 The Quality Test reports shall be submitted, while the NDT tests and
results shall be signed by certified NDT operators (accordance to EN473 or
equivalent standard).
10.6 GLUED INSULATING RAIL JOINTS
10.6.1 The Turnout shall be manufactured and supplied with or without Glued
Insulating Rail Joints based on ISR order details.
10.6.2 The Glued Insulating Rail Joints to be used in the Turnouts shall be
conformed to the requirements of ISRTS No. E-01-0023.T_June_2015
(Technical Attachment B).
The distance from the middle of the joint and the nearest weld shall not be
less than 3 meter) unless agreed differently between ISR and the supplier
for each supplied Turnout.
10.6.3 The Glued Insulating Joints quantity and position in Turnouts shall be in
accordance to ISR signaling plan as part of ISR order specific details for
each ordered Turnout.
See also technical appendix H – Standard Turnouts with glued insulating
joints position schemes.
10.6.4 Glued Insulating Joints qualification tests
The qualification test shall be carried out by The Laboratory in accordance
to ISRTS No. E-01-0023.T_June_2015 (Technical Attachment B). The
qualification test report shall be submitted.
10.6.5 Glued Insulating Rail Joints Quality Test
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No. E-01-0022 June 2015
The Quality Test shall be carried out in accordance to ISRTS No. E-01-
0023.T_June_2015 (Technical Attachment B). The Quality Test report
shall be submitted.
10.7 CONCRETE BEARERS WITH USP
10.7.1 The Concrete Bearers to be used in Turnouts shall be conformed to the
requirements of EN13230-4 and UIC 713.
10.7.2 The Concrete Bearers to be used in Turnouts shall be designed to conform
with the load/speed of 22.5 [ton]/200 [km/h] as specified in UIC713,
section 2.3.
10.7.3 The Concrete Bearers shall be designed for a minimum service life of 40
years.
10.7.4 The Concrete shall be with minimum strength class C50/60 in accordance
with EN 206-1.
10.7.5 All data for the manufacturing of the Concrete Bearer as defined in EN
13230-1, section 4.4.3 shall be submitted;
10.7.6 Technical data sheet (prEN16730, Annex F) of the USP including relevant
standards which apply to the materials shall be submitted;
10.7.7 The Concrete Bearers technical design data including static and dynamic
calculations based on the requirement specified in UIC713 and EN13230-4
prEN16730 shall be submitted and includes: design bending moments
parameters; Positioning of fastening components; Tolerances; absolute
maximum and minimum weight and all other required information in
accordance to the standards.
10.7.8 The USP Pads for Concrete Bearers under the Crossing Component shall
be with Cstat of 0.10 N/mm³ - 0.15 N/mm³.
The USP for Concrete Bearers under the rest of the Turnout Concrete
Bearers shall be with Cstat of 0.25 N/mm³ - 0.35 N/mm³.
10.7.9 The Under Concrete Bearers Pads shall be conformed to the requirements
of prEN16730 unless specified otherwise.
10.7.10 The Under Concrete Bearers Pads technical specifications with material
types, technical characteristics, chemical composition, standards number to
be complied with and drawings shall be submitted.
10.7.11 The USP dimension shall have recess from the bearer edges of 10 mm.
10.7.12 The description of the UPS to the Concrete Bearers bonding process shall
be submitted.
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10.7.13 Concrete Bearer Qualification Test

10.7.13.1 The Concrete Bearers Qualification Test shall be carried out in accordance
to EN13230-4, section 5.6., and prEN16730, section 5. The test report shall
be submitted
10.7.13.2 The Qualification Tests shall be carried out by The Laboratory with
reference to track category TC3, on:
 Under Concrete Bearers Pads alone and for concrete block with Under
Concrete Bearers Pads;
 Concrete Bearers with Under Concrete Bearers Pads.
10.7.13.3 The following tests shall be carried out on the Under Concrete Bearers
Pads alone and on the concrete block with Under Concrete Bearers Pads:
 Dimensions and masses of Under Concrete Bearers Pads in accordance
with prEN16730, sections 5.3.1 and 5.6;
 Tensile strength of Under Concrete Bearers Pad as defined in
accordance with prEN16730, sections 5.3.2 and 5.6;
 Static and low frequency dynamic vertical bedding modulus of Under
Concrete Bearers Pad alone with GBP, with reference to track category
TC3, in accordance with prEN16730, sections 5.3.3 and 5.6;
 Fatigue test with Under Concrete Bearers Pads applied on concrete
block, with reference to track category TC3, in accordance with
prEN16730, section 5.3.6;
 Capability for stacked stocking of Concrete Bearers with Under
Concrete Bearers Pad on concrete block in accordance with
prEN16730, section 5.3.8;
 Resistance to fire in accordance with prEN16730, sections 5.3.9.
 The test shall be carried out in accordance with DIN 53438 or
equivalent standard. The stage K2 shall be achieved at least.
 Resistance to ozone in accordance with prEN16730, sections 5.3.9.
10.7.13.4 The following tests shall be carried out on the Concrete Bearers with Under
Concrete Bearers Pads:
 Dimensions and masses of Concrete Bearers with Under Concrete
Bearers Pads in accordance with prEN16730, sections 5.5.1 and 5.6;
 Bond strength by pull-out of Concrete Bearers with Under Concrete
Bearer Pad in accordance with prEN16730, sections 5.5.2 and 5.6.
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No. E-01-0022 June 2015
 In a pull-off perpendicular to the bonding surface, no failure shall occur

applying strength equal or less than 0.40 MPa;
 Variation of static and low frequency dynamic vertical bedding
modulus of Concrete Bearers with Under Concrete Bearers Pads
determined with GBP in accordance with prEN16730, section 5.5.3;
 Fatigue test with Under Concrete Bearers Pads applied on Concrete
bearers in accordance with prEN16730, section 5.5.4;
10.7.13.5 The Under Concrete Bearers Pads data sheet with the parameters and the
relevant standard as prescribed in prEN16730, Annex F shall be submitted.
10.7.13.6 Drawing with dimension and tolerances of the Bearer with USP, including
prestressed elements in the bearer; dimensions and tolerances for each
individual bearer; tolerances for installing (fastening position and
geometrical dimensions); prestress design calculations; bearer
identification.
10.7.14 Concrete Bearer Quality Tests
Quality tests shall be carried out in accordance to EN13230-4, section 5.7.,
and prEN16730, section 5. And comply the requirements of this technical
specification. The Quality Test report from the month of manufacturing
shall be submitted.
USP shall be visually inspected in order to look for damages what result of
the installation of USP on the concrete block, of the storage, transport or of
the manipulation (perforation, cracking or other damage).
10.8 WOOD BEARERS
10.8.1 Wood bearers to be used in Turnouts shall be conformed to the
requirements of ISRTS No. E-01-321A.2.T_June_2015 (Technical
Attachment D).
10.8.2 The Wood Bearer technical data, including: drawing with dimension and
tolerances of the bearer section; dimensions and tolerances for each
geometrical dimensions); preservation process; bearer identification, shall
be submitted.
10.8.3 The manufacturer shall submit MSDS (Material Safety Data Sheet)
certificate on the creosote.
10.8.4 In case the wood bearers shall be planed to be fitted to the 1/30 rail
inclination the following items shall be delivered with the first order:
 3 reusable template for adzing for each type of Wood Bearers;
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No. E-01-0022 June 2015
 3 adzing machines;
10.8.5 Wood Bearer Quality Tests
In each order which wood bearers will be part of, certificates to the
seasoning and impregnation of the track bearers (method, quantities of
protective materials, etc.) shall be submitted.
10.9 STEEL HOLLOW BEARERS
10.9.1 Steel Hollow Bearers to be used in Turnouts shall be conformed to the
requirements of ISRTS No. E-01-0025.T_June_2015 (Technical
Attachment E).
10.9.2 The Steel Hollow Bearers technical data shall be submitted and include:
drawing with dimension and tolerances of the bearer; tolerances for
installing (fastening position and geometrical dimensions); bearer
identification.
10.9.3 Steel Hollow Bearers qualification tests
The qualification test shall be carried out The Laboratory in accordance to
ISRTS No. E-01-0025.T_June_2015 (Technical Attachment E). The
10.9.4 Steel Hollow Bearers Quality Tests
The Quality Test shall be carried out in accordance to ISRTS No. E-01-
0025.T_June_2015 (Technical Attachment E), section 10. The Quality Test
report shall be submitted.
10.10 FASTENING SYSTEMS
10.10.1 The Turnouts shall be equipped with Fastening Systems manufactured in
accordance with the relevant EN 13481-2, 3, 5, 7.
10.10.2 A complete set of Fastening System (in accordance with EN13481-2, 3, 5)
and special Fastening System for switches crossing and check rails (in
accordance with EN13481-7) for each type of Turnout, rail profile and
bearers, technical specification and manufacturing drawings with
dimensions, tolerances, material type, coating description and heat
treatment, etc. shall be submitted.
10.10.3 The fastening shall be supplied with all necessary Sub-components such as
screws, nuts, washer, base plates, pads, etc.
10.10.3.1 Rail Fastening System qualification test
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The qualification test shall be carried out The Laboratory in accordance to

ISRTS No. E-01-0026.T_June_2015 (Technical Attachment C). The
10.10.3.2 Rail Fastening System Quality Tests
The Quality Tests shall be carried out in accordance to ISRTS No. E-01-
0026.T_June_2015 (Technical Attachment C). The Quality Test report
shall be submitted.
10.11 MANUAL SWITCH STAND
10.11.1 Turnouts for marshalling yards shall be installed with manual switch stand.
The Manual Switch Stand shall be ordered separately from the Turnout.
10.11.2 The manual switch stand shall conform the requirements of ISRTS No. E-
01-0028.T_June_2015 (Technical Attachment G).
10.11.3 Switch stands installation and adjustment instructions shall be submitted.
10.12 SWITCH RAIL ROLLERS DEVICE
10.12.1 Turnouts shall be manufactured and supplied with and without Switch Rail
Rollers Device based on ISR order details.
10.12.2 Only proven switch rail rollers types on track in at least two railway
companies shall be offered. Reference list shall be submitted including
supplied quantity, to whom it supplied and its operation period.
10.12.3 The Switch Rail Rollers device shall be incorporated with the bearer
baseplate.
10.12.4 The Switch Rail Rollers device design and position shall not disturb the
operation of maintenance vehicles.
10.12.5 A single switch roller device could be replaced without disassemble the rest
of the switch roller devices.
10.12.6 The switch rail rollers device to be used in the Turnouts shall be lubrication
free and maintenance free.
10.12.7 The switch rail rollers device shall be designed to fit with full depth switch
rails and shallow depth switch rail. Technical drawing and specification
shall be submitted.
10.12.8 The switch rail rollers device shall be anti-corrosion protected.
10.12.9 The switch rail rollers installation instructions and drawings, including
reinstall instructions and inspection procedure shall be submitted.
10.13 OTHER COMPONENTS IN THE TURNOUTS
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10.13.1 A complete set for each type of all other Component and Sub-component
technical specification and manufacturing drawings with dimensions,
tolerances, mechanical and chemical properties, material type, coating and
heat treatment process details, method of welding (actuation system and
locking device relevant Components and Sub-components), etc. shall be
submitted.
10.13.2 List of all the Components and Sub-components, the relevant EN, UIC and
ISO standards they comply with, test method, test frequency and the
standard it manufactured in accordance shall be submitted.
11. FLASH-BUTT WELDING
11.1 The manufacturer shall conform to the requirements of EN14587-3 unless
specified otherwise hereinafter.
11.2 All welding shall be carried out on a flash butt welding machine using an
automatic, programmed welding sequence using an approval weld
procedure.
11.3 The welding operation shall be carried out by competence welding
operators with appropriate training and assessment. The operator(s)
welding certificate shall be submitted.
11.4 The manufacturer shall maintain a system of weld inspection. Instances of
non-conformity found during these inspections shall be recorded in the
traceability system.
11.5 Each Turnout shall be supplied with quality certificate for every welding.
11.6 The flash-butt welding machine
11.6.1 Type and identification number of the flash-butt welding machine being
used shall be stated in the welding quality certificate.
11.6.2 The flash-butt welding machine shall record at least the following
parameters:
a) Welding current;
b) Upset force or pressure;
c) Displacement;
d) Welding time;
e) Program identification and setting details;
f) Weld identification;
g) Post-weld heat treatment (if applicable).
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The welding parameters shall be monitored, checked against approval

limits and recorded. These records shall be referenced to the appropriate
welds.
The post-weld heat treatment parameters shall be monitored, checked
against approval limits and recorded. These records shall be referenced to
the appropriate welds.
11.7 flash-butt welding approval procedure
11.7.1 An approval test report shall be submitted for each welding machine to be
used in the crossing construction. If a machine will be replaced a new
approval test report shall be submitted before any weld will be carried out.
11.7.2 The approval tests report shall be for the following rail groups:
 Cross sectional area – 64<71 [cm2];
 Cross sectional area – 71<78 [cm2].
And the following rail grades:
 R260;
 R350HT.
11.7.3 The approval test report shall include the following tests in accordance to
the requirements in EN14587-3, section 10.4: weld geometry and
dimensions; visual inspection; surface finish; liquid penetrate testing and
magnetic particle testing; internal soundness; bend testing; fatigue testing;
micro-examination test; macro-examination; hardness testing.
It shall include photographs of the fracture faces (one per sample) of all
broken test welds as well as macro and micro examination, and the rail
profile grid, which is shown in EN14587-3, Annex C, shall be included.
Acceptance criteria in the approval tests, in accordance with EN 14587-3.
11.7.4 The approval test report carried out by The Laboratory or RA (as defined in
EN14587-3, section 3.17) shall include the information defined in EN
14587-3, section 10.5, and shall be submitted.
11.8 Weld production
11.8.1 Automatic monitoring and recording of the weld parameters shall be
available for every weld.
11.8.2 The welding program and parameters shall be as those for which approval
was guaranteed.
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11.8.3 The production test report shall include the following tests, in accordance
to the requirements in EN14587-3, section 13: weld geometry and
dimensions; visual inspection; surface finish (roughness) in accordance to
EN14587-3, section 7; liquid penetrate testing and magnetic particle testing
(in accordance EN14587-3, section 10.4.5); internal soundness; bend
testing.
The production test report template shall be submitted for ISR approval.
11.8.4 On flash-butt welds with austenitic component(s) –
11.8.4.1 Liquid penetrate testing shall be carried out on every flash-butt welding in
accordance with EN14587-3, section 10.4.5.
11.8.4.2 Internal soundness (ultrasonic testing) shall be carried out on every flash-
butt welding from the rail side in accordance with EN14587-3, Annex G.
11.8.5 On flash-butt welds without austenitic component(s):
11.8.5.1 Magnetic particle testing shall be carried out on every flash-butt welding in
accordance with EN14587-3, section 10.4.5.
11.8.5.2 Internal soundness (ultrasonic testing) shall be carried out on every flash-
butt welding in accordance with EN14587-3, section 10.4.6.
12. DRAWINGS
12.1 Turnout general layout drawings –
The drawings shall include:
 Turnouts geometry scheme;
 Welded crossing scheme;
 Crossing part scheme;
 Switch geometry scheme;
 Location of theoretical mathematical point;
 Bearers diagram including: number, length, position from stock front
joints and spaces;
 Stock rail to stock rail dimensions;
 Distance between running edges;
 Location of insulating joints (if applicable);
 Location of aluminothermic welds;
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 Table list with the following parts: Switch Panel, closure panel,
Crossing Panel, Locking panel. And there drawing numbers.
 Drawing shall be submitted for each type of Turnout.
12.2 Part assembly drawings
 Individual plans of particular part (part - as specified in section 1.2
aforementioned);
 Detail design manufacturing drawings, including: dimensions, critical
treatment, etc.
 List table with the Components, and their drawing numbers;
 Drawings shall be submitted for each part type and position in the
Turnout
12.3 Sections drawings
 Section drawings of Turnouts and Expansion Switches on each bearer
for each type.
12.4 Components and Sub-components drawings
 Components and Sub-components detail design manufacturing
drawings (including Actuation System, Locking and Detection
Devices) including: dimensions, tolerances, material type, coating
description and heat treatment, surface marking, etc.
12.5 All information prescribed in EN13232-9, section 7.5 shall be included in
the relevant drawings.
12.6 Any change in the drawing shall not be allowed without notify to ISR and
having its approval.
13. QUALITY CONTROL AND QUALITY ASSURANCE
PROCEDURES PLAN
13.1 The Turnout and Expansion Switch manufacturer shall submit his ISO9001
certificate on the field of Turnouts.
13.2 The Turnout and Expansion Switch manufacturer shall submit his quality
procedures plan for Turnout and Expansion Switch manufacturing.
13.3 The subcontractors shall have quality procedures plan which shall be
submitted.
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14. QUALIFICATION TESTS

14.1 TURNOUTS TYPE and PROTOTYPE QUALIFICATION TESTS
Each Turnout type, in accordance to technical appendix A - the Turnouts to
be supplied list, hereinafter, and Turnout prototype should be supplied only
after design calculations and test report, in accordance with EN13232-9
sections 5-7, shall be submitted. The design and calculation test report shall
include the Actuation System, Locking and Detection Devices testing
ensuring safe and comfort passage at the speeds and geometry and safety
dimensions prescribed in technical appendixes A, B and C.
14.2 EXPANSION SWITCH QUALIFICATION TESTS
Each Expansion Switch prototype should be supplied only after performing
all necessary testing and submitting report in accordance with EN13232-8
sections 6 and 7.
14.3 TURNOUT COMPONENTS QUALIFICATION TESTS
14.3.1 the Turnout manufacturer shall submit qualification tests reports which had
been carried out by The Laboratory on the following Components:
 Rails in accordance to section 10.1 aforementioned;
 Check Rails in accordance to section 10.2 aforementioned;
 Pre-Hardened Monoblock Cast Austenitic Manganese Crossing in
accordance to section 10.3 aforementioned;
 Central Monoblock Crossing Nose in accordance to section 10.4
aforementioned;
 Glue Insulating Rail Joints in accordance to section 10.5
aforementioned;
 Concrete Bearers with USP in accordance to section 10.6
aforementioned;
 Hollow Steel Sleepers in accordance to section 10.8 aforementioned;
 Fastening System in accordance to section 10.9 aforementioned;
 Actuation System, Locking and Detection Device and Manual Switch
Stand qualification test certificates in accordance to section 9.3.12
aforementioned.
14.3.2 For each of the Components and Sub-components which are not prescribed
aforementioned in section 14.3.1 certificates on the conforming to the
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requirements of the relevant ISO or EN or UIC standards, in reference to

the requirements of section 10.12 aforementioned shall be submitted.
15. QUALITY TESTS
15.1 TURNOUTS QUALITY TESTS
15.1.1 Each Turnout should be supplied only after performing the Quality Tests in
accordance with EN13232-9 section 8.
15.1.2 The manufacturer shall assemble the Turnout and to enable the Inspector
carried out the measurements to ensure the compliance of its dimensions
and tolerances.
15.1.3 It’s the manufacturer responsibility to place the necessary staff and all
measurement devices and equipment to the Inspector activities.
15.1.4 The manufacturer shall submit to the Inspector, with each completed
Turnout:
 All drawings in accordance with sections 12.1, 12.2, 12.3 and 12.4
aforementioned;
 Rails Quality Tests certificates in accordance with 10.1,
aforementioned;
 Check rails Quality Tests certificates in accordance with 10.2
aforementioned;
 Pre-Hardened Monoblock Cast Austenitic Manganese Crossing in
accordance to section 10.3 aforementioned
 Part Fabricated Crossing with Central Monoblock Crossing Nose
Quality Tests certificates in accordance with 10.4 aforementioned;
 Glue Insulating Rail Joints Quality Tests certificates in accordance with
10.5 aforementioned;
 Concrete Bearers Quality Tests certificates in accordance to section
10.6 aforementioned;
 Wood Bearers Quality Tests certificates in accordance to section 10.7
aforementioned;
 Hollow Steel Sleepers in accordance to section 10.8 aforementioned;
 Actuation System, Locking and Detection Device Quality Test
certificates in accordance to section 9.3.13 aforementioned.
15.2 EXPANSION SWITCHES QUALITY TESTS
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15.2.1 The following certificates shall be submitted to The Inspector, with each
completed Expansion Switch:
 All recorded dimensions of the Expansion Switch, in its assembled
position in complies to the drawings;
 Rails Quality Tests certificates in accordance with section 10.1,
aforementioned;
 Concrete Bearers Quality Tests certificates in accordance to section
10.7 aforementioned.
15.3 TURNOUT COMPONENTS AND SUB-COMPONENTS QUALITY TESTS

15.3.1 Each and every Turnouts Component or Sub-component shall be
manufactured in accordance to the Turnouts manufacturer's layout design
its quality management plan follows by ISO9001:2008 and based on the
relevant EN, UIC and ISO standards conforming with this technical
specification and relevant ISO or EN or UIC standards. In reference to the
technical requirements and the Quality Tests in particularly, or by their
mechanical and chemical characteristics in the non-existence of ISO or EN
or UIC standards. List of all components and the reference to the relevant
EN, UIC and ISO standards shall be submitted.
15.3.2 In every order, for each of the Components, which are not prescribed
aforementioned in section 15.1.4 and 15.2 and for each of the Sub-
components, certificate on the conforming to the requirements of the
relevant ISO or EN or UIC standards, shall be submitted.
16. TURNOUTS AND EXPANSION SWITCH INSPECTION
16.1 The Inspection of the Turnouts and the Expansion Switch and Quality Test
reports checking shall be carried out by The Inspector in accordance to the
delivery time which will be defined in ISR orders.
16.2 The manufacturer shall act in full cooperation with The Inspector. The
manufacturer shall be responsible to coordinate inspection process time
table with The Inspector , and shall enable him free access to all places of
work in which the Turnouts, Turnout parts, components and sub-
components are manufactured or stored in the Turnout manufacturer plant.
Providing all necessary assistance to The Inspector and notify him
beforehand of its intention to perform tests.
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16.3 The manufacturer shall submit all Quality Tests reports and certificates,
and if requested the Qualification Test reports, to The Inspector for
approval for every Turnout and Expansion switch in ISR orders, in
accordance with section 15.1 and 15.2 aforementioned including checking
dimensions of the Turnouts in assembled possition.
16.4 All the tools/measuring instruments for manufacturing verification and
inspection of the sub-components, components, parts, Turnouts and
Expansion Switches shall be made available by the manufacturer to The
Inspector on request.
It is the manufacturer’s responsibility to guarantee dimensional accuracy
and to ensure that the inspection is carried out with the appropriate
measuring instruments. The manufacturer shall present measuring
equipment calibration certificate validity by The Laboratory.
16.5 The Final Inspection Reports which shall include the Quality test reports
(in accordance with the requirements in sections: 15.1, 15.2 and 15.3)
signed by the Turnouts and Expansion Switches manufacturer and The
Inspector shall be submitted.
17. ACCEPTANCE TESTS
17.1 The Turnouts and Expansion Switches and components which will be
supplied shall be visually checked, no defect or missing component will be
allowed.
17.1.1 The Acceptance Test reports documents, which shall include:
 The Quality Test reports of the Turnouts and/ or the Expansion
Switches and their Components; and
 The Inspector report signed by the manufacturer and The Inspector.
shall be submitted.
18. TURNOUT AND EXPANSION SWITCH BOM LIST
18.1 A detailed BOM list in an Excel file which will be based on the format
hereinafter shall be submitted:
Turnout, expansion switch , parts , Quantity for The Turnout and The Turnout
components and sub-component designation one expansion switch and expansion
Turnout manufacturer ID switch drawing
numbers number
1 turnout 1/8, LH, R260, radius 250/190 meter,
Wood Bearers
1.1. Pre-Hardened Monoblock Cast Austenitic
Crossing with Crossing Legs – part of: turnout
1/8, LH, Radius 250/190 meter, wooden bearers
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1.1.1 Fastening System type … - component of:

turnout 1/8, LH, radius 250/190 meter, Wooden
example
Bearers
1.1.1.1 bolt type … with nut type… - Component of
Fastening System type…
…
...
1.2 LH Switch Panel 1/8 – Part of: turnout 1/8,

LH, R260, radius 250/190 meter, Wood Bearers
1.2.1 anti-creep device – Component of: LH Switch
Panel 1/8
1.2.1.1 bolt type … with nut type… - Component of:
anti-creep device
…
...
18.2 The Turnout and Expansion Switch manufacturer will fill the cells in the
Ecxel file with every Turnout, Expansion Switch, Parts, Components and
Sub-components which will be included in the agreement. And shall fill
also the quantity, ID number and drawing number.
18.3 The Turnout and Expansion Switch manufacturer will be obligated to
constant check and update it.
19. OTHER TURNOUTS DESIGN REQUIREMENTS
19.1 The sequence of the welds schemes need to be performed to assemble the
Turnouts shall be submitted.
19.2 A certificate conform that aluminothermy welds can be carried out on the
Turnouts rails (R260 and R350HT) in accordance with EN14730-1, and in
particularly Elektro-Thermit SoW-5 procedure shall be submitted.
19.3 The Bearers shall be supplied with the fastening system's base plates
already fastened.
19.4 For Turnouts on Concrete Bearers to be supplied, when equipped with
Fastening Systems, The Bearer Screws shall be greased before screwing
(for Concrete Bearers Screws Protective Coating Wax see ISRTS No. E-
01-0027.T_June_2015 - Technical Attachment F).
(Fastening system which needs to be screwed during the assembly on track
will be greased by ISR).
19.5 The Turnouts with Concrete Bearers shall be manufactured and supplied
with full length Concrete Bearers with maximum length 4400 [mm] or with
split Concrete Bearers, as requested by ISR in the order.
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19.6 The Turnouts with split Concrete Bearers design shall not include Bearers
longer than 3300 [mm]. When longer Bearer is needed, it will be perform
with 2 supplementary Concrete Bearers, which will be assembled in track
with suitable rigid support to ensure the bearers uniform vertical and
horizontal straightness and the adjustment shall guarantee the function of
the 2 supplementary Concrete Bearers as one. The supplementary Concrete
Bearers assembly instructions shall be submitted. Reference list of the
turnouts with the supplementary Concrete Bearers assembled shall be
submitted including supplied quantity, to whom it was supplied and when.
20. MARKING AND LABELING
20.1 The Turnouts shall be marked with fixed weatherproof plate, with resistant
painted engraved marking.
20.2 The Turnouts parts shall be marked with paint colors in accordance with
technical appendix G - Color marking guide for Turnouts.
20.3 Each Turnout and Expansion Switch shall have identification marking
fixed on it. The following information shall be marked:
 Manufacturer’s mark;
 Last two digits of year of manufacture;
 Unique identification Number;
 Drawing number.
20.4 Each rail, closure rail and switch rail to be used in Turnout manufactured to
grade R350HT (in accordance to EN13674-1, 2) shall be marked with
white paint for easy identification.
20.5 Each Check rail shall have identification marking fixed on it. The
following information shall be marked:
 Drawing number.
20.6 Each Half Set of Switch shall have an identification marking fixed on the
switch rail and/or stock rail. The following information shall be marked:
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 Type of switch (radius of switch, main line radius, rail profile and
hand of Turnout);
 Drawing number.
20.7 Each Crossing Panel shall have an identification marking fixed on it. The
following minimum information shall be marked:
 Last two digits of month and the year of manufacturing;
 Crossing type (rail profile, geometry, left hand, right hand);
 Drawing number.
20.8 On each concrete bearer shall be permanently marking with the following
information on it:
 Manufacturer’s mark
 Production serial number of the Turnout;
 Type of Turnout;
 Number of the concrete bearer in the Turnout (layout position in
reference to layout drawings);
 Last two digits of month and the year of manufacturing.
 Signs to enable the bearers and the rails alignment during the laying.
20.9 On each wood bearer, a metal plate shall be permanently attached, with the
following information engraved on it:
 Number of the Wood Bearer in the Turnout.
20.10 On each Steel Hollow Bearer, a metal plate shall be permanently attached,
with the following information engraved on it:
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 Number of the Steel Hollow Bearer in the Turnout.
20.11 Each other Component and Sub-component shall have:
 The type identification name.
21. PACKING LOADING TRANSPORTING AND STORING
21.1 Each manufactured Turnout and Expansion Switch shall be assembled for
Quality Test at the manufacturer's plant. All parts shall be clearly and
durably marked for re-assemble, following which the Turnout and
Expansion Switch shall be disassembled (except for the Switch Panel,
which shall remain assembled and mounted on its Bearers).
21.2 The Turnouts shall be packed with special care to prevent damage and
shipped in flat bed containers only.
21.3 Each shipment of Turnouts shall contain a packing list, the following
detailed drawings: Turnout general layout drawings, part assembly
drawings, sections drawings for all supplied Turnouts, detailed instructions
for the assembly of the Turnouts, and all additional documentation as
necessary and/or as requested by ISR in the order. All the aforementioned
documents shall be supplied in hard and soft copy.
21.4 Fastening shall be supplied by the Turnout and Expansion Switch
manufacturer for each of the Bearers supplied by him with the Turnout.
Fastening which are to be supplied as detached parts (fasteners belonging
to Bearers which are shipped unfastened to the Turnout and Expansion
Switch) shall be supplied in a separate package, clearly marked.
21.5 Packages of Rails and Bearers shall be tighten up in 5 places with steel
strapping of at least 1" width.
21.6 The Locking system and its components shall be packed separately in a
wooden red marked box.
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21.7 All moveable parts shall be protected against corrosion with corrosion
preventive compound, which shall have effective protection period of at
least 12 months for storing outdoors.
21.8 the holes in the bearers where the actuation system motor will be installed
shall be covered with easy to remove elements which will prevent entrance
of any foreign body to the holes before the actuation system motors.
21.9 The Turnout manufacturer shall submit loading, un-loading, transporting
and storing instructions.
21.10 The Components and Sub-components which will be assembled to the
switch panel and those which will be delivered separately will be submitted
for ISR approval.
21.11 the Switch panel's stock rail and switch rail in the close position shall be
tighten up in 3 places with steel strapping of at least 1" width, the stock rail
and switch rail in the open position, wooden blocks shall be put in between
them before tighten up in 3 places with steel strapping of at least 1" width.
21.12 The rods which will be installed in the Turnouts shall be protected against
buckling.
21.13 The packages shall include barcode in accordance to ISR requirements.
22. LAYING, MAINTENANCE, REPLACE AND INSPECTION
INSTRUCTION MANUALS
22.1 Manuals of recommendations guide lines for laying, maintaining, replacing
of Turnouts, Expansion Switches and Turnouts parts, to ensure safe and
comfort passage at the speeds geometry and safety dimensions prescribed
in technical appendixes A, B and C shall be submitted.
22.2 The inspection part shall include detailed inspection recommended
procedures and actions for defects and wear and maximum permissible
wear with:
 Rails R350HT;
 Monoblock Cast Austenitic Manganese Crossing;
 Pre-Hardness Monoblock Cast Austenitic Manganese Crossing;
 Central Monoblock Crossing Nose
22.3 The maintaining part shall include instructions for: assembly and
maintenance of the Part Fabricated Crossing with Central Monoblock
Crossing Nose;
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22.4 The maintaining part shall include recommendations for types of grease
and procedures and actions for reducing friction and wear on the slide
baseplates.
22.5 Detailed drawings of special instruments for assembly, maintenance and
inspection shall be submitted. It shall include: detail design manufacturing
drawings including: dimensions, tolerances, material type, coating and heat
treatment description, etc.
30 sets of each special instrument shall be supplied with first order with no
extra charge.
23. LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S
PROPOSAL
23.1 List of all Components and Sub-component and the reference to the
relevant EN, UIC and ISO standards. (section 1.6)
23.2 All materials shall be conformed to the latest relevant ISO or EN or UIC
standards. Material examination certificates of mechanical and chemical
characteristics shall be submitted. (section 5.12).
23.3 Foot clearance of each type of proposed Turnout. (section 6.12).
23.4 Neutral position of each type of proposed Turnout. (section 6.13).
23.5 Negative force value and tolerance of each type of proposed Turnout.
(section 6.14).
23.6 The Actuation System mechanical components technical data including:
drawing with dimension and tolerances, including tolerances for installing;
materials mechanical and chemical characteristics; coating and heat
treatment process details; design rod non-buckling calculations; etc.
(section 9.3.9).
23.7 The Locking Device mechanical components technical data including:
mechanical and chemical characteristics; drawing with dimension and
tolerances, including tolerances for installing; materials mechanical and
chemical characteristics; coating and heat treatment process details; design
rod non-buckling calculations; etc. (section 9.3.10).
23.8 The Detection Device mechanical components technical data including:
mechanical and chemical characteristics; drawing with dimension and
tolerances, including tolerances for installing; materials mechanical and
chemical characteristics; coating and heat treatment process details; design
rod non-buckling calculations; etc.. (section 9.3.11).
23.9 Rails qualification test report. (section 10.1.2).
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23.10 Technical drawings for each type of Check Rails for each Turnout and
speed. (section 10.3.5).
23.11 The required crossing pre-heating procedure (section 10.4.5).
23.12 Pre-Hardened Monoblock Cast Austenitic Manganese Crossing
qualification process test (section 10.3.10).
23.13 Pre-hardened monoblock cast austenitic crossing qualification process test
report from the last 2 years. (section 10.3.10.2)
23.14 Central Monoblock Crossing Nose qualification process test (section
10.4.7)
23.15 Glued Insulating Joints qualification tests (section 10.5).
23.16 The Concrete Bearer with USP technical data including: drawing with
dimension and tolerances of the bearer section, including prestressed
elements in the bearer; dimensions and tolerances for each individual
bearer; tolerances for installing (fastening position and geometrical
dimensions); presstressing design calculations; bearer identification.
(section 10.6)
23.17 Concrete Bearer with USP qualification test report (section 10.6.13)
23.18 The Wood Bearer technical data, including: drawing with dimension and
tolerances of the Bearer section; dimensions and tolerances for each
geometrical dimensions); preservation process; Bearer identification.
(section 10.7.2).
23.19 The manufacturer shall submit MSDS (Material Safety Data Sheet)
certificate on the creosote. (section 10.7.3).
23.20 Steel Hollow Bearers qualification test report (section 10.8.3).
23.21 A complete set of rail fastening system (in accordance with EN13481-2, 3,
5) and special rail fastening system for switches crossing and check rails
(in accordance with EN13481-7) for each type of Turnout, rail profile and
bearers, technical specification and manufacturing drawings with
treatment, etc. (section 10.9.2).
23.22 Rail Fastening System qualification test (section 10.9.3.1).
23.23 Switch stands installation and adjustment instructions (section 10.10.2)
23.24 Proven Switch Rail Rollers types on track companies reference list
including supplied quantity, to whom it supplied and its operation period.
(section 10.11.2)
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23.25 Technical drawing and specification of switch rail rollers types including
technical solution for full depth switch rails and shallow depth switch rail.
(section 10.11.7)
23.26 The switch rail rollers installation instructions and drawings, including
reinstall instructions and inspection procedure. (section 10.11.9)
23.27 The Under Concrete Bearers Pads data sheet (section 10.6.6).
23.28 The Concrete Bearers with USP drawings with dimension and tolerances of
the Bearer with USP, including prestressed elements in the bearer;
dimensions and tolerances for each individual bearer; tolerances for
installing (fastening position and geometrical dimensions); prestress design
calculations; bearer identification shall be submitted (section 10.6.13.5).
23.29 The Under Concrete Bearers Pads drawings shall be submitted (section
10.6.10).
23.30 The description of the Under Concrete Bearers Pads to the Concrete
Bearers bonding process. 10.6.12).
23.31 List of all the Components and Sub-components, the relevant EN, UIC and
ISO standards they comply with, test method, test frequency and the
standard it manufactured in accordance shall be submitted. (section
10.12.2).
23.32 The flash-butt operator(s) welding certificate (section 11.3).
23.33 An approval test report shall be submitted for each welding machine to be
used in the crossing construction ( 11.7.4).
23.34 Turnout general layout drawings for each type of Turnout (section 12.1).
23.35 Part assembly drawings for each part type and position in the Turnout
(section 12.2).
23.36 Sections drawings for each type of Turnout (section 12.3)
23.37 The Turnout and Expansion Switch manufacturer ISO9001 certificate on
the field of Turnouts (section 13.1).
23.38 The Turnout and Expansion Switch manufacturer shall submit his quality
procedures plan for Turnout and Expansion Switch manufacturing (section
13.2).
23.39 The subcontractors quality procedures plan (section 13.3).
23.40 Each Turnout type, in accordance to technical appendix A - the Turnouts to
be supplied list, hereinafter, test report, in accordance with EN13232-9
sections 5-7, including the Actuation System, Locking and Detection
49
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No. E-01-0022 June 2015
Devices testing ensuring safe and comfort passage at the speeds and
geometry and safety dimensions prescribed in technical appendixes A, B
and C (section 14.1)
23.41 Expansion Switch qualification testing report (section 14.2)
23.42 qualification tests reports which had been carried out by The Laboratory on
the following Components: Rails; Check Rails; Monoblock cast austenitic
manganese crossing; Pre-Hardened Monoblock cast austenitic manganese
crossing; Central Monoblock Crossing Nose; Glue Insulating Rail Joints;
Concrete Bearers; Fastening System; Actuation System, Locking And
Detection Device. (section 14.3.1).
The tests reports which wouldn’t be submitted with bidder's proposal must
be submitted before signing the agreement.
23.43 for each of the Components and Sub-components which are not prescribed
aforementioned in section 13.4.1 certificates on the conforming to the
requirements of the relevant ISO or EN or UIC standards, in reference to
the requirements of section 9.11 aforementioned. (section 14.3.2)
23.44 The sequence of the welds schemes need to be performed to assemble the
Turnouts shall be submitted. (section 18.1)
23.45 A certificate conform that aluminothermy welds can be carried out on the
Turnouts rails (R260 and R350HT) (section 18.2)
23.46 The 2 supplementary Concrete Bearers assembly instructions (section
18.4.1)
23.47 Reference list of the turnouts with the supplementary Concrete Bearers
assembled, including supplied quantity, to whom it supplied and its
operation period (section 18.6).
23.48 The Wood Bearer manufacturer Quality management system certificate
shall be submitted (ISO9001 certificate and/or WAI certificate and/or
AWPA certificate and/or equivalent quality management certificate).
(Technical specification for manufacture of Wood Bearers for Turnouts
No. E-01-0321A.2-T June 2015, section 6.1(Technical Attachment D))
23.49 The Wood Bearer comprehensive quality control and assurance program
which will be used during the manufacturing shall be submitted. (Technical
specification for manufacture of Wood Bearers for Turnouts No. E-01-
0321A.2-T June 2015, section 6.2 (Technical Attachment D)).
23.50 The manufacturer shall submit certificates to the seasoning and
impregnation of the Wood Bearers (method, quantities of protective
materials, etc.). (Technical specification for manufacture of Wood Bearers
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No. E-01-0022 June 2015
for Turnouts No. E-01-0321A.2-T June 2015, section 6.3 (Technical

Attachment D)).
23.51 The Material Safety Data Sheet (MSDS) shall be submitted. (Technical
specification for manufacture of Wood Bearers for Turnouts No. E-01-
0321A.2-T June 2015, section 6.4 (Technical Attachment D)).
23.52 Drawings with dimensions, tolerances, mechanical and chemical
properties, material type, coating and heat treatment process details,
method of welding (actuation system and locking device relevant
Components and Sub-components), etc. shall be submitted.
List of all the Sub-components, the relevant EN, UIC and ISO standards
they comply with shall be submitted. (Technical Specification for
manufacture of Manual Switch Stand No. E-01-0028.T June 2015, section
7.1 (Technical Attachment G).
23.53 A complete set of technical drawings of Steel Hollow Bearers shall be
submitted including dimensions, tolerances and material main
characteristics for 60E2 and 54E1 rails of the following: The assembled
unit including the ALD components; The steel hollow sleeper body
including steel pipes, and steel stud plates; Elastic rail fastening system
with tension clamp SKL-W. (Technical specification for manufacture of
STEEL HOLLOW BEARERS for ALD (Actuation System, Locking
Device and Detection Device) INTEGRATION No. E-01-0025.T June
2015, section 6 (Technical Attachment E)).
23.54 The qualification test reports for Steel Hollow Bearers. (Technical
specification for manufacture of STEEL HOLLOW BEARERS for ALD
(Actuation System, Locking Device and Detection Device)
INTEGRATION No. E-01-0025.T June 2015, section 7 (Technical
AttachmentE)).
23.55 A complete set of technical drawings of Glued Insulated Rail Joints for
60E2 and 54E1 rails profiles and including their Sub-components with
dimensions, tolerances and material main characteristics, coating
description, heat treatment, etc., shall be submitted. Technical Specification
for manufacture of Fastening Systems for Turnouts No. E-01-0026-T June
2015, section 6 (Technical Attachment C).
23.56 A complete set of technical drawings of fastening system including their
Sub-components with dimensions, tolerances and material main
characteristics, coating description, heat treatment, etc., shall be submitted.
Technical Specification for manufacture of GLUED INSULATED RAIL
51
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No. E-01-0022 June 2015
JOINTS for TURNOUTS No. E-01-0023.T June 2015, section 6

(Technical Attachment B)).
24. LIST OF DOCUMENTS TO BE SUBMITTED BEFORE SIGNING
THE AGREEMENT (Precedent Documentation)
24.1 A complete set of Turnouts, Expansion Switches, Parts, Components and
Sub-components manufacturing drawings with dimensions, critical
dimensions, tolerances, material type, coating and heat treatment
description, etc. (section 5.10).
24.2 A complete set of Parts, Components and Sub-components technical
specifications with material types, technical characteristics, chemical
composition, standards number to be complied with, coating and heat
treatment process details, etc. (section 5.11).
24.3 A complete set for each type of all other Component and Sub-component
technical specification and manufacturing drawings with dimensions,
tolerances, mechanical and chemical properties, material type, coating and
heat treatment process details, method of welding (actuation system and
locking device relevant Components and Sub-components) , etc. shall be
submitted. (section 10.12.1).
24.4 Qualification tests reports which had been carried out by The Laboratory
on the following Components: Rails; Check Rails; Monoblock cast
austenitic manganese crossing; Pre-Hardened Monoblock cast austenitic
manganese crossing; Central Monoblock Crossing Nose; Glue Insulating
Rail Joints; Concrete Bearers; Fastening System; Actuation System,
Locking And Detection Device. (section 14.3.1)
The tests reports which didn’t submit with bidder's proposal shall be
submitted before signing the agreement.
24.5 BOM list (section 17)
24.6 Loading, un-loading, transporting and storing instructions (section 20.9).
24.7 The Components and Sub-components which will be assembled to the
switch panel and those which will be delivered separately (section 20.10)
24.8 Manual of recommendations guide lines for laying, maintaining, replacing
of Turnouts, Expansion Switches and Turnouts Parts, (section 21.1).
24.9 Detailed drawings of special instruments for assembly, maintenance and
inspection (section 21.6).
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No. E-01-0022 June 2015
24.10 The Protective Coating Wax safety data sheet (MSDS) shall be submitted.
(Technical Specification for concrete bearers screws protective coating
wax_No. E-01-0023.T June 2015, section 3 (Technical Attachment B)).
25. LIST OF DOCUMENTS TO BE SUBMITTED WITH EVERY
ORDER
25.1 Qualification tests for new prototype of Turnout and/ Expansion Switch
type and there Parts, Components and Sub-components.
25.2 The Acceptance Test reports documents:
25.2.1 Material examination certificates of mechanical and chemical
characteristics shall be submitted. (section 5.12).
25.2.2 Rails Quality Test reports (section 10.1.3).
25.2.3 Check Rails Quality Test reports (section 10.2.7).
25.2.4 Glued Insulated Rail Joints Quality Test (section 10.5.5).
25.3 Concrete Bearer Quality Test reports (section 10.6.14).
25.3.1 Wood Bearer Quality Tests reports (section 10.7.4).
25.3.2 Steel Hollow Bearers Quality Tests reports (section 10.8.4).
25.3.3 Rail Fastening System Quality Tests (section 10.9.3.2)
25.3.4 Actuation System, Locking And Detection Device and Manual switch
Stand Quality Tests
25.3.5 Other Components in the Turnouts mechanical and chemical properties,
material type, coating and heat treatment process details, method of
welding, etc. (section 10.12.1).
25.3.6 The Final Inspection Reports signed by the manufacturer and The Inspector
25.4 During the agreement period Pre-hardened monoblock cast austenitic
crossing Qualification Test report shall be submitted every 2 years. (section
10.3.10.3).
25.5 The flash-butt welding production test report template (section 11.8)
25.6 If a flash-butt welding machine will be replaced a new approval test report
shall be submitted before any weld will be carried out (section 11.7.1).
25.7 Turnout general layout drawings for each type of Turnout (section 12.1).
25.8 Part assembly drawings for each part type and position in the Turnout
(section 12.2).
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No. E-01-0022 June 2015
25.9 Section drawings of Turnouts and Expansion Switches on each Bearer for
each type. (section 12.3).
25.10 Changes in BOM list when new type is supply (section 17.1).
TECHNICAL APPENDIX A - THE TURNOUTS TO BE SUPPLIED

LIST
A.1 TURNOUTS
MAXIMUM MAXIMUM
PERMISSIBLE PERMISSIBLE RADIUS RAIL RAIL
SPEED SPEED CROSSING SWITCH RAIL INCLINATION BEARERS
GRADE TYPE
IN MAIN LINE IN BRANCH
[KM/H] LINE [KM/H]
Pre-Hardened
Monoblock
Cast Austenitic full depth R260
Manganese 18/S
120 30 190 54E1
Crossing
Central
Monoblock shallow depth R350HT
Crossing Nose
Wood
Pre-Hardened full depth
Monoblock
Cast Austenitic R260
Manganese shallow depth
120 30 250/190 54E1 1/8L
Crossing
Central full depth
Monoblock R350HT
Crossing Nose shallow depth
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Pre-Hardened
Monoblock full depth
120 30 Cast Austenitic R260
Manganese shallow depth 0520912 60E2 1/8
Crossing
Central full depth
120 30 Monoblock R350HT
Pre-Hardened full depth

Monoblock
180 40 Cast Austenitic 05280/2 R260 54E1
shallow depth
Manganese
1/9
Crossing
Central full depth
180 40 Monoblock 0528021 R350HT 60E2
full depth R260

180 70 Pre-Hardened 42686/5 54E1
Monoblock shallow depth R350HT 1810
Cast Austenitic
full depth R260
180 70 Manganese 42286/2 60E2
Crossing shallow depth R350HT
full depth R260
180 100 Pre-Hardened 022281322 54E1
Cast Austenitic 1/20
full depth R260
180 100 Manganese 1222813// 60E2
Crossing shallow depth R350HT
full depth R260
200 40 Pre-Hardened
Monoblock 05280/2 54E1
shallow depth R350HT
Cast Austenitic 1/9
Manganese full depth R260
200 40 Crossing 0528021 60E2
full depth R260
200 70 Pre-Hardened
42686/5 54E1
Cast Austenitic 1/12 concrete
200 70 Crossing 42286/2 60E2
full depth R260
200 100 Pre-Hardened
Monoblock 022281322 54E1
Cast Austenitic 1802
200 100 Crossing 1222813// 60E2
full depth 0528021 R260
200 40 Pre-Hardened 60E2 1/9
Monoblock shallow depth 0528021 R350HT Slab
Cast Austenitic
full depth 42286/2 Track
Manganese R260
200 70 Crossing 60E2 1/12
shallow depth 42286/2 R350HT
A.2 DIAMONDS
Track
MAXIMUM MAXIMUM
center
SPEED SPEED RAIL RAIL INCLINATION
CROSSING SWITCH RADIUS to track BEARERS
IN MAIN IN BRANCH GRADE TYPE
center
LINE [KM/H] LINE [KM/H]
[mm]
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No. E-01-0022 June 2015
102 full
30 Pre- R260
depth
Hardened 190/190 54E1
102 shallow
30 Monoblock R350HT 4700;
depth Scissor
Cast 5000;
full Crossover 1/8
102 30 Austenitic R260 6000
depth
Manganese 190/190 60E2
102 Crossing shallow
30 R350HT
depth
full
180 40 Pre- R260
depth
shallow
180 40 Monoblock R350HT 4700;
depth Scissor
Cast 5000;
full Crossover 1/9
depth
Crossing shallow
180 40 R350HT
depth
full
180 70 Pre- R260
depth
shallow
180 70 Monoblock R350HT 4700; Scissor
depth
Cast 5000; Crossover
full
180 70 Austenitic R260 6000 1/12
depth
Crossing shallow
180 70 R350HT
depth
Wood
full
180 100 Pre- R260
depth 1300/
Hardened 54E1
shallow 2000
180 100 Monoblock R350HT 4700; Scissor
depth
full
180 100 Austenitic R260 6000 1/20
depth 1300/
Manganese 60E2
Crossing shallow 2000
180 100 R350HT
depth
102 full 1528122
30 Pre- R260
depth
Hardened 54E1
102 shallow 1528122
30 Monoblock R350HT
depth Double Slip
Cast ----
full 1/8
102 30 Austenitic 1528122 R260
depth
Manganese 60E2
102 Crossing shallow 1528122
30 R350HT
depth
full 12280//
180 40 Pre- R260
depth
Hardened 54E1
shallow 12280//
depth Double Slip
Cast ----
full 1/9
180 40 Austenitic 12280// R260
depth
Manganese 60E2
Crossing shallow 12280//
180 40 R350HT
depth
102 full
30 Pre- R260
depth
102 shallow
30 Monoblock R350HT 4700;
depth Scissor
Cast 5000;
full Crossover 1/8
depth
102 Crossing shallow Concrete
30 R350HT
depth
Pre- full
200 40 R260
Hardened depth 4700;
280/250 54E1 Scissor
200 Monoblock shallow 5000;
40 R350HT Crossover 1/9
Cast depth 6000
200 40 Austenitic full 290/250 R260 60E2
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No. E-01-0022 June 2015
Manganese depth
40 R350HT
depth
200 full
70 Pre- R260
depth
200 shallow
70 Monoblock R350HT 4700; Scissor
depth
200 full
70 Austenitic R260 6000 1/12
depth
70 R350HT
depth
200 full
100 Pre- R260
depth 1300/
Hardened 54E1
200 shallow 2000
100 Monoblock R350HT 4700; Scissor
depth
200 full
100 Austenitic R260 6000 1/20
depth 1300/
Manganese 60E2
100 R350HT
depth
102 full 1528122
30 Pre- R260
depth
Hardened 54E1
102 shallow 1528122
30 Monoblock R350HT
depth Double Slip
Cast ----
full 1/8
102 30 Austenitic 1528122 R260
depth
Manganese 60E2
30 R350HT
depth
full 12280//
200 40 Pre- R260
depth
Hardened 54E1
shallow 12280//
depth Double Slip
Cast ----
full 1/9
200 40 Austenitic 12280// R260
depth
Manganese 60E2
Crossing shallow 12280//
200 40 R350HT
depth
022 /2 Pre- full Scissor
489/600 R260
Hardened depth Crossover
Monoblock 1/12
Slab
Cast 60E2 4700
shallow Track
022 /2 Austenitic 489/600 R350HT
depth
Manganese
Crossing
A.3 SPECIAL TURNOUTS AND DIAMONDS SYSTEMS

MAXIMUM
MAXIMUM
SPEED
SPEED
IN SWITCH RAIL RAIL
REMARKS IN MAIN CROSSING RADIUS INCLINATION
BRANCH RAIL GRADE TYPE
LINE
LINE
[KM/H]
[KM/H]
 superelevation -
Pre-
55[mm];
Hardened R260
Monoblock
 special flexible blades /5 62 full 1/9 + wood
Cast 573 54E1
depth 1/12 in-curve
Austenitic
- 13.910 [m]
Manganese
Crossing
 special stock rail – R350HT
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No. E-01-0022 June 2015
15.050 [m]
check rail – 10 [m]

and 6.400 [m]
Pre-
Hardened R260
Monoblock Diamond
142 32 full wood
Cast 54E1 Crossover
depth
Austenitic Tg. 0.264
R350HT
Manganese
Crossing
Pre-Hardened R260 Scissor wood
Monoblock Crossover 1/12
1/2 /2 Cast full 4700 mm with 3
Austenitic 54E1 LH turnouts
depth R350HT
Manganese
Crossing
152 68G1 Turnout 1/8 grooved

80 30 R260
20m length
MAXIMUM Track
MAXIMUM SPEED center to
SPEED IN RAIL RAIL track INCLINATION
CROSSING SWITCH RADIUS BEARERS
IN MAIN LINE BRANCH GRADE TYPE center
[KM/H] LINE [mm]
[KM/H]
full R260 54E1 Scissor wood
180 70 Pre-Hardened
Monoblock Cast
depth 4700 Crossover
Austenitic shallow mm 1/12 with 3 concrete
200 70 R350HT 60E2
Manganese Crossing
depth LH turnouts
Special
Pre-Hardened full R260 Scissor
Monoblock Cast depth 54E1 4700; Crossover 1/8
Austenitic 5000; with 1 Double
Manganese shallow R350HT 60E2 6000 Slip + 3
Crossing depth turnouts
full R260 54E1 Special
Pre-Hardened depth Scissor
Monoblock Cast 4700; Crossover 1/8
Austenitic shallow 5000; with 2 Double
Manganese R350HT 60E2 6000
depth Slips + 2
Crossing turnouts
120 30
Austenitic shallow 5000; with 3 Double wood
depth Slips + 1
Crossing turnout
Pre-Hardened full Special
R260 54E1
Monoblock Cast depth 4700; Scissor
Austenitic 5000; Crossover 1/8
Manganese shallow 6000 with 4 Double
R350HT 60E2
Crossing depth Slips
Special
1/2 62 Manganese shallow 6000
R350HT 60E2 Slip + 3
Crossing depth turnouts
Pre-Hardened full R260 4700; Special
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No. E-01-0022 June 2015
Austenitic 54E1 6000 Crossover 1/9

Manganese with 2 Double
Crossing shallow R350HT 60E2 Slips + 2
depth turnouts
Special
Manganese shallow 6000
R350HT 60E2 Slips + 1
Crossing depth
turnout
Special
full R260
Pre-Hardened Scissor
depth 54E1
Manganese shallow 6000 Slips
R350HT 60E2
Crossing depth

Monoblock Cast Crossover 1/8
Austenitic shallow 0222 with 3 Double
Manganese R350HT 60E2
depth Slips + 1
Crossing turnout
102 32
Pre-Hardened Special
full R260
Monoblock Cast 54E1 Scissor
depth
Austenitic 7000 Crossover 1/8
Manganese shallow with 4 Double
R350HT 60E2
Special
Crossing depth
turnouts
depth Slips + 2
Crossing turnouts
102 32
Monoblock Cast 4700; Crossover 1/8 concrete
depth Slips + 1
Crossing turnout
Pre-Hardened full Special
R260 54E1
R350HT 60E2
Special
Monoblock Cast depth 54E1 4700;
022 62 Crossover 1/9
Crossing depth
turnouts
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No. E-01-0022 June 2015
Special
Pre-Hardened full R260
4700; Scissor
Monoblock Cast depth 54E1
5000; Crossover 1/9
Austenitic with 2 Double
shallow 6000
Manganese R350HT 60E2 Slips + 2
Crossing depth
turnouts
Special
R350HT 60E2 Slips + 1
Crossing depth
turnout
Pre-Hardened Special
full R260
Monoblock Cast 54E1 4700; Scissor
depth
R350HT 60E2
TECHNICAL APPENDIX B - THE TURNOUTS TO BE SUPPLIED

GEOMETRY SCHEMES
TURNOUTS
1/20 60E2 1/20 54E1
28966 37382 28966 37399
Tg 0.05 Tg 0.05
1867 1868
37382 37396
1/12 60E2 1/12 54E1

19592 24413 19592 23414
Tg 0.085 Tg 0.085
2070 1984.5
24413 23414
1/9 60E2 R 1/9 54E1

14363 18918 14346 18318
Tg 0.11 Tg 0.11
2072 2005.8
18918 18318
1/8 60E2 1/8L 54E1

13564 15896
13556 15904
Tg 0.13
Tg 0.13
2054
2054.5
15896 61 15904
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No. E-01-0022 June 2015
1/8 GROOVED RAILS 68G1 1/8S 54E1

6618 73331 10216 15904
Tg 0.13 Tg 0.13
1725.2 2054.5
13382 15904
DIAMONDS
Scissors Crossover 1/8 54E1
Tg0.13 Tg0.13
4.7 R 190/190 4.7 R 190/190
13.56 36.15 13.56 10.22 36.15 10.22

63.27 56.59
Tg0.13 Tg0.13
5 R 190/190 5 R 190/190
13.56 38.46 13.56 10.22 38.46 10.22
65.58 58.9
Tg0.13
6 Tg0.13
R 190/190 6 R 190/190
13.56 46.15 13.56 10.22 46.15 10.22

73.27 66.59
Scissors Crossover 1/9 60E2 Scissors Crossover 1/9 54E1

Tg0.11
4.7 R 290/250 Tg0.11
4.7 R 280/250
14.35 42.73 14.35 14.35 14.35

42.73
71.43 71.43
Tg0.11 Tg0.11
5 R 290/250 5 R 280/250
14.35 45.45 14.35 14.35 45.45 14.35

74.15 74.15
Tg0.11 Tg0.11
6 R 290/250 6 R 280/250
14.35 54.55 14.35 14.35 54.55 14.35

83.25 83.25
Scissors Crossover 1/12 60E2 Scissors Crossover 1/12 54E1

Tg0.085 Tg0.085
4.7 R 489/600 4.7 R 485/600
19.59 55.29 19.59 19.59 55.29 19.59

94.47 94.47
Tg0.085 Tg0.085
5 R 489/600 5 R 485/600
19.59 58.82 19.59 19.59 58.82 19.59

74.15 74.15
61
Tg0.085
6 R 489/600
19.59 70.59 19.59

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No. E-01-0022 June 2015
Tg0.085
6 R 485/600
19.59 70.59 19.59

109.77
Scissors Crossover 1/20 54E1 and 60E2

Tg0.05 Tg0.05 Tg0.05
4.7 R 1300/2000 5 R 1300/2000 6 R 1300/2000
28.97 94 28.97 28.97 100 28.97 28.97 120 28.97

151.94 157.94 177.94
Double Slip 60E2/54E1 1/8
11100.5 17397
1944
Tg0.13
77171 15207
37373
Double Slip 60E2/54E1 1/9

3980 73773 17397
17
1870.7
Tg0.11
17083 17083
34166
Diamond Crossing 54E1 Tg. 0.264

8913
8913 2298
Tg 0.264
2298
8913
17826
Special turnouts and Diamonds systems

Special crossover including one special LH turnout special in-curve 1/12 + one special LH
turnout 1/9 + specific transition between turnout 54E1
7457
18318 32664
62
21486 21486
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No. E-01-0022 June 2015
2006
23414 7230
1609 Tg.0.11
Tg.0.085
1985 18318
Special Scissor Crossover 1/12 54E1 4700 mm with 3 RH turnouts
Tg0.085
6360 R 485/600 4700
19592 55294 19592
94408
Special Scissor Crossover 1/8 60E2/54E1 Special Scissor Crossover 1/8 60E2/54E1
4700 mm with 1 Double Slip + 3 turnouts 4700 mm with 2 Double Slips + 2 turnouts
Tg0.13 Tg0.13
4700 4700
Tg0.13 Tg0.13
5000 5000
Tg0.13 Tg0.13
6000 6000
4700 mm with 3 Double Slips + 1 turnout 4700 mm with 4 Double Slips
Tg. 0.13 Tg. 0.13

4700 4700
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No. E-01-0022 June 2015
Tg. 0.13 Tg. 0.13

5000 5000
Tg. 0.13 Tg. 0.13

6000 6000
Tg0.11 Tg0.11
4700 4700
Tg0.11 Tg0.11
5000 5000
Tg0.11 Tg0.11
6000 6000
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No. E-01-0022 June 2015
Tg. 0.11 Tg. 0.11

4700 4700
Tg. 0.11 Tg. 0.11

5000 5000
Tg. 0.11 Tg. 0.11

6000 6000
TECHNICAL APPENDIX C - ISRR OF TURNOUT SAFETY

GEOMETRY CRITERIA
Table 1: Safety Geometric Criteria for Turnouts Laying Acceptance
class max speed Twist longitudinal superelevation alignment

[km/h] (measured level (cross level)
every 2.5 10 m chord 10 m chord
meter)
1 160-022 3 3 2 3
2 120-160 4 6 4 3
3 80-120 4 7 5 4
4 40-80 6 10 8 7
5 0-40 6 10 8 7
Level A - maximum dimension of assembled turnout during acceptance procedure
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No. E-01-0022 June 2015
Table 2.1 – Turnout 60E2 rail profile – safety dimensions and permissible
tolerances during Turnout Quality test in the manufacturing plant
9002 9090 901 90/

permissible
permissible
permissible
permissible
dimensions
dimensions
dimensions
dimensions
tolerance
tolerance
tolerance
tolerance
safety measurement points
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No. E-01-0022 June 2015
1435 1435 1435 1435 a Entrance

1435 1435 1435 1439 b Switch Toe
1435 1435 1435 1435 c1
End of Planning
1435 1435 1435 1443.5 c2
1435 1435 1435 1435 d1
On Heal
0, +2
0, +2
0, +2
0, +2
1435 1435 1435 1445 d2
1435 1435 1435 1435 e1 Entrance of the Closure
1435 1435 1435 1445 e2 Panel
1435 1435 1435 1435 l1 Middle of the Crossing
1435 1435 1435 1445 l2 Panel
1435 1435 1435 1435 j1 Exit from the Closure
1435 1435 1435 1445 j2 Panel
-0.5, +0.5
-0.5, +0.5
-0.5, +0.5
-0.5, +0.5
1395 1395 1395 1395 m1
protection of the crossing
point
1395 1395 1395 1395 m2
1370 1370 1370 1370 n1

-3, +3
-3, +3
-3, +3
-3, +3
free wheel passage at check rail

entry
1370 1370 1370 1370 n2
Table 2.2 – Turnout 54E1 rail profile – safety dimensions and permissible
tolerances during Turnout Quality Test in the manufacturing plant
9002 9090 901 90/

Dimensions
permissible
permissible
permissible
permissible
dimensions
dimensions
dimensions
tolerance
tolerance
tolerance
tolerance
safety measurement points
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1437 1435 1435 1435 a Entrance

1437 1435 1439 1439 b Switch Toe
1435 1435 1435 1443.5 c1
End of Planning
1437 1435 1435 1435 c2
1437 1435 1445 1445 d1
On Heal
0, +2
0, +2
0, +2
0, +2
1437 1435 1435 1435 d2
1437 1435 1445 1445 e1 Entrance of the Closure
1437 1435 1435 1435 e2 Panel
1435 1435 1445 1445 l1 Middle of the Crossing
1435 1435 1435 1435 l2 Panel
1435 1435 1445 1445 j1 Exit from the Closure
1435 1435 1435 1435 j2 Panel
-0.5, +0.5
-0.5, +0.5
-0.5, +0.5
-0.5, +0.5
1395 1395 1395 1395 m1
protection of the crossing
point
1395 1395 1395 1395 m2
1370 1370 1370 1370 n1

-3, +3
-3, +3
-3, +3
-3, +3
Balancing of the stock rail

1370 1370 1370 1370 n2 - heel
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TECHNICAL APPENDIX D - WHEEL PROFILE DRAWING: DSB_2A_17409

– DBS82-
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TECHNICAL APPENDIX E – WHEELS - PERMITTED WEAR BEFORE

USING OF LATHE
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TECHNICAL APPENDIX F – FISHPLATE BOLT HOLES POSITION IN

RAIL WEB
F.1 – for 54E1
HOLE Ø 28 mm
69.90 mm
230 mm
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F.2 – for 60E2
HOLE Ø 28 mm
76.25 mm
230 mm
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TECHNICAL APPENDIX G – COLOR MARKING GUIDE FOR TURNOUTS
G.1 – for 54E1 Rails
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G.2 – for 60E2 Rails
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TECHNICAL APPENDIX H – STANDARD TURNOUTS WITH GLUED

INSULATING JOINTS POSITION SCHEMES
H.1 Turnout 1/8 HS
H.2 Turnout 1/8 LS short
H.3 Turnout 1/9 HS
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H.4.1 Turnout 1/12 HS
H.4.2 Turnout 1/12 HS
H.5 Turnout 1/20 HS
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TECHNICAL APPENDIX I – SWITCH AND STOCK RAILS CLOSING

MEASUREMENT PRINCIPLE SCHEME
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TECHNICAL APPENDIX J - ISRAEL CLIMATE AND

J.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
J.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)
J.3 Suspended Particulate Matter (SPM)

Particle size to 0.5-1 micron
J.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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TECHNICAL ATTACHMENT A
- TECHNICAL SPECIFICATION FOR MANUFACTURE AND SUPPLY OF

54E1 AND 60E2 RAILS R260 AND R350HT GRADES
NO.E-01-0004.T_JUNE_2015
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ISRAEL RAILWAYS LTD

Technical Specifications
for Manufacture
of
54E1 and 60E2 Rails
with
R260 and R350HT Grade
for
No. E-01-0004.T
June 2015
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CONTENTS
1. SCOPE
2. STANDARDS REFERENCES
3. DEFINITIONS
QUALITY CONTROL AND QUALITY ASSURANCE
5.
PROCEDURES PLAN
7. QUALITY TESTS
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1. SCOPE
1.1 This technical specification prescribes the technical requirements of
manufacturing the Turnout and Expansion Switch Components -
Rails.
1.2 The Rails shall be have the 60E2 and 54E1 rail profiles with Grade
R260 or R350HT to be used in Turnouts and Expansion Switches.
EN 13674-1 Railway applications - Track - Rail - Part 1
Vignole railway rails 46 kg/m and above;
EN 13674-2 Railway applications - Track - Rail - Part 2
Switch and crossing rails used in conjunction with
Vignole railway rails 46 kg/m and above;
EN 13232-1 Railway applications - Track - Switches and
crossings - Part 1: Definitions;
(*) latest edition of the referenced document.
3. DEFINITIONS
Rails switch rails, closure rails, stock rails,
crossing legs, rails in glued insulated
rail joints, crossing machined from
standard rails;
turnout as defined in EN13232-1, section 3.2;
Diamond as defined in EN 13232-1, sections
4.3.1-4.3.10;
Turnouts turnouts and Diamonds;
Expansion Switch as defined in EN 13232-8, section 3.2.2;
The laboratory the laboratory performing the qualification
tests shall be certified with at least the
following certifications:
26. A laboratory certified in accordance
with ISO/IEC17025 in the field of
relevant Component testing.
or
27. A laboratory accredited by national
field of Component quality testing.
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4.1 Unless otherwise and to the extent specified hereafter, the Rails
shall comply in every aspect with the latest edition of EN 13674-1
and EN13674-2.
4.2 The Rails shall be made of steel profile 54E1 or 60E2 and Grade
R260 or R350HT (based on ISR order details) in accordance with
EN 13674-1. The manufacturing process shall be continuous
casting and no other process shall be approved.
4.3 The rails steel shall be in accordance with EN 13674-2, Table 3a
and Table 3b.
4.4 The Rails dimension tolerances shall be according with EN 13674-
2, paragraph 9.2
4.5 The size and location tolerances of drilled holes and the squareness
of Rail ends tolerance shall be in accordance EN13674-2 Table 8.
4.6 The Rails manufacturing process shall be complied with the
requirements in accordance with EN 13674-2, section 7.
4.7 The Rails identification branding and stamping shall be according
with EN 13674-2, section 7.4.
5. QUALITY CONTROL AND QUALITY ASSURANCE
PROCEDURES PLAN
The Rails manufacturer's comprehensive quality control and quality
assurance procedures plan follow by ISO9001 in accordance with
EN13674-1 and EN13674-2 and this technical specification shall be
submitted.
6.1 The Rails qualification tests shall be carried out in accordance with
EN13674-1, section 8 and EN13674-2, section 8. Qualification test
report by The Laboratory shall be submitted.
6.2 The tests shall be carried out on the 60E1 or 60E2 profiles.
7. QUALITY TESTS
7.1 All the tests described in EN 13674-2, section 9 shall be carried out.
A Quality Test report shall be submitted for each rail in every
Turnout and Expansion Switch.
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TECHNICAL ATTACHMENT B
TECHNICAL SPECIFICATION FOR MANUFACTURE AND

SUPPLY OF GLUED INSULATING RAIL JOINTS FOR
TURNOUTS NO.E-01-0023.T_JUNE_2015
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ISRAEL RAILWAYS LTD

for Manufacture of
GLUED INSULATED RAIL

JOINTS
for TURNOUTS
No. E-01-0023.T
June 2015
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Contents
1 SCOPE
2 STANDARDS REFERENCES
3 DEFINITIONS
4 GENERAL REQUIREMENTS
5 SUB-COMPONENTS REQUIREMENTS
5.1 STEEL FISHPLATE
5.2 STEEL BOLTS AND NUTS
5.3 WASHERS
5.4 INSULATING SUB-COMPONENTS: BOLT INSULATED SLEEVES,
INSULTED ENDPOST AND FISHPLATE POLYMER LAMINATION
5.5 GLUE
6 TECHNICAL DRAWINGS
7 MANUFACTURE
8 MARKING
9 QULIFICATION TESTS
10 QUALITY TESTS
APPENDIX A - ISRAEL CLIMATE AND
ENVIRONEMENTAL CONDITIONS
APPENDIX B – ROLLING LOAD TEST SCHEME
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1. SCOPE
manufacturing the Turnout Component - Glued Insulated Rail Joints.
1.2 The Glued Insulated Rail Joints shall be designed to be installed in
Turnouts with 60E2 and 54E1 rail profiles for appropriate signaling
operation.
EN 13674-1 Railway applications - Track – Rail - Part 1:
Vignole rails 46 kg/m and above;
UIC 864-2 Technical specification for the supply of steel
track bolts;
UIC 864-4 Technical specification for the supply of fish-
plates or sections for fish-plates;
EN ISO 898-1 Mechanical properties of fasteners made of
carbon steel and alloy steel -- Part 1: Bolts,
screws and studs with specified property classes
- Coarse thread and fine pitch thread
EN ISO 898-2 Mechanical properties of fasteners made of
carbon steel and alloy steel - Part 2: Nuts with
specified property classes - Coarse thread and
fine pitch thread
EN ISO 4759-3 Tolerances for fasteners - Plain washers for
bolts, screws and nuts. Product grades A and
C;EN 10139 Cold rolled uncoated mild steel
narrow strip for cold forming. Technical delivery
conditions;
EN 10025 Hot rolled products of structural steels;
ISO/IEC 17025 General requirements for the competence of
testing and calibration laboratories;
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3. DEFINITIONS
ISR Israel Railways
Diamond as defined in EN 13232-1 sections 4.3.1-4.3.10
Turnout any type of turnouts and Diamonds;
Sub-Component any constituent of the Glued Insulated Rail
Joints;
The Laboratory the laboratory performing the qualifying tests,
which shall have the following certificate:
28. A laboratory certified in accordance with
ISO/IEC17025 in the field of relevant
Component testing.
or
field of relevant Component quality
testing.
4.1 The Glued Insulated Rail Joints shall have different design in
accordance with rail profiles: 60E2 and 54E1 rails and rail grades:
R260 and R350HT (rail profiles and grade types in accordance with
EN13674-1)
The Glued Insulated Rail Joints shall be designed to be used in
Turnouts enable railway vehicles run safety at speed up to 200 km/h
and maximum axle load of 22.5 ton.
4.2 The Glued Insulated Rail Joints shall be designed in such a way that
it cannot be damaged as a result of rail maintenance work (tamping,
dynamic stabilization etc.) or by the operations of bearers replacing.
4.3 All insulted Sub-Components (including Glue) shall be designed to
resistant Israel climate condition (in accordance to appendix A).
High corrosion environment shall be considered as well.
4.4 The Glued Insulated Rail Joints shall have life cycle of not less than
10 years.
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4.5 The Glued Insulated Rail Joints shall include 2 rails, each rail length
shall be at least of 3 meters, with one of the following types:
 Type 60E2 R260;
 Type 54E1 R260;
 Type 60E2 R350HT;
 Type 54E1 R350HT.
The rails to be used shall be manufactured in accordance with
technical specification E-01-0004.T and EN13674-1.
4.6 The Glued Insulated Rail Joints shall have the following main Sub-
Components:
Polymer Laminated Steel Fishplates,
Steel Bolts and Nuts,
Washers,
Bolt Insulated Sleeves,
Insulted Endpost,
Glue.
Other Sub-components of the Glued Insulated Rail Joints in
accordance with manufacturer design.
4.7 Each and every Insulated Rail Joint Sub-Component shall be
manufactured in accordance to the Turnouts and Expansion Switches
manufacturer's quality management plan complying with ISO 9001
and based on the relevant EN, UIC and ISO standards, or by their
mechanical and chemical characteristics, only, in the non-existence
of ISO or EN or UIC standards.
5. SUB-COMPONENTS REQUIREMENTS
5.1 STEEL FISHPLATE
5.1.1 Types
The Glued Insulated Rail Joints shall include 2 Polymer Lamination
Steel Fishplates of one of the following types:
 Type 60 - length of at least 900 mm with 6 holes for 60E2 rails,
 Type 54 - length of at least 800 mm with 6 holes for 54E1 rails.
5.1.2 Characteristics
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The Steel Fishplate, before polymer laminated, shall be

manufactured in accordance with this technical specification and
UIC 864-4.
The source of steel supply and the steel making and casting
processes employed shall be submitted. The manufacturer shall not
alter these without the ISR approval.
The steel used for the manufacture of steel fishplates shall have
tensile strength of 600±50 N/mm2 and minimum elongation of 18%.
The Steel Fishplate dimensions shall be in accordance with the

manufacture drawing within the following tolerances:
Tolerances (in mm)
Height of the fishplate ±1
Straightness Vertical direction 0.1% of the chord length.
Centre should not be lower than the end
Horizontal direction 0.16% of the length
Length +3
End squareness +2
Other dimensions
defining the cross ±1
section
The dimensions of the holes shall remain within the tolerances:
Dimensions (in mm) Tolerances (mm)
D≤32 ±0.5
Diameter of bolt holes
D>32 ±1
Bolt holes shall have a 1 mm chamfer.
5.1.3 Tests and Inspection
For every order, testing certificates of polymer laminated fishplates
showing the source and method of steelmaking/casting used and
prescribed the results of the mechanical and chemical tests,
dimensions and finish inspection in accordance with this technical
specification and UIC 864-4 shall be submitted.
5.2.1 General
The Glued Insulated Rail Joints shall include 6 Steel Bolts and Nuts.
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The Steel Bolts and Nuts material, quality, manufacturing tests and
acceptance conditions shall be in accordance with this technical
specification and these standards: UIC 864-2, EN ISO 898-1 and EN
ISO 898-2.
The steel making process and grade of steel shall obtain the
following mechanical properties:
Tensile strength steel grade 10.9 and tensile stress of 1000-1150
N/mm2 and minimum elongation 9%.
The sulfur and phosphorus content shall not exceed 0.035%.
The Steel Bolts shall be manufactured from single piece, without
welding. Their head shall be upset by hot-working.
The steel used for the manufacture of the Nut must be in keeping
with the grade of quality of the Steel Bolt or with the nearest grade
below.
The Steel Bolts and Nuts shall be galvanized. The steel bolts and
nuts must be free from any trace of grease, paint, etc. before the
galvanization.
For every order, testing certificates of the Steel Bolts and Nuts
prescribed the dimensions, strength, surface and structure in
accordance with this technical specification and these standards: UIC
864-2, EN ISO 898-1, EN ISO 898-2 shall be submitted.
For every order, certificates of steel bolts and nuts galvanization
shall submitted.
5.3 WASHERS
5.3.1 General
The Glued Insulated Rail Joints shall include 6 steel washers.
The washer shall be manufactured by hot or cold rolled steel process,
with steel category according to EN 10139 or EN 10025.
The washer dimensions and tolerances shall be in accordance with
EN ISO 4759-3 or equivalent.
The conditions of manufacture of the washer obtained from bars of
the same casting must be identical.
The section shall be of even thickness and slightly rounded at the
edges.
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The washer shall be regular and clean, and free from superficial
cracks, flaws, burrs, and deficiency in metal, folds, or any other
defects likely to affect the use for which they are intended. The
outside surface, in particular, must be smooth and free from burrs.
The washer shall be galvanized. The washers must be free from any
trace of grease, paint, etc. before the galvanization.
For every order, testing certificates of the washers showing the
source and method of steelmaking/casting used and prescribed the
results of the mechanical tests and measured dimensions shall be
submitted.
For every order, certificates of washers' galvanization shall be
submitted.
5.4 INSULATING SUB-COMPONENTS: BOLT INSULATED
SLEEVES, INSULTED ENDPOST AND FISHPLATE POLYMER
LAMINATION
5.4.1 General
5.4.1.1 The Glued Insulated Rail Joints shall include an Insulated Endpost of
one of the following types:
 Insulated Endpost for 60E2 rails;
 Insulated Endpost for 54E1 rails.
The Insulated Post shall be designed with minimum width of 4 mm.
5.4.1.2 The Glued Insulated Rail Joints shall include 6 Bolt Insulated Sleeves
of the following type:
 Bolt Insulated Sleeves 60E2 and 54E1 rails.
5.4.1.3 The Steel Fishplates in the Glued Insulated Rail Joints shall be
polymer laminated.
The insulated Sub-Components mechanical, electrical and thermal
properties values shall be submitted.
5.5 GLUE
The Glue type, its technical specification and safety data sheet
(MSDS) shall be submitted.
6. TECHNICAL DRAWINGS
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6.1 A complete set of technical drawings of Glued Insulated Rail Joints

for 60E2 and 54E1 rails profiles and including their Sub-
Components with dimensions, tolerances and material main
characteristics, coating description, heat treatment, etc., shall be
submitted.
7. MANUFACTURE
7.1 The Glued Insulated Rail Joints shall be manufactured in accordance
with the technical drawings and with this technical specification and
shall present a clean surface, smooth and free from blow-holes,
flaws, cracks, folds or other faults.
8. MARKING
8.1 Each Glued Insulated Rail Joints shall be inscribed with at least the
following marks:
 The manufacturer's mark,
 The last two figures of the year of manufacturer,
9. QULIFICATION TESTS
9.1 The qualification tests shall be carried out by The Laboratory on
three Glued Insulated Rail Joints as follows:
 Two Glued Insulated Rail Joints shall be tested in accordance
with section 9.2;
 The third Glued Insulated Rail Joints shall be first tested in
accordance with section 9.3 than shall be tested in accordance
with section 9.4
 After completion of the rolling load test the Glued Insulated
Rail Joints shall be electrical resistance retested.
9.2 Longitudinal Force Test process
The qualifying criterion for the longitudinal force test shall be as
follows:
At no time shall any of the Glued Insulated Rail Joints show any
indication of slippage during or before the total prescribed load for
the rail section involved is applied to the joint. At the completion of
the test after the load on the rail has been released, the relative
position of the rail and joint bar shall be within 0.5 mm of its original
value.
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The insulated rail joint with capability to transfer forces in turnout as

integral part of CWR track:
 For 60E1 or 60 E2 rails - at least 1950 kN,
 For 54E1 rail - at least 1500 kN.
9.3 Electrical Resistance Test process
A Glued Insulated Rail Joints shall be fully assembled in accordance
with manufacture's recommendations on two lengths of rail for an
electrical resistance test. The dry rail and joint assembly shall be
supported on dry nonelectrical conducting material.
9.4 Megohmeter test:
Apply 500 volts D.C. rail to rail, each test for duration of 5 second
and there shall be a minimum resistance of 10M.
9.5 High potential test:
Apply 3000 volts A.C. RMS, rail to rail which shall be held for
duration of not less than 60 second without flashover or puncture
between all metallic parts.
9.6 Rolling load test process
A wheel load of 195 kN shall be applied to the rail. The stroke shall
have a range of 825mm, centered as shown in appendix B. The load
on the rail shall be applied for 2 million cycles and the deflection of
the rail at the center line of rail shall be measured and recorded when
the load is over both points A and B every 500,000 cycles and
recorded to nearest 0.02 mm.
Alternative method of testing the joint dynamically may be
submitted to the ISR for approval.
At all times the deflection of the insulated rail joint shall not exceed
1.65mm.
9.7 For each design and/or material change, the manufacturer shall be
required to re-perform the qualification tests.
10. QUALITY TESTS
10.1 Each Glued Insulated Rail Joint shall be tested with: Megohmeter
test - Applying 500 volts, D.C. rail to rail, each test for duration of 5
second, and there shall be a minimum resistance of 10M.
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APPENDIX A - ISRAEL CLIMATE AND ENVIRONNEMENTAL

CONDITIONS
A.1 Climate and Environmental Conditions

A.2 Dust Conditions in the atmosphere

Value* Value*
NOx 1064 560 71
SO2 780 260 21
O3 312 143 84
Suspended - 350 100
Dust
A.3 Suspended Particulate Matter (SPM)

A.4 Sea Salt Concentrations in the Atmosphere

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
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APPENDIX B – ROLLING LOAD TEST SCHEME
Dimensions in millimeters
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TECHNICAL ATTACHMENT C
TECHNICAL SPECIFICATION FOR MANUFACTURE AND SUPPLY

FASTENING SYSTEMS FOR TURNOUTS
NO.E-01-0026.T_JUNE_2015
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ISRAEL RAILWAYS LTD

for Manufacture
of
Fastening Systems for Turnouts
and Expansion Switch
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No. E-01-0026.T
June 2015
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CONTENTS
1. SCOPE
3. DEFINITIONS
5.1 TENSION CLAMPS
5.2 ANGLED GUIDE PLATES
5.3 BEARERS SCREWS
5.5 RAIL SEAT PADS FOR TURNOUTS ON WOOD BEARERS
5.6 RAIL SEAT PADS FOR TURNOUTS ON CONCRETE BEARERS
5.7 BASE PLATES
5.8 BASE PLATES PADS
5.9 SPRING WASHER / DOUBLE SPRING WASHER
5.10 WASHERS
5.11 Plastic Dowels
5.12 HEIGHT ADJUSTMENT PLATE
6. DRAWINGS
TECHNICAL APPENDIX A – ISRAEL CLIMATE AND
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1. SCOPE
manufacturing the Turnout and Expansion Switch Components –
Fastening Systems
1.2 The Rails in Turnouts and Expansion Switches shall be fastened to the
Bearers with elastic rail fastening system which will be equipped with
tension clamp: for Wood Bearers - SKL-W12; and for Concrete Bearers
- SKL-W14 or other equivalent SKL-W. And fastened in Slab Track
with elastic rail fastening systems which will be equipped with tension
clamp: SKL-W15 (W-300-1 – BOGL system; and/or W-300 - RHEDA
2000) and/or SKL-W14 (LVT system)
Additional special fastening systems and their suitable Sub-Components
all for switch panels, closure panels, crossing panels and check rails
(secured within the overall fastening system (not independently fixed to
the Bearers)) ("Fastening Systems for Turnouts") on Wood, Concrete,
Hollow Bearers and for Slab Track for the 60E2 and 54E1 rail profiles.
1.3 The Concrete Bearers are designed with USP as prescribed in ISRTS
No. E-01-0022. The Fastening System set and all its Sub-Components
shall be designed for achieving uniform stiffness along the entire turnout
(including the Crossing Part) to insure the rolling-stock, freight trains
and railbound vehicles safe and comfort passage.
1.4 The main Sub-Components of the Fastening Systems for Turnouts shall
be:
 Tension Clamps;
 Angled Guide Plates (if applicable);
 Bearers Screws;
 Track Bolts (if applicable);
 Rail Seat Pads;
 Base Plates (if applicable);
 Base Plates Pads (if applicable);
 Double Spring Washer (if applicable);
 Spring Washers (if applicable);
 Washers (if applicable);
 Plastic Dowels (if applicable);
 Height Adjustment Plates;
 Other Sub-components.
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1.5 Unless otherwise and to the extent specified hereafter, the Fastening
Systems shall conform in every aspect with EN 13481 parts: 2, 3, 4, 5, 7
and EN13146 parts: 1-7 and 9.
1.6 The Fastening Systems shall be designed to comply with category C in
accordance with EN13481 parts: 2, 3, 4, 5, 7, section 1.
EN 13481-2 Railway applications - Track - Performance
requirements for fastening systems - Part 2:
Fastening systems for concrete sleepers;
Fastening systems for wood sleepers;
Fastening systems for steel sleepers;
Fastening systems slab track with rail on the surface
or rail embedded in a channel;
requirements for fastening systems - Part 7 Special
fastening systems for switches and crossings and
check rails;
EN 13146-1 Railway applications - Track - Test methods for
fastening systems - Part 1: Determination of
longitudinal rail restraint;
fastening systems - Part 2: Determination torsional
resistance;
attenuation of impact loads;
fastening systems - Part 4: Effect of repeated
loading;
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electrical resistance;
fastening systems - Part 6: Effect of severe
environmental conditions;
clamping force;
stiffness;
EN 13674-1 Railway applications - Track – Rail - Part 1:
Vignole rails 46 kg/m and above;
prEN 16730 Railway applications - Track - Concrete sleepers
and bearers with under sleeper pads
UIC 864-1 Technical specification for the supply of sleepers
screws;
UIC 864-2 Technical specification for the supply of steel track
bolts;
UIC 864-3 Technical specification for the supply of spring
steel washers for the use in the permanent way;
UIC 864-5 Technical specification for the supply of rail seat
pads;
UIC 864-6 Technical specification for the supply of baseplates
or sections of plates made of rolled steel;
EN 10139 Cold rolled uncoated mild steel narrow strip for
cold forming. Technical delivery conditions;
EN 10025 Hot rolled products of structural steels;
EN ISO 898-1 Mechanical properties of fasteners made of carbon
steel and alloy steel -- Part 1: Bolts, screws and
studs with specified property classes - Coarse thread
and fine pitch thread
EN ISO 898-2 Mechanical properties of fasteners made of carbon
steel and alloy steel - Part 2: Nuts with specified
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property classes - Coarse thread and fine pitch

thread;
EN ISO 1133 Plastics – Determination of the melt mass-flow rate
(MFR) and melt volume-flow rate (MVR) of
thermoplastics –
EN ISO 4759-3 Tolerances for fasteners - Plain washers for bolts,
screws and nuts. Product grades A and C;
EN ISO 179 Plastics - Determination of Charpy impact
properties;
EN ISO 527-2 Plastics - Determination of tensile properties -- Part
2: Test conditions for moulding and extrusion
plastics
EN ISO 868 Plastics and ebonite — Determination of
indentation hardness by means of adurometer
(Shore hardness)
EN ISO 1183-1 Plastics - Methods for determining the density of
non-cellular plastics - Part 1: Immersion method,
liquid pyknometer method and titration method;
ISO 6507 Metallic materials — Vickers hardness test;
IEC 60093 Methods of test for volume resistivity and surface
resistivity of solid electrical insulating materials;
IEC 60167 Methods of test for the determination of the
insulation resistance of solid insulating materials;
ISO/IEC 17025 General requirements for the competence of testing
and calibration laboratories;
3. DEFINITIONS
ISR Israel Railways
turnout as defined in ISRTS No. E-01-0022, section
1.1;
Diamond as defined in EN 13232-1, sections 4.3.1-
4.3.10
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Expansion Switch as defined in EN 13232-8, section 3.2.2

Sub-Component any constituent of the Fastening Systems;
Sleeper/Bearer Pad (USP) as defined in prEN16730, sections 3.9
The laboratory the laboratory performing the Components
Qualification Tests, which shall have the
following certificate:
30. A laboratory certified in accordance
with ISO/IEC17025:2005 in the field
of relevant Component testing.
or
laboratory accreditation authority in
the field of Component quality
testing.
or
32. Prüfamt Für Bau Von
Landverkehrswegen, Technische
Universität, München.
4.1 The Fastening Systems shall comply with requirements of EN 13481-2,
3, 4, 5, 7.
4.2 The Fastening Systems qualification tests shall be accomplished in
accordance to EN 13146 parts: 1-7 and 9,
4.3 Qualification tests procedure shall be applied to a complete fastening
assembly.
4.4 Each and every Sub-Component shall be manufactured in accordance to
the Turnouts and Expansion Switches manufacturer's quality
management plan complying with ISO 9001 and based on the relevant
EN, UIC and ISO standards, or by their mechanical and chemical
characteristics, only, in the non-existence of ISO or EN or UIC
standards.
4.5 All parts which are non-metallic shall be made of hot weather resistant
materials, suitable for use at temperature of up to 70°C and under high
corrosion conditions. Plastic parts shall be UV protected.
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5.1 TENSION CLAMPS
The Tension Clamp raw material shall be from alloy Silicone-
manganese spring steel according EN 10089 or equivalent with the
following chemical composition:
 0.35 ≤ C% ≤ 0.42
 1.5 ≤ Si% ≤ 1.8
 0.5 ≤ Mn% ≤ 0.8
 S% ≤ 0.025
 P% ≤ 0.025
The tension clamps shall be heat treated to achieve a surface hardness in

the range 400-460 HV 30 in accordance with ISO 6507 or equivalent. It
shall be free from surface and internal defects.
The tension clamps shall be provided with protective coating.
For every order, testing certificates of tension clamps dimensions,
strength, surface and structure shall be submitted.
5.2 ANGLED GUIDE PLATES
The angled guide rail material shall be made from Polyamide 6/6.6 with
approximately 50% fiberglass reinforcement and resistance to
ultraviolet radiation or equivalent material with the same physical
properties.
The angled guide rail material impact strength shall be greater than 40
kJ/m2 according EN ISO 179.
The angled guide rail material density shall be 1.35 – 1.45 g/cm3
according with EN ISO 1183-1.
The angled guide rail material moisture contents shall be 1%-2.5%.
The angled guide rail material volume resistivety shall be greater than
108 Ohm·cm in accordance with IEC 60093 / IEC 60167.
Tensile strength at maximum force shall be greater than 110 N/mm2, in

accordance with EN ISO 527-2.
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Elongation at maximum force shall be greater than 3%, in accordance

with EN ISO 527-2.
The angled guide rail surface must be free of cracks and damages
affecting performances.
5.2.2 Tests And Inspection
For every order, testing certificates of angled guide plates dimensions,
material density, viscosity, moisture and glass content, volume
resistivity and surface shall be submitted.
5.3 BEARERS SCREWS
The Bearers Screws material quality manufacturing and acceptance
conditions shall be in accordance with UIC 864-1.
The Bearers Screws shall be manufactured from single piece, without

welding. Their head shall be formed by hot-working from the bar-stock.
The Bearers Screws steel category shall be in accordance with EN

10139 or EN 10025.
The Bearers Screws tensile strength shall be greater than 500 N/mm2.
The Bearers Screws elongation shall be greater than 20%.
The Bearers Screws limit of elasticity shall be greater than 300 N/mm2.
The Bearers Screws shall be galvanized. The Bearers Screws must be

free from any trace of grease, paint, etc. before the galvanization.
The complete surface of the Bearers Screws shall be suitably trimmed.

Care shall be taken to ensure that trimming does not give rise to any
tearing of the metal or leave any roughness on the contact surfaces.
The threads must be clean, uniform and complete. If the threads of the
Bearers Screws are stripped or if there is a lack of material in their
shank, they shall not be accepted.
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For every order, testing certificates of Bearers Screws in accordance
with this technical specification and UIC 864-1 shall be submitted
manufacturer submit.
For every order, certificates of Bearers Screws and nuts galvanization
shall submitted.
The Steel Bolts and Nuts material, quality, manufacturing tests and
acceptance conditions shall be in accordance with this technical
specification and these standards: UIC 864-2, EN ISO 898-1 and EN
ISO 898-2.
The steel making process and grade of steel shall obtain the following
mechanical properties:
The Steel Bolts tensile strength category 5.6- strength shall be greater
than 500 N/mm2, elongation greater than 20% and limit of elasticity
shall be greater than 300 N/mm2.
The sulfur and phosphorus content shall not exceed 0.06%.

The Steel Bolts shall be manufactured from single piece, without
welding. Their head shall be upset by hot-working.
The steel used for the manufacture of the Nut must be in keeping with
the grade of quality of the Steel Bolt or with the nearest grade below.
The Steel Bolts and Nuts shall be galvanized. The Steel Bolts and Nuts
must be free from any trace of grease, paint, etc. before the
galvanization.
For every order, testing certificates of the Steel Bolts and Nuts
prescribed the dimensions, strength, surface and structure in accordance
with this technical specification and these standards: UIC 864-2, EN
ISO 898-1, EN ISO 898-2 shall be submitted.
For every order, certificates of steel bolts and nuts galvanization shall
submitted.
5.5 RAIL SEAT PADS FOR TURNOUTS ON WOOD BEARERS
The rail pad is manufactured from EVA (Ethylen-Vinylacetat-
Copolymerisat)
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The rail pads shall be water oil and grease resistant, and shall be
stabilized against light/ UV damage.
It shall be protected against oxidation and rotting.
The rail seat pads shall have 32 - 47 shore hardness-D in accordance

with EN ISO 868.
The rail seat pads shall have Melt Flow Rate (MFR 190/2.16) ≤ 5.2 g/10
min in accordance with ISO 1133.
The rail seat pads shall have density 0.932- 0.952 g/cm3 in accordance
with EN ISO 1183.
The rail seat pads static stiffness shall be Cstat 450 kN/mm.
The rail seat pads electrical volume resistivety shall be greater than 10 8
Ohm·cm according with IEC 60093.
The surface shall be free of cracks and damages affecting performances.
5.6 RAIL SEAT PADS FOR TURNOUTS ON CONCRETE BEARERS

The Rail Seat Pads material shall be manufactured from TPU
(Thermoplastic Polyurethanes) or equivalent and shall be design to
achieve rail deflection of approximately 1 mm and more.
The rail pads shall be water oil and grease resistant, and shall be
stabilized against light/ UV damage. It shall be protected against
oxidation and rotting.
The Rail Seat Pads shall have 82-90 shore –A in accordance with EN
ISO868:2003.
The Rail Seat Pads density shall be 1.13-1.17 g/cm3 in accordance with
EN ISO 1183.
The rail seat pads static stiffness shall be Cstat= 60±10 kN/mm.
The rail seat pads shall have a soft dynamic stiffness < 100 MN/m.
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The rail seat pads electrical volume resistivety shall be greater than 10 8
Ohm·cm according with IEC 60093 / IEC 60167.

5.7 BASE PLATES
The base plates material quality manufacturing, tests and acceptance
conditions shall be according UIC 864-6.
The base plates tensile strength shall be greater than 410 N/mm2.
The base plates elongation at fracture shall be greater than 24%.
The base plates yield strength shall be greater than 265 N/mm2.
The base plates on the bearers shall guarantee rail inclination of 1/30.
5.7.2 Tests And Inspection
For every order, testing certificates of the steel bolts and nuts prescribed
the dimensions, strength, surface and structure in accordance with this
technical specification and UIC 864-6 shall be submitted.
5.8 BASE PLATES PADS
Base Plates Pads to be inserted between the Base Plates and the
Concrete Bearers shall be a Sub-Component of the Fastening System.
Its characteristics shall be in accordance with UIC 864-5 or shall have
equivalent characterstics.
5.9 SPRING WASHER / DOUBLE SPRING WASHER
The Spring Washer/Double Spring Washer shall be manufactured from
spring steel.
The Spring Washer/Double Spring Washer quality manufacturing, tests
and acceptance conditions shall be according UIC 864-3.
The Spring Washer/Double Spring Washer steel category shall be 38S7,

Chemical composition of the raw material:
 0.35 ≤ C% ≤ 0.42
 1.5 ≤ Si% ≤ 1.8
 0.5 ≤ Mn% ≤ 0.8
 S% ≤ 0.045
 P% ≤ 0.045
The Spring Washer/Double Spring Washer tensile limit elasticity shall
be greater than 1030 N/mm2.
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The Spring Washer/Double Spring Washer tensile strength shall be

greater than 1180 N/mm2.
The Spring Washer/Double Spring Washer elongation at fracture shall
be greater than 6%.
The Spring Washer/Double Spring Washer shall be hardened and
tempered the hardness shall be 430-515 HV 30.
For every order, testing certificates of Spring Washer/Double Spring
Washer in accordance with this technical specification and UIC 864-3
shall be submitted.
For every order, certificates of Bearers Screws and nuts galvanization
shall submitted.
5.10 WASHERS
The washer shall be manufactured by hot or cold rolled steel process,
with steel category according to EN 10139 or EN 10025.
The washer dimensions and tolerances shall be according with EN ISO
4759-3.
The washer shall be galvanized. The washers must be free from any
trace of grease, paint, etc. before the galvanization
For every order, testing certificates of the Washers prescribed the
dimensions, strength, surface and structure in accordance with this
technical specification shall be submitted.
submitted.
5.11 PLASTIC DOWELS
The Plastic Dowel material shall be design to guarantee the pull out
force from the Bearers of minimum 70 [kN].
The Plastic Dowel Density shall be greater than 0.950 g/cm3 in

accordance with EN ISO 1183.
The Plastic Dowel Density electrical volume resistivity shall be greater

than 108 Ohm·cm according with IEC 60093 / IEC 60167.
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For every order, testing certificates of the Washers prescribed the
dimensions, strength, surface and structure in accordance with this
technical specification shall be submitted.
submitted.
5.12 HEIGHT ADJUSTMENT PLATE
5.12.1 Height Adjustment Plate – Characteristics
The height adjustment plate shall be manufactured from HDPE (High
Density Poly Ethylene) and shall be stabilized against light / UV
damage.
The surface must be free from cracks and damages affecting

performance.
The height adjustment plate shall have approx. 65 Shore - D in

accordance with DIN 53505.
The height adjustment plate shall have (MFR 190/2.16)3.1-18 g/10

minimum in accordance with DIN ISO 1133:2005.
The height adjustment plate shall have density of 0.940-0.960 g/cm3 in

accordance with EN ISO 1183.
The height adjustment plate electrical volume resistivety shall be greater

than 108 Ohm·cm according with IEC 60093/IEC 60167.

For every order, testing certificates of the Height Adjustment Plate
prescribed the dimensions, strength, surface and structure in accordance
with this technical specification shall be submitted.
6. DRAWINGS
6.1 The Turnout manufacturer shall submit a complete set of technical
specification and manufacturing drawings of Fastening Systems for
Turnouts (for every type) with dimensions, tolerances material type,
coating description and heat treatment, etc.
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6.2 The Turnout manufacturer shall submit, together with his proposal,
drawings of the assembled unit (the interface between the fastening
system Sub-components and the Bearers), for each rail fastening system
unit type, for each rail type, for each Bearer type. The drawings shall be
included with:
6.2.1The external gauge point of rail fastening system which defines the
track gauge;
6.2.2The dimension and the tolerance between internal and external
gauge points for the rail section for which the fastening assembly is
designed;
6.2.3Drawing with dimensions and tolerances of every components of
the fastening system;
6.2.4The nominal inclination of the Rail Seat.
6.3 The Fastening Systems for Turnouts overall dimensions shall be
designed to avoid interface with vehicles including track maintenance
vehicles in accordance to EN 13481-2, section 5.8; EN 13481-3, section
5.7; EN13481-4, section 5.6; and EN 13481-5, section 5.6.
6.4 The manufacturer shall submit calculations to show the maximum
variation in static track gauge which can arise from the fastening
system. The calculations shall be based on the nominal of the rail
section given in EN 13674-1and shall include any assumption about the
position of the rail within the fastening assembly and the tolerances on
all component parts of the fastening system. The value variation in track
gauge, calculated in this way, shall conform to EN 13481-2, section 5.9;
EN 13481-3, section 5.8; EN13481-4, section 5.7; and EN 13481-5,
section 5.7.
7.1 The qualification tests shall carried out by The Laboratory on fastening
systems for Turnouts as an assembled unit according to EN13481-2
sections 5.1-5.10 and 5.12; EN13481-3 sections 5.1-5.9 and 5.11;
EN13481-4 sections 5.1-5.9 and 5.11; EN13481-5 sections 5.1-5.8 and
5.10; EN 13481-7 sections 5.1-5.11 and 5.13, and EN13146 parts 1-7
and 9. Test report shall be submitted the relevant certificates to ISR.
7.2 The following measurement shall be performed before and after
repeated loading. The change in performance shall not exceed the values
shown:
 Longitudinal rail restraint (EN 13146-1) change ≤ 20%;
 Vertical stiffness (EN 13146-4) change ≤ 25%;
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 Clamping force (EN 13146-7) change ≤ 20%.
8. LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S

PROPOSAL
8.1 The manufacturer shall submit hard copies and also magnetic copy of all
the drawings pointed out in paragraph 6 above.
8.2 The manufacturer shall add to the drawings hard copies and magnetic
copy the relevant technical descriptions of every Sub-component.
8.3 The manufacturer shall submit calculations to show the maximum
variation in static track gauge which can arise from the fastening system
pointed out in paragraph 6.4.
8.4 The manufacturer shall state the nature and main characteristics of the
steel and the non-metallic materials making process.
8.5 The manufacturer shall submit ISR hard copy and also magnetic copy of
installation and maintenance manuals.
9. LIST OF DOCUMENTS TO SUBBMIT with delivery
9.1 The manufacturer shall submit copies of all the drawings pointed out in
section 3 above.
9.2 The manufacturer shall add to the drawings the relevant technical
descriptions of the Bearer and all fastening accessory components, and
certificate for Bearers steel type.
9.3 The manufacturer shall notify which standard and process description
will be used for carried out tensile and bend tests on steel casts and test
reports.
9.4 The manufacturer shall state the nature and main characteristics of the
steel making process.
9.5 The manufacturer shall submit a certificate confirming that the Sub-
components materials comply with the requirements.
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APPENDIX A - ISRAEL CLIMATE AND ENVIRONNEMENTAL

CONDITIONS


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


Salt Element Na (**) Cl (**) SO4 (**)
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
(**) - Microgram per m³ atmosphere
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TECHNICAL ATTACHMENT D
TECHNICAL SPECIFICATION FOR MANUFACTURE AND SUPPLY OF

WOOD BEARERS NO. E-01-321A.2.T_JUNE_2015
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ISRAEL RAILWAYS LTD.
for Manufacture
of
WOOD BEARERS
for Turnouts
No. E-01-321A.2.T
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June 2015
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CONTENTS
1. GENERAL
3. DEFINITIONS
4. DIMENSIONS
5. PRESERVATION TREATMENT
6. QUALIFICATION TEST
7. QUALITY TEST
8. OTHER REQUIRMENTS
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1. GENERAL
1.1. This technical specification prescribes the technical requirements
of manufacturing the Turnout Components - Wood Bearers.
1.2. The conditions for the manufacture and acceptance shall be
according EN13145 except as stated hereinafter.
1.3. Wood Species: Wood Bearers shall be made of European Oak or
Tropical timber (as defined in EN13145, Table 1 – List of wood
species).
1.4. The Wood Bearers defects and quality features shall be measured/
assessed after seasoning and before preservation treatment as
defined in EN13145 section 6.2, table 2.
EN 13145 Railway applications - Track - Wood sleepers
and bearers
EN 13991 Derivatives from coal pyrolysis - Coal tar based
oils: creosotes - Specifications and test methods
3. DEFINITIONS
Diamond as defined in EN 13232-1, sections 4.3.1-4.3.10;
Turnout turnouts and Diamonds.
4. DIMENSIONS:
4.1. Bearers class: according to EN13145, section 5.1 form E1,
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l - equal to 260 mm;

e - equal to 160 mm;
r - equal to 100 mm;
d - equal to 200 mm.
4.2. Bearers length: 2300 - 4900 [mm].
4.3. The Wood Bearers tolerance shall apply the tolerances defined in
EN13145 section 5.3.
5. PRESERVATION TREATMENT
5.1. The preservative process procedure shall be submitted.
5.2. Preservative material:
The preservative material must comply with EN13991 grade B or
C.
The Material Safety Data Sheet (MSDS) shall be submitted.
5.3. Seasoning:
Prior to the preservation treatment the Wood Bearers and shall be
completely air seasoned for not less than 8 month. Maximum
period between felling and delivery shall be 12 month.
5.4. Method of treatment
The Wood Bearers are to be impregnated with Pressure process to
match hazard class 4 preservatives according EN13145, section
7.2.2. (The specific process shall be indicated).
5.5. Penetration
Treated Wood Bearers shall meet the requirements of penetration
class 8 (P8: full sapwood penetration), according EN13145,section
7.2.3.
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5.6. Retention
The Wood Bearers minimum retention requirement shall be equal
to the critical value for hazard class 4 of the preservative used,
according EN13145, section 7.2.4.
6. QUALIFICATION TEST
The following documents shall be submitted:
6.1. Quality management system certificate shall be submitted
(ISO9001 certificate and/or WAI certificate and/or AWPA
certificate and/or equivalent quality management certificate).
6.2. A comprehensive quality control and assurance program which
will be used during the manufacturing shall be submitted.
6.3. The manufacturer shall submit certificates to the seasoning and
impregnation of the Wood Bearers (method, quantities of
protective materials, etc.).
6.4. The Material Safety Data Sheet (MSDS) shall be submitted.
7. QUALITY TEST
7.1. In Every Order which include Wood Bearers documentation
according EN13145, section 9, shall be supplied.
8. OTHER REQUIRMENTS
8.1. Every Wood Bearer shall bear an identification mark of the
producer.
8.2. Every Wood Bearer shall be protected and immunized against
crack by gang nails and steel bands 3/4" wide on each side of the
Bearer.
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TECHNICAL ATTACHMENT E

SUPPLY OF STEEL HOLLOW BEARERS FOR ALD (ACTUATION
SYSTEM, LOCKING DEVICE AND DETECTION DEVICE)
INTEGRATION NO. E-01-0025.T_JUNE_2015
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for Manufacture of
STEEL HOLLOW
BEARERS
for
ALD (Actuation System, Locking
Device and Detection Device)
INTEGRATION
No. E-01-0025.T
June 2015
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CONTENTS
1. SCOPE
3. DEFINITIONS
5. TECHNICAL REQUIREMENTS
6. MANUFACTURE'S TECHNICAL DRAWINGS
TECHNICAL APPENDIX A – ISRAEL CLIMATE AND
ENVIRONEMENTAL CONDITIONS
TECHNICAL APPENDIX B – SKETCH OF THE HOLES
DIMENSIONS AT THE BOTTOM OF THE STEEL HOLLOW
BEARERS
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1. SCOPE
manufacturing the Turnout Components – Steel Hollow Bearers.
1.2 The Steel Hollow Bearers shall be designed for integration of ALD
in Turnouts, and shall protect the ALD from mechanical damage.
1.3 The Steel Hollow Bearers will be equipped with indirect elastic rail
fastening system, with tension clamp SKL-W (one of the types
defined in the ISRTS E-01-0026.T_November 2014), design for
track with 60E2 and 54E1 rails.
EN 16431 Railway applications - Track - Hollow sleepers
and bearers;
Fastening systems for steel sleepers;
EN13232-1 Railway applications - Track - Switches and
UIC 842-4 Technical specification for the protection against
corrosion and painting wagons and containers;
ISO/IEC 17025 General requirements for the competence of
testing and calibration laboratories;
3. DEFINITIONS
ISR Israel Railways
ALD Actuation System, Locking Device and
Detection Device;
Diamond as defined in EN13232-1, sections 4.3.1-
4.3.10;
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Sub-Component any constituent of the Steel Hollow

Bearers;
The Laboratory the laboratory performing the
qualification tests shall be certified with
at least the following certifications:
33. A laboratory certified in
accordance with
ISO/IEC17025:2005 in the field
of relevant Component testing.
or
34. A laboratory accredited by
national laboratory accreditation
authority in the field of
Component quality testing.
4.1 The Steel Hollow Bearer shall be designed for use with 60E2 and
54E1 rails in Turnouts.
4.2 The Steel Hollow Bearers and their fastening system set shall be
designed for use on standard gauge 1435 mm railway track. The rail
seats on each Bearer shall have nominal inclination of 1:30 (sleeper
with zero inclination and Base Plate with inclination of 1:30).
designed to enable railway vehicles run safety at speed up to 200
km/h.
design for loads of 22.5 ton/axle.
4.5 The Steel Hollow Bearer and the fastening system set design shall
also include insulation elements which shall enable the proper
attachment to 60E2 and 54E1 rails.
4.6 The Steel Hollow Bearer weight completely assembled, including
rail fastening system set, cover plates (not including the ALD system
weight) shall be not less than 260 kg and not more than 330 kg.
4.7 The Steel Hollow Bearer shall be designed for use on electrified
track with 25 kV AC.
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4.8 Rated bending moment underneath the rail bearing surfaces and in
the centre of the Steel Hollow Bearer with symmetric load
application 25 kNm.
4.9 The fastening system set shall be designed to guarantee insulation
between the rail and the Steel Hollow Bearers in Turnouts, CWR
track and jointed track in accordance with EN 13841-4 paragraph
5.4.
4.10 The fastening system overall dimension shall be designed to avoid
interface with vehicles including track maintenance vehicles in
accordance with EN13481-4 paragraph 5.6.
4.11 The Steel Hollow Bearer shall be designed in such a way that it
cannot be damaged as a result of track maintenance work (tamping,
leveling, dynamic stabilization, etc.) or while the Bearers are
assembled or replaced.
4.12 The Steel Hollow Bearers top body shall be covered with steel plates
including the ALD. The plates shall be screwed to the Steel Hollow
Bearers body.
4.13 The Steel Hollow Bearers shall be designed and manufactured with
holes at the bottom of the Steel Hollow Bearer for sufficient drainage
(see sketch in technical appendix F).
4.14 If Steel Hollow Sleeper construction required welding the steel to be
used shall be weldability steel in accordance to the relevant EN, ISO
standard or equivalent. A Certificate of the steel weldability shall be
submitted.
4.15 Israel climate condition should be considered (see technical appendix
I). All parts which are non-metallic shall be made of hot weather
resistant materials, suitable for use at temperature of up to 70°C
(maximum rail temperature) and under high corrosion conditions.
Plastic parts shall be UV protected.
4.16 The Steel Hollow Bearers body, steel cover stud plates shall be
corrosion protected and painted in accordance with UIC842-4 or
equivalent standard.
4.17 The steel cover stud plates between the rails and both sides outside
the rails and shall be reflective painted in accordance with UIC842-4
or equivalent standard.
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4.18 The Steel Hollow Bearers life cycle shall not be less than 25 years.
5. TECHNICAL REQUIREMENTS
5.1 STEEL HOLLOW BEARERS
5.1.1 Metallic body materials shall be specified with their relevant
standards.
5.1.2 The nature and main characteristics of the steel material and
chemical composite shall be stated and could not be modified
without ISR approval.
5.1.3 The dimensions of the Steel Hollow Bearers shall be in accordance
with this technical specification and the manufacturer technical
drawings.
5.1.4 The Steel Hollow Bearer length shall be 2600 mm.
5.1.5 the height between the top of the rail and the bottom of the hollow
bearer shall be the same as the neighboring bearers, so the bottom of
the hollow bearer should be aligned at the same level as the bottom
of the adjacent bearers in order to guarantee stability (mounting on
same ballast level);
5.1.6 The Steel Hollow Bearer maximum width shall be 310mm.
5.1.7 Moving away the covers - it should bear at least 15 years without
losing its functionality.
5.1.8 Cover must be fixed to the Steel Hollow Bearer in such away, that it
should be easy to dismantle, but it should be able to prevent the
unauthorized intervention.
5.1.9 The covers should be strong enough to bear the worker weight (100
kg) stepping on them without permanent deformation.
5.2 FASTENING SYSTEM - TECHNICAL REQUIREMENTS
5.2.1 The Fastening Systems shall comply with requirements of ISRTS E-
No. 01-0026.T_June_2015.
6. MANUFACTURE'S TECHNICAL DRAWINGS
A complete set of technical drawings shall be submitted including
dimensions, tolerances and material main characteristics for 60E2
and 54E1 rails of the following:
 The assembled unit including the ALD components;
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 The steel hollow sleeper body including steel pipes, and steel stud
plates;
 Elastic rail fastening system with tension clamp SKL-W.
7.1 The qualification test reports for Steel Hollow Bearers shall be
submitted, it shall include the following tests:
7.1.1 A comprehensive quality control and assurance program which will
be used during the manufacturing shall be submitted.
7.1.2 The effect of repeated loading, as defined in EN 16431 sections 5.2.1
and 6.1.1 (The Steel Hollow Bearers with the Fastening System);
7.1.3 Fixation of the fastening system on body, as defined in EN 16431,
sections 5.2.2 and 6.1.2;
7.1.4 Attenuation of impact load as defined in EN 16431, section 5.2.3 and
6.1.3;
7.1.5 Pad and assembly stiffness as defined in EN 16431, section 5.2.4 and
6.1.4
7.1.6 Bending test for the body, as defined in EN 16431, section 5.3 and
6.2;
7.1.7 Electrical resistance, as defined in EN 16431 sections 5.4 and 6.3.
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No. E-01-0022 June 2015
TECHNICAL APPENDIX A - ISRAEL CLIMATE AND



Value* Value*
NOx 1064 560 71
SO2 780 260 21
O3 312 143 84
Suspended - 350 100
Dust


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
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No. E-01-0022 June 2015
TECHNICAL APPENDIX B – SKETCH OF THE HOLES

DIMENSIONS AT THE BOTTOM OF THE STEEL HOLLOW
BEARERS
Dimensions in millimeters
R 15
4 holes R15
30
430 580 60
2600
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No. E-01-0022 June 2015
TECHNICAL ATTACHMENT F

SUPPLY OF CONCRETE BEARERS SCREWS PROTECTIVE
COATING WAX NO. E-01-0027.T_JUNE_2015
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No. E-01-0022 June 2015
ISRAEL RAILWAYS LTD

for
CONCRETE BEARERS SCREWS

PROTECTIVE COATING WAX
No. E-01-0027.T
June 2015
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1. GENERAL
Concrete Bearers Screws Protective Coating Wax based on
petrolatum and synthetic products and free of solvents.
It shall be used to release the screws without damage to the
Concrete Bearers and for screws corrosion protection.
1.2 Concrete Bearers to be supplied, when equipped with Fastening
Systems the rail screws shall be covered with the Screws Protective
Coating Wax before screwing.
2. TYPICAL PROPERTIES
2.1 the Concrete Bearers Screws Protective Coating Wax shall have the
following properties:
2.1.1 Congealing point between 70-76 [ᵒC]
2.1.2 Needle penetration at 25 [ᵒC] 17 [mm/10]
2.1.3 Viscosity at 100 [ᵒC] between 12-16 cSt
2.1.4 Solubility in water insoluble
2.1.5 Flash point (COC-Cleveland open cup) greater than 250 [ᵒC]
2.1.6 Liquid density at 85[ᵒC] between 0.795-0.805 [kg/m3]
2.1.7 Thermal decomposition None
2.1.8 Dangerous reactions None
3. DECOMUTATION
The Protective Coating Wax safety data sheet (MSDS) shall be
submitted.
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TECHNICAL ATTACHMENT G

SUPPLY OF MANUAL SWITCH STAND
NO.E-01-0028.T_JUNE_2015
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ISRAEL RAILWAYS LTD

for Manufacture
of
Manual Switch Stand
No. E-01-0028.T
June 2015
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No. E-01-0022 June 2015
CONTENTS
1. SCOPE
3. DEFINITIONS
5. MANUFACTURE
6. MARKING
7. DOCUMENTATION
TO BE USED ONLY AS PART OF TECHNICAL SPESIFICATION No. E

0022
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No. E-01-0022 June 2015
1. SCOPE
manufacturing the Turnout Components – Manual Switch Stand.
1.2 The Manual Switch Stand shall be used to ensure the correct
movement of the moveable components of the switch panel and the
movable Components of the Manual Actuation System.
EN13232-1 Railway applications - Track - Switches and
crossings - Part 1: Definitions.
3. DEFINITIONS
Diamond as defined in EN 13232-1, sections
4.3.1-4.3.10;
Switch Panel as defined in EN 13232-1, section 6.2
Actuation System as defined in EN 13232-4, section 3.1.1
(a part of the Turnout)
Component any constituent of the Part;
Sub-component any constituent of the Component;
4.1 The Manual Switch Stand design shall enable minimum switch
flangeway of .
4.2 The Manual Switch Stand design shall enable Switch and Stock
Rails adjacent (proper closing) of at least 3 [m] from the switch rail
toe.
4.3 The Manual Switch Stand design shall enable simple accurate
setting.
4.4 The Manual Switch Stand shall be designed with mechanical

fixation of the lever and it's clearing by a pedal.
4.5 The Manual Switch Stand lever movement shall not be more than
120 degrees.
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4.6 The Manual Switch Stand Sub-Components shall include high

strength steel. The working Sub-Components shall be heat treated.
4.7 The Manual Switch Stand Sub-Components shall be anti-corrosion

protected.
4.8 The Manual Switch Stand shall include fixed colored indication
showing the close side of the switch rail.
5. MANUFACTURE
5.1 A complete set of Components and Sub-components technical
specifications with material types, technical characteristics,
chemical composition, standards number to be complied with,
coating and heat treatment process details and weld, method of
welding, etc., shall be submitted.
5.2 All materials shall be conformed to the latest relevant ISO or EN or
UIC standards. Material examination certificates of mechanical and
chemical characteristics shall be submitted.
6. MARKING
6.1 Each Sub-component shall have:
7. DOCUMANTATION
7.1 Drawings with dimensions, tolerances, mechanical and chemical
properties, material type, coating and heat treatment process details,
method of welding (actuation system and locking device relevant
Components and Sub-Components), etc. shall be submitted.
List of all the Sub-components, the relevant EN, UIC and ISO
standards they comply with shall be submitted.
989

Technical Specification Turnouts and Expansion Switches - 0 (ISRAEEL SWITCH)

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ISRAEL RAILWAYS LTD

Turnouts and Expansion Switches

14. QUALIFICATION TESTS 37

Turnouts and Expansion Switches

14.3 TURNOUT COMPONENTS QUALIFICATION TESTS 38

TECHNICAL APPENDIX A - THE TURNOUTS TO BE SUPPLIED LIST 54

Turnouts and Expansion Switches

TECHNICAL ATTACHMENT A - Technical specification for manufacture

TECHNICAL ATTACHMENT F - Technical specification for manufacture and

Turnouts and Expansion Switches

1.1 This technical specification prescribe the technical requirements for

Turnouts and Expansion Switches

Turnouts and Expansion Switches

EN 13674-2 Railway applications - Track - Rail - Part 2: Switch and

Turnouts and Expansion Switches

EN 13146-6 Railway applications - Track - Test methods for fastening

Turnouts and Expansion Switches

(*) latest edition of the referenced standard.

3. RELATED ISR TECHNICAL SPECIFICATIONS REFERENCE

Turnouts and Expansion Switches

Expansion Switch as defined in EN 13232-8, section 3.2.2

Turnouts and Expansion Switches

BOM (Bill of materials) list of the Turnouts, Expansion Switches , Parts,

Turnouts and Expansion Switches

Acceptance Test tests carrying out in Israel on the delivered

Turnouts and Expansion Switches

Turnouts and Expansion Switches

 Distance from the end of the panel: 230 [mm];

6.6 Locking Device opening with Actuation System (Minimum switch

6.7 Opening with Manual Switch Stand: .

Turnouts and Expansion Switches

6.12 Foot clearance: in accordance with the Turnouts manufacturer's layout

6.14 Negative force: in accordance with the Turnouts manufacturer's layout

6.17 Turnouts' geometry: in accordance with technical appendix B – The

Turnouts and Expansion Switches

 Wheels of Ø850 with profile DSB 82-1 in accordance with technical

6.20 Axle bogies

 Free wheel passage at check rail entry 1370 mm [±3];

Turnouts and Expansion Switches

Turnouts and Expansion Switches

9.1.1 The Switch Panel shall be supplied fully assembled.

Turnouts and Expansion Switches

9.2.2.1 The Pre-Hardness Monoblock Cast Austenitic Manganese specifications

Turnouts and Expansion Switches

Turnouts and Expansion Switches

Turnouts and Expansion Switches

10.2.2 Grooved Rails Quality Test

Turnouts and Expansion Switches

Turnouts and Expansion Switches

Test method Test frequency (*) Test requirements

10.4.10.2 Pre-hardened monoblock cast austenitic crossing qualification test report

Turnouts and Expansion Switches

Turnouts and Expansion Switches

- at depth of 10 mm underneath the running

Turnouts and Expansion Switches

accordance with section

10.5.7 Central Monoblock Crossing Nose Quality Tests

Turnouts and Expansion Switches

Turnouts and Expansion Switches

Turnouts and Expansion Switches

Turnouts and Expansion Switches

10.7.13 Concrete Bearer Qualification Test

Turnouts and Expansion Switches