TECHNICAL SPECIFICATIONS

FOR
UIC54 SIMPLE TURNOUT

1. Introduction
1.1 General
This Specification shall be applied for the supply of R54 simple turnout concerning works
of Design, Manufacture, Inspection and testing for Railway Project in Indonesia, which
are used to ensure consistent products.

1.2 Applicable Standards and Specifications

All track materials and works for this specification shall be designed, manufactured and
performed in conformity with the latest revision of relevant Standards as follows.

 JIS (Japan Industrial Standards)

 UIC (Union International of Railways)
 ASTM (American Society for Testing and Materials)
 AREA (American Railway Engineering Association)
 AREMA (American Railway Engineering and Maintenance of Way Association)

1.3 Warranty period shall remain valid for 5 years

2. Scope Of Supply
2.1 The manufacturer quality certificate
The manufacturer shall operate an independently approved and audited quality
assurance system conforming to the requirements of ISO 9002 or higher level (ISO 9001).
The approval certificate is to be presented as an annex of the supplier's
qualification/bidding documents.

2.2 The Supply shall include

 All switch rails, stock rails and closure rails with rail fastenings
 Manganese crossing
 Check rail assembly
 Accessories including bolts, nuts, spring washers, joint bars, tie plates, fillers and
screw spikes
 PC sleepers
 Submissions of Technical Documents

2.3 Scope of Design and Drawing productions

The Contractor shall prepare standard layout drawings for Turnout with detailed drawings
for the major components giving leading dimensions and setting out data for installation.
3. Basic Specifications of Turnout
3.1 General

 Rails shall be set in vertical within turnout

 The track gauge shall be 1067 mm
 There shall be zero cant throughout the layout
 The standard sleeper spacing shall be 600 mm

3.2 Design Criteria

 Maximum train speed for design purpose shall be 120 km/hr

 Maximum cant deficiency is limited within 70 mm
 Turnout speed shall be maximum 120 km/hr in straight and ^0 km/hr in curved line
 The axle load of vehicle shall be 18 tons

3.3 Geometry
The basic geometries of turnouts shall be tan 1 : 12th
3.4 Trackforms
The turnout shall be supported on the PC sleeper in ballast track

3.5 Crossing
Mono block high manganese crossings should be produced according to UIC code 866-0

3.6 Sleeper
Sleeper shall be PC sleeper in accordance with AREMA-part 4-1996 and AREA-Chapter
10-part 1- 1996
3.6.1 Concrete
min. 150 mm cube compressive strength :
At 28 Days : 60 Mpa
At Prestressing : 30 Mpa
3.6.2 Steel
low relaxation prestressing force : 631 kN
3.6.3 Stirrups
Diameter 4 mm, low carbon steel wire MSW-8 (JIS G 3532). Tensile Strenght : 441-
932 Mpa
3.6.4 Weight
Approx. 128 Kg/meter
3.7 Rail fastening systems
The standard rail fastening systems of turnout shall be elastic fastening system.

This system chosen must give the stock rail the right elasticity with approximately 11,800
Newton elastically to absorb any impact due to overrunning.

3.8 Baseplate Anchorage

The holding down for each baseplate on PC sleeper shall be performed by bolts and nuts.

4. Technical Specification of major components

4.1 General

4.1.1 All proprietary components used shall be subject to be reviewed by the Engineer.
4.1.2 The major components shall incorporate materials and technical standards in
accordance with applicable specification. As for special materials to be required
and not to be specified herein they shall be of a general standard and the quality
shall be compatible with corresponding specification which shall be submitted to
the Engineer for review.
4.2 Rails

4.2.1 Stock rails shall be UIC54 profile with 900A grade head-hardened.
4.2.2 Closure rails shall be U1C54 profile with 900A grade head-hardened.
4.2.3 Running rails shall be UIC54 profile with grade 900A steel.
4.2.4 Check rails shall be UIC33 profile with grade 1100.
4.2.5 witch rails shall be UIC54B asymmetrical rail with min. 310 Brinell hardness with
standard grade 900A steel. The switch rail shall be forged to match the UIC54 rail
profile at the end.
4.3 Crossings

4.3.1 The detail specification of manufacturing and inspection for manganese crossing
shall be carried out in accordance with UIC866-0.
4.3.2 High manganese crossing should be welded to four pieces of rails by means of
flash-butt welding method as per drawings.
4.4 Insulated Joints
All insulated joints in the turnouts shall be Glued Insulated Joints with six (6) hole fish
plate glued to the UIC54 rail by synthetic resins, insulating insert, and high tensile bolts
tied strongly.
4.5 Distance Blocks or Fillers
The material to be used for distance block or fillers shall be in accordance with JIS G5501,
FC200 (Gray iron casting-class 3) conforming to the requirement as specified below.
4.5.1 Diameter as cast of test specimen: 30mm
4.5.2 Minimum tensile strength: 200 N/mm2
4.5.3 Maximum hardness, 223 HB
4.5.4 Distance blocks shall be ground if necessary during assembly to give the correct
fit against the web of the rail
4.6 Bolt
All bolts and nuts for fastening shall be galvanized with at least 8 µm thickness and flat
washers shall have a suitable coating as well.

5. MANUFACTURE
5.1 General

5.1.1 Turnout components shall be manufactured in accordance with the best

procedures applicable at the time and as reviewed by the Engineer prior to the start
of manufacture.
5.1.2 No part of the assembly shall be bruised or otherwise damaged during any
manufacturing or assembly operation.
5.1.3 All turnout components shall be machined and fabricated strictly to the drawings
and technical specification.
5.2 Tolerances of manufacturing and assembly
The turnout shall be assembled and manufactured according to the tolerances given in
Table 1.

5.3 Templates and Gauges

Templates and gauges used in machining, assembly of components and also marking
templates shall be checked and calibrated before manufacturing begins.

5.4 Machining of Switch & Crossing Rails

5.4.1 The method of holding the rails and components to a machine and the methods of
machining shall be such that the finished machined face shall follow the design
alignment.
5.4.2 Embossed rail information on the web covered by block faces or glued insulated
joints shall be removed by grinding.
5.4.3 No welds or joints shall be allowed within the sliding portion of the switch rail.
5.4.4 The design of the layout shall be such as to prevent the switch rail toes from lifting
into the path of an approaching wheel.
5.5 Cutting of Rails

5.5.1 Rails cut to length shall be cold cut square across the section. No part of the rail
shall be flame cut. Ad burrs shall be removed and the ends smoothed.
5.5.2 Rail ends which are to be cut to length on site or joined by welding shall not be
drilled.
5.5.3 Closure rails shall be cut to fit the appropriate space at 20 mm without gaps for
tight jointed fishplate or flash butt welds unless otherwise stated.

[TABLE 1] Tolerances of manufacturing and assembly

PART ITEM TOLERANCE

Rails cut to length ±5mm
General Tolerances
Perpendicularity of rail end (Vertical transverse) Within 1.0mm
Track Gauge Main Line ±1.0mm
(In Factory) Diverging ±1.0mm
Flangeway ±2mm
Turnout Lead ±10mm
Perpendicularity of switch ±2mm
Layout Tolreances Cross Level ±2mm
Longitudinal Level ±2mm
Toe Opening 0, +1mm
Turnout offset ±2mm
Baseline Offset ±2mm
Sleeper Spacing ±10mm
Height ±1mm
Drilled Holes Longitudinal position from datum end ±1mm
Diameter of bond holes ±1mm
Stock and Switch machining to gauge ±0.5mm
Top Planning of switch ±0.5mm
Switches Final Height at toe end ±1.0mm
Gap Between rail heads Max 1.0mm
Gap Between rail and distance blocks Max 1.0mm

5.6 Bending of Rails

5.6.1 Every endeavor must be made to remove machining marks, particularly those
indenting the surface in a transverse plane, around the point where a bend (set) is
to be made.
5.6.2 If a bend is to be applied to a rail which has had the foot machined, the corners
created by the machining shall have a 6 mm minimum radius applied to the outside
of the bend in such a manner that any marks produced in applying the radius are
in the longitudinal direction.
5.7 Drilling of Rails

5.7.1 All holes shall be drilled in accordance with the applicable specification.
5.7.2 No holes additional to those shown on the drawings or specified herein shall be
introduced into the rail to aid machining or assembly.
5.7.3 No holes other than bond holes shall be plugged.
5.8 Manganese Crossing
The casting of high manganese steel content shall be made in accordance with UIC
866 - O

6. Identification
6.1 Branding

6.1.1 Rail
Brand marks shall be rolled in relief on one side and in the middle of the web of
each rail, The brand marks in the rail shall be clearly legible and shall be 25 mm
high raised to at least 0.8 mm and 1.5 mm maximum.
The branding line to denote the steel grade shall be 40 mm in length for the long
branding line and 20 mm in length for the short branding line.

The brand marks shall include :

a. the identification of the mill,
b. the steel grade,
c. the last two figures of the year of manufacture,
d. the month of manufacture,
e. the profile identification.

6.1.2 Crossing
Each casting shall bear in relief, so as to be readily visible. These mark shall be
located as shown on drawings submitted for approval by the Contractor; they shall
be between 20 and 40 mm high.
The brand marks shall include :
a. The manufacturer’s mark,
b. The month of manufacture in Roman numerals and the last two figures of
the year of manufacture,
c. Reference number (order number or such other symbol as the purchaser)
may require,
d. The symbol of the rail profile and' angle of crossing, or simple the crossing
type symbol,
e. The serial number by crossing type and an arrow showing the direction of
casting the metal.
6.2 Host Stamping

In addition to the branding requirements of sub-clause 6.1 each rail shall be identified by
a numerical and/or alphabetical code system, hot stamped on the non-branded side of
the rail web by machine and each rail shall be hot stamped.
The figures and letters used shall be clearly legible and shall be 16 mm high. The letters
and numbers shall be on a 10o angle from the vertical and shall have rounded corners.
The stamping shall be between 0.5 mm and 1.5 mm in depth along the centre of the web.
The identification system employed shall be such as to enable the hot stamped marking
to be collated with :

a. the number of the heat from which the rail has been rolled,
b. the number of the strand and position of the bloom within the strand, and
c. the position of the rail within the bloom (A, 8, C………..; Z is reserved for the last
rail of the bloom).
Example : 1234 A 102
1234 : the number of the heat
102 : 1 : the number of the strand
02 : the position of the bloom within the strand
A : the position of the rail within the bloom

7. Assembling
7.1 General

7.1.1 The bottom of the rail providing a common support in an assembly shall be in the
same plane within 1mm.
7.1.2 The switch end stock rails shall bear evenly on all slide base piates when placed
on a plane surface, due allowance being made for baseplate camber.
7.1.3 When in the closed position, with the stock rail to the correct alignment, the
switch rail shall bear evenly against the stock rail throughout the length of the
head planning and against stopper or distance blocks without external aid.
7.2 Layout Requirements

7.2.1 Where turnout items are to be supplied complete with base plates, they shad be
built into the item before dispatch.
7.2.2 All layouts shall be laid down to a horizontal baseline. Curves must be set out to
offsets from the baseline or as shown on the Drawings. This information is to
be incorporated into the junction layout drawings.
8. Test and Inspection
8.1 General

8.1.1 The Contractor shall be responsible of performing inspection and testing for all
materials, consumables to demonstrate and verify that all the requirements of
specifications have been me.
8.1.2 The Contractor shall submit I.T.P (Inspection & Test Plan) for turnout to be
approved by the Engineer in order to clarify the witness point and hold point of each
manufacturing process of turnout.
8.1.3 The manufacturer shall provide all gauges and equipments necessary for the
inspection by the Engineer of the turnout components, assemblies and layouts.
8.2 Product Qualification Tests

8.2.1 The major components identified by the Engineer shall be inspected and tested
by the manufacturer and the Engineer or the Representative for the accuracy and
compliance with the Specification prior to dispatch at the Contractor's
manufacturing facility unless otherwise specified.
8.2.2 The Contractor shall submit two copies of inspection and test report after the
completion of each inspection or test.
8.3 Pre-Assembly Tests

8.3.1 One of turnout shall be pre-assembied in the workshop and jointly inspected with
the Engineer prior to being dismantled into sections small enough to be delivered
to site.

9. Delivery

9.1 After completion of a successful inspection, the layout shall be disassembled for
shipment to site.
9.2 Switch rails shall be securely fixed to the stock rail with wire or other suitable means
before lifting to protect the assembly from damage during handling and transport. The
weight of all sub-assemblies shall be clearly indicated.
9.3 Where necessary to avoid crippling the rail and for safety, two cranes and/or lifting
beams shall be used for lifting. Safe lifting points shall be marked on the components
and assemblies by the manufacturer.
9.4 To protect individual items from damage , all loads shall be securely fastened down with
straps in such a way as to prevent distortion or movement during transport.
9.5 All crossings shall be fully supported by a lifting cradle.
9.6 The use of chains is prohibited.
9.7 All Special Track work is to be given a spray coat of red oxide primer paint, bitumen
paint or similar prior to shipment. All steel work is to be shipped as below deck cargo, or
containerized.

10. Packing
The Contractor shall provide all packing, including crate and marking according to the
Contractor's standard which is fully compatible with the following :
10.1 Each case, crate or package shall be waterproof of robust construction and suitable for
the intended purposes.
10.2 Each case, crate or package shall be legibly and indelibly marked in large letters with
the site address, contractor number, opening points and other markings as necessary
to permit materials to be readily identified and handled during transit and when received
at site.
10.3 Each case, crate or package shall contain a comprehensive packing list showing the
number, mark, size, weight and contents together with any relevant drawings. A second
copy of the packing list shall be enclosed in a watertight enclosure on the outside of
each case or package. Distribution of additional copies of each packing list shall be in
accordance with the Engineer's instruction.
10.4 All items heavier than 100 kg shall be marked on the outside of the case to show the
gross and net weight, the points for slinging, and where the weight bearing.
10.5 Care shall be taken to prevent movement of items within cases, crates or packages by
the provision of bracings, straps and securing bolts as dearly identified by well-secured
metal labels on which the quantity and name of the parts or catalogue number have
been stamped.
10.6 All packing shall be free from sharp edges to prevent injury to person or other objects.
10.7 Each bulky/heavy case, crate or package shall include wedge for easy loading and
unloading by mechanical handling equipment such as forklift truck.

11. Flag and Shipment

Transportation of the material for the project will be preferable to use the Indonesian flag
shipment or shipment arrangement through an Indonesian Freight Forwarding Company.