0032 Pandrol User Guide Edition 8 v6

Track Fastening Systems
User Guide - Edition 8
Other PANDROL publications available

Pandrol FASTCLIP system literature
Provides detailed information on installing PANDROL FASTCLIP.
Pandrol FASTCLIP FE system

The literature describing the new generation of FASTCLIP.
Contents
Introduction Clip Applications & Colour Coding Insulator Applications & Colour Coding
03 04 09 15 18 19 22 27 36
Pandrol VANGUARD
Provides detailed information on Pandrols very resilient track form for the highest vibration mitigation.
Pandrol Re system
Literature describing the new Re system for re-railing applications on older sleepers.
Pad Identification Baseplate Assemblies for Timber Sleepers Concrete and Steel Sleeper Assemblies
Pandrol VIPA
Provides detailed information on Pandrols noise and vibration isolation system.
Pandrol SFC baseplates

Provides detailed information about SFC single resilience baseplates.
Special Applications Identification of Pandrol Hand-Tools Use Of Hand-Tools Machines for automated installation and extraction of FASTCLIP systems.
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Pandrol FASTCLIP Track Installation Guide

Providing practical instructions for the safe installation of the FASTCLIP system.
Track Report 2011

The journal of Pandrol Rail Fastenings 2011. This technical magazine contains authoritative articles written by railway experts from around the world about high-profile rail projects. It is published every 12 to 18 months.
Track Support baseplates for Noise & Vibration mitigation. Anchorage Systems for Pandrol Baseplates Identification Chart for Anchorage Components
41 45 47
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Pandrol Track Fastening Systems User Guide - Edition 8
www.pandrol.com
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Introduction and how to contact PANDROL

This guide is intended for use by all those involved in the specification, installation and maintenance of Pandrol products for Network Rail in the UK. The products and systems are not applicable to other railways as system details vary between customers.
Clip Applications & Colour Coding

FINISHES: Clips are available with either STANDARD or CORROSION PROTECTION (previously called SHERARDISED) finishes. CORROSION PROTECTION (CP) finish should be used in the following areas: Wet tunnels Coastal areas Note: 10kN = 1 Tonne Level crossings Adjacent to heavily salted roads and platforms
Standard Finish: Green 57/48048 CP Finish: Purple 57/48055
History of the Company

Pandrol is owned by the Delachaux Group and has been established in the business of resilient rail fastenings since 1937. Our first rail fastening was the Elastic Rail Spike, the very first resilient rail fastening for timber sleepers. This was manufactured at Worksop, largely for export, with factories being opened in South Africa and Australia in the early 1950s. In the early 1960s European railways began to move to concrete sleepers fitted with continuous welded flat bottom rail. The classic Pandrol PR clip was introduced at this time, firstly in the UK and then around the world. In the mid 1970s the Pandrol e clip was introduced offering a higher clamping force at a lower component cost due to more effective use of the steel section. During this period the number of factories world wide increased to twelve. In the early 1990s the Pandrol FASTCLIP system was introduced which combined the traditional virtues of the Pandrol system with pre-assembly of the fastening at the sleeper factory. This has led to major productivity gains wherever it has been introduced in particular with the new generation of automated track relaying equipment such as the TRT and NTC machines.
Type: FC 1504
Used on G44 and EG47 concrete sleepers also Series 560, 560H, 600, HH10, Mk2 and HH12 steel sleepers. Nominal toe load per clip = 10kN
Standard Finish: Red 57/48033
CP Finish: Grey Gloss 57/48056
Type: FC 1501
New information since Edition 7

This edition of the booklet has been revised and many new products and systems have been added, including: 1. Pandrol Re system 2. ZLR systems for rail free applications 3. Glue-in and replacement shoulders 4. Clips around IBJs. 5. Clips around Balise units 6. More efficient and safer hand-tools for FASTCLIP 7. Expanded section on vibration mitigation baseplates for slab track and steel bridges This booklet is intended to answer the most frequently asked questions relating to our products. However, if further information is needed, Pandrols Customer Support Engineers can be contacted for advice on:
Used on F41 and EF36 concrete sleepers and Series 500 steel sleepers. Nominal toe load per clip = 10kN
Standard Finish: Cat. No. not allocated.
CP Finish: Blue 57/02029
Type: FC 1503
Used only for Pandrol Type SFC baseplates for slab track. Nominal toe load per clip = 10 kN
T. 01909 476101 F. 01909 500004
E. support@pandrol.com www.pandrol.com
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CP Finish: Matt Grey 57/48031
Type: e1809
For use in F40 sleepers with a Blue (HVN) insulator. For use in all other sleepers with an Orange (Nylon) insulator. Must not be used with Grey Cast Iron PAN Type Baseplates. Nominal toe load per clip = 9kN
Type: e-Plus - eP20127

Used on F27, EF28 and W402 sleepers where extra resilience and insulator durability is required. Fitted with integral Type 9903 toe insulator. Nominal toe load per clip = 12.5kN
Standard Finish: Yellow 57/48256
CP Finish: Black Gloss 57/48043
Type: e1810
Left handed version of e1809. Used in IBJs in various situations, see page 25. Nominal toe load per clip = 9kN

Used on NR60 S&C, also on EG49 sleepers with 60E1 rail. Nominal toe load per clip = 12.5 kN
Standard Finish: Green 57/48236
CP Finish: Blue Gloss 57/48308
Standard Finish: Purple 57/48247
CP Finish: Bright Red Gloss: 57/48044
Type: e2001
High toe load clip for F27/EF28 sleepers, used in difficult areas where insulator crushing or creep is occurring. Must be used with white insulator, either type 2433 or type 6924. Nominal toe load = 12.5 kN

Left hand version of eP20129. Nominal toe load per clip = 12.5kN
Standard Finish: Yellow 57/48252
CP Finish: Purple Gloss 57/48309
Standard Finish: Blue 57/48248
Type: e2007
High toe load clip which is interchangeable with either PR401A or e1809 clip types. Should NOT be used in applications fitted with orange insulator type 724a. Also used with IBJs in NR60 S&C. See page 25. Nominal toe load = 12.5 kN
Type: Re Clip - Re1609

Used on F23 to F27, EF28, 5EF28, W402 sleepers for re-railing operations, used in conjunction with pad type 14229. Clip is fitted with integral toe insulator not separately available. Nominal toe load per clip = 9 kN
CP Finish: Matt Grey Cat No. Not allocated
CP Finish: Green 57/48587
Type: e2071
Clip only used for Zero Longitudinal Restraint (ZLR), to convert the following sleeper types to rail free assemblies: F23 to F27, EF28, 5EF28, W402, F40 & 5F40, with other specialist components. (See separate section on page 23)
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Left-Handed Clips
Non-symmetrical clips (PR, e, e-PLUS, & Re) are normally right-handed and should be inserted into the shoulder anchor point from the right-hand side of the shoulder, when facing the rail. Left-handed variants are required in areas of restricted access around the shoulders, and are fitted from the opposite end of the shoulder (i.e the left-hand side of shoulder). Left-handed clips are typically needed around IBJs and S&C layouts. The equivalence chart below shows which clips are interchangeable between the standard right-handed and left-handed variants. Right-Handed Clips PR401A PR427A e1809 eP20129 Equivalent Left-Handed Clips PR402A PR428A e1810 eP20130
Type: PR401A
For concrete sleepers and all PAN plates EXCEPT obsolete PAN1 to PAN5 where PR303 clips were used. Nominal toe load per clip = 6.5kN
Type: PR402A
Left handed version of PR401A. Nominal toe load per clip = 6.5kN
Standard Finish: Blue 57/48243
Type: Panlock
Clip for Bull Head Rail
Type: PR427A
Maintenance replacement for PR303 in PAN 1 to PAN5 baseplates. NOT suitable for other types of baseplate. Nominal toe load per clip = 6.5kN
Standard Finish: Purple 57/48245
CP Finish: Bright Red Gloss 57/48242
Catalogue No. 57/48781
A1 Spike
Original A1 Elastic Rail Spike. Elastic spikes are only supplied in Standard finish. The A1 spike is red colour.
Type: PR428A
Maintenance replacement for left handed PR304 in PAN 1 to PAN5 baseplates. NOT suitable for other types of baseplate. Nominal toe load per clip = 6.5kN
Standard Finish: Green 57/48244
CP Finish: Yellow Gloss 57/48249
AL23 Maintenance Spike

Maintenance replacement for A1 Spike Elastic spikes are only supplied in Standard finish. The AL23 spike is supplied in two parts. The inner part is black and the outer part is red, and fit together as shown.
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Insulator Applications & Colour Coding

FASTCLIP Type 8582
Sidepost Insulator (Blue)
16.4 mm sidepost thickness. For use on the FIELD side of the 56E1 rail when fitted to G44, EG47, Series 560, 560H, 600, HH10 Mk2 and HH12 sleepers. Also used to replace obsolete insulator type 9373 previously used for hook-in shoulders with steel sleepers. Catalogue Number: 57/48064
Catalogue Number: 57/48118
FASTCLIP Type 8277

Side post insulator (Yellow)
13mm sidepost thickness, for use on HH10 Mark 1 sleepers with Type 9922 hook in shoulders.
e-PLUS Type 9132

Sidepost Insulator (Blue)
Used with eP20127 clip on F27, EF28, W402 sleepers and NR56V S&C.
FASTCLIP Type 7551

Sidepost Insulator (White)
8mm sidepost thickness. Used on G44, EG47, Series 560, 560H, 600, HH10 Mk2 and HH12 sleepers with 60E1 rail. Used on F41, 5F41, 5EF36 and Series 500 steel sleepers with 56E1 rail. Also used to replace obsolete insulator type 8914 previously used for hook-in shoulders with steel sleepers.
e-PLUS Type 9875

Sidepost Insulator (White)
Used with eP20129 clips on F40 sleepers and NR60 S&C.
FASTCLIP Type 8690

Sidepost Insulator (Black)
10mm sidepost thickness. For use on the GAUGE side of the 56E1 rail when fitted to G44, EG47, Series 560, 560H, 600, HH10 Mk2 and HH12 sleepers. Also used to replace obsolete insulator type 9374 previously used for hook-in shoulders with steel sleepers.
Catalogue Number: 57/48066 Catalogue Number: 57/48114
e-PLUS Type 9877

Gauge Management Insulator (Black)
10mm sidepost insulator, used for NR60 S&C.
FASTCLIP Type 8691

Sidepost Insulator (Green)
6mm sidepost thickness. Used in limited areas where oversize 60E1 rail was supplied. Used in place of the GAUGE side Type 7551 sidepost Insulator.
e-PLUS Type 9876

Gauge Management Insulator (Green)
6mm sidepost insulator, used for NR60 S&C
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FASTCLIP Type 8494
Toe Insulator (White)
Blue (GRN) Type 4452.
For use on all sleeper types fitted with the FASTCLIP system.
8mm sidepost thickness x 8mm blade thickness used on: F40 and 5F40 sleepers
e-PLUS Type 9903

Toe Insulator (White)
White (GRN) Type 2433

5mm sidepost x 8mm blade thickness (previously coloured black) used with e2001 clip. Also used on F40 & 5F40 sleepers as part of the range of gauge management insulators to adjust the track gauge, by moving the rail across the rail seat. This insulator can be upgraded to use HVN by substituting insulator type 6924, which is an identical size.
Previously coloured blue. Not supplied separately, always supplied already fitted to the e-PLUS clip types
Orange (Nylon) Type 724a

5mm sidepost thickness x 5mm blade thickness. Used for: F23 , F24 series, EF25, F27, EF28, EF29, EF32, EF33, F34, F35 concrete sleepers and 400 series, steel sleepers with 56E1 or BS110A or BS110A rails.
Catalogue Number: Not allocated
White Type 6924

White (HVN) type 6924, 5mm side post x 8mm blade thickness used with e2001 clip. Also can be used with NR56V S&C to replace composite insulators. This HVN insulator is sufficiently flexible to be used as a replacement for Blue nylon insulator Catalogue No. 57/48423 with either 98lb or 109lb rail, but can ONLY be used with e2001 clips
Blue (Nylon) Type 724a

5mm sidepost thickness 5mm blade thickness used where 98lb and 109lb rail is installed. Used for concrete sleeper types: F23, F24, EF25, F27, EF28, EF29, EF33, F34, & F35, as well as steel sleepers 400 Series. note: This insulator is not commonly available, and can be replaced with Pandrol type 6924 provided this is used with clip type e2001.
Brown(HVN) Type 7583

12mm sidepost x 8mm blade thickness. Used as part of the range of Pandrol insulators to provide gauge management by adjusting the position of the rail in the rail seat. A separate data-sheet is available to advise the methods and adjustment range achievable. Gauge management can be provided for concrete sleeper types: F40, & 5F40.
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Red (HVN) Type 10274
Insulator for 56E1 rail on FIELD side of:
Composite (Black) Type 2786/1

6mm sidepost thicknesses
1. NRS1/NRS2/Combi baseplates 2. EG49 concrete sleepers
Composite (Blue) Type 2786/2

7.5mm sidepost thicknesses
Yellow (HVN) Type 10275

Insulator for 56E1 on GAUGE side of:
1. NRS1/NRS2/Combi baseplates. 2. EG49 concrete sleepers
Composite (Red) Type 2786/3

9mm sidepost thicknesses
Green (HVN) Type 5720

Insulator for use with 60E1 rail using:
1) NRS1/NRS2/Combi baseplates with 60E1 rail. 2) 6 Hole IBJs on NR60 S&C 3) EG49 Concrete sleepers
Catalogue Number: 57/48060 Catalogue Numbers: 4mm = 57/48169 8mm = 57/48170 12mm = 57/48171
Composite Cover Plates

Composite cover plates Type 2787, to provide 4, 8 and 12mm blade thicknesses
Composite
(Nylon with cast iron cover plate) for:
1. Concrete S&C bearers. 2. As a substitute for ORANGE (Nylon) insulators where the wear rate is unacceptable. NOTE. This insulator insulator is not commonly available, and can be replaced with Pandrol type 6924 provided this is used with clip type e2001.
Catalogue Number depends upon insulators and cover plates selected
Composite Insulators
For level and gauge adjustment on slab track installations.
Plastic insulators and metal cover plates are combined to give a variety of blade and sidepost thicknesses.
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Pad Identification
PANDROL pads are an important part of the rail fastening system.Rail pads provide a conforming layer between the rail seat and the rail, provide electrical resistance, and protect concrete sleepers from impact loading. Modern pads are 10 mm thick. Low stiffness studded rubber pads are used for 25t axle loads on concrete sleepers. Stiffened pads are used for 30t axle loads on concrete sleepers to prevent excessive dynamic gauge widening. Steel sleepers use hard EVA pads of 10mm thickness.
Pad No. 8531

Thickness: 10mm Material: Studded EVA Used on FASTCLIP steel sleepers 56E1 rail.
Pad No. 14229

Studded EVA rail pad 8mm thick bonded to HVN side insulators of 5.5mm thick. Used with Re1609 clip for re-railing to replace orange insulators on older sleeper types F23 to F27, EF28, 5EF28, W402, HH10 (Mk1).
Pad No. 4548

Thickness: 10mm Material: Studded Rubber Used on F40 and 5F40 sleepers.
Pad No. 2061/3

Thickness: 5mm Material: Flat EVA Used with W402 sleepers and PAN baseplates. Can also be used with concrete sleeper types: F23, F24 ,EF25, F27, EF28, EF32, EF33, F34, F35.
Pad No. 6650

Thickness: 10mm Material: Studded Rubber Used on FASTCLIP concrete sleepers with 56E1 rail.
Pad No. 9970

Thickness: 10mm Material: Studded EVA Used on FASTCLIP steel sleepers with 60E1 rail. Supersedes / interchangeable with 7850.
Pad No. 8854

Thickness: 10mm Material: Studded Rubber Used on FASTCLIP concrete sleepers with 60E1 rail.
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Pad Identification
Pad No. 9286
Thickness: 8mm Material: Studded Rubber Used on F27 and EF28 sleepers when fitting the e-Plus system.
Baseplates for Timber Sleepers

Baseplate Types Pandrol Clips Used
Originally fitted with with PR427A x 2
Number of Pandrol Housings

4
Comments
PAN 1 to PAN 5 PR303, can be fitted PAN 1 to PAN PR401A x 2 12 and PAN 14
Baseplates no longer available. Only 2 housings and clips should be used Only 2 housings and clips should be used in any of these baseplates. Note the extra housings should only be used in the event of the first housings wearing or failing Checkrail baseplates
Either 2 or 4
Pad No. 9328

Thickness: 10mm Material: Studded Rubber Used on e-Plus RT60 and NR60 layouts.
CC PAN 1 - 44 HO PAN PAN 14SG
PR401A x 1 PR402A x 1 PR401A X 1 PR402 X 1 e1809 x 2
2 Only 2 housings should be used. Only use e clips with SGI grade cast-iron. Only 2 housing should be used in any of these baseplates. Dual rail baseplate for either 56E1 or 60E1/2. Other components: Pad Type 7031 Insulator Types: 60E1 = 5720 56E1 = 10274 & 10275
Pad No. 5197

Thickness: 10mm Material: Studded Rubber Used on EG49 sleepers with either 56E1 or 60E1 rails.
Various other baseplates including: V, VN, CV, RCV NRS1 & NRS2, or Combi baseplates
PR401A x 2
Either 2 or 4
e2007
Pad No. 7031

Thickness: 10mm Material: Studded Rubber Used on NRS 1, NRS2, and Combi baseplates.
The Vortok Coil is used to refurbish timber sleepers with worn screw spike holes. The coils restore 90% of both the original pull-out strength and the torque of the screw to improve the positioning and dynamic gauge performance of the baseplates.
Catalogue Nos: Standard Coil 057/048034 Large Coil 057/048298
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Concrete & Steel Sleeper Assemblies

Sleeper Type(s) Clip Insulators Pad Nominal Track Gauge

Current CONCRETE sleepers

Pad 6650, except: Curves less than 400m FIELD side: 8582 (Blue) radius, fit EVA type 8531 GAUGE side: 8690 (Black) Low line speed, fit EVA type 8531
Discontinued / serviceable older CONCRETE sleeper types EG49 for 56E1 rails
1436mm e2007 e2007 FIELD side: 10274 (Red) GAUGE side: 10275 (Yellow) Both sides: 5720 (Green) Pad 5197 Pad 5197 Pad 6650, except: Curves less than 400m radius, fit EVA type 8531 Low line speed, fit EVA type 8531 Pad 4548 1436mm 1438mm
G44, EG47 for 56E1 rails
FC1504 with 8494 toe
EG49 for 60E1/2 F41 & EF36
Both sides: 7751 (White)
1435mm
G44, EG47 for 60E1/2 rails
Pad 8854, except: Curves less than 400m radius , fit EVA type 9970 Both sides: 7751 (White) Low line speed, fit EVA type 9970
1438mm
F40 5F40
e1809
Both sides: 4452 (Blue)
1432mm 1435mm
Alternative assemblies for F23 to F27, EF28, EF29, EF33 sleepers: Current STEEL sleepers 560H for 56E1 rails
1. Standard toe-loads FC1504 with 8494 toe FIELD side: 8582 (Blue) Pad 8531 GAUGE side: 8690 (Black) 1436mm 2. Increased toe-loads e2001 56E1 rails: Pad 5mm rubber or EVA Both sides: 2433 (GRN White), pad type 2061/3 or 6924 (HVN White) 56E1 rails: Both sides: 9132 1432mm PR401A or e1809 56E1 rail: Both sides: 724a (Orange) 98lb or 109lb rails: Both sides: 724a (Blue) Pad 5mm rubber, or 7.5mm rubber maintenance pad, or EVA Pandrol type 2061/3.
1432mm
NOTE. This sleeper is fitted with hook-in shoulder type 9482.
560H for 60E1 / 2 rails
3. e-PLUS system eP20127 FC1504 with 8494 toe Both sides: 7751 (White) Pad 9970 1438mm 4. Pandrol Re system Re1609
Pad 9286
1432mm
NOTE. This sleeper is fitted with hook-in shoulder type 9482.
56E1 rails: No separate insulator
Composite pad type 14229
1432mm
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Special Applications
1. Replacement shoulders for concrete and steel sleepers, and concrete slab track. This identifies the shoulders to be used for replacement in the unlikely event of damage in track. Shoulder Type Shoulder type 8888R Sleeper Type(s)
G44, and EG47
Discontinued / serviceable older STEEL sleeper types HH10 (Mk 2), HH12, for 56E1 rails FC1504 with Shoulder types: 8494 toe HH10 = shoulder 9922 HH12 = shoulder 9482 HH10 (Mk 2), HH12, FC1504 with for 60E1/2 rails HH10 = shoulder 9922 8494 toe HH12 = shoulder 9482 500 Series W402 Series HH10 (Mk1) for 56E1 rail
FC1501 with 8494 toe PR401A or e1809 FIELD side: 8582 (Blue) GAUGE side: 8690 (Black)
Comments
Pad 8531
1436mm This shoulder is ONLY available as part of a complete supply and replacement service provided through the approved specialist subcontractor HOLEMASTERS.
Catalogue No. Not allocated Both sides: 7751 (White) Pad 9970 1438mm
Both sides: 7751 (White)
Pad 8531
1435mm
Modification of standard shoulder. Shoulder type 9922
HH10
Hook-in shoulder for 10mm thick steel sleepers.
56E1 rail: Both sides: 724a (Orange)
Pad 5mm EVA 1435mm Pandrol type 2061/3.
Alternative assembly converting HH10 (Mk1) FC1504 with to FASTCLIP system 8494 toe using shoulder type 9922 The following obsolete sleepers may be converted to Pandrol e clip assemblies: F10 using BJB fastenings RNB6 also known as KENITRA sleepers HEYBACK sleepers
Both sides: 8277 (Yellow)
Pad 8531
1435mm
Shoulder type 9482
HH12, 560H Series.
Hook-in shoulder for 12mm steel sleepers.
Conversion of obsolete fastenings on very old concrete sleepers

Shoulder type 7250 Whilst conversions have been available and undertaken in large volumes in the past, the components are no longer readily available, generally regarded as uneconomic, and anyone attempting this process should contact Pandrol directly for advice.
Concrete slab track Standard finish: Catalogue No. 057/048071 For slab track in tunnels: Sherardised finish Catalogue No. 057/048063
For use with 10mm pads and either: e clip assembly using GRN insulator type 4452 (blue) Or e-PLUS assembly using eP20129
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2. Zero longitudinal restraint (ZLR) assemblies to provide rail free longitudinal movement of the rail. Used to provide differential movement between the rails and long bridge structures, or stressing relief for ground subsidence due to mining activities. ZLR assemblies use normal toe-load clips, but divert the clamping force in other directions providing a gap over the rail foot and allowing the rail to slide longitudinally in the gap. In the event of the rail moving to close gap (such as rail roll) the nominal toe-load is immediately available to prevent further overturning movement. The components below can be used with existing sleeper configurations to alter the fastening assembly into a ZLR assembly. Sleeper Type(s)
F23 to F27, EF28 5EF28, and W402
Sleeper Type(s)
G44, EG47 and EG47-3R
Pandrol Assembly No.

15208 for 56E1 rail
Components & Catalogue Nos.

EVA 10mm pad type 8531 Sub-assembly 15227 comprising clip type FC1504 with ZLR insulator
Pandrol Assembly No.

15206 (covers all sleeper types)
Components & Catalogue Nos.

EVA 5.5mm pad type 2061 Cast-iron cover plate type 7015 Clip type e2071 NOTE: Sherardised finish ONLY 15229 for 60E1 / 2 rail
Catalogue Number: 057/048589 NOTE:The ZLR insulator is BLACK
EVA 10mm pad type 9970 Sub-assembly 15227 comprising clip type FC1504 with ZLR insulator
Catalogue Number: 057/048521 F40 and 5F40 15207 (covers all sleeper types) EVA 10mm pad type 12697
Catalogue Number: 057/048586 Cast-iron cover plate type 7015
Catalogue Number: 057/048587 Clip type e2071 NOTE: Sherardised finish ONLY
Catalogue Number: 057/048589 NOTE:The ZLR insulator is BLACK
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3. Insulated Block Joints
4. Anchorage for Balise mounting frames. Vortok Balise Mounting System (BMS) The Vortok BMS is fitted to either concrete or steel sleepers using the rail clips to hold the beams in place between the shoulders of the sleepers. The beams are used with either e clip or FASTCLIP as shown below.
FASTCLIP with IBJS

6-hole IBJ on concrete sleeper type EG47.
6-hole IBJ on steel sleepers, showing standard FASTCLIP components. The clips fit snuggly into the recesses of the IBJ, and clip extraction is carried out using a rear-arch FASTCLIP extractor.
Balise units on FASTCLIP sleepers TYPES G44 / EG47, F41 & EF36
e Clips with older concrete sleepers

6-hole IBJ on older types of concrete sleepers. The clips should be: Right handed locations: e1809 Left handed locations: e1810 Both clip types are used with orange or composite insulators , except for F40 sleepers which use blue GRN type 4452 insulators.
The frame sits beneath the rear arch of the standard FASTCLIP in each sleeper type.
Other clips with S&C layouts

NR60 details in e-PLUS (eP20129) layout. NOTE: e-PLUS clips do not fit beneath the IBJ bolts. The clips should be: Right handed locations: e2007 Left handed locations: e1810 Both clip types are used with green insulator type 5720 In layouts to NR56V design the IBJ will be mounted on 8mm thick pads, and the clips should be: Right handed locations: e2001 Left handed locations: e1810 Both clip types are used with orange or composite insulators.
e Clips with older concrete sleepers

The frame is anchored in position using Pandrol clip type e2001. The new clip should replace the original clip on the GAUGE side of the rail seat, and is usually supplied as part of the BMS system by Vortok.
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Identification of Pandrol Hand-Tools

The new range of FASTCLIP tools also for VIPA-SFC
The new tools, which react from the rail, are more efficient, faster and safer because they are not prone to slipping from the shoulder reaction points. Additionally, the tools offer compatibility with a wide range of Pandrol systems, including FASTCLIP FC & FASTCLIP FE and the Pandrol baseplate types VIPA-SP & SFC baseplate. Finally, because the reaction point for the installation tool has been moved to the head of the rail, the installer is able to lift sleepers (about 20mm) as part of the normal action of the tool, lifting from the rear arches of the clip before driving the clip into the installed position.
Discontinued FASTCLIP and VIPA-SP tools.

The original versions of the FASTCLIP hand-tools are illustrated below, and these remain suitable for use. Pandrol has discontinued the original versions from sale.
The original FASTCLIP tools have now been superseded with new tools which are more efficient, faster to use and safer. Both of the new tools look different from the earlier tools, because they react from the rail instead of from the shoulder in the sleepers. See the section on the opposite page. The original versions of the VIPA-SP & SFC hand-tools are illustrated below, and these remain suitable for use. Pandrol has discontinued the original versions shown below.
Installer (FASTCLIP FC, FE, VIPA-SP, SFC) FASTCLIP Installer LP18681 Catalogue No. 39/47850 Extractor (FASTCLIP FC, FE, VIPA-SP, SFC) FASTCLIP Installer LP18679 Catalogue No. 39/47851
The original version of the sleeper lifter can still be used in conjunction the new installer where sleepers need to be lifted more than 20mm. The rear arch extractor remains available to extract clips around IBJs.
Sleeper lifter for FASTCLIP FC, & FE PANDROL No. LP12608 Catalogue No. 39/47852 Rear arch extractor for FASTCLIP FC PANDROL No. LP15177 Catalogue No. not allocated
The original VIPA-SP tools have now been superseded with new tools which are more efficient, faster to use and safer. See FASTCLIP hand-tools on the opposite page The new tools are compatible with FASTCLIP FC and FASTCLIP FE systems, as well as VIPA-SP & SFC baseplates, reducing the risk of the selecting the incorrect tools.
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Hyrdaulic tools for VANGUARD and FASTCLIP

Vanguard Hydraulic Tool

Catalogue Number: Not Allocated
PANPULLER Type D For PR, & e Clips

PANDROL No. LP7632 Especially for e2001 and e2007clips but NOT for 4-shoulder baseplates. NOTE hook positions for max efficiency: Upper pivot: Clip installation Lower pivot: Clip extraction
PANDROL No. LP15647 Catalogue No. Not Allocated Vanguard Installer & Extractor
Refer to separate Pandrol instructions for the use of the VANGUARD hydraulic tool.
Fastclip Hydraulic Tool
PANPULLER Type C for PR, & e Clips

PANDROL No. LP1180 And for 4 shoulder baseplates
RAILTECH TYPE CDH 16 Catalogue No. Not Allocated
Catalogue No. Not allocated
e-PLUS PANPULLER LP12717

PANDROL No. LP12717 Colour: Red working head (matches the appropriate e-PLUS clip type), and yellow handle. For use with eP20127 clips for retrofitting to sleeper types: F27, EF28, 5EF28, and for the new S&C designs to NR56V.
Rosenqvist Handy Clipper (Network Rail Acceptance Certificate PA05/03211)
A versatile lightweight clipping/unclipping machine dedicated to Pandrol FASTCLIP. With one man operation, the Handy Clipper is easily transported to site and will fit in the back of an estate car. It incorporates automatic sleeper lifting of up to 10mm. At maximum output 10 sleepers a minute can be achieved.
e-PLUS PANPULLER LP15923

PANDROL No. LP15923 Colour: White The tool is used with the eP20129 green or eP20130 yellow e-PLUS clips, mostly with RT60 and NR60 S&C layouts.
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Replacement Hook for Types C and D PANPULLER

PANDROL No. 3-P2260

PANSETTER for PR, e, e-PLUS & Re clips

PANDROL No. 2-P9559
Replacement Hooks e-Plus PANPULLERS

PANDROL No. LP12717 PANDROL No. LP15923
use replacement hook type 2P5931 use replacement hook type 3P16127
LP12717 - Catalogue Number: Not Allocated LP15923 - Catalogue Number: 39/42742
THE PANSETTER is suitable for all Network Rail Sleepers fitted with PR, e & e-PLUS
Optional Handles Catalogue Nos. for tools with straight insulated handles.
Catalogue No. 39/30100 All Pandrol hand-tools can be supplied with optional insulated handles, which have recently been upgraded to 35mm diameter cylindrical handles with T cross bars for improved ergonomic and safer use. The photograph shows a typical handle attached to a FASTCLIP sleeper lifter. PANPULLER type C: PANSETTER: Catalogue No. 39/40129 Catalogue No. 39/40133 Catalogue No. 39/40135 Catalogue No. not allocated Catalogue No. not allocated Catalogue No. not allocated
PANPULLER Hook Wear - Gauge

PANDROL No. 3-P6536
Use of Wear Gauges

Place curve of gauge into hook. Gauge can be used with out removing the hook from the PANPULLER. Surfaces A and C in contact and gap at B Hook suitable for use. Surfaces B and C in contact and gap at A Hook unsuitable for use. Replacement Hooks for e-Plus Panpuller: Catalogue Number 39/42742 Pandrol Number 3P16127 Replacement Hooks for Standard Panpuller: Catalogue Number 39/42743 Pandrol Number 3P2260
PANLOCK Puller: FASTCLIP installer: FASTCLIP extractor: FASTCLIP lifter:
Tools with cranked handles for operation in the 4-foot.

A further option is available on Pandrol hand-tools for operation whilst standing in the 4-foot, typically needed through platform areas, or in track with 3rd rail electrification. Cranked handles alter the swept arc of the handle to operate safely whilst standing in the 4-foot. All the FASTCLIP tools have optional cranked handles.
It is recommended for safety reasons that contractors should formally check and record the wear of the hooks at intervals of 6-months using the wear gauge described above. The gauge is suitable for all types of PANPULLER or e-PLUS PANPULLER. The wear gauge provides easy Go / No-Go assessment of when to replace the hook. Worn hooks have a tendency to slip off the clips, which can present a significant risk to operators.
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Handtools for Panlock and Elastic Spikes
Hammers should NEVER be used for either insertion or extraction of PANLOCK. Hammers may be used for the loosening of rusty PANLOCK, but NOT to fully extract. Hammers can be used for the insertion of elastic spikes.

Vortok Stressing Roller (VSR)
The VSR is a multi function stressing roller. It combines both the side and under roller requirements for stressing rail. It also incorporates a lift function removing the need for track jacks.
PANLOCK Puller
The Vortok Stressing Roller is available for: FASTCLIP (0094/018014) e clip (0094/018013) FASTCLIP FE (Application Pending)
Catalogue No. 094/018014 Catalogue No. 94/018013
PANDROL No. LP8452
Elastic Spike Extractor
Side Roller LP16668 for Pandrol Vipa

Hooks over the shoulder on the inside of the track curve, and tightens using the screw to adjust the ball-bearing to touch the web of the rail. Use at least one roller every 10 rail seats, depending upon the severity of the curve.
Under Roller LP17469 for Pandrol Vipa

This simple wire roller fits on top of the rail pad once the rail has been lifted out of the rail seat. It is a low friction roller designed to provide an even distribution of the tension from the hydraulic stressing jacks.
Elastic Spike extractor available from Tool and Steel; Product code: TASTE112
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Discontinued Rollers for FASTCLIP
PANDROL UNDER-ROLLER Type 1P10385 is now obsolete and should NOT be used for stressing with FASTCLIP. Pandrol side rollers for dual rail sleeper types have been discontinued. However the original side rollers should only be used with conventional under-rollers. Therefore the recommendation for stressing is to use VSR equipment detailed on page 34.
Cat No. 0039/47855
Use Of Hand-Tools
PANDROL PR and e-CLIP & Re clip types Installation Instructions Instructions for Panpuller LP1180 and e-Plus Panpuller LP12717
Insert centre leg of clip into housing. Place pivoted hook over the inside of the front arch of clip with foot of Panpuller behind clip housing and ensure lip of the hook is under the front arch. Taking up a natural stance behind the Panpuller, with both hands on tee handle at top of Panpuller, pull strongly towards chest until refusal. The Panpuller automatically pulls clip to the correct position
Side Roller FC1500l - 56
Cream with BLUE handle for 113A rail on FIELD side.
Cat No. 0039/47856
Side Roller - FC1500l - 44
e-Plus Panpuller -eP20129

Pandrol Number - LP15923
Cream with BLACK handle for 113A rail on GAUGE side.
e-Clip and Re Clips
Pull until refusal. Panpuller does not act as a stop due to shorter centre leg of clip.
Cat No. 0039/47857
Side Roller FC1500l - 52

e-Plus Clip When correctly installed the centre leg of ALL types of e-PLUS clips, protrude beyond the shoulder to hold the side-insulator in the correct position.
Cream all over for CEN60 rail on either side of rail seat.
For instructions on the use of FASTCLIP tools and methods, refer to the separate booklet entitled: PANDROL FASTCLIP Track Installation Guide
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Use Of Hand-Tools
PANDROL PR and e-CLIP & Re type clips Reverse the Panpuller.
Taking up a natural stance on the same side as for installation, place hook on the outside of the front arch of the clip, the foot of the Panpuller resting on the baseplate/housing just above the centre leg of clip (as illustrated). Standing behind Panpuller with both hands on the tee handle at the top of Panpuller, give a strong firm push away from your chest. If clips have been in situ for many years, it may be necessary to use a hammer to loosen them taking safety precautions. If the clips will not move then use the Rusty Clip Extractor can be used for PR clips.
NOTE. It is mandatory to wear eye protection when removing or fitting any clips where hammer assistance might be necessary.
Use Of Hand-Tools
Extraction Instructions PANDROL PR , e, e-PLUS and Re Clips Pansetter
Used for lifting the sleeper to the rail foot. It pushes the rail over, leaving the correct gap between the rail foot and the Pandrol housing, so that the insulator can be easily placed in the correct position. Catalogue Number 39/42900 Pandrol Number 2P9559
PANDROL PR
Rusty Clip Extractor

If the clips have not been disturbed for a long time, rust can develop between the centre leg of the clip and the inner face of the housing. This problem has mainly occurred with concrete sleepers in tunnels. With this situation, considerable force may be needed to remove the clips from their housings. By using such force the concrete around the housing may break away, making the sleeper unserviceable. To overcome this difficulty, Pandrol has developed the Rusty Clip Extractor to remove whole clips. If the clip has broken then the tool will remove the clip centre leg. Suitable for PR401A clips only. NOT suitable for use on slab track.
Soft-faced hammers
Soft-faced hammers can be used to extract PR, ee-PLUS and Re type clips, provided the following has been agreed on each site. The use of hammers should only be attempted with the agreement of Network Rail, using suitably trained and supervised track teams. The risks of the inappropriate use of soft faced hammers fall into 2 categories. PR, e and e-PLUS & Re type clips can generally withstand the use of hammers so the risks are: 1. PR, e and e-PLUS & Re type clips MUST be caught at the point of extraction to prevent clips flying. See the boot of the operator in the photograph. 2. Poorly controlled hammers can injure personnel and damage other components
The photograph shows the typical use of a soft faced hammer to extract any of the following clip types: PR, e, Re, e-PLUS.
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Use Of Hand-Tools Pandrol Rail Fastenings for Bull Head Rail

PANDROL PANLOCK Installation Instructions
Place Panlock in chair from right hand side with open curled end to rail web. Place Panlock-Puller head against rail head and on top of chair jaw with lower arm under rail foot. Ensure curved toe of handle enters leading curve of Panlock. Take up a firm stance with both hands on the tee handle and pull until Panlock is fully installed when Panlock-Puller toe will disengage from Panlock. Remove tool. Check Panlock is located centrally in chair.
Machines for automated installation and extraction of FASTCLIP systems.

Most track renewal sites now use FASTCLIP machines to insert or remove the clips and achieve significant productivity and efficiency gains. Fastclip Clipping Machine Mark 4A:
Petrol or Diesel Engine Sleeper Lifting Device Optional Unclipping Module Self Propelled Umbilical Remote Control Suitable for Concrete or Steel Sleepers Clipping Module (4 clips simultaneously) Clipping Rates about 8 Sleepers per minute with Sleeper Lifting
Panlock Puller: Catalogue Number 40/60549 Pandrol Number LP8452 Insulated Panlock Puller: Catalogue Number 39/040135
Rosenqvist CD500 High Output Clip Driver:

Self-propelled high speed clipping machine Clipping and unclipping actions On & off tracking is self-powered. Clipping / Unclipping rate: up to 75 slprs/min for stressing. Sleeper lifting capability for renewal work.
PANDROL PANLOCK
Extraction Instructions
Place Panlock-Puller head against rail head and on top of chair jaw with lower arm under rail foot. Ensure curved toe of handle enters right hand curve of Panlock behind centre section. Take up a firm stance with both hands on the tee handle and pull until Panlock is driven through the chair and out. Remove tool.
Rosenqvist CD400 Clip Driver:

Sleeper lifter Clipping / Unclipping action Hydraulically operated attachment or self propelled Ideal for track renewal and stressing Clipping rates: 12 sleepers per Min for renewals. 25 sleepers per Min for stressing. Suitable for concrete or steel sleepers Fits 3rd rail conductor systems without removing conductor rails
IMAGE REQUIRED
If the Panlock has been installed for a long time, it may be necessary to loosen the fastening with a hammer prior to extraction with the PANLOCK PULLER. N OTE. It is mandatory to wear eye protection when removing or fitting any clips where hammer assistance might be necessary. F or maximum effectiveness Panlocks should not be mixed with other bull head rail fastenings. Also ensure the chair is square to the rail. For instructions on the use of FASTCLIP tools and methods, refer to the separate booklet entitled: PANDROL FASTCLIP Track Installation Guide
Rosenqvist CD200:
Clipping and unclipping action. Sleeper lifting option Clipping and unclipping rates up to 12 sleepers per Min
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Track Support baseplates for Noise and Vibration mitigation.

1. Baseplates and Modular Assemblies Pandrol provides 3 different baseplate systems incorporating different levels of resilience for different required levels of vibration mitigation. The stiffness can be engineered to achieved different levels of resilience within limits, but generally Pandrol VANGUARD is the softest possible system, followed by VIPA-SP then SFC baseplates the firmest. All of these systems can be supplied in different variants, most of which are already Product Accepted by Network Rail. The baseplates can be installed on concrete slab track or steel structures using a range of anchorage systems shown on the following pages.
Pandrol VIPA-SP:
Assembly 11308 for 56E1
Pandrol VIPA-SP:
Assembly 10435 for CEN60
Pandrol SFC:
Pandrol VIPA-SP:
Pandrol SFC:
Pandrol VANGUARD:
Assembly No. 10395 for CEN60 See pages 43 and 44 for description of loose components
Not relevant to loose components
Pandrol VIPA-SP:
Pandrol VANGUARD:
Assembly No. 10853 for 56E1 See pages 43 and 44 for description of loose components
Not relevant to loose components
Pandrol VIPA-SP:
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Track Support baseplates for Noise and Vibration mitigation.

1. Vanguard Components These tables depict the differing components needed for the most frquently used variant of the VANGUARD range being the baseplate variant. Network Rail has formally accepted this variant for either 56E1 or 60E1 or 2 rails but the components are different to reach the differing rail sizes. The Network Rail Product Acceptance certificate is: PA05/00569. This explains and illustrates the differing components.
Remaining Components Unique to Each Rail Size Rail Size 56E1

Rubber Wedge Assembly 9456
Rail Size 60E1 or 60E2

Rubber Wedge Assembly 9769
Common Components for Both Rails

Baseplate Type 10396 Hook-In Shoulder Type 9705
Bump-Stop Pad Type 9766
VANGUARD Locking Wdge Type 9242
Side Arm Type 9413
Side Arm Type 9765
Catalogue No. 057/0060026 Catalogue No. 057/048350 Catalogue No. 057/060025
VANGUARD Retention Clip Type 7920
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Anchorage Systems for Pandrol Baseplates

3. Anchorage Assemblies The choice of anchorage assembly is determined by the installation method selected by the contractor. The methods listed below describe the techniques used by contractors. The corresponding anchorage should be specified as part of the Pandrol scope of supply to maintain the Product Acceptance validity.
The anchorage assemblies shown below can be used with either method of top-down construction. Installation and the choice is determined by other factors such as track curvature or height adjustment limits required. Generally plastic inserts can used for track where curvature is greater than 400 metres, and height adjustments less than 15 mm.
Top-Down Method
Assemby with M24 bolt, and cast-iron insert.
Components List for Each Hold-Down Assembly

Bottom-up Method
Bottom-up method on concrete slab track
24 Stud Type: M24 Nut Type: 2 Qty. Flat Washers: 2 Qty. Disc Springs: 11249 11368 11244 11242 Top-Hat Bush: 11032-24 Serrated Washer: 9978 Conforming Pad: 10401 Heights Adjusting Shims Type: 10854 (Thickness available: 3, 5, 10mm)
Slab track concrete poured to beneath the baseplate or set with concrete sleepers.
M24 Bolt Type: 13110 Serrated Washer: 9978 Cast Iron Insert: 9744 Construction Shim: 11361 Top-Hat Bush: 11032-24 (wet poured concrete) 2 Qty. Flat Washers: 11244 Conforming pad: 10401 2 Qty. Disc Springs: 11242 (on sleepers)
Pandrol does NOT supply grout for the anchor stud
Drilled and grouted anchors, with poured grout pad beneath baseplate
Top-Down Method
Height adjusting shims are NOT required using this method, unless downward adjustment is later required
The Top-down method uses the same components as above, with the exception of swapping the Conforming pad, for a: Construction shim: 11361 Pandrol does NOT supply grout for the anchor stud, NOR the grout for beneath the construction shim
Top-Down Method
Assemby with Anchor Screww and plastic insert.
Slab track concrete poured to beneath the baseplate or set with concrete sleepers.
Anchor Screw Serrated Washer: 9978 22mm Type: 10886 Construction Shim: 11361 Plastic Insert: 10887 (wet poured concrete) Top-Hat Bush: 11032-23 Conforming pad: 10401 2 Qty. Flat Washers: 11244 (on sleepers) 2 Qty. Disc Springs: 11242 Height adjusting shims are NOT required using this method, unless downward adjustment is later required
Bottom-up Method
Bottom-up method on steel deck
M24 Bolt Type: M24 Nut Type: 2 Qty. Flat Washers: 2 Qty. Disc Springs: 13110 11368 11244 11242 Top-Hat Bush: 11032-24 Serrated Washer: 9978 Conforming Pad: 10401 Heights Adjusting Shims Type: 10854 (Thickness available: 3, 5, 10mm)
NOTES. 1. The lengths of anchor studs, bolts, and screws can be calculated with the aid of separate data-sheets from Pandrol. 2. The factors of safety for the various Pandrol anchorage systems can be calculated by Pandrol from track and site parameters. Contact Pandrol for details.
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4. Identification Chart for Anchorage Components

The anchorage components identified below form part of the scope of supply only with the relevant Pandrol baseplates. These components are NOT supplied separately, and can only be warranted when used within the defined Pandrol assembly.
Inserts
Cast-Iron Type 9744 Note: The blue epoxy finish is optional. Standard finish is natural cast-iron
Bolts, Studs and Nuts

M24 Anchor Stud Type 11249 Lengths from 225mm to 320mm
Plastic Insert Type 10887

M24 Bolts Type 13110 Lengths from 140mm to 210mm
Washers and Disc Springs

Anchor Screw Type 10886 For use with plastic inserts
M24 Flat Washer Type 11244 For use with plastic inserts
M24 Nut Type 11368
M24 Disc Spring Type 11242
NOTE: The standard finish on bolts, anchor studs, screws, and nuts is spun galvanised.
NOTE: Washers are zinc plated, and disc springs are additionally passivated yellow colour.
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Identification Chart for Anchorage Components

Bushes and Serrated Washers
Pads and Shims

Conforming pad Type 10401 3mm thick for preformed concrete and steel decks
Height Adjusting Shim Type 10854-3 3mm thick
Top-Hat Type 11032-23
Construction Shim Top-Hat Type 11032-24 Type 11361 10m thick for poured concrete and grout
Height Adjusting Shim Type 10854-5 5mm thick
1mm - Catalogue No. 57/01950 2mm - Catalogue No. 57/01951
Serrated Washer Type 9978 (Top)
Steel Half-Shim with Slotted Holes Type 14954 Range:1,2mm thick Height Adjusting Shim Type 10854-10 10mm thick
Serrated Washer Type 9978 (Bottom)
HDPE Half Shim with Slotted Holes 3mm - Catalogue No. 57/01952 Type 14953 Range: 3, 5 10mm thick
5mm - Catalogue No. 57/01953 10mm - Catalogue No. 57/01954
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Pandrol UK Limited Gateford Road Worksop Notts S81 7AX T. 01909 476101 F. 01909 500004
www.pandrol.com
Design by Andy Marsden: t. 07960 085647 e. andy.marsden76@gmail.com

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Track Fastening Systems

User Guide - Edition 8

Other PANDROL publications available

Pandrol FASTCLIP FE system

Pandrol SFC baseplates

Pandrol FASTCLIP Track Installation Guide

Track Report 2011

Pandrol Track Fastening Systems User Guide - Edition 8

Introduction and how to contact PANDROL

Clip Applications & Colour Coding

History of the Company

Standard Finish: Red 57/48033

CP Finish: Grey Gloss 57/48056

New information since Edition 7

Standard Finish: Cat. No. not allocated.

CP Finish: Blue 57/02029

T. 01909 476101 F. 01909 500004

Pandrol Track Fastening Systems User Guide - Edition 8

Clip Applications & Colour Coding

Standard Finish: Red 57/48255

CP Finish: Matt Grey 57/48031

Type: e-Plus - eP20127

Standard Finish: Red 57/48237

CP Finish: Grey Gloss 57/48307

Standard Finish: Yellow 57/48256

CP Finish: Black Gloss 57/48043

Type: e-Plus - eP20129

Standard Finish: Green 57/48236

CP Finish: Blue Gloss 57/48308

Standard Finish: Purple 57/48247

CP Finish: Bright Red Gloss: 57/48044

Type: e-Plus - eP20130

Standard Finish: Yellow 57/48252

CP Finish: Purple Gloss 57/48309

Standard Finish: Blue 57/48248

CP Finish: Grey Gloss 57/48045

Type: Re Clip - Re1609

Standard Finish: Red 57/48469

CP Finish: Matt Grey Cat No. Not allocated

CP Finish: Green 57/48587

Pandrol Track Fastening Systems User Guide - Edition 8

Clip Applications & Colour Coding

Standard Finish: Red 57/48239

CP Finish: Matt Grey 57/48253

Standard Finish: Blue 57/48243

CP Finish: Grey Gloss 57/48234

Standard Finish: Red 57/48450

CP Finish: Matt Grey 57/48046

Standard Finish: Purple 57/48245

CP Finish: Bright Red Gloss 57/48242

Catalogue No. 57/48781

Standard Finish: Green 57/48244

CP Finish: Yellow Gloss 57/48249

Catalogue No. 57/48785

AL23 Maintenance Spike

Pandrol Track Fastening Systems User Guide - Edition 8

Insulator Applications & Colour Coding

Catalogue Number: 57/48118

FASTCLIP Type 8277

Catalogue Nos: Standard Coil 057/048034 Large Coil 057/048298