Rail reprofiling

1 Purpose

This specification sets out objective requirements to enable suppliers to deliver reprofiling of rails and switches&crossings that meet the expectations of Bane NOR.

2 Scope

This specification applies to the reprofiling of rails and switches&crossings on the Bane NOR network. A distinction is made between corrective and preventive reprofiling. Corrective reprofiling is performed to improve the longitudinal and transverse profile of the rails. Preventive reprofiling is performed to reduce roughness and unevenness following rolling, inlaying and welding of rails.

3 Longitudinal profile

Acceptance criteria and requirement for measurement are given in EN 13231-2.

Work is to be performed to Class 1 or Class 2, normally depending on the maximum line speed (V_max) on the section to be reprofiled, as shown in Table 1. In some cases Class 1 may be chosen even if the line speed is below 130 km/h.

Table1: Quality class longtitudinal profile

4 Transverse profile

• Acceptance criteria and requirement for measurement are given in EN 13231-2.
• Work is to be performed to Class 1 or Class 2, normally depending on the maximum line speed (V_max) on the section to be reprofiled, as shown in Table 2. In some cases Class Q may be chosen even if the line speed is below 130 km/h. On the Norwegian part of the ore line Kiruna–Narvik (Ofotbanen) Class Q shall apply.

Table 2: Quality class transverse profile

• Measurement of the transverse profile shall be done at maximum intervals of 500 m.
• For reprofiling on heavy haul lines, measurements shall be performed with “Miniprof” instrument. Alternatively, measurement results must be exported to “Miniprof” format.
• When reprofiling turnouts, measurements are to be according to Reprofiling of switches and crossings.

4.1 Target profiles

• On the main network, the transversal target profile is the original profile, 60E1, 54E3, 54E2 or 49E1 in accordance with EN 13674-1 and with rail inclination 1:20, unless other target profiles are specified.
• On heavy haul lines (Ofotbanen and Dunderlandsbanen), the transversal target profiles are MB6, MB4 , MB1 v2 and MB1 v2Ass, with rail inclination 1:30. Drawings and coordinates for the target profiles are given in annex A.

4.1.1 Target profiles for Heavy Haul lines

On the heavy haul lines Ofotbanen and Dunderlandsbanen, the target profiles depend on curve radius as shown in Table 3. Profile toleranses are given in Table 4 and Table 5.

Table 3: Target profiles Heavy Haul lines

Table 4: Transverse profile tolerances Heavy Haul lines Target profile MB6, MB4 and MB1 v2

Table 5: Transverse profile tolerances Heavy Haul lines Target profile MB1 v2Ass

5 Metal removal

• A minimum of 0.2 mm of material is to be removed, irrespective of the longitudinal and transverse profile of the rails.
• Requirements for measurements are given in EN 13321-2.

6 Surface quality

• The surface quality of the reprofiled rails shall be according to quality class 2 according to EN 13231-2. I.e the quality index shall be ≤ 5.
• The quality index shall be measured and determined according to 13231-2.

7 Visual appearance

• Acceptance criteria are given in EN 13231-2.
• For reprofiling on heavy haul lines, the facet width shall not exceed 5 mm on any part of the rail head, except for the top facet on the MB5 and MB4 profiles from +5° to -5°.

8 Removal of rolling contact defects

When the purpose of the reprofiling is to remove rolling contact fatigue cracks, the following requirements apply:

• Necessary depth to remove the cracks shall be estimated using eddy current testing.
• The extent and depth of remaining rolling contact fatigue cracks after reprofiling shall be documented using eddy current testing.
• Requirements for eddy current testing system are given in EN 16729-2.
• The protocol after the first and last reprofiling pass shall be saved and delivered as a .csv file and as a PDF file. The protocol shall include for each probe:
  • Location (GPS, track number and km)
  • Density of cracks
  • The size of the deepest crack/meter
  • The average depth of cracks

9 Reprofiling of switches and crossings

The following conditions apply to the reprofiling of switches:

1. Bane NOR may define more than one target profile for a single turnout.
2. The reprofiling equipment used must be capable of reprofiling the running rails behind the check rails without removal of the latter.
3. The reprofiling area is to cover the switch and 20 m ahead of and beyond the switch.
4. Any snow covers must be removed before reprofiling.
5. Switches and crossings shall be reprofiled to a rail inclination 1:20 on the main network and 1:30 on “Ofotbanen”.
6. There shall be no reprofiling in the crossing nose between the nose tip and where the witdth of the nose is 70 mm, see Figure 1.
7. Where the crossing nose width is between 70 mm and 120 mm, the nose can be reprofiled from -1° to -70°.
8. The switch blade is to be reprofiled when it is resting against the stock rail. Before reprofiling, the switch blade shall be lifted 4–6 mm with shims.
9. The stock rail can be reprofiled from -70° to +12° when the switch blade is not closed to the stock rail.
10. After reprofiling, the adjustment of the switch blade to the stock rail, shall be checked according to Bane NOR regulation Teknisk regelverk: Overbygning/Vedlikehold/Sporveksler/Vedlegg/Undersøkelse av tungeanordningerEkstern lenke. 
11. Longitudinal rail profile shall be measured for all 4 rail strings in the S&C.
12. After reprofiling, the transverse rail profile shall be measured at measuring point 3–6 according to Figure 1. When requested, the transverse rail profile shall also be measured at measuring points 1, 2, 7, 8, 9 and 10.
13. After reprofiling, any reprofiling dust, slag and other waste material must be removed, particularly between the switch blades and stock rails, around insulated rail joints and around switch slide plates.
14. The switch must be lubricated immediately after reprofiling.
    

10 Collection of waste and dust

• After the reprofiling is completed, all waste, slag, milling chips, and other steel particles shall be removed from the track.
• Reprofiling vehicles shall be fitted with equipment for collecting dust and emissions.

11 Inspection and approval

11.1 Inspection by the supplier

• Reprofiling vehicles shall be equipped with instruments for measuring and checking the following properties of the rail head:
  
  • transverse profile
  • longitudinal profile
  • surface quality
  • metal removal
  • RCF surface cracks
• The results of these measurements shall be capable of processing and comparison with those produced by Bane NOR’s own inspection equipment.
• The reprofiling contractor is responsible for any necessary data conversion.

11.2 Approval

• Completed work will be approved on the basis of daily reports and quality documents.
• If the client so wishes, random checks may be carried out in addition.
• The documents must be signed by the reprofiling supervisor and by a representative of Bane NOR on handover.

11.3 Quality documents

Quality documents must include, as a minimum:

• Measurements of longitudinal profile before reprofiling and after the final pass
• Measurements of transverse profile before reprofiling and after the final pass
• Measurements of surface quality
• Measurements of material removal
• Results from eddy current testing of the rail head surface

Q-documents for sections on which reprofiling is complete must be signed and handed over at 14-day intervals. These documents are to be collated every 14 days and after completion of the reprofiling contract. The collated Q-documents are to be accompanied by a summary of the extent to which the work complies with the requirements of this specification.

12 Reference Documents

• EN 13231-2: 2020 – Railway applications – Track – Acceptance of works – Part 2: Acceptance of reprofiling rails in plain line, switches and crossings and expansion devices
• EN 13674-1: 2011+A1 2017 – Railway applications – Track – Rail-Part 1: Vignole railway rails 46 kg/m and above
• EN 16729-2: 2020 – Railway applications – Infrastructure – Non-destructive testing on rails in track – Part 2: Eddy current testing of rails in track

13 Compliance list

Download compliance list for completion.

14 Change log

Endringslogg for Reprofilering av skinner