Rail technical guide
Rail technical guide
Contents 03 Introducing ata Steel 04 Investment and innovation 06 Steelmaking and rolling 08 esting, inspecti on and fnishing 10 Product range and applications 14 Much more than rail 16 rade selection 18 echnical services 19 echnical data
II AA S As a leading global steelmaker, ata Steel combines metallurgical expertise with rail-industry knowledge and a collaborative ethos, enabling it to manuacture fnished steel products that directly address customer needs. Tata Steel – setting the global standard in steelmaking ata Steel, ormerly known as orus, is one o urope’s largest steel producers. We serve many dierent and demanding markets worldwide, including rail, aerospace, automotive, construction, energy and power, and packaging. ur primary steelmaking operations in the K and the etherlands are supported by a global sales and distribution network. Innovation and continuous improvement are at the heart o our perormance culture. We aim to create value by oering a sustainable and value-added steel product range supported by unrivalled customer service. By working in partnership with you, we fnd the best solutions to meet your needs and help your business to perorm.
Supporting rail industry growth and development he company’s drive or innovation and market leadership is clearly maniested in its rail manuacturing operations. Building on 140 years o rail production expertise, the company today works closely with rail customers to understand the demands o the sector and develop products that directly address those needs. hat means ata Steel is playing a central role in helping the rail industry rise to the challenges o higher trac volumes, heavier axle loads and aster train speeds. As a diversifed steel manuacturer, ata Steel not only supplies specially designed, high-perormance rail products, but also a wealth o structural steel components to support all rail sector construction and engineeringprojects.
ur uropean operations are a subsidiary o ata Steel roup, one o the world’s top ten steel producers. With a combined presence in nearly 50 countries, the ata Steel roup including the urope operations, ata Steel hailand and atSteel Asia, has approximately 80,000 employees across fve continents and a crude steel production capacity o over 28 million tonnes. 02
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Rail technical guide
IVSM A IVAI ontinuous investment in plant, technology, research and development, combined with our unrivalled metallurgical knowledge and track design expertise, ensure that ata Steel delivers the high-perormance rail demanded by today’s rail operators.
ata Steel has rail manuacturing expertise stretching back 140 years. oday the company manuactures the highest quality steel rails or some o the most arduous service conditions in the rail sector. Since 2000, we have invested more than £160m (€210m) in our advanced rail manuacturing acilities at Scunthorpe in the K and Hayange in France – ensuring that we remain at the oreront o rail innovation, perormance and value, always working in close partnership with our customers. Both o our mills eature state-o-the-art equipment including servo-stands allowing high dimensional accuracy rotary stampers to uniquely identiy each rail. his allows complete traceability, rom steelmaking to the fnished product. omputer-controlled cambering operations installed on precision-engineered cooling banks, and dual plane roller straighteners ensure excellent straightness and atness while maintaining low residual stress within the rail. Scunthorpe invests in steelmaking, rolling and fnishing Investments in steelmaking and casting at Scunthorpe enable us to produce the quality and quantity o bloom eedstock required or both o our rail rolling mills. At Scunthorpe, a major enhancement to the existing rolling mill saw the introduction o a new urnace and a close-coupled seven-stand fnishing mill train – a world frst or rail rolling.
dimensional accuracy and rails totally ree o surace or metallurgical deects. he service centre enables us to produce rails up to 120m long with precisely controlled properties that meet our customers’stringent specifcations. A state-o-the-art welding plant means we can produce rails up to 216m long or delivery and installation in one piece – meeting the industry’s need or longer rails and simplifed supply chains. Hayange invests in long length heat treat rail capability Investments at Hayange in France have enabled this dedicated rail manuacturing acility to produce 108m-long heat treat rails. Advanced heat treatment machinery is able to produce our ultra wear-resistant micro head hardened (MHH) rail, designed or heavy haul and high-duty track environments, as well as standard heat treated grades according to the uropean or American standards. ails with hardness values above 400HB can now be manuactured here, while the unique patented heat treatment creates rails with exceptionally low residual stress levels. he technique or universal rolling o rails was invented at Hayange to deliver the precise dimensional consistency and accuracy required or high-speed tracks, as well as complex-shaped grooved rails or urban networks. he technique has been adopted and urther developed at Scunthorpe. It has proved so successul that, in April 2007, SF broke the world train speed record on the new French V st line constructed using ata Steel universal-rolled rails.
A new rail service centre has been constructed to carry out essential rail fnishing operations using the world’s best available technology, including a ull range o non-destructive testing () systems to ensure exceptional
Process innovations and product development initiatives at ata Steel are ocused unwaveringly on delivering the high-perormance rails required to support advances in train technology, as well as meeting the longer in-service product lie and reduced maintenance costs demanded by rail network operators. 04
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Rail technical guide
Rolling he ata Steel rolling mills at Scunthorpe and Hayange use the latest process technology, computer modelling, computer-controlled heating and cooling, and novel roll-pass design to produce exceptional quality rails.
SMAKI A I
6 5 4
Steelmaking he Scunthorpe integrated steelmaking plant produces eedstock or a diverse range o steel products. he precision-controlled steelmaking process delivers only the highest-grade, consistent-quality steel blooms or our rail rolling mills. 4 3
2
1 Blast urnace Iron ore is reduced with coke in blast urnaces. he liquid iron is treated in desulphurisation units. Hot liquid iron with low levels o residual elements is the essential eedstock or heavy-duty rail steel.
Basic Oxygen Steelmaking (BOS) converters iquid iron is refned through the controlled oxidation o carbon and other elements in 300-tonne capacity oxygen steelmaking vessels called converters. he entire steelmaking operation is precisely controlled using advanced computer sotware and intelligent processcontrol systems.
Secondary steelmaking Secondary steelmaking takes place in three ladle arc urnaces and two H degassers. he desired steel chemistry is achieved by the careul addition o alloying elements to the molten steel. emperature control is essential to ensure low levels o segregation in the cast bloom. he H recirculating degassers reduce hydrogen and oxygen content in the steel.
Continuous casting ontinuous bloom casting,combined with tight control over alloy additions, ensure the internal integrity o the steel by eliminating oxide inclusions.
3 2 1
5 Qualitycontrol Quality is assured by closely controlling every stage o steel making and casting, with regular sampling and analysis o steel chemistry and other properties.
Re-heating Blooms are re-heated in natural gas urnaces. onsistent product dimensions and surace quality are assured by tight control o rolling temperatures.
Descaling High-pressure descaling beore and during rolling ensures a high standard o surace fnish. Surace quality is monitored using a hot surace inspectionmachine.
Rolling olling begins in two accurately controlled roughing and intermediate stands, ollowed by a multi-standuniversal fnishing train (see diagram below).
Branding and stamping uring the fnal rolling pass, rails are relie-branded with the rail profle, steel grade and year and site o manuacture. Ater leaving the fnishing stand, the rails are hot stamped with a unique identifcation mark – or permanent traceability.
Sawing and cooling olled profles are hot cut to standard lengths, then transerred to cooling banks. hey are pre-cambered to compensate or the natural curvature that occurs during the cooling process.
Straightening omputersynchronised horizontal and verticalstraightening machines produce the ultra-straight, ultra-at rails with low residual stresses that are essential or high-speed rail tracks.
ecentinvestments in mould electromagnetic stirring and dynamic spray control ensure cast bloom consistency, with minimalsegregation and no hinge, side or corner cracks.
Universal rolling Universal rolling of rails was pioneered by Tata Steel’s Hayange works. Four rollers are positioned on all four sides of the steel feedstock, rather than the conventional pair of rollers in a two-high rolling stand – delivering exceptional dimensional accuracy and strengthening of the rail head.
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Rail technical guide
SI, ISPI A FIISHI he advanced testing and fnishing systems that complete the ata Steel rail manuacturing process ensure that all rail products meet the high standards required or all rail applications – rom high-speed and heavy-haul networks to urban and industrial railways. Rigorous tests or complete qualityassurance An array o technically advanced testing and inspection equipment ensures that every rail meets customer specifcations and is ree rom any internal or surace imperections that could impede perormance or reduce service lie. ddy current testing is used to detect any surace imperections that exceed specifcation limits. ails also require a uniorm internal metallurgical structure to ensure strong perormance, and any irregularities that could adversely aect the rail’s in-service lie are detected using in-line ultrasonic testing. Any deects identifed are checked manually using portable ultrasonic equipment. A cold profle gauge, installed in the non-destructive testing () lines, continuously measures rail dimensions. aser beams are used or optical sectioning o the rail, and sophisticated sotware analyses pictures taken o all rail dimensions by an array o cameras so that dimensions can be careully controlled. o meet the extreme straightness requirements o high-speed tracks we use laser technology to measure rail surace and side-o-head atness and straightness, ensuring rails meet all customer and statutory specifcations.
08
Finished to individual customer specifcations ails are fnished by cutting to length or each customer order. Sawing and drilling are carried out by high-speed combined machines that give the greatest accuracy. ther fnishing processes include: • rail coating or corrosion protection ail destined or corrosive or harsh environments, such as coastal routes, tunnels, level crossings or marine environments can be protected using corrosion-resistant rail coatings to deliver an extended service lie. • extensive acceptance testing Acceptance tests can be carried out to individual customer specifcations, in the presence o the customer i requested. hese tests can include hardness, tensile, decarburisation, segregation and steel cleanness assessments.
Reliable,on-time delivery – worldwide ata Steel plants are strategically located or ast, ecient delivery o rail products worldwide, using road, rail, river or marine transport. Welded rails up to 216m long are despatched rom Scunthorpe on specially designed trains able to handle and directly ooad these extended rail lengths. ur proven and ecient despatch processes ensure that delivery costs are minimised. omplete supply chain control enables us to make just-in-time deliveries that acilitate ecient and timely track replacement and minimise disruption to rail users.
• seamless rail welding ata Steel leads the market in rail welding expertise, having developed and patented the ‘invisible’narrow heat aected zone weld. In the K, the rail service centre’s integral welding plant enables rail lengths o up to 216m to be produced as part o the rail fnishing process. he ash butt welding method used creates a strong weld made purely o the parent material, providing consistent steel properties along the entire 216m length.
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Rail technical guide
P A A APPIAIS he wide spectrum o track and trac conditions ound in the modern railway environment is matched by ata Steel’s comprehensive range o steel rail products – ulflling every demand o the international railway industry.
ur technical team is available to provide advice and support, helping you to optimise your rail selections. ail products and grades can be matched precisely to track conditions, track types, environmental conditions and a host o other variables to ensure that every rail we deliver provides optimum perormance throughout its service lie. High-speed railways Long,straight,at,atigue-resistantrail orrecord-breakingperormance. High-speed railways oer benefts in saety, environmental perormance and passenger comort over road and air transport. racks are usually dedicated to high-speed trac, comprising predominantly tangent and large radius curves. he challenge or rail manuacturers is to provide consistency in long, straight and at rails, combined with dimensional accuracy and steel integrity to deliver trouble-ree, decades-long service lie. he principal causes o degradation in high-speed rail are: • Vertical and side wear • olling contact atigue (F) • iscrete deects such as squats or belgrospies
The Tata Steel products suitable or high-speed railways are: Tata Steel product grade
Key attributes
Customer benefts
R260 (and other standard grades)
Class A straightness. Class X dimensions.
Cost-eective standard rail with typical service life of approximately 30 years.
Heat treated grades R350HT/ R350LHT
Increased resistance to wear and RCF compared to R260.
Increased life in track with tighter curves.
HPrail
Increased resistance to wear and RCF.
Wear and RCF resistance where this impacts rail life. Reduced grinding frequency.
Bainitic rail B320/B360
Highest resistance to RCF.
Controls RCF with reduced grinding frequency. Used for switches and crossings and other high RCF areas.
Sogenox
Achieves perfect electrical contact between rail and train wheel in areas of low trac.
Maintains robust signalling and prevents premature rusting of the rail head.
Heavy-duty railways Hardened rails or unrivalled wear resistance in extreme conditions. High-strength rails are required or tracks subject to very high loads and extreme wear stresses. hese tracks include those used by trains with very high axle loads (25-35 tonnes) and high annual gross tonnage. Many heavy-haul rail operators have recognised the need to introduce high-perormance rail to deliver longer lie and reduce lietime costs. Speeds on these tracks are relatively low and so wear resistance determines the requency o rail replacement.
The Tata Steel products suitable or heavy-duty railways are: Tata Steel product grade
Key attributes
Customer benefts
AREMA 325 HB intermediate strength
Good wear resistance.
Proven, predictable performance – widely used on heavy-haul tracks.
HPrail
Improved wear resistance and RCF resistance compared to AREMA 325HB.
Extended rail life in areas where RCF or wear are the main causes of degradation.
MHH
Highest resistance to wear and plastic deformation, with very low residual stress.
MHH provides the most wear-resistant rail for the most arduous conditions.
he principal causes o rail degradation are: • Side and vertical wear • Plastic deormation • olling contact atigue (F) • iscrete deects such as squats
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Rail technical guide
Mixed trafc railways Full range o rail grades each tailored or specifctrack conditions. onventional speed mixed trac railways have the dicult task o optimising track perormance or the mix o relatively high-speed passenger trains and slower, high axle weight reight services. evertheless, inrastructure managers need to reduce the lie cycle costs o track maintenance by extending rail component lie. he key causes o rail degradation in mixed-use railways are: • Side and vertical wear – rate increases with decreasing track radius • olling contact atigue (F) • iscrete deects such as squats • Plastic deormation o low rail
Tramway systems The Tata Steel products suitable or mixed-use railways are: Tata Steel product grade
Key attributes
R200
Relatively soft grade promoting rapid wheel-rail prole conformity to reduce contact stresses.
May reduce susceptibility to discrete defects such as squats on tangent track.
R260
Increased rail life compared to R200.
Used on tangent, large radius and low-tonnage track.
Heat treated R350HT/R350LHT
Increased resistance to wear and RCF compared to R260.
Increased life in track with tighter curves.
HPrail
Increased resistance to wear and RCF compared to R260.
Ideal for transitions and curves of less than 3,000m for: – wear and RCF resistance – control of low rail plastic deformation – reduced grinding frequency
MHH
Finest pearlitic microstructure with high Ideal for tight radius curves for: resistance to wear and RCF. – wear and RCF resistance Very low residual stress. – control of low rail plastic deformation – reduced grinding frequency
Sogenox
Achieves perfect electrical contact between rail and train wheel in areas of low trac.
Maintains robust signalling and prevents premature rusting of the rail head.
Metro railways Resilient rail grades to withstand high-requency trafc and tight curves. Although metro systems are characterised by lighter axle loads than their mainline counterparts, they generally comprise larger proportions o tighter radius curves, more requent stations, a larger number o axle passes and greater trac density. he combination o these track and trac characteristics creates very complex and demanding stress conditions at the wheel-rail interace. he key causes o rail degradation in metro railways are: • Side and vertical wear – rate increases with decreasing track radius • orrugation • olling contact atigue (F) • Plastic deormation o low rail
Specialist rails or quiet,wear-resistant operation and easy maintenance.
Customer benefts
Most modern tramway networks comprise both embedded and ballasted track in which the benefts o the much lower axle loads are more than eroded by very tight curve radii, as low as 15m, and steep gradients. qually, the requency o passenger service and the need to share parts o the inrastructure with other road users places unusually demanding conditions on the rail. he key causes o degradation to grooved and at-bottomed rails in tramway systems are: • Side wear (in addition to gauge corner and side wear on tight radius curves, grooved rails also experience wear to the keeper section o the adjacent rail) • Vertical wear – since side wear is weld restorable, rail lie is determined by the magnitude o vertical wear • orrugation – inuenced by a range o track system eatures
The Tata Steel products suitable or tramway systems are: Tata Steel product grade
Key attributes
Customer benefts
R200 and R220G1
Relatively soft grades with baseline level of wear resistance.
Traditionally used for tangent track or very shallow radius curve track experiencing little or no corrugation and low rates of vertical or side wear.
R260
Standard grade with greater wear resistance than R200 and R220G1 with the added benet of being weld restorable using the Tata Steel process.
Improved life cycle cost option (with weld restoration) for all track of <100m radius. Weld reparable for second or third life extension.
Grooved rails:
High perormance Microstructurally engineered steel grooved rail giving higher resistance to wear than grades with higher levels of hardness.
Flat-bottom rail (Vignole): R260
Standard grade with a hardness level to give baseline wear resistance and rail life.
Generally suitable for all larger radii or tangent track.
HPrail
Increased resistance to wear and rolling contact fatigue.
Lower life cycle cost option for all track of <100m radius, but also suitable for larger radii track.
Crane rail The Tata Steel products suitable or metro railways are:
Strong,hard-wearing special rail profles.
Tata Steel product grade
Key attributes
R200
Relatively soft grade promoting rapid wheel-rail prole conformity to reduce contact stresses.
Suited to tangent or shallow radius curve track experiencing little or no corrugation, low vertical wear but susceptible to discrete squat defects.
Increased rail life compared to R200.
Used on tangent, large radius and low-tonnage track.
R260
Customer benefts
HPrail
Increased resistance to wear and RCF compared to R260.
Ideal for transitions and curves of less than 3,000m for: – wear and RCF resistance – control of low rail plastic deformation – reduced grinding frequency
MHH
Finest pearlitic microstructure with high resistance to wear and RCF. Very low foot residual stress.
Transition and tight radius curves, generally <1,000m, where rail life is curtailed by wear and RCF.
ata Steel supplies a range o special crane rail profles, manuactured to I 536 part 1. Six sizes o rail are available in three dierent specifcations to meet customer tensile strength requirements – with minimum strengths ranging rom 690/mm to 880/mm. he six crane rail sizes we supply are shown in the table:
The Tata Steel products suitable or cranes in all applications are: Rail
Kg/m
K
B3
B1
H1
H2
F3
R1
R6
A65
43.1
65
38
175
75
34
10
6
5
A75
56.2
75
45
200
85
39.5
11
8
6
A100
74.3
100
60
200
95
45.5
12
10
6
A120
100.0
120
72
A150
150.3
150
80
220
150
64.5
14
10
6
MRS87A
86.8
101.6
34.9
152.4
152.4
50.8
31.75
8
12.7
220
105
55.5
14
10
6
All dimension are in mm. Quotations for other sizes and specications available on request. Crane rails are normally supplied in 12m cold sawn lengths, with a cutting tolerance of + 100 / – 0 mm. Other lengths are available.
Diagram or A65, A75, A100, A120, A150
Diagram or MRS87A K r1
h2
K r1 h2 h1
h1
b3
b3 f3
r6 b1 12
Lowest life cycle cost option (with weld restoration) for all track of <100m radius. Increased wear resistance and weld repairability provides the most cost-eective solution for tight curves. Also suitable for all larger radius track.
f3
r6 b1
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Rail technical guide
MH M HA AI
As a major steel manuacturer, ata Steel produces a host o steel products or construction and engineering applications in the rail industry.
SilentTrack ®
Railcote®
Steel sleepers
Railwaystructures
Reduces overall train pass-by noise by 3-7 dB (A).
Corrosion-resistantrail coatingor harsh environments.
Cost-eective,long-lie, easy-install steel sleepers.
Precision-manuacturedcomponents or constructionand engineeringprojects.
ata Steel has developed Silentrack ® to help rail operators save costs on lines that pass through urban areas where noise levels must be minimised. Silentrack ® uses sound absorbers on the rail web and upper part o the oot to reduce noise – eliminating the need to construct expensive noise-abatement walls alongside the tracks.
For harsh environments where tracks could be subject to heavy wear or corrosion, ata Steel can supply rails treated with ailcote – a high-purity zinc coating ideal or tracks in tunnels, at level crossings and in marine environments.
Steel sleepers oer savings on installation time and cost due to their low weight, stackable design and reduced ballast requirement. hey oer improved in-service perormance too, through enhanced lateral stability and reduced maintenancerequirements.
As a major, diversifed steel producer, ata Steel manuactures a vast array o steel products used throughout the rail industry.
Steel sleepers have a typical lietime o 50 years and generally have lower maintenance costs over this time. hey can be designed to overcome some major engineering challenges. For example, lower height construction can be achieved by eliminating level-adjustment problems in tunnels, as well as over underpasses and can accommodate platorm constraints. ata Steel sleepers are compatible with all modern astening systems, including Pandrol, Vossloh and abla.
Structural sections, tubes and steel cladding can be used to construct the ull range o railway buildings, rom stations to oce blocks. hese essential structural components oer all the benefts o long lie, high strength, dimensional accuracy and ease o installation that make steel the frst-choice building material or today’s sustainable construction industry. Steel sections are also used to construct catenary gantries on electrifed railway lines, as well as signalling gantries, bridges and other track-side structures. Modular steel platorms provide a ast, cost-eective way to construct train platorms, even in the most challenging site conditions. he use o standardised, lightweight galvanised steel components allows these systems to be installed quickly and with minimal noise and waste – creating a robust, long-lasting solution suitable or all platorm profles. Modular steel construction can also be used to create entire stations quickly, cost eectively and sustainably.
Please contact us at
[email protected] or more inormation about any o our rail and related steel products. 14
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Rail technical guide
A SI ata Steel took a leading role in Innotrack, a uropean project that produced a comprehensive guideline or the selection o rail grades. We have urther developed the rail grade selection process by combining knowledge o degradation mechanisms with the metallurgical attributes o rail grades, helping customers to maximise rail lie.
The graph opposite illustrates the Tata Steel grade selection process. Area 1 represents very tight curves requiring the most wear-resistant steel combined with eective lubrication to maximise rail lie. he recommended grade is our low stressed MHH rail which combines the highest wear resistance with good oot atigue properties. Area 2 is where both wear and rolling contact atigue (F) are relevant degradation mechanisms. ypically these conditions occur on track radii o around 700m to 2,500m on track that experiences a range o vehicle types. he degradation rate depends on the proportion o more damaging stier vehicles in the trac mix and the range o speeds. HPrail® is highly recommended or use in these conditions
Generic grade selection graph or European mixed trafc High
n o i t a d a r g e d o t y t i l i b i t p e c s u S
1
2
4
Wear:
Wear and F:
MHH
HPrail® or low stress heat treat
nexpectedly high degradation levels – explore root causes*
Key
3
ow degradation levels: R260 ow
Sharp
Premium products should be used to address high degradation whenever this occurs; this is dependent on the inrastructure and rolling stock and so actual perormance may deviate considerably rom the typical wear and F lines. 16
Curvature
epresents typical wear perormance against track radius epresents typical F perormance against track radius
MHH A patented heat treatment process at Hayange creates a range o rail products with enhanced hardness, including the world’s most wear-resistant micro head hardened (MHH) grade. As well as increasing steel hardness, the heat treatment creates rail with extremely low residual stresses delivering a step change in resistance to oot atigue.
Shallow
We are committed to working in partnership with customers and are happy to help you select the optimum grade or your track requirements.
HPrail® A metallurgically engineered steel with superb resistance to wear and rolling contact atigue, to maximise rail lie and reduce grinding requirements.
but the use o low stress heat treat rail also provides excellent perormance, especially when improved oot atigue properties are required e.g. areas prone to oot corrosion. Area 3 represents an area where there are low levels o degradation, which is oten seen on near tangent track operating with a wellmanaged rail wheel interace or where there are low levels o trac running on the line. In this region the current rail solution should be maintained unless opportunities or step change cost reductions could be identifed e.g. i grinding requency is high, it may be possible to reduce or eliminate this expense using the appropriate premium grade rail.
Area 4 is where degradation is above acceptable levels on gentle curves or tangent track. *he root cause o degradation should be explored as best practice management o the rail/wheel interace might oer the most cost eective solution e.g. profle management, lubrication, grinding. se o premium grade rail can extend lie e.g. HPrail® i wear and F are present or bainitic rail to minimise the grinding requency i F is the main concern.
Bainitic rail ow carbon carbide-ree bainitic rail oers excellent resistance to rolling contact atigue. It is proven or switch and crossing applications and shallow radius track with high susceptibility to rolling contact atigue. Tata Steel makes the ull range o steel grades in compliance with euronorms, AREMA and the specifcations o all major railways.
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Rail technical guide
HIA SVIS C Y
he rail technology specialists at ata Steel oer a comprehensive range o services to help improve operational eciency and network integrity on both light rail and heavy rail networks.
HIA AA
X
X
H
A
Y
ur unrivalled rail and metallurgical knowledge, combined with world-class on-site laboratory acilities, enable us to conduct detailed materials and product testing on behal o customers. ur investigations can provide rail operators with the necessary approvals and inormation to guide uture development.
The range o rail technical and consultancy services available includes: Light rail ata Steel carries out detailed condition surveys and provides reports covering all aspects o fxed inrastructure. his eectively benchmarks the assets by, or example, assessing rail degradation due to wear and corrugation. Heavy rail We can advise network operators on the most cost-eective material selection and design or new track installations, as well as adding value to maintenance strategies or existinginrastructure. Metallurgy and materials technology xperienced metallurgists and materials technologists help to design and select track system components to meet specifc duty requirements. he team works closely with network operators and maintainers to enhance network perormance and saety. Failureanalysis ur extensive knowledge o rail steel metallurgy and understanding o racture mechanics enables us to provide a comprehensive range o investigative services to establish the root causes o ailure, as well as recommending corrective and preventative actions. Track system modelling ata Steel modelling specialists combine site inormation with proven track behaviour data, oering a ast, cost-eective method o track modelling. ur sophisticated modelling tools enable us to determine uture deects and consequences o uture track degradation, helping customers to develop cost-eective maintenance and renewal policies.
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Track monitoring ur multi-disciplined team has many years’ experience o monitoring the in-service perormance o rail networks. Monitoring techniques range rom detailed visual inspections to using precise instrumentation and non-destructive testing. he fndings can be used to identiy causes and rates o degradation, helping rail operators to develop appropriate techniques or controlling track quality. Weldingtechnology ur welding technology consultancy service helps customers to reduce weld maintenance costs and extend rail lie. We can develop welding schedules designed to control weld geometry, optimise weld process control and enhance process monitoring and analysis. Laboratorytesting We can conduct a range o standard laboratory tests to international standards, as well as designing and building bespoke test arrangements. hese provide customers with independent certifcation o the perormance o saety-critical railway components. aboratory testing can also be used to investigate the perormance o worn components.
Rail profle
Equivalent profle name
46E1
SBB I
46.17
145.00
65.00
14.00
125.00
1641.10
298.20
46E2
U33
46.27
145.00
62.00
15.00
134.00
1642.70
329.30
Assetmanagement ur theoretical and practical investigative techniques can be applied to enhance understanding o the in-service perormance o complete railway systems. his asset data can be used to support inormed decisions about inspection maintenance and renewal activities.
Section weight kg/m
46.66
Rail height mm (H)
142.00
Head width mm (C)
73.72
Web thickness mm (A)
14.00
Foot width mm (P)
120.00
Moment o inertia, Ixx cm 4
1605.90
Moment o inertia, Iyy cm4
46E3
NP 46
49E1
DIN S49
49.39
149.00
67.00
14.00
125.00
1816.00
319.10
50E1
U50E
50.37
153.00
65.00
15.50
134.00
1987.80
365.00
307.50
50E2
50EB-T
49.97
151.00
72.00
15.00
140.00
1988.80
408.40
50E3
BV 50
50.02
155.00
70.00
14.00
133.00
2057.80
351.30
50E5
50 UNI
49.90
148.00
67.00
14.00
135.00
1844.00
362.40
50E6
U 50
50.90
153.00
65.00
15.50
140.00
2017.80
396.80
52E1
52 RATP
52.15
150.00
65.00
15.00
150.00
1970.90
434.20
54E1
UIC 54
54.77
159.00
70.00
16.00
140.00
2337.90
419.20
54E2
UIC 54 E
53.82
161.00
67.00
16.00
125.00
2307.40
341.50
54E3
DIN S54
54.57
154.00
67.00
16.00
125.00
2074.00
54E4
–
54.31
154.00
67.00
16.00
125.00
2056.20
352.70
54E5
54E1HC
54.42
159.00
70.20
16.00
140.00
2308.10
416.30
55E1
U55
56.03
155.00
62.00
19.00
134.00
2150.40
418.40
56E1
BS113Ib
56.30
158.75
69.85
20.00
140.00
2321.00
421.60
60E1
UIC 60
60.21
172.00
72.00
16.50
150.00
3038.30
512.30
60E2
–
60.03
172.00
72.00
16.50
150.00
3021.50
510.50
Equivalent profle name
Section weight kg/m
Rail height mm (H)
Head width mm (C)
Web thickness mm (A)
Foot width mm (P)
Moment o inertia, Ixx cm 4
354.80
AREMA Rail profle
Noise and vibration monitoring oise and vibration is a concern or many tramway systems that operate in urban environments. ata Steel specialists can carry out detailed noise and vibration analyses, provide detailed reports and, where appropriate, recommend solutions or reducing noise or vibration.
P
EN13674-1 2011 Flat bottom rails >46kg/m
Momento inertia, Iyy cm4
100RE
–
50.35
152.40
68.26
14.29
136.53
2039.50
247.40
100CP-RE
–
50.85
153.99
65.60
14.29
136.53
2064.40
386.30
115RE
–
56.82
168.28
68.04
15.88
139.70
2726.30
445.60
115RE 10
–
56.98
168.28
68.00
15.88
139.70
2741.60
447.00
119RE
–
58.88
173.04
67.47
15.88
139.70
2971.90
449.50
132RE
–
65.39
180.98
75.17
16.67
152.40
3658.30
597.60
133RE
–
66.19
179.39
73.02
17.46
152.40
3589.00
601.00
136OP
–
67.17
185.74
74.01
17.46
152.40
3910.30
600.40
136RE
–
67.49
185.74
73.74
17.46
152.40
3921.10
601.60
136RE10
136.10
67.36
185.74
74.61
17.46
152.40
3920.90
601.00
136RE14
–
67.76
73.71
17.46
136CN04
–
67.62
186.53
73.74
17.46
152.40
3949.60
604.80
141RE
141AB
69.88
188.91
185.74
74.32
17.46
152.40
152.40
4180.50
3954.50
620.80
604.10
Other rail proles are available please contact us and we would be pleased to discuss your requirements. 19
Rail technical guide
C
C Y
Y
X
UIC,ASCE & other specifcations Equivalent profle name
Section weight kg/m
Rail height mm (H)
Head width mm (C)
Web thickness mm (A)
Foot width mm (P)
Moment o inertia, Ixx cm 4
Moment o inertia, Iyy cm4
BCK 40
40KDL
39.76
130.00
62.00
13.00
120.00
1139.00
243.00
80 ASCE
–
39.87
127.00
63.50
13.89
127.00
1101.10
258.10
85 ASCE
–
42.20
131.76
65.09
14.29
131.76
1255.80
288.70
90 RAA
–
44.48
142.88
62.81
14.29
130.18
1567.00
308.10
BS 90R
–
44.58
142.88
66.68
13.89
136.53
1587.30
333.70
43 CHINE
–
44.60
140.00
70.00
14.50
114.00
1481.00
258.00
BS 90 AM
–
44.91
142.88
67.17
13.89
127.00
1550.50
283.50
BS 95 N
–
47.26
147.64
69.85
13.89
139.70
1790.00
354.00
SAR 48
–
48.07
150.00
127.00
14.00
68.00
1855.00
323.00
50 CHINE
–
51.50
152.00
70.00
15.50
132.00
2027.00
375.00
IRS 52
–
51.74
155.97
67.07
15.48
136.13
2108.00
357.00
SAR 57
–
57.44
165.00
71.31
16.00
140.00
2648.00
442.00
AS 60
–
60.64
170.00
70.00
16.50
146.00
2926.30
489.60
60 CHINE
–
60.80
176.00
70.79
16.50
150.00
3216.90
524.00
122 CB
–
60.74
172.24
72.53
16.67
152.40
3065.10
528.90
124 JK
–
61.39
174.63
73.48
15.88
139.70
3164.10
483.80
R 65
–
64.87
180.00
73.00
18.00
150.00
3543.00
568.00
C
H X
X
H
Y
X
X A
H
Y P
Y P
Special rail sections
X
X
Y
P
Equivalent profle name
Section weight kg/m
Rail height mm (H)
Head width mm (C)
Web thickness mm (A)
54E1A1
A69,UIC54B, Zu UIC54B
68.95
129.00
70.00
40.00
147.00
1544.00
767.60
60E1A1
A73,UIC60B, Zu 1-60
72.97
134.00
72.00
44.00
140.00
1726.90
741.20
50E6A1
U59
64.98
50E6A2
U60
54.21
155.00
65.00
16.00
148.00
2213.00
497.40
54E1A3
54D20
68.62
129.00
69.91
32.50
145.00
1552.50
772.50
54E1A4
54D40
68.74
129.00
69.98
32.50
145.00
1560.50
771.80
60E1A4
60D
69.83
142.00
71.91
32.50
150.00
2025.80
764.40
60E1A5
60D40
69.95
142.00
71.98
32.50
150.00
2035.80
764.30
60E2A2
Zu60E2-40
72.78
134.07
72.03
44.00
140.00
1715.10
739.60
65.00
28.00
142.00
Moment o inertia, Ixx cm 4
2327.20
Moment o inertia, Iyy cm4
550.80
Rail profle
Equivalent profle name
Section weight kg/m
Rail height mm (H)
Head width mm (C)
Web thickness mm (A)
Foot width mm (P)
60E1T1
A61, UIC60C
61.11
142.00
72.00
28.00
150.00
Moment o inertia, Ixx cm 4
50E2T1
A63, EB63T
62.97
151.00
72.00
30.00
140.00
2166.00
493.20
54E1T1
A65, UIC54A
65.40
159.00
70.00
28.00
140.00
2513.80
504.10
60E1T2
A74, UIC60A
74.24
172.00
72.00
30.00
150.00
3301.40
615.30
Web thickness mm (A)
Foot width mm (P)
1866.50
Moment o inertia, Iyy cm4 519.90
X A
Y P
Rail profle
Equivalent profle name
Section weight kg/m
Rail height mm (H)
Head width mm (C)
Moment o inertia, Ixx cm 4
Moment o inertia, Iyy cm4
Equivalent profle name
Section weight kg/m
Rail height mm (H)
Head width mm (C)
Web thickness mm (A)
Foot width mm (P)
Moment o inertia, Ixx cm 4
BS95RBH
–
47.07
145.26
69.85
19.05
69.85
1458.00
171.00
35E1
Section 75 Conductor
–
75.17
138.00
89.00
22.50
140.00
2163.93
891.66
36E2
36kg (S-40)
36.59
128.00
58.27
13.00
115.00
1020.10
202.70
39E1
BS 80A
39.77
133.35
63.50
13.10
117.47
1204.90
219.60
Section 65 Conductor
–
40E1
S41 R14
40.95
138.00
67.00
12.00
125.00
1366.90
262.10
41E1
S41 R10
41.24
138.00
67.00
12.00
125.00
1382.10
265.30
45E1
BS 90A
45.11
142.88
66.67
13.89
127.00
1564.10
284.70
45E2
DSB 45
45.51
141.00
69.30
13.76
126.00
1535.90
297.00
102.00
T 52
–
52.41
100.50
MATRA
–
62.85
120.00
RATP
–
68.33
140.00
33C1
U69, UIC33, RL 1-60
32.99
92.81
89.00
70.00
45.00 12.00 80.00
70.00
677.04
Moment o inertia, Iyy cm4
EN 13674-4:2006+A1:2009 (E) – Flat bottom rails 27kg/m to 46kg/m
Rail profle
65.41
H
A
Rail profle
155.00
Foot width mm (P)
X
EN 13674-2:2006+A1:2010 (E) Switch and crossing symmetric thick web rails
C Y
Y
H
Y P
EN 13674-2:2006+A1:2010 (E) Switch and crossing asymmetric rails
Rail profle
X A
483.57
101.00
543.80
376.20
250.00
1998.00
2887.00
12.00
230.00
2518.90
2926.60
20.00
40.00
297.00
218.80
Xa
35.76
125.00
58.00
12.00
110.00
936.30
174.50
Other rail proles are available please contact us and we would be pleased to discuss your requirements. 20
21
Rail technical guide
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Care has been taken to ensure that this information is accurate, but Tata Steel Europe Ltd, including its subsidiaries, does not accept responsibility or liability for errors or information which is found to be misleading. Copyright 2013 Tata Steel
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RTG/LJ/ENG/V1/04.13 24
