Fastenings - Definition

All the components, which together form the

structural connection between rail and sleeper,
To resist forces induced by traffic; and Temperature
change

Purpose:
To maintain track gauge and to transmit forces acting on and
in the rails to sleepers
Forces on fastenings

Vertical Forces
Vertical forces acting on rail fastenings can
be damped by Elastic Rail Pads (below rail)
and by their in-situ spring function.
Forces on fastenings

Lateral forces:
 Due to parasitic motions and due to
longitudinal compression (under
tendency of buckling)
 Rail has tendency to move laterally
on sleeper
 Complete Track has tendency to
move laterally
 Forces on fastenings

Lateral forces:
 May be very high (usually ~1 T, high ~18-20 T)
 Able to withstand lateral force without any excess lateral
movement, or gauge widening.
 Very rigid system cause higher wear.
 Forces transmitted directly to the sleeper by the means in
which foot of rail is connected to sleeper
 Rail fastenings transmit them to sleeper via firm connection
 If it is not possible, forces will increase to such an extent that,
the rail will overturn or sleeper will be crushed.
 Fastenings - Forces
 Longitudinal forces:
 Thermal forces (function of Stress-free
temperature)
 Tractive/ braking forces (usually < 1 T)
Resisted by fastenings and consolidated
surrounding ballast
Movement of rail / rail-sleeper assembly
Vibrations in Track

• Vibrations:
 Low frequency vibration due to parasitic motion
 Causes deterioration in track geometry parameters
 High frequency vibration due to rail wheel
interaction/contact, 700-1200 Hz and amplitude of
0.1 mm to 0.3 mm with accelerations of 70g to
100g
Effects of High Frequency
Vibrations in Track
Shakes-ups of entire Track Assembly
And result in:
 Loosening of fastenings
 Loosening of ballast packing
 Loss of toe load
 Wear and tear of entire track assembly
 Rail corrugation (wave length is similar)
 Fatigue failure
 Affects ride quality & rolling stock components
General functions and
requirements of Fastening System

 To absorb rail forces elastically & transfer to

sleeper
 Sufficient clamping force in all situations for
longitudinal and lateral resistance (even in
worn conditions)
 Limit breathing length/limit gaps in case of rail
fracture.
 To damp vibration and impact
 To retain track gauge and rail inclination
 To provide electrical insulation
 Ideal Fastening System
 Safeguard Track Parameters:
 Resistance against deterioration
 Vertical/Horizontal hold of fastenings on Rail
under static and dynamic conditions.

 Resistance to longitudinal forces

 Rail creep preventers
 Sufficient contact pressure, which is not
weakened considerably during service life.
Fastening Types

Rail free
Rigid
Elastic
Objectives of Elastic Fastenings
Elastic Rail clip
 Exert sufficient and continuous toe load
on the rail foot under static and dynamic
conditions.
 To ensure no separation between rail and
rubber pad
 To ensure minimum uplift under
percussion wave.
 Provide creep resistance
 Keep contact with rail at all times
Objectives of Elastic Fastenings
Elastic Rail Pad
 Distribute load uniformly (prevents crushing of
sleeper seat)
 Absorbs and damp high frequency vibrations
 No hammering affect
 No separation between rail and pad under
dynamic conditions
 Increased frictional resistance to longitudinal and
lateral movement
 Provide insulation
 Reduce noise level
 Mechanism
LOAD
ENERGY
ABSORBED

ERC & GRP

60 %

BALLAST
25%

FORMATION
15%

Very little vibrations/pressure gets transmitted to the Formation

Elastic Fastenings

Essential components
 Elastic Rail Clip
 Elastic Rail Pad
Types of Elastic Fastening
 TYPE I (Spike Type)
 Toe load derived from frictional grip or
nailing effect
ERS, DS 18 and MACBETH
 TYPE II (Screw Type)
 Load application through a screw thread
HM, NABLA, VOSSLOH
 TYPE III (Clip Type)
 Predetermined load generated by fitting
of clip
PANDROL Clip (ERC)
Nabla Fastening
Nabla Fastening
Vossloh Fastening

Sleeper screw in
dowel

Tension clamps

Guide plate

Rail Pad
Vossloh Fastening
Vossloh Fastening
Vossloh Fastening
 Extensively used on German railway
 Positive anchorage system with 13
mm Silico-Manganese spring steel
 Tension clamp
 W shaped, 1100 kg load, deflection of 13.5 mm
 Plastic angled plate guide
 Transmits lateral loads, screws remain unaffected
 Sleeper screws and dowel
 Pitch of 12.5 mm
 Rail Pad
 6-7 mm, Ethylene- Vinyl Acetate - Co-polymerized
ERC
Toe Load

Downward Force on foot of rail

caused by elastic fastening is
called toe load
 Depends on relative positioning of
crown of insert hole, shoulder of
insert and rail seat level.
Relative position of legs of ERC determine toe load
Assembly
Longitudinal resistance

 At-least 15 kN
 Much greater than longitudinal (sleeper) shear resistance in
the ballast bed (5kN) for half sleeper
 In case of large axial forces in Rail
 Fastenings remain in-tact and sleepers move in ballast bed
Requirement of Toe Load

 LWR theory
 Rail and Sleeper to act as frame
 No relative movement
 How it is ensured?
ERC mark III has average Toe load of 1000 kg
The average Static Toe Load = 1000 × 4 = 4000 kg
Assuming 0.5 as coefficient of friction between rubber pad
and rail, the rail to sleeper resistance is approx. 2000 kg.
Average Sleeper to ballast resistance ≈ 1000 kg
Possibility of relative rail to sleeper movement (?)
Assembly
ERC Mark III
 42.5
ERC Mark V
41.8

? OF TOE

68
= 12°APPROX
L = 2° APPROX:

50.5
21.2
4.9
54 15
110 34.7 48.7
ELEVATION SIDE ELEVATION
12+1
-2

35±2
DIAMETER:
A-B = 23mm
B-C = PRECISION TAPERING OF DIAMETER
FROM 23mm TO 20.64mm TO BE DONE
20.64

BY HYDRO COPYING TURNING MACHINE IN A

23

LENGTH OF 8mm ON THE STRIGHT CUT BAR

C B C-D = UNIFORM DIA: OF 20.64 mm TO BE ACHIEVED
BY TURNING USING HYDRO COPYING MACHINE

A MANUFACTURER'S INITIAL/TRADE
82 MARK, LAST DIGIT OF THE YEAR OF

90
MANUFACTURE AND LOT NO. ARE
TO BE INSCRIBED HERE e.g. AB 3/1 RDSO / T-5919
PLAN
Elastic Rail Clip (ERC)

Specifications
IRS/T-31-1992
(up-to Corrigendum No. 4)
 Elastic Rail Clip
Toe Load Toe Deflection Dia. Weight
Year ERC Type
(Kg) (mm) (mm) (Kg)
1970 T-1892 Round Toe 645-800 11.4 20.64/20.20 1.000
1987 T-3701 Mark III 850-1100 13.5 20.64 0.910
1990 T-4158 ERC - J (GJ clip) 300 3.5 20.64 0.915
1998 T-5919 Mark V 1200-1500 13.5 23/20.64 1.14/1.08
2014 T-8258 ERC - J (GJ clip) 600-800 20.64
2003 T-6254-6255, Anti-theft ERC 850-1100 13.5 20.64 0.937
with Circlip
Manufacturing of Clips

Manufactured from rolled bars by

hot forming
Subsequently oil hardened and
tempered to obtain uniform
hardness across entire section
The clips shall conform to the
requirements of drawing and all
tests stipulated in the specifications
 Elastic Rail Clip
Item Value
Silico Manganese Spring Steel
Material GR-55-Si 7
(Confirming to IS:3195)
Hardness BHN 375-415
Diametre 20.64 mm
Toe Load 0.85 to 1.1 T for Mark III
Deflection at Toe Load 13.5 mm
Torsional Resistance 24 T-m
Weight 0.91 KG.
 Flow chart of Manufacturing
ERC Mk-III
20.64 mm (dia) Spring Steel
Raw Material
Grade 55Si7 to IS:3195

Cutting of Bars Square-ness & Chamfering

(approx. 350mm) Length within +1.5 & -0 mm

Heating Temp. around 930°C

Forming of Clips Within 20 Seconds

Temp. not to Exceed 70°C

Oil Quenching
Quench Time 12 min (min.)

Tempering Temp. Around 450°C

 Flow chart of Manufacturing
ERC Mk-V
23 mm (dia) Spring Steel
Raw Material
Grade 55Si7 to IS:3195

Cutting of Bars Square-ness & Chamfering

(approx. 350mm) Length within +1.5 & -0 mm
Turning length - 82mm (20.64dia)
Turning Taper length - 82mm

Heating Temp. around 930°C

Forming of Clips Within 20 Seconds

Temp. not to Exceed 70°C

Oil Quenching
Quench Time 12 min (min.)

Tempering Temp. Around 450°C

 Technical Specifications

 Steel:
Silico-Manganese Spring Steel (as Rolled Bars)
Grade: 55 Si 7 as per IS:3195-1992,
Section: 20.64 mm dia. / 23 mm dia.
with tolerance of +1.0% & - 0.8%

 Chemical Composition (Tested as per IS:228)

 CARBON 0.50 - 0.60 % ± 0.03 %
 MANGANESE 0.80 - 1.0 % ± 0.04 %
 SILICON 1.50 - 2.0 % ± 0.03 %
 SULPHUR 0.04 % (max.) + 0.005 %
 PHOSPHORUS 0.04 % (max.) + 0.005 %
 Technical Specifications
• Grain Size:
Average number of grain per sq mm. (ASTM grain size 5 -248)
6 or finer as per IS:2853-1964
• Inclusion Rating:
Non-metallic particles embedded in the steel matrix during
manufacturing process.
Not worse than 2.5 A, B, C, D (Thick/Thin series) as per IS:4163:1982
• Hardness:
Approx. 270 BHN (for raw material); &
375-415 BHN or 40-44 HRC (for finished material)
As per IS:1500:1983
 Technical Specifications
• Depth of de-carburization:
During process of heating of bars carbon particles oxidized from the
surface of bars
0.15 mm (for raw material);
0.25 mm (for finished material)
At 100 × magnification as per IS:6396-1983
• Freedom from surface defects:
Reasonably smooth, free from distortion & harmful defects which may
impair serviceability.
However seam size up-to 0.25 mm may be permitted in as-rolled bars
 Markings on Clips
Clear inscription of stamp at the heel of the clip
 Manufacturer's initial (XY),
 last digit of year of manufacture (6); and
 lot number of corresponding heat in a particular year (3).

XY 6
3
Specified Characteristics of ERC Mk-III (RT-3701)

Hardness 40-44 HRC or 375-415 BHN

Depth of Decarburization Not more than 0.25 mm

Contact length of surface of Minor Axis ≥ 9.5 mm

Flat toe Major Axis ≥ 28.0 mm

Deflection 13.5 mm

Toe load 850-1100 Kg.

Approx. Weight 910 grams

Dimensions As per Inspection Gauge drawing

Specified Characteristics of ERC Mk-V (RT-5919)

Hardness 40-44 HRC or 375-415 BHN

Depth of Decarburization Not more than 0.25 mm

Contact length of surface of Minor Axis ≥ 9.5 mm

Flat toe Major Axis ≥ 28.0 mm

Deflection 13.5 mm

Toe load 1200-1500 Kg.

Approx. Weight 1.08 Kg.

Dimensions As per Gauge drawing

Anti-theft ERC
Anti-theft ERC

Silico Manganese Spring Steel

Grade: 55 Si 7 as per IS:4072
Rubber Pad
Rubber Pad – Functions

 To reduce sleeper strain caused by high

frequency load components by damping high
frequency vibrations
Mechanism – molecules brought closer under
force, energy dissipation when force is removed
 Absorbs shocks and Vibrational isolation of rail
 Increases frictional resistance for longitudinal &
lateral movement of rail
 Transfer and Distributes load uniformly over
sleeper, while filtering out high frequency
components
Rubber Pad – Functions

 Provide electric insulation between rail

and sleeper
Higher creep resistance
Reduced noise level
Attenuates load impact from
 Bad joints
 Track irregularities
 Faults in rolling stock

 Increases service life of track

components
Mechanism
LOAD
ENERGY
ABSORBED

ERC & GRP

60 %

BALLAST
25%

FORMATION
15%
Rubber Pad

 Common types of pad:

 Pimpled pads

 Grooved pads

 Thickness
 4.5 mm

 6.0 mm

 6.2 mm

 10 mm
Why grooved ?
 Why Grooved Rubber Pad?
Solid rubber pad under compression
Tendency to slip, from rail seat, under vibrations.
 Compresses under load (0.5 to 0.7 mm)

Due to hollow and ridges (Grooves/Pimples)

 Help in lateral expansion
 Higher deflection possible with thinner pads
 Greater resilience and distribution of shear forces
 Load Deflection Characteristics
25
20 SOLID PAD
PRESSURE ON RAIL(T)

15

10 GROOVED PAD

0
0 10 20 30 40 50 60
DEFLECTION 1/100 MM
Rubber Pad

 Top surface, in contact with rail, execute

very high frequency 1000Hz (low
amplitude 0.05-0.1mm) vibrations.
 While the bottom surface, in contact
with sleeper, execute low frequency 20
Hz vibrations
 For better performance
 Top side should be of harder material (higher
modulus of elasticity)
 Bottom side should be of softer material.
Composite Rubber Pad

Top layer is hard, bottom layer is

soft
Soft layer (~ 3 mm) is for sticking to
the sleeper
6.2mm Thick Composite GRSP
10mm Thick Composite GRSP
10mm Thick Composite GRSP
Rubber Pad

Material:
 Natural Rubber
 Ribbed Smoked Sheet Rubber
 Blend Of Styrene Rubber/Poly
Butadiene Rubber
Rubber Pad

RDSO Drawing
 52 kg PSC sleeper – T-3703
 60 kg PSC sleeper – T-3711
 60 kg PSC sleeper – T-6618 (6.2mm, Composite)

 PSC sleeper for 136 RE rail – T-7010 (10mm, composite)

 PSC sleeper for 136 RE/60 kg rail – T-8528 (10mm, composite)
Specification
- IRS T-47-2006 (up-to Amendment No. 3)
- RDSO/M&C/RP-198/2006 (Prov.) – for Composite GRSP

- RDSO/M&C/RP-200/2007 (Prov.) – for 10 mm th. Composite GRSP

Liners
Liners
Liners

Functions:
Distribution of toe load over larger
area
Allows use of different rail sections
on same sleeper
Provide insulation between rail and
insert
Liners

Requirements of a liner:
 Proper slope to match with rail foot
slope
 Vertical leg of liner should fit properly
between rail and MCI/SGCI insert to
maintain gauge
Easy to manufacture & fix at site
Liners
Liners
Liners
Liners

METAL
GFN – 66 (66% Nylon & 33% Glass
Fibre)
Liners

 For WIDER sleeper (25 t)

 RDSO/T-8616 – 60 kg/m rail (GS)
 RDSO/T-8617 – 60 kg/m rail (NGS)
 RDSO/T-8618 – 136 RE (67.5 kg/m) rail

 Specification
 Glass Filled Nylon (GFN) liners
 IRS T-44-1995 (up-to Corrigendum No. 6)
 Metal liners
 Provisional 2013
Thank You