Dual Gauge Turnouts

Presenter: Glenn Lorenz

Company: Vossloh Cogifer Australia

Date: May 2013

Location: Newcastle

Dual Gauge Turnouts are an integral element of linking state to state through the

various Dual Gauge rail networks within mainland Australia.

Vossloh Cogifer Australia is a designer and manufacturer of Turnouts and rail components in Australia and throughout Asia, VCA has been involved in Dual Gauge

Turnout design and manufacture since the inception of dual gauge lines in Australia.

Introduction

Broad Gauge / Standard Gauge Dual Gauge Turnouts.

Standard Gauge / Narrow Gauge Dual Gauge Turnouts.

Geometries and Configurations

Design Considerations.

Manufacturing Considerations.

Switch options and movement.

Crossing Design.

Guarding.

Fastening.

Introduction

Summary 1435mm

1067mm

762mm

610mm

1600mm

1435mm

1067mm

1000mm

1600mm

1435mm

762mm

1600mm

1435mm

762mm

1435mm

1600mm

1067mm

762mm

610mm

1600mm

1435mm

1067mm

Common Rail – is the rail opposite the dual rails, the common rail is always in use regardless of the trains bogey arrangement.

Dual Gauge Rails – The two parallel rails that run opposite the common rail.

Dual Gauge Turnout – Dual rails continue through on the straight or mainline track as well continuing through on the turnout or diverge leg of the turnout arrangement.

Mixed Gauge Turnout – Turnout on dual gauge line where the dual gauge does not continue through both legs of the turnout, either one or both of the turnout legs are single gauge. Some parts of the industry will refer to these also as Dual Gauge Turnouts.

Gauge Separation Turnouts – Turnout on a Dual Gauge Line, which splits the lines into two singular gauge lines.

Terminology

Dual (Mixed) Gauge Geometric Configurations.

LH Turnouts RH Turnouts

There are multiple Standard Dual and Mixed Gauge turnout configurations. For true dual gauge turnouts there are technically only the two types, 1 & 8.

Dual Gauge Turnouts

Dual Gauge Turnouts

• Australian rail networks, which have dual rail lines and dual gauge turnouts,

have different identifications for the same typical geometries.

Dual (Mixed) Gauge Turnout Identification.

Typical Broad/Standard Dual Gauge Turnout. Common Rail

Typical Standard/Narrow Dual Gauge Turnout.

Dual Rails

Distinctions between Narrow/Standard &

Standard/Broad Dual Gauge Turnouts

Generally the Standard/Narrow Dual Gauge turnouts present fewer problems with

both design and manufacture than the Standard/Broad Dual Gauge designs.

More standard componentry can be used for Standard/Narrow Dual Gauge

Turnouts.

Standard/Narrow Dual Gauge Turnouts enable the use of standard fastenings in

most areas.

The Standard/Narrow Double V Crossing is basically two standard crossings.

Switch movement for Narrow/Standard Dual Gauge Turnouts is essentially the

same for conventional turnouts.

Switch movement for Standard/Broad Dual Gauge is considerably limited.

Guarding for Standard/Broad Dual Gauge Turnouts provides problems, again due

to the limited gap between the gauges.

Rail profile chosen has a bearing on fastening decisions.

Standard/Narrow Dual Gauge Turnout

Broad/Standard Dual Gauge Turnout.

Distinctions between Narrow/Standard &

Standard/Broad Dual Gauge Turnouts

Many of the components which make up Dual Gauge turnouts are found in conventional

turnout designs. The areas which are unique to Dual Gauge turnouts are:

Inner and Outer Switch and Stock Rail assemblies.

Double V Crossing Assembly.

K Crossings.

Special Guarding.

Plating and Bearer requirements.

Standard Dual Gauge Turnout Componentry

Standard Dual Gauge Components

Dual Gauge Turnouts –

Switch Assemblies

Dual Gauge

Switch plates

Standard Switch

plates

Standard Heel Block

Assembly

Dual Gauge Heel

Block Assembly

Standard/Narrow Dual Gauge Switch assembly. Broad/Standard Dual Gauge Switch assembly.

Special Inner

Stock Rail

Special Guard

Special Outer

Switch Rail

Special

H Plate

Dual Gauge Turnouts

V Crossings

Wing/Heel Rail

Double V Crossing for a

Standard/Narrow dual gauge is

essentially two standard V crossings.

with a relatively minor modification to

join the two individual crossings.

The Fabricated Double V Crossing

for a Broad/Standard dual gauge

turnout requires design considerations

which include provision for broad and

standard flangeway clearances as well

as adequate guarding within the one

assembly.

Solid Cast Manganese Steel

Double V Crossings may be

considered a more suitable design

alternative to the fabricated type

Broad/Standard crossing.

K Crossings

K Crossings for Broad/Standard Dual Gauge

Turnouts show very little resemblance to a

Standard/Narrow K crossing.

Minimal distance between the dual rails.

Only one point rail can be accommodated in the

assembly

The K Crossing is required in a Dual/Mixed Gauge turnout

wherever the inner or outer dual rails cross over each other.

K Crossing for a Standard/Narrow Dual Gauge turnout is not

too dissimilar in appearance to the conventional K crossings in a

Diamond.

The major difference between the Standard/Narrow Dual Gauge

K and the conventional K crossings in a Diamond is the

noticeable absence of two housed rails.

K Crossing Assembly for Standard /Narrow Dual Gauge

K Crossing Assembly for Broad/Standard Dual Gauge

Switchable K Crossing

Switchable K Crossings provide a direct wheel transfer from the moveable point rail to the running

rails.

The Switchable K design provides a much improved wheel transfer over the fixed type K Crossings.

This design does not require point guarding.

The Switchable K design does require switch-operating gear to move the points.

Dual Gauge Plating

S/N Dual Guard Plate

Where possible plating should remains the same for Dual Gauge turnouts as conventional turnouts.

This is generally only possible for the common rail assemblies and the common rails.

For the dual gauge assemblies and rails, extended length plates are required to accommodate the

dual rails.

The dual rail plates require adequate bracing and provision to ensure the dual rails and assemblies are secured to the platework.

S/N Dual Guard Plate

S/N Dual Switch Plate

B/S Dual Plate 50kg

B/S Dual Plate 53kg

19mm Gap

38mm Gap

An essential element of any fixed nose crossing is to ensure the point noses are

adequately protected and the correct wheel path is maintained

Conventional guarding of dual gauge crossings for Standard/Narrow turnouts is possible

for most configurations.

Guarding for Broad/Standard Turnouts requires much more consideration with respect to

fitting of guards into limited positions due to the smaller distance between the dual rails.

Dual Gauge Guarding

Point Rails

Guarding For opposing K

Crossing Noses.

Dual Gauge Bearers

Design of Bearers is generally in accordance with conventional turnout bearers.

The length of the dual gauge bearer is based on the greater of the two gauges.

Structurally the bearer would be designed to accommodate the same forces as a conventional turnout.

As Dual Gauge turnouts have longer plates to support the dual track and assemblies, consideration must be given to fixing points of plates to bearer to ensure the fixing points are located and centred correctly on the bearer.

Special Dual/Mixed Gauge Assemblies

Common Rail Transfer:

The Common Rail Transfer simply swaps the common rail

from one side to the other whilst maintaining the dual gauge

line.

It is installed for a number purposes where transferring the

common rail is required:

Clearances with vehicles approaching platforms.

Leading into existing yards where the common rail is on the

opposite side.

Leading into gauge separation turnouts where the common

rail is required to be on the opposing side.

Close a loop where again the common rail needs to swap to

the opposing side of the line.

Special Dual/Mixed Gauge Assemblies

Gauntlet Switch.

The purpose of the gauntlet switch is to transfer rolling

stock from dual gauge track to gauntlet track.

The 3 rails on the dual track are converted into 4 rails for

the gauntlet track.

Once through the gauntlet switch the gauges run

independently of each other.

There is no common rail.

This provides both similar platform clearances for different

gauges.

Safe and comfortable access to passengers.

Special Dual/Mixed Gauge Assemblies

TR Type Gauge Separation

Turnouts.

There are a number of TR Turnout

configurations in service in the

Victorian Rail Network.

The majority are gauge separation

units.

They have fixed point transfer zones.

Speed through these turnouts is

minimal.

The transfer zones are often

produced using solid manganese

steel castings

Common Rail Dual Rail

Broad Gauge

Standard Gauge

BG Guard

Figure 30. TR4 Fixed Point Transfer

Special Dual/Mixed Gauge Assemblies

Typical TR Switch and Stock Assembly Replacement

Broad Gauge

Standard

Gauge

TR Replacement:

Currently a number of the TR Turnouts are being replaced with a more conventional Switch/Stockrail assembly.

Designed to be retrofitted to the existing TR Turnouts.

Increased speed through the transfer area.

No guarding is required.

Requirement of addition of switch operating gear to move the replacement switchblade.

Consideration must be given to signalling requirements.

Dual/Mixed Gauge Diamond:

There are a number of possible configurations for

diamonds.

If we assume the dual gauge line is Broad/Standard the

possible configurations are:

Dual through Dual.

Dual through Broad.

Dual through Standard.

Standard through Broad.

The same configurations occur with Standard/Narrow

Turnouts.

Special Dual/Mixed Gauge Assemblies

Can we replace Dual Gauge Turnouts?

Conclusion Dual gauge configurations are complex as

compared to standard turnouts and configurations.

Design and manufacturing issues of the Broad/Standard Dual Gauge Turnouts are greatly compounded as compared with the Standard/Narrow type Dual Gauge Turnouts.

The complexities of Dual gauge turnouts and lines also extend to maintenance, operations and signalling areas.

Dual Gauge Turnouts and configurations will continue play a part in linking state to state through the various Dual Gauge rail networks within mainland Australia.

Considering the sometimes complex nature of Dual Gauge Turnouts and configurations, their introduction has been relatively successful in assuring effective guidance of rail traffic on Dual Gauge Lines.

Dual Gauge Turnouts

Glenn Lorenz

Vossloh Cogifer Australia Pty Ltd