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ISRAEL RAILWAYS LTD.
INFRASTRUCTURE DIVISION
Technical Specification
for
Manufacture and Supply
of
Rail Fastening System KS
with SKL W12
for Wooden Sleepers and
Bearers
No. E-01-0001.3
March 2020
ISRAEL RAILWAYS LTD
Rail Fastening System KS with SKL W12 for Wooden Sleepers
No. E-01-0001.3 March 2020
1
:AMENDMENTS
March 2.0100-10-iffers from version No. EThis technical specification d
:as follows 2020
i. Section 5.2.2 has been revised;
ii. Section 5.2.3 has been revised;
iii. Section 5.2.4 has been revised;
iv. The technical specification has been editorially revised.
ISRAEL RAILWAYS LTD
Rail Fastening System KS with SKL W12 for Wooden Sleepers
No. E-01-0001.3 March 2020
2
CONTENTS
1. SCOPE ........................................................................................................................ 3
2. REFERENCE DOCUMENTS ....................................................................................... 3
3. DEFINITIONS............................................................................................................. 5
4. GENERAL REQUIREMENTS ..................................................................................... 6
5. SUB-COMPONENTS - REQUIREMENTS ................................................................... 7
5.1. TENSION CLAMPS .................................................................................................... 7
5.2. BASE PLATES ............................................................................................................ 8
5.3. DOUBLE SPRING WASHERS .................................................................................... 9
5.4. SLEEPER SCREWS .................................................................................................. 11
5.5. T-HEAD BOLT AND NUTS ...................................................................................... 12
5.6. FLAT WASHERS ...................................................................................................... 14
5.7. RAIL SEAT PADS .................................................................................................... 16
6. TECHNICAL DRAWINGS AND CALCULATIONS ................................................... 17
7. QUALITY CONTROL AND QUALITY ASSURANCE ............................................... 18
8. QUALIFICATION TESTS ......................................................................................... 18
9. QUALITY TESTS ..................................................................................................... 19
10. LABORATORY ........................................................................................................ 19
11. INSPECTION BY A REPRESENTATIVE OF ISR ...................................................... 20
12. MARKING ................................................................................................................ 20
13. PACKING AND DELIVERY ..................................................................................... 21
14. LIST OF DOCUMENTS TO SUBBMIT TO INSPECTOR ........................................... 21
15. LIST OF FILES (in PDF Format) TO BE SUBMITTED WITH BIDDER'S PROPOSAL. 22
16. LIST OF FILES (in PDF Format) TO BE SUBMITTED WITH EVERY ORDER ........... 23
TECHNICAL APPENDIX A - ISRAEL CLIMATE AND ENVIRONMENTAL CONDITIONS .. 24
TECHNICAL APPENDIX B - RAIL FASTENING KS SYSTEM SET ....................................... 26
TECHNICAL APPENDIX C - TENSION CLAMP SKL W12 .................................................... 27
TECHNICAL APPENDIX D - BASE PLATE ........................................................................... 28
TECHNICAL APPENDIX E - DOUBLE SPRING WASHER Fe6 ............................................. 29
TECHNICAL APPENDIX F - SLEEPER SCREW Ss8 .............................................................. 30
TECHNICAL APPENDIX G - T-HEAD BOLT Hs32-55 ........................................................... 31
TECHNICAL APPENDIX H - WASHER Uls6 ......................................................................... 32
TECHNICAL APPENDIX I - RAIL SEAT PADS ..................................................................... 33
ISRAEL RAILWAYS LTD
Rail Fastening System KS with SKL W12 for Wooden Sleepers
No. E-01-0001.3 March 2020
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1. SCOPE
1.1 Theses technical specifications describe the requirements for
manufacture and supply of:
Elastic Rail Fastening System KS with Tension Clamp SKL W12
("Rail Fastening System KS"), to assemble rails with 60E2, 60E1,
54E1 and 50E6 rail profiles to Wooden sleepers and Bearers for
use on Railway tracks and turnouts.
1.2 The Rail Fastening System KS shall be indirect fastening with
Base Plate, simple to install, capable of easy visual inspection and
of screwed type, and shall provide support, guidance, resilience
between rail and sleeper.
1.3 The Rail Fastening System KS Sub-Components shall be:
Tension Clamps SKL W12;
Base Plate;
Double Spring Washers;
Sleeper Screws;
T-Head Bolts
Washers;
Rail Seat Pads.
2. REFERENCE DOCUMENTS
EN10025 Hot rolled products of structural steels;
EN10089 Hot rolled steels for quenched and tempered
springs. Technical delivery conditions;
EN10168 Steel products – Inspection documents;
EN10204 Metallic products - Types of inspection
documents;
EN13145 Railway applications - Track – Wood sleepers
and bearers;
EN13146-1 Railway applications - Track - Test methods
for fastening systems - Part 1: Determination
of longitudinal rail restraint;
EN13146-2 Railway applications - Track - Test methods
for fastening systems - Part 2: Determination
of torsional resistance;
ISRAEL RAILWAYS LTD
Rail Fastening System KS with SKL W12 for Wooden Sleepers
No. E-01-0001.3 March 2020
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EN13146-4 Railway applications - Track – Test methods
for fastening systems - Part 4: Effect of
repeated loading;
EN13146-6 Railway applications - Track – Test methods
for fastening systems - Part 6: Effect of severe
environmental conditions;
EN13146-7 Railway applications - Track – Test methods
for fastening systems - Part 7: Determination
of clamping force and uplift stiffness;
EN13146-9 Railway applications - Track – Test methods
for fastening systems - Part 9: Determination
of stiffness;
EN13146-10 Railway applications - Track – Test methods
for fastening systems - Part 10: Proof load test
for pull-out resistance;
EN13481-1 Railway applications - Track – Performance
requirements for fastening systems – Part 1:
Definitions;
EN13481-3 Railway applications - Track – Performance
requirements for fastening systems – Part 3:
Fastening systems for wood sleepers;
EN13674-1 Railway applications - Track – Rail – Part 1:
Vignole railway rails 46 kg/m and above;
ISO868 Plastics and ebonite — Determination of
indentation hardness by means of a durometer
(Shore hardness);
ISO898-1 Mechanical properties of fasteners made of
carbon steel and alloy steel Part 1: Bolts,
screws and studs with specified property
classes - Coarse thread and fine pitch thread;
ISO898-2 Mechanical properties of fasteners made of
carbon steel and alloy steel - Part 2: Nuts with
specified property classes - Coarse thread and
fine pitch thread;
ISO898-3 Mechanical properties of fasteners made of
carbon steel and alloy steel - Part 3: Flat
washers with specified property classes;
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No. E-01-0001.3 March 2020
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ISO965 General-purpose metric screw threads —
Tolerances;
ISO6157-1 Fasteners -- Surface discontinuities - Part 1:
Bolts, screws and studs for general
requirements;
ISO6157-2 Fasteners -- Surface discontinuities - Part 2:
Nuts;
ISO6305-2 Railway components — Technical delivery
requirements — Part 2: Non-alloy carbon steel
baseplates;
ISO6507 Metallic materials -- Vickers hardness test
ISO10684 Fasteners — Hot dip galvanized coatings;
ISO9001 Quality management systems - Requirements;
ISO/IEC17025 General requirements for the competence of
testing and calibration laboratories;
UIC864-3 Technical specification for the supply of
spring steel washers for the use in the
permanent way;
UIC864-6 Technical specification for the supply of
baseplates or sections of plates made of rolled
steel;
IEC 62631-3 Dielectric and resistive properties of solid
insulating materials - Part 3: Determination of
resistive properties (DC methods).
Note – the latest edition of the referenced document should be
considered
3. DEFINITIONS
3.1. ISR Israel Railways Ltd.;
3.2. Sub-Component any constituent of the Fastening Systems;
3.3. The Inspector shall have the meaning assigned to it in
Section 10 aforementioned;
3.4. The Laboratory shall have the meaning assigned to it in
Section 9 aforementioned;
3.5. Rail Profile 50E6 as defined in EN13674-1, Annex A,
figure A.13;
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3.6. Rail Profile 54E1 as defined in EN13674-1, Annex A,
figure A.15;
3.7. Rail Profile 60E1 as defined in EN13674-1, Annex A,
figure A.23;
3.8. Rail Profile 60E2 as defined in EN13674-1, Annex A,
figure A.24;
4. GENERAL REQUIREMENTS
4.1 The Rail Fastening System KS shall be manufactured with
different design in reference to the rail profiles: 60E2; 60E1; 54E1
and 50E6 (rail profiles are in accordance with EN13674-1), to
enable fasten the rails to wood sleepers and bearers (wood sleepers
and bearers are in accordance with EN13145).
4.2 The Rail Fastening System KS shall comply with the requirements
of EN 13481-3.
The Rail Fastening System KS Sub-Components shall be
manufactured in accordance to the Manufacturer's quality
management plan complying with ISO9001 and based on the
relevant EN, UIC and ISO standards and these Technical
Specifications.
4.3 The Rail Fastening System KS shall be designed to comply with
fastening category C in accordance with EN13481-3, section 1.
4.4 All the Sub-Components shall be designed to resistant Israel
climate condition, in accordance with Technical Appendix A. High
corrosion environment shall be considered as well.
4.5 All Sub-Components which are non-metallic shall be made of hot
weather resistant materials, and UV protected, suitable for use at
temperature of up to 50 [°C] (ambient temperature).
4.6 The Rail Fastening System KS installation and maintenance
manual, shall be submitted.
4.7 Detailed List of subcontractors, which are the Sub-Components
Manufacturers, shall be submitted (Name and Factory address, E-
mail, experience).
Sub-Components shall be manufactured only by the Sub-
Components Manufacturers, which are listed in the Detailed List.
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5. SUB-COMPONENTS - REQUIREMENTS
5.1. TENSION CLAMPS
5.1.1 Tension Clamps - General
The assembled Rail Fastening System KS shall include 2 Tension
Clamps (to fasten one rail to a sleeper) of the following type:
Type SKL W12 - for 60E1, 60E2, 54E1 and 50E6 rail
profiles.
See sketch in the Technical Appendix C;
5.1.2 Tension Clamps - Characteristics
The Tension Clamp raw material shall be from alloy silicone-
manganese spring steel – 38Si7, in accordance with EN10089,
with the following chemical composition:
Property class
Chemical composition limit
(cast analysis, %)
C
min. – max.
Si
min. – max.
Mn
min. – max.
P
max.
S
max.
38Si7 0.35 – 0.42 1.5 – 1.8 0.5 – 0.8 0.025 0.025
And with the following mechanical properties:
The tensile limit elasticity shall be greater than 1150[MPa].
The tensile strength shall be greater than 1300[MPa].
The elongation at fracture shall be greater than 8%.
The Tension Clamps shall be heat treated to achieve a surface
hardness in the range 400-460 HV 30 in accordance with
ISO6507 or equivalent. It shall be free from surface and
internal defects.
The Tension Clamps shall be provided with protective coating.
The protective coating type and the relevant standard shall be
submitted.
5.1.3 Tension Clamps – Technical Drawings and Technical Descriptions
The Technical Drawings and Technical Descriptions of Tension
Clamps, including dimensions, material main characteristics,
coating description, heat treatment, marking, etc., complying with
EN10089, ISO6507, and the relevant standard for preventive
coating and these technical specifications, shall be submitted.
5.1.4 Tension Clamps – Quality Tests
For every order of less than, or equal to 40,000 Tension Clamps -
visual inspection, surface finish, geometry, mechanical properties
and chemical composition, and protective coating tests results shall
ISRAEL RAILWAYS LTD
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No. E-01-0001.3 March 2020
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conform with the requirements of these technical specification and
EN10089; ISO6507, and in additional EN 10204, Type 3.1; or
Type 3.2, these results shall be submitted.
For every order greater than 40,000 Tension Clamps, for every
batch of up to 40,000 Tension Clamps - visual inspection, surface
finish, geometry, mechanical properties and chemical composition
tests results shall conform with the requirements of these technical
specification and EN10089; ISO6507, and in additional EN 10204,
Type 3.1; or Type 3.2, these results shall be submitted.
5.2. BASE PLATES
5.2.1 Base Plates – General
The assembled Rail Fastening System KS shall include 1 Base
Plate (to fasten one rail to a sleeper) of the following types:
Type Rp_1/30 150/30/160 - for 60E1 and 60E2 rail profiles;
Type Rp_1/30 140/30/160 - for 54E1 and 50E6 rail profiles.
see sketch in the Technical Appendix D.
5.2.2 Base Plates - Characteristics
The Base Plates shall be manufactured by cutting to length a rolled
section or steel casting.
The steel category shall be in accordance with EN10025 or
EN10340 or other relevant EN and/or ISO standard, with the
following mechanical properties:
The Base Plates tensile limit elasticity shall be greater than
265[MPa].
The Base Plates tensile strength shall be greater than
410[MPa].
The Base Plates elongation at fracture shall be greater than
22%.
The Base Plates shall have inclination of 1/30.
The Base Plates shall possess smooth and level surfaces and be
free from breaks in continuity, repairs, cracks, scratches, deep
flaws or any other faults.
5.2.3 Base Plates – Technical Drawings and Technical Descriptions
The Technical Drawings and Technical Descriptions of the Base
Plates, including dimensions, material main characteristics, coating
description, heat treatment, marking, etc., complying with
ISO6305-2, UIC864-6, or EN10340 or other relevant EN and/or
ISRAEL RAILWAYS LTD
Rail Fastening System KS with SKL W12 for Wooden Sleepers
No. E-01-0001.3 March 2020
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ISO standard and these technical specifications, shall be submitted.
5.2.4 Base Plates - Quality Tests
For every order of less than, or equal to 40,000 Base Plates - visual
inspection, surface finish, geometry, mechanical properties and
chemical composition, and protective coating tests results shall
conform with the requirements of these technical specification and
ISO6305-2; UIC 864-6, or EN10340; other relevant EN and/or
ISO standard, and in additional EN10204, Type 3.1; or Type 3.2,
these results shall be submitted.
For every order greater than 40,000 Base Plates, for every batch of
up to 40,000 Base Plates - visual inspection, surface finish,
geometry, mechanical properties and chemical composition tests
results shall conform with the requirements of these technical
specification and ISO6305-2; UIC 864-6, or EN10340; other
relevant EN and/or ISO standard, and in additional EN10204, Type
3.1; or Type 3.2, these results shall be submitted.
5.3. DOUBLE SPRING WASHERS
5.3.1 Double Spring Washers – General
The assembled Rail Fastening System KS (for each rail) shall
include 4 Double Spring Washers of the following type:
Type Fe6 - for 60E1, 60E2, 54E1and 50E6 rail profiles.
See sketch in Technical Appendix E.
5.3.2 Double Spring Washers – Characteristics
The Double Spring Washers shall be from alloy Silicone-
manganese spring steel – 38Si7, in accordance with EN10089,
with the following chemical composition:
Property class
Chemical composition limit
(cast analysis, %)
C
min. – max.
Si
min. – max.
Mn
min. – max.
P
max.
S
max.
38Si7 0.35 – 0.42 1.5 – 1.8 0.5 – 0.8 0.025 0.025
And with the following mechanical properties:
The tensile limit elasticity shall be greater than 1150[MPa].
The tensile strength shall be greater than 1300[MPa].
The elongation at fracture shall be greater than 8%.
The Double Spring Washer shall be hardened and tempered to
achieve a surface hardness in the range 430-515 HV 30 in
accordance with ISO6507 or equivalent.
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No. E-01-0001.3 March 2020
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The Double Spring Washers shall be manufactured by helicoidal
coiling of steel bar. The spiral shall be entirely regular.
The conditions of the Double Spring Washers obtained from bars
of the same casting shall be identical.
The internal and external surfaces of the Double Spring Washers
of rectangular section shall be parallel to the coiling axis when the
Double Spring Washer is in flatted position; the section shall be
slightly rounded at the edges.
The Double Spring Washer surface shall be knurled.
When fully compressed, the coils shall be fully superimposed one
above the other. The end surfaces shall then be situated on the
plane running through the axis of the coiling spiral.
The Double Spring Washer shall be regular and clean, and free
from superficial cracks, flaws, burrs, and deficiency in metal,
folds, or any other defects likely to affect the use for which they
are intended. The outside surface, in particular, must be smooth
and free from burrs.
The Double Spring Washer shall be hot dip galvanized, to conform
the requirements of ISO10684, all surfaces shall be thoroughly
covered.
5.3.3 Double Spring Washers – Technical Drawings and Technical
Descriptions
The Technical Drawings and Technical Descriptions of Double
Spring Washer, including dimensions, material main
characteristics, coating description, heat treatment, marking, etc.,
complying with EN10089, UIC 864-3, ISO6507 and ISO10684
and these technical specifications, shall be submitted.
5.3.4 Double Spring Washers - Quality Tests
For every order of less than, or equal to 40,000 Double Spring
Washers - visual inspection, surface finish, geometry, mechanical
properties, chemical composition and hot dip galvanized tests
results shall conform with the requirements of these technical
specification and EN10089; UIC864-3; ISO6507, ISO10684 and in
additional EN 10204, Type 3.1; or Type 3.2, these results shall be
submitted.
For every order greater than 40,000 Double Spring Washers, for
every batch of up to 40,000 Double Spring Washers - visual
inspection, surface finish, geometry, mechanical properties,
ISRAEL RAILWAYS LTD
Rail Fastening System KS with SKL W12 for Wooden Sleepers
No. E-01-0001.3 March 2020
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chemical composition and hot dip galvanized tests results shall
conform with the requirements of these technical specification and
EN10089; UIC864-3; ISO6507, and in additional EN 10204, Type
3.1; or Type 3.2, these results shall be submitted.
5.4. SLEEPER SCREWS
5.4.1 Sleeper Screws – General
The assembled Rail Fastening System KS (for each rail) shall
include 4 Sleeper Screws of the following type:
Sleeper Screw type Ss8-150 - for 60E1, 60E2, 54E1 and 50E6
rail profiles.
See sketch in Technical Appendix F.
5.4.2 Sleeper Screws - Characteristics
The Sleeper Screws shall be made from carbon steel with property
class of 5.6, in accordance with ISO898-1, with the following
chemical composition, which conform the requirements of
ISO898-1, table 2:
Property class
Chemical composition limit
(cast analysis, %)
C
min. – max.
P
max.
S
max.
5.6 0.13 – 0.55 0.05 0.06
And with the following mechanical properties:
The tensile limit elasticity shall be greater than 300[MPa].
The tensile strength shall be greater than 500[MPa].
The elongation shall be greater than 20%.
The Sleeper Screws shall be hot dip galvanized coated to conform
the requirements of ISO10684, all surfaces shall be thoroughly
covered.
The Sleeper Screws tolerances shall conform with the
requirements of ISO965.
The Sleeper Screws shall be manufactured from single piece,
without welding. The head shall be upset by hot-working.
The Sleeper Screw shanks shall be perfectly smooth and straight,
without flow or cracks. The head shall be clearly cut and correctly
centered in relation to the shanks.
The complete surface of The Sleeper Screws shall be suitably re-
burred. Care shall be taken to ensure that the re-burring does not
ISRAEL RAILWAYS LTD
Rail Fastening System KS with SKL W12 for Wooden Sleepers
No. E-01-0001.3 March 2020
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give rise to any tearing of the metal or leave any roughness on the
contact surfaces.
The threads shall be clean, uniform and complete. If the threads of
The Sleeper Screws are stripped or if there is a lack of material,
they shall not be accepted.
5.4.3 Sleeper Screws – Technical Drawings and Technical Descriptions
The Technical Drawings and Technical Descriptions of Sleeper
Screws, including dimensions, material main characteristics,
coating description, heat treatment, marking, etc., complying with
ISO898-1, ISO965, ISO6157-1, ISO10684 and these technical
specifications, shall be submitted.
5.4.4 Sleeper Screws - Quality Tests
For every order of less than, or equal to 40,000 Sleeper Screws -
visual inspection, surface finish, geometry, mechanical properties,
chemical composition, and hot dip galvanized tests results shall
conform with the requirements of these technical specifications
and ISO898-1, ISO965, ISO6157-1, ISO10684, and in additional
EN 10204, Type 3.1; or Type 3.2, these results shall be submitted.
For every order greater than 40,000 Sleeper Screws, for every
batch of up to 40,000 Sleeper Screws - visual inspection, surface
finish, geometry, mechanical properties, chemical composition and
hot dip galvanized tests results shall conform with the
requirements of these technical specification and ISO898-1,
ISO965, ISO6157-1, ISO10684, and in additional EN 10204, Type
3.1; or Type 3.2, these results shall be submitted.
5.5. T-HEAD BOLT AND NUTS
5.5.1 T-Head Bolt and Nuts – General
The assembled Rail Fastening System KS (for each rail) shall
include 2 T-bolt screws type Hs32 with suitable 2 Nuts M22 Width
across flats 39[mm], for 60E1, 60E2, 54E1 and 50E6 rail profiles.
See sketch in Technical Appendix G.
5.5.2 T-Head Bolt and Nuts - Characteristics
The T-Head Bolts shall be manufactured from single piece,
without welding. Their head shall be upset by hot-working, and
shall have steel property class of 5.6, in accordance with ISO898-
1,
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with the following chemical composition, which conform the
requirements of ISO898-1, table 2:
Property class
Chemical composition limit
(cast analysis, %)a
C
min. – max.
P
max.
S
max.
5.6 0.13 – 0.55 0.05 0.06
And with the following mechanical properties:
The tensile limit elasticity shall be greater than 300[MPa].
The tensile strength shall be greater than 500[MPa].
The elongation shall be greater than 20%.
The Nuts shall have Hexagon shape, and be made from carbon
steel with property class of 5, in accordance with ISO898-2,
with the following chemical composition, which conform the
requirements of ISO898-2, table 3:
Property class
Chemical composition limit
(cast analysis, %)
C
max.
Mn P
max.
S
max.
5.6 0.58 0 0.06 0.15
And with the following mechanical properties:
Proof load values for Nuts with coarse thread shall be greater
than 190,900 [N].
Hardness properties for Nuts with Coarse Thread 146-302 HV
in accordance with ISO6507 or equivalent.
The T-Head Bolts and Nuts shall be galvanized, to conform the
requirements of ISO10684, ISO965. The T-Head Bolts and Nuts
must be free from any trace of grease, paint, etc. before the
galvanization.
The complete surface of the T-Head Bolts and Nuts shall be
suitably re-burred. Care shall be taken to ensure that the re-burring
doesn't give rise to any tearing of the metal or leave any roughness
on the contact surfaces.
The shanks shall be perfectly smooth and straight, without flow or
cracks. The head shall be clearly cut and correctly centered in
relation to the shanks.
The same shall be applying in the case of the Nuts.
In additional, no folding of the metal shall occur on the head at the
point of junction with the shank. The contact surfaces of the T-
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No. E-01-0001.3 March 2020
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Head Bolts and Nuts must be level and perpendicular in relation to
the longitudinal axis.
The threads must be clean, uniform and complete. If the threads of
the T-Head Bolt and Nuts are stripped or if there is a lack of
material, they shall not be accepted.
5.5.3 T-Head Bolts and Nuts – Technical Drawings and Technical
Descriptions
The Technical Drawings and Technical Descriptions of T-Head
Bolts and the Nuts, including dimensions, material main
characteristics, coating description, heat treatment, marking, etc.,
complying with ISO898-1, ISO898-2, ISO965, ISO 6157-1, ISO
6157-2, ISO10684, and these technical specifications, shall be
submitted.
5.5.4 T-Head Bolts and Nuts - Quality Tests
For every order of less than, or equal to 40,000 T-Head Bolts and
the Nuts - visual inspection, surface finish, geometry, mechanical
properties, chemical composition, and hot dip galvanized tests
results shall conform with the requirements of these technical
specification and ISO898-1, ISO898-2, ISO965, ISO6157-1,
ISO6157-2 ISO10684, and in additional EN 10204, Type 3.1; or
Type 3.2, these results shall be submitted.
For every order greater than 40,000 T-Head Bolts and the Nuts, for
every batch of up to 40,000 T-Head Bolts and the Nuts - visual
inspection, surface finish, geometry, mechanical properties,
chemical composition and hot dip galvanized tests results shall
conform with the requirements of these technical specification and
ISO898-1, ISO898-2, ISO965, ISO6157-1 ISO6157-2, ISO10684,
and in additional EN 10204, Type 3.1; or Type 3.2, these results
shall be submitted.
5.6. FLAT WASHERS
5.6.1 Flat Washers – General
The assembled Rail Fastening System KS (for each rail) shall
include 2 Flat Washers of the following type:
Flat Washer type Uls6 – for 60E1, 60E2, 54E1 and 50E6 rail
profiles.
See sketch in Technical Appendix H;
5.6.2 Flat Washers – Characteristics
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The Flat Washer material selection shall be at the manufacturer
discretion, provided that it fulfills the requirements of ISO898-3.
table 2 and table 3,
And with the following mechanical properties:
Hardness properties for Flat Washers 100-250 HV in
accordance with ISO6507 or equivalent.
The Flat Washers shall be hot dip galvanized coated to conform
the requirements of ISO10684, all surfaces shall be thoroughly
covered.
The conditions of manufacture of the washer obtained from bars of
the same casting must be identical.
The section shall be of even thickness and slightly rounded at the
edges.
The Flat Washers shall be regular and clean, and free from
superficial cracks, flaws, burrs, and deficiency in metal, folds, or
any other defects likely to affect the use for which they are
intended. The outside surface, in particular, must be smooth and
free from burrs.
5.6.3 Flat Washers – Technical Drawings and Technical Descriptions
The Technical Drawings and Technical Descriptions of Flat
Washers, including dimensions, material main characteristics,
coating description, heat treatment, marking, etc., complying with
ISO898-3, ISO 4759, ISO10684, and these technical
specifications, shall be submitted.
5.6.4 Flat Washers - Quality Tests
For every order of less than, or equal to 40,000 Flat Washers -
visual inspection, surface finish, geometry, mechanical properties,
chemical composition and hot dip galvanized tests results shall
conform with the requirements of these technical specifications
and ISO898-3, ISO4759, ISO10684, and in additional EN 10204,
Type 3.1; or Type 3.2, these results shall be submitted.
For every order greater than 40,000 Flat Washers, for every batch
of up to 40,000 Flat Washers - visual inspection, surface finish,
geometry, mechanical properties, chemical composition and hot
dip galvanized tests results shall conform with the requirements of
these technical specification and ISO898-3, ISO4759, ISO10684,
and in additional EN 10204, Type 3.1; or Type 3.2, these results
ISRAEL RAILWAYS LTD
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shall be submitted.
5.7. RAIL SEAT PADS
5.7.1 Rail Seat Pads - General
The assembled Rail Fastening System KS (for each rail) shall
include 1 Rail Seat Pads of the following types:
Type Zw687-148/165 for 60E2 and 60E1 rail profiles,
Type Zw-138/165 for 54E1 and 50E6 rail profiles,
See sketches in Technical Appendixes I;
5.7.2 Rail Seat Pads - Characteristics
The Rail Seat Pads material shall be manufactured from EVA
(Ethylen-Vinylacetat-Copolymerisat).
The Rail Seat Pads shall be stabilized against light/ UV damage.
The Rail Seat Pads shall have 32 - 47 Shore – D in accordance
with ISO868 or equivalent standard.
The Rail Seat Pads shall have melt flow rate (MFR 190/2, 16) less
than or equal to 5.2[g/10] in accordance with ISO1133.
The Rail Seat Pads density shall be 1.13-1.17 [g/cm3] in
accordance with ISO1183.
The Rail Seat Pads static stiffness shall be greater than or equal to
450 [kN/mm].
The Rail Seat Pads electrical volume resistivity shall be greater
than 108 [Ohm·cm] according with IEC62631-3.
The surface shall be free of cracks and damages affecting
performances.
5.7.3 Rail Seat Pads – Technical Drawings and Technical Descriptions
The Technical Drawings and Technical Descriptions of Rail Seat
Pads, including dimensions, material main characteristics,
marking, etc., complying with ISO 868, ISO1133, ISO1183, IEC
62631-3, shall be submitted.
5.7.4 Rail Seat Pads – Quality Tests
For every order of less than, or equal to 40,000 Rail Seat Pads -
visual inspection, surface finish, geometry, mechanical properties
and chemical composition tests results shall conform with the
requirements of these technical specification and ISO898-2,
ISO1133, ISO1183, IEC62631-3, these results shall be submitted.
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For every order greater than 40,000 Rail Seat Pads, for every batch
of up to 40,000 Rail Seat Pads - visual inspection, surface finish,
geometry, mechanical properties and chemical composition tests
results shall conform with the requirements of these technical
specification and ISO898-2, ISO1133, ISO1183, IEC62631-3,
these results shall be submitted.
6. TECHNICAL DRAWINGS AND CALCULATIONS
6.1. The Technical Drawings of the assembled unit (the interface
between the Rail Fastening System KS and the sleeper), based on
the sketches in the Technical Appendixes B-I, shall be submitted.
The following details shall be included in the drawings:
6.1.1. The external gauge point of rail fastening system which
defines the track gauge;
6.1.2. The dimension and the tolerance between internal and
external gauge points for the rail section for which the
fastening assembly is designed;
6.1.3. Drawing with dimensions and tolerances of every
components of the fastening system;
6.1.4. The nominal inclination of the rail seat.
6.2. The Technical Drawings of each Sub-Component, based on the
provided Sub-Components sketches in the Technical Appendixes
C-I, and the Technical requirements for each Sub-Components in
section 4, shall be submitted.
6.3. The Technical Drawings shall include dimensions, tolerances,
material type, coating description and heat treatment, etc.
6.4. The Rail Fastening System KS overall dimensions shall be
designed to avoid interface with vehicles including track
maintenance vehicles in accordance with EN13481-3 section 5.7,
drawings shall be submitted.
6.5. The calculations to show the maximum variation in static track
gauge which can arise from the Rail Fastening System KS shall be
submitted.
The calculations shall be based on the nominal of the rail section
given in EN 13674-1, and shall include any assumption about the
position of the rail within the Rail Fastening System KS assembly
and the tolerances on all component parts of the Rail Fastening
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System KS. The variation in track gauge, calculated in this way,
shall not exceed ±1 [mm].
7. QUALITY CONTROL AND QUALITY ASSURANCE
7.1. The Rail Fastening System KS shall be manufactured, in
accordance with the manufacturer technical drawings, under a
comprehensive quality control management system, which shall
ensure confidence consistently compliance in the conformity of the
finished product, including documented evidences, all in
accordance with these technical specifications and ISO9001,
EN13481-3, EN13146 parts: 1-10 (excluding parts – 3; 5; 8),
EN10025, ISO6305-4, ISO898-1, ISO898-2, ISO10684, ISO965-1,
ISO965-4, ISO4759-1, ISO 6157-1 and ISO 6157-2, DIN65151,
EN10204, EN10168 and any other relevant standard to provide
assurance of product safety in track.
7.2. The production control management system procedures, and
ISO9001 certificate shall be submitted.
8. QUALIFICATION TESTS
8.1. The Fastening Systems KS tests shall be accomplished in
accordance to EN 13146 parts: 1-10 (excluding parts - 3; 5 and 8),
8.2. The Qualification Tests procedure shall be applied to a complete
fastening assembly, and shall met the following requirements:
Longitudinal rail restraint (EN13146-1) > 12 [kN];
Torsional resistance (EN13146-2) --
for the rail displacement of 1 [⁰], moment force of more
than 0.9 [kNm] shall be apply,
for the rail displacement in the opposite direction of 1[⁰], moment force of more than 0.65 [kNm] shall be apply.
Effect of repeated loading, for fastening category C
(EN13146-4) --
Longitudinal rail restraint changes - less than or equal to
20%,
Vertical stiffness change - less than or equal to 25%,
Clamping force change - less than or equal to 20%;
Severe environmental conditions (EN13146-6) – following
the test, the fastening assembly shall be capable of being
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dismantled, without failure of any component and re-
assembled using manual tools;
Clamping force and uplift stiffness (EN13146-7) greater
than or equal to 12 [kN] per Tension Clamp, and greater
than or equal to 24 [kN] per rail set;
Pad low frequency dynamic stiffness (EN13146-9) greater
than or equal to 450 [kN/mm] at room temperature.
assembly high frequency dynamic stiffness (EN13146-9);
Attenuation of noise and vibration (EN13146-9);
Proof load test for pull-out resistance (EN13146-10).
8.3. The Qualification Test Report carried out by the Laboratory on a
complete fastening assembly of Rail Fastening System KS in
accordance with EN13481-3 sections 5.1-5.9; 5.11; 6 and
EN13146 parts: 1-10 (excluding parts: 3; 5 and 8), shall be
submitted.
9. QUALITY TESTS
9.1. The Quality Tests shall be carried out on each Rail Fastening
System KS Sub-Components, in accordance with the requirements
of these Technical Specifications, sections 6.1.4; 6.2.4; 6.3.4;
6.4.4; 6.5.4; 6.6.4; 6.7.4.
10. LABORATORY
10.1. The Qualification Tests
10.1.1. The Laboratory, that is carrying out the Qualifying Tests shall be
one of the following:
"Prüfamt für Verkehrswegbau" of the Technical University of
Munich (TUM), in Munich, Germany;
or
Alternative University Laboratory, with proven experience and
capability to perform technical tests on Fastening System in
accordance with EN13416 parts 1-10. The experience and
capability, to perform all the Qualification Tests, of the Alternative
University Laboratory shall be submitted.
10.2. The Quality Tests
10.2.1. The Laboratory, that is carrying out the Quality Tests is certifying
with at least the following certifications:
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The Laboratory certified in accordance with ISO/IEC17025 in
the field of material quality testing in reference with the Sub-
Component;
or
The Laboratory accredited by national laboratory
accreditation authority in the field of material quality testing
in reference with the Sub-Component;
10.2.2. The Laboratory certificate, include its appendixes, approving its
compliance with the requirements of section 10.1.1, above, shall be
submitted.
11. INSPECTION BY A REPRESENTATIVE OF ISR
11.1. The ISR technical team and/or an inspection body appointed by the
ISR ("The Inspector") shall the privilege to inspect the
manufacture processes and/or the Rail Fastening System KS,
during or after production.
11.2. It is the manufacturer’s responsibility to guarantee dimensional
accuracy and to ensure that the inspection is carried out with the
appropriate measuring instruments.
11.3. The Manufacturer shall be responsible to coordinate inspection
process time table with The Inspector in accordance to the delivery
date defined in the purchase order.
11.4. The Manufacturer shall extend, to The Inspector, all necessary
assistance and cooperation, and shall give access to all test records,
calibrations and calculations that contribute to the final results.
11.5. All the gauge/measuring instruments for manufacture verification
and inspection of The Rail Fastening shall be made available by
The Manufacturer to The Inspector on request.
11.6. The Manufacturer shall provide, for every purchase order, all Tests
results to The Inspector on request.
11.7. The Calibration Certificates of the gauge/measuring instruments
signed shall be made available to The Inspector on request.
12. MARKING
Each of the Rail Fastening System KS Sub-Component shall be
inscribed with at least the following marks:
The product identification type;
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The supplier mark or name;
The month and year of manufacture.
13. PACKING AND DELIVERY
13.1. Each rail fastening metal components shall be packed separately.
Sub-Components shall be packed in wooden boxes tied by metal
bands.
The dimensions of the wooden shall be according to EN standard,
to enable maximum effective storage capacity in containers.
It shall be possible to put at least 3 wooden boxes one on the other.
wooden boxes will be tied to one another, and to wooden platform
by metal bands, and all shall be wrapped with Stretch wrap.
Each package gross weight shall not exceed 1 [ton].
Each package shall be labeled with the following details:
o Component name and type;
o Production batch number;
o date of manufacture;
o Component barcode;
o Component quantity in box;
o Gross and net weight;
o Manufacturer recognition number or name;
o ISR recognition number;
o ISR order number;
o Ordinal number on the packing list.
The labeling shall be with black letters and shall be on 3 spots on
the package (one on top of the package and the two others on the
sides).
The packed Double Spring Washers and Washers shall not adhere
to one another.
13.2. Each order shall be delivered with certificate that the components
has manufactured in accordance with the Technical Specifications
E-01-0001.1 and the supplier drawing.
14. LIST OF DOCUMENTS TO SUBBMIT TO INSPECTOR
14.1. The inspection and acceptance of rail fastening system KS will be
performed be ISR representative, an authorized company
(inspector), according to ISR instructions.
14.2. The manufacturer shall submit copies of all the drawings pointed
out in paragraph 6 above.
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14.3. The manufacturer shall add to the drawings the relevant technical
descriptions of the sleeper and all fastening accessory components,
and certificate for sleepers steel type.
14.4. The manufacturer shall notify which standard and process
description will be used for carried out tensile and bend tests on
steel casts and test reports.
14.5. The manufacturer shall state the nature and main characteristics of
the steel making process.
14.6. The manufacturer shall submit a certificate confirming that the
non-metallic materials comply with the requirements.
15. LIST OF FILES (in PDF Format) TO BE SUBMITTED
WITH BIDDER'S PROPOSAL
15.1. The Rail Fastening System KS installation and maintenance
manual. (see section 4.6)
15.2. Detailed List of subcontractors, which are the Sub-Components
Manufacturers, shall be submitted (Name and Factory address, E-
mail, experience). (see section 4.7)
15.3. The Tension Clamps protective coating type and the relevant
standard. (see section 5.1.2)
15.4. The Technical Drawings of the assembled unit (the interface
between the Rail Fastening System KS and the sleeper), based on
the sketches in the Technical Appendixes B-I. (see section 6.1)
15.5. The Technical Drawings of each Sub-Component, based on the
provided sketches in the Technical Appendixes C-I, and the
Technical requirements for each Sub-Components in section 4.
(see sections: 5.1.3; 5.2.3; 5.3.3; 5.4.3; 5.5.3; 5.6.3; 5.7.3 and 6.2)
15.6. The drawing of the Rail Fastening System KS overall dimensions
avoiding interface with vehicles including track maintenance
vehicles in accordance with EN13481-3 section 5.7. (see section
6.4)
15.7. The calculations showing the maximum variation in static track
gauge which can arise from the Rail Fastening System KS. (see
section 6.5)
15.8. The Rail Fastening System KS production control management
system procedures. (see section 7.2)
15.9. The Rail Fastening System KS manufacturer ISO9001 certificate.
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(see section 7.2).
15.10. The Qualification Test Report carried out by the Laboratory on a
complete fastening assembly of Rail Fastening System KS in
accordance with EN13481-3 sections 5.1-5.9; 5.11; 6 and
EN13146 parts: 1-10 (excluding parts: 3; 5 and 8). (see section 8.3)
15.11. The experience and capability, to perform all the Qualification
Tests, of the Alternative University Laboratory. (section 10.1.1)
16. LIST OF FILES (in PDF Format) TO BE SUBMITTED
WITH EVERY ORDER
16.1. The Sub-Components Quality Tests results, as specified for each
Sub-Component. (see sections: 5.1.4, 5.2.4, 5.3.4, 5.4.4, 5.5.4,
5.6.4, 5.7.4)
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TECHNICAL APPENDIX A - ISRAEL CLIMATE AND
ENVIRONMENTAL CONDITIONS
A.1 Climate and Environmental Conditions
Max. ambient temperature 50 °C (shade)
Min. ambient temperature -5 °C
Relative humidity 10 to 90 %
Altitude -400 to +800 meter
Sunny 3300 hours per year
UV Radiation 360 to 600 MJ/m² per year
Rainfall 400 to 800 mm/year
A.2 Dust Conditions in the atmosphere
Maximum Half Hour
Value*
Maximum Daily
Value*
Average
NOx 1064 560 71
SO2 780 260 21
O3 312 143 84
Suspended
Dust
- 350 100
*(Microgram per m³ atmosphere)
A.3 Suspended Particulate Matter (SPM)
Particle size to 0.5-1 micron
A.4 Sea Salt Concentrations in the Atmosphere
Salt Element Na* Cl* SO4*
Position Dry Wet Dry Wet Dry Wet
Sea Air at Coast Line 7.3 16.0 12.0 22.0 5.3 7.0
600 m from Shore 3.1 4.8 4.2 7.9 1.9 2.0
6000 m from Shore 1.1 1.4 1.5 1.7 1.3 1.4
* (Micrograms per m³ atmosphere)
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TECHNICAL APPENDIX B - RAIL FASTENING KS SYSTEM SET
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TECHNICAL APPENDIX C - TENSION CLAMP SKL W12
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TECHNICAL APPENDIX D - BASE PLATE
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TECHNICAL APPENDIX E - DOUBLE SPRING WASHER Fe6
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TECHNICAL APPENDIX F - SLEEPER SCREW Ss8
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TECHNICAL APPENDIX G - T-HEAD BOLT Hs32-55
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TECHNICAL APPENDIX H - WASHER Uls6
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TECHNICAL APPENDIX I - RAIL SEAT PADS
Rail Seat Pad Zw687/148/165 for 60E1 and 60E2 Rail Profiles
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Rail Seat Pad Zw-138/165 for 54E1 and 50E6 Rail Profiles