Operation and Maintenance Manual

Pandrol Double Resilient Baseplate Assembly Fastening System

Drawing No. 13145
Mumbai Metro Line 7, India
Report: Issue C
Date: 01.03.2019
Copyright 2010 PANDROL Track Systems

Pandrol Rahee Technologies Private Limited

Flat No. 1C, 1st Floor
4, Ho Chi Minh Sarani
Kolkata - 700071
West Bengal, India
Email id: info@pandrolrahee.com
Telephone: + (91) 33 6455 2126
Telefax: + (91) 33 2669 8282
Contents
1. Introduction .......................................................................................... 2
1.1. Standard Maintenance Features ..................................................... 2
2. Technical Details ................................................................................. 3
3. Components ........................................................................................ 4
4. Installation Methods ............................................................................. 4
5. Clip Installation, Extraction and Insulator Setting with Hand Tools ...... 26
5.1. Clip Installation ................................................................................ 26
5.2. Clip Extraction ................................................................................. 27
6. Gauge and Vertical Height Adjustment ................................................ 28
6.1. Gauge Adjustment .......................................................................... 28
6.2. Vertical Height Adjustment .............................................................. 29
7. Inspection and Maintenance ................................................................ 32
8. Methodology for Repair of Loose Anchor Bolts ................................... 35
9. Methodology for Repair of Non-Vertical Anchor Bolts.......................... 38

060-26 _ C Page 1 of 43
1. Introduction

Figure 1 - Pandrol 13145 Double Resilient Baseplate Assembly

The Pandrol 13145, Double Resilient Baseplate Assembly is a modular rail

Baseplate assembly, suitable for situations where the mitigation of ground-borne
noise and/or vibration is required. The low vertical stiffness of the assembly works
with the mass of both the track and vehicles to reduce the transmission of noise,
vibration and impact forces to the supporting structure.

The Pandrol 13145, Double Resilient Baseplate Assembly is supplied as a standard

full toe-load assembly, complete with all parts required. The assembly is designed
for long life and can be fully dismantled for inspection and maintenance purposes,
with fully replaceable components.

1.1.Standard Maintenance Features

 Lateral adjustment (up to +/- 3 mm) without component change
 Total lateral adjustment of +/- 5 mm per rail seat.
 Height adjustment + 12 mm.
 Eccentric bush - positive lock increments in 1 mm steps.
 Self-tensioned rail fastening without threaded elements.
 Same clip can be utilized in turnouts, depot and ballasted track.
 High quality precision casting manufacture
 High electrical insulation (>25 kΩ) per Baseplate.

060-26 _ C Page 2 of 43
2. Technical Details
Detail Comment

Static Stiffness 22.27 kN/mm measured in the range 1-34.4 kN

Clamping Force > 18kN per rail seat

Longitudinal Restraint > 7kN per rail seat

Electrical Resistance >25kΩ

Std. Horizontal Adjustability ±5mm per rail seat, (±10mm Total Gauge
Adjustment)

Std. Vertical Adjustability +12mm per assembly

Std. Fixing 2 or 4 x M27 Cast in Anchor Studs

Rail Inclination 1 in 20, applied by the Baseplate

Table 1- Pandrol 13145 Double Resilient Baseplate Assembly Technical Details

060-26 _ C Page 3 of 43
3. Components
Each resilient baseplate assembly consists of the following components:
Part Spec
# Item Description Qty. Comments
No. No.
1 13146 Cast Iron Baseplate 1 EC-K
2 14613 Rubber Baseplate Pad 1 DC-E
3 14614 EVA Rail Pad 1 DC-D
4 2759 e2007 Pandrol e-Clip 2 A-A
5 5720 8mm HVN Insulator 2 BC-H
Only used for lateral
5a 8605 6mm HVN Insulator A/R BC-H
adjustment
Only used for lateral
5b 8604 10mm HVN Insulator A/R BC-H
adjustment
6 12683 Eccentric Nylon Bush 2/4 GC-C
7 10108 Compression Spring 2/4 KC-G
8 12740 Plastic Collared Washer 2/4 GC-C
9 12791 M27 Nyloc Nut 2/4 LC-B
10 12717 M27 Anchor Stud 2/4 LC-B
15385
11 Conforming Shim 1 DC-AB
/IND
Table 2 - Component List

As standard this assembly incorporates ±3mm of horizontal adjustment using the

eccentric bushes with additional ±2mm by using different insulators as indicated in
drawings.

The quantity of these components is dependent on the track radius for curved and
tangent track, but should not be less than four each on curves less than 500m
radius, and for tangents two each. This however will be guided by the instruction of
the client / contract document.

All of these components are easily maintainable, with spare parts being readily
available direct from Pandrol.

4. Installation Methods
4.1. Introduction
This proposed methodology is for the use of a dummy plate assembly to accurately
position the rail alignment and ensure a good quality finish of concrete beneath the
assembly as shown in Figure 2.

060-26 _ C Page 4 of 43
The designs of the dummy plates have the following features:

 The base of the dummy plate shall be perforated to prevent water and air from
becoming trapped and causing voids.

 The dummy plate is designed such that it accurately positions the anchor
bolts and ensures their verticality and height above the concrete. The
verticality is achieved by mating the external threads of the threaded spacer
bushes with the internal threads of the dummy plate when the threaded
spacer bushes are located through the cast baseplate holes. A rubber O-ring
is fitted to the anchor bolt to seal the gap between the anchor stud and
dummy plate hole to prohibit the ingress of liquid concrete, during concreting
stage. The spacer bush also has an internal thread which mates with the
Anchor Stud thread for centralising and maintaining the correct anchor bolt
height.

 The dummy plate assembly simulates the thickness of the final assembly to
ensure correct vertical alignment of the rail.

 The dummy plate works in co-ordination with a pre-prepared anchor bolt

incorporating a rubber O-ring which prevents concrete ingress inside the
dummy plate thread.

Note:
A quality assurance check is necessary to inspect all important dimensions. Failure
to check the threaded dummy plates and threaded spacer bush can result in
inaccuracies of the final assembly construction.

Figure 2

060-26 _ C Page 5 of 43
4.2. Surface Preparation (Coating) of Anchor Bolts:

Before installing the anchor studs in the dummy plate for concreting, the followings
are important:

 To ensure good cohesion between the anchor studs and the concrete, the lower
part of the anchor studs should be prepared using either of the following
methods. Note that these are recommendations and local environmental
conditions may influence results.

Figure 3 - Slurry Method

Method A: Slurry

1. Create a slurry mix with crushed stone, water and cement with proper ratio.
Crushed stone aggregate should be clean and of particle size 2-4mm.

2. Thoroughly mix the slurry.

3. Dip the anchor bolt for 2-3 seconds into the slurry mix to a depth between 140
– 145mm.

Figure 4– Cement Slurry Application

060-26 _ C Page 6 of 43
Method B: Resin

1. Dip the bolt for 2-3 seconds into a polymer resin to a depth between 140 –
145mm. Pandrol recommends polymer resins ‘Sikatop 77’ or ‘Kuna Latex’
water resistant bonding agent. Mix cement to the polymer resins as required
for better cohesion.

2. Sprinkle a handful of small particle (2-4mm) aggregate, i.e. sieved ‘GP2’ or

crushed stone chippings, ensuring the dipped portion of the anchor is fully
coated.

A rubber O-ring is made to roll in from the top of the anchor stud till an approximate
length of 121 mm from the top. See Figures 5 and 6. In each case, after dipping in
the cement slurry or resin mixed with cement (as shown in Fig. 4 to 8), the anchor
stud should be allowed to fully cure before use. Failure to follow the above shall
result in loose bolts.

Figure 5 Figure 6

060-26 _ C Page 7 of 43
 Figure 7 Figure 8

4.3. Installation of Dummy Plate

An accurate inspection of the dummy plates should be carried out by the contractor
before use. In particular the following should be checked against the drawing.

1. Hole position
2. Hole size
3. Overall dummy plate thickness
4. Plate flatness

Failure to check these positions could result in misalignment of the final assembly
construction.

It is recommended that in straight track, the remaining unused holes in the 4-hole
dummy plate should be sealed in the bottom with plugs and/or strong adhesive tape
to prevent ingress of concrete and avoid uneven concrete surface.

It is also recommended that Gauges be used to check the dummy plate to ensure
the coordinate dimensions of the anchor stud before casting. Figure 9

060-26 _ C Page 8 of 43
 Figure9: Typical Gauge for Checking of Dummy Plate

Installation Sequence:
For ease of installation and speed, it is recommended that two men are used to
install the dummy plate assembly; one man on the fieldside of the rail and one man
on the gauge side.

 Place the railpad into the railseat of the cast baseplate and offer up the cast
baseplate/railpad to the underside of the rail foot. One man on each side. Ensure
the field and gauge side cast baseplate orientation is correct. Figure10.

Figure 10

 Insert the sidepost insulators to field and gauge side. Figure 11.

060-26 _ C Page 9 of 43
 Figure 11

 Attach the shoulder retention clamps to field and gauge side. They should be
firmly hand tight so the baseplate cannot move side to side. Figure12. During this
procedure ensure that the baseplate is pushed firmly in the direction of the gauge
side. This ensures that there is no gap between the insulator and rail foot on the
field side. This is required to compensate for any manufacturing tolerances of
components and allows the track gauge to be correctly set after casting. For
added security a spacer may be added between the gauge side clip housing and
the insulator.

Spacer

Figure 12

 Offer up the dummy plate to the underside of the cast baseplate. The dummy
plate is not specific to field or gauge side; however the flat side should be face
down to the concrete. Figure13.

060-26 _ C Page 10 of 43
 Figure 13

 Apply machine grease to the threaded portion of the spacer bush and machine oil
to the dummy plate hole and the anchor stud top few threads (4 to 5) for easy
removal of dummy components post concreting. Figure 14 & 15.
Note: ensure no grease/ oil contaminates the portion of anchor stud that is cast
below concrete level. This could prevent the stud from adhering to the concrete
resulting in loose bolts.

Figure14 Figure 15
 Align the dummy plate holes with the holes in the cast baseplate and hold it from
both ends. The dummy plate will need a more precise alignment during the
following stage. Figure16

060-26 _ C Page 11 of 43
 Figure 16

 Push the spacer bush through the cast baseplate and screw it to the threaded
dummy plate holes. It should be mated such that the largest diameter of the
spacer bush should sit flush with the top surface of the cast baseplate. Figure17&
18.

Bush sits flush on

top surface of
Baseplate after
proper tightening.
This ensures
Verticality of Stud.

Figure 17

 Insert the anchor bolt from underneath the dummy plate and mate the threaded
portion to the internal thread present in the spacer bush till it is completely tight
and secured. This is only necessary by hand. This will set the anchor bolt to the
060-26 _ C Page 12 of 43
 correct height desired from top of anchor to surface of concrete after casting.
After the anchor stud is secured push the rubber O-ring such that it touches the
bottom of the dummy plate and covers the dummy plate hole to prevent
ingression of concrete through the dummy plate holes. If using a 2 anchor system
then the opposing anchor studs should be offset and also use plugs on the
unused holes to prevent ingression of concrete. Figure18 to 21.

Figure 18

Figure 19

060-26 _ C Page 13 of 43
 Anchor Stud
tightened
completely up to
the top of the
Spacer Bush
ensures desired
Height of Stud
from TOC
Figure 20

Figure 21
 Place a protective plastic cover over the anchor studs, shoulder retention clamps
and spacer bushes to protect the components from concrete during pour. See
examples in Figure22.

Figure 22
060-26 _ C Page 14 of 43
  Carry out the following checks before casting:

1. Inspect if the external threads of the spacer bush mates properly with the
internal threads of the dummy plate holes and also the thread of the
anchor stud matches with the internal thread of spacer bush to ensure the
Anchor stud is vertical and maintains the appropriate height.

2. Ensure the anchor stud is not contacting any reinforcing bars. If so,
manipulate the reinforcing to avoid stud contact. If the reinforcing contacts
the anchor it will cause a) The anchor to be non-vertical and b) Affect the
electrical conductivity. Figure23.

Figure 23

3. Ensure the anchor stud feels firm and cannot be moved from side to side.
4. Pour concrete up to the bottom of the dummy plate, vibrating as
necessary. Note that experimentation will be required with the concrete
mix to ensure the correct workability, flow and surface finish etc. Figure24.

DO NOT WALK on the fastening assembly after the assembly is fixed in

position. This is especially relevant during concrete pour.

060-26 _ C Page 15 of 43
 Figure 24

 After the concrete achieves sufficient strength, loosen the shoulder retention
clamps on field and gauge side to allow for any thermal expansion or
contraction of rail. Figure 25.

Figure 25

When the concrete has reached sufficient strength, unscrew the spacer bushes
using a wrench/ spanner. As an aid to increase productivity during the casting of
anchor studs 12717, Pandrol recommend that the spacer bush can be removed from
the concrete slab surface 3 days after casting. At which time the anchor bolt integrity
within the concrete should be sufficient to allow removal.
 Due to the variation in concrete mix and environments, it is strongly
recommended that initial trials be carried out to assure the process. If loose
bolts are found during the normal course of activities then the contractor
060-26 _ C Page 16 of 43
 should consider increasing the dummy plate and Spacer bush removal time.
See the below Figure 26 and 27.

Figure 26

Figure 27

 Lift the rail to clear over the top of the anchor studs. Detach the cast
baseplate and dummy plate from rails. Timing of dummy plate removal is
subject to the local environment, the concrete mix, and any additives, etc. but
practice adopted successfully to date suggests curing the concrete to
approximately 85% of full strength. Strength of concrete can be determined by
on site tests.

060-26 _ C Page 17 of 43
Ensure dummy plate is thoroughly cleaned and checked with a receiving gauge prior
to re-use.

4.4. Requirements
The following requirements should be fulfilled.

1. The verticality of the anchor stud shall be within ±1 degree of 90 degrees to

the top surface of the grout/concrete in all directions.

However, there can be difficulties measuring accurately the verticality of the

anchor with respect to railseat flatness. In this case, if the assembly will fit
together as per the recommended design then this will be acceptable.

2. The anchor studs shall be placed at the centre position corresponding to the
slotted holes provided in the baseplate, or the zero setting corresponding to
the eccentric bushes in the baseplate.

3. After the concrete has cured the studs must not be loose in the concrete.

4. The top of the anchor stud thread shall be nominally 121 ± 4mm from the
concrete surface. This will allow full vertical height adjustment of the
assembly.

5. The anchor stud shall be able to withstand a vertical load of 60kN for 3
minutes without showing any signs of cracking or spalling.

6. The support area above which the baseplates shall be installed including the
area under which any lateral adjustment may cause the baseplate to be
located shall conform to:

Flatness/Finish of the concrete plinth-

 The concrete finish under the baseplate assembly shall give at least
85% bearing surface to the assembly and shall not contain individual
voids greater than 25mm diameter.

 The surface finish of the concrete shall be flat across the top of the
bearing area with no discernible gap under a straight edge across any
part greater than 1.5mm.

 The difference in height elevation between one railseat bearing area to

the adjacent rail seat bearing area shall be not more than 1 mm.

 The surface shall not contain total voids in excess of 15% of the total
area, evenly distributed. Voids with a diameter <2mm can be ignored.

060-26 _ C Page 18 of 43
  The difference in height elevation between one railseat bearing area to
the corresponding rail seat bearing area across the track gauge shall be
not more than 2mm from the design position.

 The top of slab / plinth shall be parallel to design position of the plane of
the rails to within +/-1 degree unless otherwise stated in the design
criteria for track work, in which case that document will take priority.

Figure 28 – Correct Surface Figure 29 – Incorrect Surface

7. The top surface shall be clean of any grout/concrete material, foreign or other
material before final installation of the fastening assembly with anchorage at
the final installed position.

8. There shall be no gaps deeper than 1.5mm between the underside of the
fastening assembly and the grout/concrete surface extending for more than
25mm under the assembly at any position around the assembly.

9. The rail shall be installed in the baseplate assembly with no gap between the
rail edge and the fieldside insulator in the railseat, with the insulator hard up
against the baseplate shoulder.

10. The highest level of grout/concrete under the baseplate assembly shall be
used as a reference for any finishing work required.

4.5. Installation of Components for Assembly of Fastening:

1. The concrete must have had sufficient curing time before installation is
started. Figure 30.

060-26 _ C Page 19 of 43
 Figure 30

2. A 3mm 15385 LLDPE Conforming shim can be used under the assembly to
improve the surface and compensate for any minor irregularities in the
concrete finish. Figure 31.

Figure 31

3. The 14613 baseplate pad is then placed over the anchors, followed by the
13146 baseplate. Figure 32 and 33.

060-26 _ C Page 20 of 43
 Figure 32 Figure 33

4. Next, the 12683 eccentric bushes are placed over the anchors into the correct
setting on the baseplate, ensuring the notches on the bush are fully located in the
locators. On initial installation, try to set the eccentric bush at the ‘0’ - Zero
position against the triangular mark as shown below. Figure 34 and 35.

Figure 34 Figure 35
5. A 10108 compression spring is placed over each stud, followed by a 12740
plastic collared washer, and finally a 12791 M27 Nyloc nut. See below Figure
36 to 43.

Figure 36 Figure 37

060-26 _ C Page 21 of 43
 Figure 38

5. Tighten the nuts until each compression spring is compressed to 34.5mm

±0.5mm. For this purpose a “plastic height gauge” of 50mm I.D. and
38.5mm long is recommended. See Fig 39 and 40 below.

50mm 38.5mm
m

Figure 39 Figure 40
The clearance of the internal diameter of the bush allows it to sit on the top face of
the eccentric bush, and also allows its removal post tightening of the compression
spring.

Figure 42 below shows how an electrically operated hand-wrench is used to tighten

the nyloc nut using the recommended 41mm long series socket. The internal depth
of the socket should allow enough clearance to prevent damaging the nyloc nut and
the anchor stud threads. Figure 41

060-26 _ C Page 22 of 43
 Figure 41 Figure 42

The nyloc nut is tightened until the bottom of long series socket sits on the top face
of the “plastic height gauge”, when the said top surface of the plastic bush will be at
the same level as the top surface of 12740 collared washer. The length of the bush
assures the spring is compressed to 34.5 ± 0.5mm.Figure 43, showing correct
tightening of the nut.

Figure 43
Note: It is not possible to provide a torque setting due to the variability of the nyloc
nut frictional forces and low compression spring stiffness. The torque required to
overcome the nylon is initially greater than the torque after the thread has been cut in
the nylon. The spring stiffness is so low that a sensible value cannot be determined.

6. Insert the 14614 rail pad in the rail seat then the rail can be placed back in
the rail seat. Figure 44.

060-26 _ C Page 23 of 43
 Figure 44

7. The appropriate insulators are then installed on either side of the rail.
Upon initial installation, two 8mm thick green 5720 insulators are used. If
lateral adjustment is needed, these insulators may be changed to
insulators 8604 and 8605 as discussed in Section 6, Gauge Adjustment.
See below Figure 45.

Figure 45

8. Install the e2007 Pandrol clips as detailed in Section 5. The baseplate

should be square to the rail, with all components held tightly. Figure 46
and 47.

060-26 _ C Page 24 of 43
 Figure 46

Figure 47

9. In order to prevent water collecting in the unused holes of the two anchor
system, a plastic baseplate plug as in Figure48can be inserted into the
unused holes.

Figure 48

060-26 _ C Page 25 of 43
5. Clip Installation, Extraction and Insulator Setting with
Hand Tools
The installation of the Pandrol e2007 clip is undertaken using a Pandrol Type D
Panpuller (Part number AE18068), which are available directly from Pandrol / PRT.
Same to be manufactured by Pandrol approved manufacturer. The hook on the
Panpuller should be checked for wear every 6 months, using a Pandrol Panpuller
Hook Wear gauge (Part number AE17170) available separately. Worn hooks have
an increased tendency to slip off clips during installation and extraction and should
be replaced immediately.

5.1. Clip Installation

To install a Pandrol e-Clip, simply follow the 5 steps below: Grease is not required.

1. Insert the clip into the shoulder on the baseplate, with the toe of the clip over
the insulator.

2. Position the hook in the upper hole on the Panpuller.

3. Place the hook over the top of the main arch of the clip, as shown in Figure
49, with the foot of the Panpuller on the baseplate, against the shoulder.

4. Take up a stable standing position behind the Panpuller with both hands on
the T-shaped handle.

5. Pull firmly towards the chest until the whole of the straight stem of the clip is
inside the shoulder.

Figure 49 – Installation of e2007 Clip

060-26 _ C Page 26 of 43
5.2. Clip Extraction

Clip extraction uses the same tool, but in the opposite direction

1. Position the hook in the lower hole on the Panpuller

2. Place the hook over the main arch of the clip, with the small notch on the
bottom of the Panpuller on the shoulder as shown

3. Take up a stable standing position behind the Panpuller with both hands on
the T-shaped handle

4. Ensuring nobody is immediately behind you, pull firmly into your chest until
the clip is removed

Figure 50 – Extraction of e2007 Clip

060-26 _ C Page 27 of 43
6. Gauge and Vertical Height Adjustment
6.1. Gauge Adjustment

As standard, the 13145 assembly allows for up to ±3mm per rail seat, using the
adjustability of the eccentric bush. Additional ±2mm lateral adjustment is available
through differential sidepost insulators.

The 12683 eccentric bush has seven settings from -3 to +3. Initially this bush should
be set at 0-zero as shown in Figure 51. The bush setting is indicated by the position
of the triangular mark circled in red.

Note; clips are to be removed to allow for baseplate movement during adjustment via
the eccentric bush. Additionally the same setting should be applied on all the bushes
on a single assembly. If the sidepost insulators have to be changed, remove the clips
as detailed in 5.2 above, replace the insulators as detailed below and then reinstall
the clips as detailed in 5.1 above.

Figure 51 – Eccentric Bush Location

060-26 _ C Page 28 of 43
The gauge adjustment table is found on the 13145 assembly drawing, but is
summarised below for reference.

The adjustment should be made in the following sequence. Adjustment should be

made in the eccentric bush first.

High rail Low Rail

Gauge Gauge Gauge
Bush Field Side Field Side Bush
Adjustment Side Side
Setting Insulator Insulator Setting
Insulator Insulator
-10 -3 10 6 6 10 -3
-9 -3 10 6 6 10 -2
-8 -3 10 6 8 8 -3
-7 -2 10 6 8 8 -3
-6 -3 8 8 8 8 -3
-5 -3 8 8 8 8 -2
-4 -2 8 8 8 8 -2
-3 -2 8 8 8 8 -1
-2 -1 8 8 8 8 -1
-1 -1 8 8 8 8 0
0 0 8 8 8 8 0
1 +1 8 8 8 8 0
2 +1 8 8 8 8 +1
3 +2 8 8 8 8 +1
4 +2 8 8 8 8 +2
5 +3 8 8 8 8 2
6 +3 8 8 8 8 +3
7 +2 6 10 8 8 +3
8 +3 6 10 8 8 +3
9 +3 6 10 10 6 +2
10 +3 6 10 10 6 +3

Table 3 – Gauge Adjustment of 13145 Assembly

6.2. Vertical Height Adjustment

Pandrol VIPA DRS assembly 13145 allows for up to +12mm vertical adjustment
during the track construction stage or for maintenance of the track. Any height
adjustment used during the construction stage will reduce the amount of height
adjustment for track maintenance.

Height adjustment shims can be supplied in sizes of 2 mm / 3 mm / 5 mm and 10

mm of HDPE material. A maximum combination of three height adjustment shims
can be used in addition to the conforming shim. Note that the +12mm adjustment is
inclusive of the conforming shim. Height adjustment shims are to be placed between
the studded baseplate pad and the conforming shim.

060-26 _ C Page 29 of 43
  Height Adjustment Procedure(Construction)

During installation it may be necessary to correct localised assemblies/rail seats with

height adjustment, most likely due to errors made during casting of concrete slab.

1. Identify any rail seat requiring height adjustment correction, refer to Section 4.4
requirements. This can be carried out either by:

a) Performing a track survey prior to assembly build with suitable

surveying instrumentation.

b) Checking between baseplate 13146 and baseplate pad 14613 for any
visual gaps following assembly build. Identified assemblies should be
unclipped and clearance measured between underside of rail foot and
top side of rail pad 14614. Noted clearance will be approximate shim
thickness to add between baseplate pad and conforming shim. After
noting the clearance, replace the rail clips.

2. Release nyloc nuts 12791, such that rail and baseplate can be lifted sufficiently
to insert shim beneath baseplate pad 14613. Note – prior to lifting the rail
ensure a sufficient quantity of nyloc nuts are released on a number of
baseplates either side of the section to be adjusted.

3. Lift rail.

4. Insert height adjustment shim between baseplate pad 14613 and conforming
shim 15385. Where two part split shim is used ensure correct engagement of
the two parts.

5. Lower rail.

6. Tighten nyloc nuts until compression spring 10108 has a vertical dimension of
34.5+/- 0.5mm.

060-26 _ C Page 30 of 43
  Height Adjustment Procedure (Maintenance)

The operation below is a post installation maintenance procedure and assumes all
track is clipped up and fully assembled.

1. Identify amount of height adjustment required and ensure sufficient amount of

correct shims are available on site.

2. Release nyloc nuts 12791, such that rail and baseplate can be lifted
sufficiently to insert shim beneath baseplate pad 14613. Note – prior to lifting
the rail ensure a sufficient quantity of nyloc nuts are released on a number of
baseplates either side of the section to be adjusted.

3. Lift rail.

4. Insert height adjustment shim between baseplate pad 14613 and conforming
shim 15385. Where two part split shim is used ensure correct engagement of
the two parts.

5. Lower rail.

6. Tighten nyloc nuts until compression spring 10108 has a vertical dimension
34.5 +/- 0.5mm.

060-26 _ C Page 31 of 43
7. Inspection and Maintenance
It is recommended that a visual inspection is carried out every 3 months, or as part
of the standard maintenance regime of the maintaining organisation. This inspection
can easily be undertaken while inspecting other components such as rail or concrete
slab.

The visual assessment should include the inspection of all the components of the
assembly. The modular construction of the Pandrol resilient baseplate assembly
allows simple dismantling, replacement of components and reassembly should the
need arise. All spare parts are available direct from Pandrol.

In isolated cases, the replacement of damaged, corroded or missing components is

not urgent and can be scheduled into the normal maintenance routine of the
maintainer. However, if these issues are apparent over a significant number of
assemblies, in close proximity to one another, the problem should be addressed as
soon as possible.

The Pandrol resilient baseplate assembly is designed for long life, and under normal
operating conditions should not require serious maintenance for many years. Should
any parts need to be replaced; the assembly can easily be dismantled using basic
hand tools, allowing easy replacement of parts within short engineering access
hours.

At times of major work, such as a rail change, it is possible to fully dismantle the
assembly for a thorough inspection, and if required, the replacement of any/all
components. There is normally no need to remove the assembly from track to
undertake this operation.

The standard inspection criteria for each component and associated actions are
shown in Table 4 below.

Component and Action to be taken

Observation

Cast Iron Baseplate

Broken or Cracked Replace.

Baseplate

Corroded Baseplate Monitor and replace if corrosion is severe.

Damaged clip housing If the rail is still restrained laterally and vertically,
then monitor until the next inspection. If rail is free
to move, replace the baseplate.

060-26 _ C Page 32 of 43
Component and Action to be taken
Observation

Pandrol e2007 Clip

Clip not fully installed Pull clip fully in position. See section 5 for details.

Missing Clip Replace.

Broken Clip Replace the clip, ensuring the correct lateral

position of the assembly.

Side post Insulator

Worn Insulator Monitor dimensions A and B.

If dimension A is less than 5mm replace the
insulator.
If dimension B is more than 3mm below the
nominal insulator sidepost dimension (for
instance, in the case of a 5720 8mm insulator, if
dimension B is less than 5mm), replace the
insulator.

Broken Insulator Replace.

Missing Insulator Replace.

Rail Pad

Extruded Pad Consider replacement if less than 75% of the rail

foot area is supported by the pad.

Worn Pad Monitor. Replace if pad thickness is less than

7mm, measured from the top to the bottom of the
studs.

Missing Pad Replace.

060-26 _ C Page 33 of 43
Component and Action to be taken
Observation

Baseplate Pad

Extruded Pad Consider replacement if less than 75% of the rail

foot area is supported by the pad.

Worn Pad Monitor. Replace if pad thickness is less than

8.5mm, measured from the top to the bottom of
the studs.

Missing Pad Replace.

Anchor Stud

Broken Stud Replace stud.

Damaged Stud If baseplate is still laterally and vertically

restrained, monitor until the next visual
assessment. If the baseplate is not restrained,
replace stud.

Eccentric Bush

Worn Bush If baseplate is still laterally and vertically

restrained, monitor until the next assessment. If
the baseplate is not restrained, replace bush. Up
to 3mm wear is permissible.

Broken Bush Replace bush.

Washer

Worn Washer If the spring is held concentrically around the

anchor stud, monitor until the next visual
assessment. If the spring is not held correctly,
replace washer.

Broken Washer Replace washer.

Compression Spring

Broken/Damaged Spring Replace.

Nyloc Nut

Missing or Damaged Nut Replace.

Table 4 – Inspection and Maintenance

060-26 _ C Page 34 of 43
8. Methodology for Repair of Loose Anchor Studs
Checking of Anchors

 All the anchors should be inspected. Loose anchors should be determined,

marked and recorded for evaluation.

Figure 52 - Identification of loose anchor

Drilling of Holes for Epoxy Injection

 The holes can be drilled with the assembly in position

 Using a 14mm drill bit the hole should be drilled approximately 75-100mm
from the bolt/concrete interface at 30-45 degrees into the concrete.

 Continue drilling until the drill bit hits the anchor stud.

 After drilling, the hole should be cleaned with compressed air or brush

Figure 53.Drilling Adjacent to Identified Anchor

060-26 _ C Page 35 of 43
Injection Material and Pressure Gun

Pandrol recommend Sikadur 52 which is a two-component, without solvent, low

viscosity injection epoxy. See attached product data sheets (last 2 sheets).

Figure 54 - Dispenser Type

Figure 55 - Pressure Injection Systems

Injection – Sikadur 52

 Make sure that ~15ml is pumped through the nozzle before application
begins. This will ensure the two components are mixed.

 Sikadur 52 epoxy grout is applied by using a pressure gun until the grout
appears on the surface. At this point the gun becomes stiff to pump which
indicates the void is filled. Grout comes out of periphery of the bolt or
through cracks in the concrete.

060-26 _ C Page 36 of 43
 Figure 56 - Repair of Anchor

 Anchor is checked after 24 hours. If it is still loose, the same operation is

repeated.

 Refer to product data sheets for recommended cure times, after cure the
components can be assembled and the nuts tightened to the correct
position achieving the spring compression of 34.5mm.

060-26 _ C Page 37 of 43
9. Methodology for Repair of Non-Vertical Anchor Studs
Equipment required

Coredrilling unit with platform including water lubrication

Marking out equipment
Rags/cleaning equipment i.e. air compressor etc.
Soft hammer
Water supply
240/110v electricity supply
Steel / plastic repair tube – 56mm long x 32mmI.D.
Pandrol anchor stud 12717
Anchor stud repair materials:-

a. 54mm Coredrillbit to be used only in conjunction with:

 Hilti RE500. Product catalogue attached at the end of document.

Or

b. 72mm Coredrill bit to be used in conjunction with:

 FosrocNito-Bond/ FosrocConbextra GP2. Product catalogue attached at
the end of document.

Procedure

This methodology describes the process to replace anchor studs that are either non-
vertical or cast too high or low in the concrete.

1. Prior to assembling the fastening system: Identify the anchor stud which is
outside the verticality tolerance of +/-1 deg or has been cast either too high or
too low in the concrete. Figure 57.

Figure 57

060-26 _ C Page 38 of 43
 2. Select suitable coredrilling equipment fitted with either 54mm or 72mm core
drill bit. The Coredrill should allow the removal of a complete anchor stud.
Ensure the drilling fixture is secure and lined up perpendicular to the concrete
surface in the x and y plane. Figure 58.

 In the event the anchor stud is inclined to an extent that the above core
drill bit cannot reach the plinth for drilling, then the anchor stud should be
cut off above the plinth using an angle grinder as shown in Figure 59.

Note: Prior to coredrilling the correct center co-ordinate of the non-vertical anchor
should be established with respect to the location of the remaining vertical anchors,
such that the replaced anchor is positioned correctly as per drawing tolerance in the
railseat.

Figure 58

060-26 _ C Page 39 of 43
 Figure 59

3. Drill the hole to an approximate depth of 150mm. If the anchor has been cast
into the concrete greater than 150mm then calculate the depth from the
remaining length above concrete level. The total length of the Pandrol anchor
stud is 270mm +/-6mm. Figure 60.

Figure 60

060-26 _ C Page 40 of 43
 4. When the hole is sufficiently deep enough, withdraw the drill and break off the
core in the concrete. A tap with a hammer to the anchor stud top will break off
the concrete core quite easily. Figure 61.

Figure 61

5. Thoroughly clean out the hole and surrounding area with rags and
compressed air to remove debris and moisture. Figure 62 and 63.

Figure 62 Figure 63
060-26 _ C Page 41 of 43
 6. For a 54mm coredrill bit, inject Hilti RE 500 epoxy adhesive into the hole.
Figure 64. For a 72mm Coredrill bit, prepare the hole first with FosrocNito-
Bond following manufacturers guidelines then pour Fosroc GP2 into the hole.
Figure 65. Estimate the quantities required to avoid overspill.

Figure 64 Figure 65

7. Insert the replacement anchor stud into the hole centrally and clean off any
excess sealing material or top up if necessary, which should be level with
concrete surface. Figure 66.

Figure 66

8. Re-install all the components except compression spring and use the
eccentric bushes at zero position to align the bolt vertically and in the correct
geometric position. In place of the compression spring insert a 56mm long
tube with internal diameter of 32mm over the replacement anchor stud to sit
on the eccentric bush. Install the nyloc nut hand tight until it clamps the tube.
This will set the height of the repair stud to 121mm above the concrete
surface. Figure 67.

060-26 _ C Page 42 of 43
 Figure 67

Refer to the material supplier’s guidelines attached for cure times.

After curing, the tube can be removed and components reassembled as per
guidelines.

Note:

 This method has been tested and approved by DMRC in India and tested and
approved by Pandrol Ltd in the UK.

 Using either Hilti 500 or Fosroc GP2 to the above procedure, the anchor stud
is capable of withstanding the 60kN minimum load requirement for 3 minutes
as specified in EN13481-2.

060-26 _ C Page 43 of 43