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Uncontrolled When Printed Railway Group Standard

GC/RT5020
Issue Two
Date December 1998

Track Standards
Manual -
Section 3:
Rail Joints

Synopsis
This section of the Track Standards
Manual sets down the minimum
requirements to fishplated (both
insulated and opening) and welded
joints. It also includes the requirement
for emergency clamped fish plates and
for rail end strengthening.

Signatures removed from electronic version

This document is the property of

Submitted by
Railtrack PLC. It shall not be
reproduced in whole or in part without
Patricia Dingwall the written permission of the Controller,
Standards Project Manager Railway Group Standards,
Railtrack PLC.
Authorised by
Published by
Safety & Standards Directorate,
Richard Spoors
Controller, Railway Group Standards Railtrack PLC,
Floor DP01, Railtrack House,
Euston Square,
London NW1 2EE

© Copyright 1998 Railtrack PLC

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Track Standards Manual - Section 3: Issue Two
Rail Joints Date December 1998
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Contents
Section Description Page

Part A
Issue Record 2
Responsibilities 2
Compliance 2
Health and Safety Responsibilities 2
Supply 2

Part B
1 Purpose 3
2 Scope 3
3 Definitions 3
4 General 4
5 Fishplated Joints 5
6 Insulated Joints 6
7 Welded Joints 7
8 Temporary Rail Joints 8
9 Rail Joint Straightening 9

Appendices
A Minimum Action to be taken upon the discovery of Broken or 10
Cracked Fishplates in a Running Line
B Minimum Action to be taken upon the discovery of Flame Cut Holes 11
in Rails in Running Lines

References 12

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Part A
Issue Record
This Standard will be updated when necessary by distribution of a complete
replacement.

Amended or additional parts of revised pages will be marked by a vertical black

line in the adjacent margin.

Issue Date Comments

One December 1995 Original Document
Two December 1998 Revised document incorporating temporary
non-compliance CE97-09

This Standard forms part of GC/RM5600 ‘Track Standards Manual’.

Responsibilities
Railway Group Standards are mandatory on all members of the Railway Group*
and apply to all relevant activities which fall within the scope of each individual’s
Railway Safety Case. If any of those activities are performed by a contractor, the
contractor’s obligations in respect of Railway Group Standards is determined by
the terms of the contract between the respective parties. Where a contractor is
a duty holder of a Railway Safety Case then Railway Group Standards apply
directly to the activities described in the Railway Safety Case.

* The Railway Group comprises Railtrack and the duty holders of the Railway
Safety Cases accepted by Railtrack.

Compliance
The provisions in this Railway Group Standard are to be complied with from
5 February 1999.

Health and Safety

Responsibilities
In issuing this Standard, Railtrack PLC makes no warranties, express or implied,
that compliance with all or any Railway Group Standards is sufficient on its own
to ensure safe systems of work or operation. Each user is reminded of its own
responsibilities to ensure health and safety at work and its individual duties
under health and safety legislation.

Supply
Controlled and uncontrolled copies of this Standard may be obtained from the
Industry Safety Liaison Dept, Safety and Standards Directorate, Railtrack PLC,
Railtrack House DP01, Euston Square, London, NW1 2EE.

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Part B
1 Purpose
This Standard defines the mandatory requirements for the safe joining of rails.

2 Scope
The contents of this Standard apply to both fishplated and welded joints in
running lines and sidings on Railtrack controlled infrastructure.

3 Definitions
Back-hole Fished
Describes a rail joint in which the fishplates are clamped to the rails by means of
bolts through the fishbolt holes furthest from each rail end.

Continuous Welded Rail (CWR)

Rails welded together to form a continuous length greater than a nominal 36m in
length.

In a number of locations welded lengths of rail exist between nominal 36m and
54m in length; for each of these locations Railtrack shall ensure that
maintenance instructions exist.

NOTE: On lines formerly owned and maintained by London Underground

Limited (LUL) bullhead rails welded into nominal 90m (300ft) lengths and Tight
Jointed fishplated together to form nominal 800m (½ mile) sections may be
found. Adjustment switches are provided between adjacent sections.

Emergency Bridging Pieces

Inverted channel sections used to bridge a large gap (up to 165mm (6½″))
between 2 rail ends in an emergency.

Fly-Fished
The joining of two rails by means of a pair of fishplates which are fixed to one rail
only.

Insulated Joint
The connection of two rails by means of fishplates which are insulated from the
rail steel and bolts by a non-conducting medium.

Ordinary or Expansion Joint

Non-insulated connection of two rails by means of fishplates and bolts, designed
to accommodate longitudinal thermal expansion of the rails.

Temporary Rail Clamping System

Specially forged fishplates held together with clamps which can be applied to a
rail at a defect (or some breaks) to hold the rails to line and level.

Tight Joint
Non-insulated connection of two rails by means of fishplates and bolts but
without an expansion gap between the rail ends.

Welded Joint
Flash Weld: Weld between abutting rail ends made by the electric Flash
Welding process.
Alumino-thermic Weld: Weld between abutting rail ends made by the Alumino-
thermic Welding process.

Railtrack
Where this Standard refers to ‘Railtrack’ this will have the meaning of the
Railtrack Line organisation at Zone level responsible for compliance with Railway
Group and Corporate Standards.

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4 General
4.1 Higher Grade Steels
Rails made from the following steel types shall be treated as Higher grade steels
for the purposes of cutting and welding of rails:

• Wear resisting Grade B;

• 110kg Chrome;
• Low Carbon AMS (LCAMS);
• High Carbon AMS (HCAMS).

4.2 Normal Grade Group (of rail steels)

Rails made from the following steel types shall be treated as normal grade for
the purpose of this standard:

• BS11 Normal Grade;

• BS11 Wear Resisting Grade A;
• UIC Wear Resisting Grade A;
• BS AREA 90;
• Bainitic (NOTE: for Alumino-thermic Welding processes only);
• Heat Treated (HT) (NOTE: For drilling and welding only).

4.3
All joints within CWR - or strengthened S&C - shall be either:

• welded;
• fitted with Tight Joint fishplates approved for use in CWR;
• fitted with Insulated Joints approved for use in CWR.

4.4
The minimum lengths of rails which may be installed in the track are specified in
GC/RT5019.

4.5
Where flame-produced holes exist in fishplates trains shall be restricted to 5mph.

4.6
Where Fly-Fished joints exist in running lines, trains shall be restricted to 20mph
and permanent repairs made within 7 days.

4.7 Fishbolt and other holes

4.7.1
The minimum requirements for the drilling of fishbolt and other holes in rails are
specified in GC/RT5019.

4.7.2
The minimum action required to be taken if a flame cut hole is discovered in a
running line shall be as detailed in Appendix A.

4.7.3
For serviceable rail Railtrack shall specify the maximum number and the
permissible positions of bond wire holes in rails such that any cracks in the rail
around fishbolt or other holes are still detectable using normal ultrasonic rail
testing procedures.

4.8 Cutting of rail ends

4.8.1
The requirements for the cutting of rail ends are specified in GC/RT5019.

4.8.2
Where rail ends have been sawn or disc cut in preparation for site Alumino-
thermic Welding, the maximum permitted speeds shall be 50mph for:

• Joints fitted with a Temporary Rail Clamping System (see section 8.1)
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• Joints Back Hole Fished.

5 Fishplated Joints
5.1
All fishplated joints shall be fitted with the designed number of bolts each fitted
with a nut and washer(s) - or other approved fastener system - and shall be
correctly tightened (except as permitted in section 4.8.2 above).

Fishplates shall be appropriate to the rail section to be joined, the location of the
joint and the nature of the traffic passing.

5.2
When joining two rails together by means of a fishplated joint the following shall
be considered:

• the condition of the rail ends. If there are any obvious rail end defects then
the rail ends shall be cut back and rechecked for defects or a replacement
rail obtained;
• the compatibility of the two rail sections (including sidewear);
• the expansion gap or other gap required;
• the characteristics (i.e. materials, spacing etc.) of the sleepers immediately
on either side of the joint shall be the same;
• the alignment and level of the rail ends.

On completion of the fishplated joint the following shall be checked:

• the running surfaces of the two rail ends shall be nominally coplanar;
• the rail ends shall be in line laterally.

5.3
Fishplated joints in plain rails including Insulated Joints (other than as detailed
below), shall not be less than:

• 9m from another fishplated joint;

• 4.5m from a Welded Joint (see exception below);
• 4.5m from the end of a longitudinal timber (or at the mid point where the
timber is less than 4.5m long of the longitudinal timber).

EXCEPTION: It is permissible to reduce the above minimum distance of 4.5m

from a Welded Joint to a fishplated joint to a minimum of 1.8m
when necessary provided that the rail is supported on at least 3
sound sleepers and it has been approved by Railtrack.

5.4
Wherever reasonably practicable fishplated joints shall not be located on bridges
or in level crossings and shall not be located less than 2.5m from the end of a
bridge.

5.5
Rail Joints shall normally be square across gauge on straight track but may be
allowed to stagger. Railtrack shall ensure a process is in place to control track
twist before approving the use of staggered joints.

5.6
On concrete sleepered bullhead jointed track where the skirted fishplates are
more than 10 years old Railtrack shall assess the risk of failure by considering
the following:

• line speed;
• tonnage passing;
• history of failures.

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If the risk is assessed to be unacceptable the fishplates shall be replaced by

either:

• fatigue resistant fishplates on joints where the rail depths are the same, fitting
pairs of joints at the same time; or
• new deep skirted fishplates.

5.7
Expansion gaps for 18m and 36m rails shall be provided and shall take account
of the following:

• coefficient of expansion of rail steels;

• maximum / minimum rail temperature.

The maximum permitted expansion gap between two rails is 15mm.

5.8
All rail joints in running lines (except those at cast crossings), insulated and non-
insulated, both in CWR and in jointed track, shall be examined ultrasonically at
the frequencies set out in GC/RT5019.

5.9
Joints at the leg ends of cast crossings shall be examined in accordance with the
requirements of GC/RT5011.

5.10
Where a non-insulated fishplated joint is required to connect;

• cast monobloc crossing to plain rail;

• jointed rails within S&C in CWR;

Tight Joint fishplates shall be used.

5.11
The minimum actions to be taken upon the discovery of cracked or broken
fishplates in a running line shall be as detailed in Appendix B.

6 Insulated Joints
6.1
In addition to the requirements in section 5 above, the requirements in this
section are mandatory for Insulated Joints.

6.2
Any rail end lipping which threatens track circuit operation shall be removed,
worn insulation shall be renewed and damaged end posts shall be replaced.

6.3
Insulated Joints for use with CWR shall be type approved by Railtrack and do
not require adjustment switches to protect them.

6.4
Insulated Joints shall be located where specified which shall meet the minimum
rail length detailed in section 5.3 above.

7 Welded Joints
7.1
Railtrack shall ensure that welds having defects are recorded, assessed and
appropriate action taken.

7.2
When joining two rails together by means of an Alumino-thermic Weld, the
following shall be considered:

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• the top and alignment of the rails shall be suitable for welding;
• the sleeper spacing shall be correct;
• the rail section(s) / rail steel(s) / rail wear of the rails to be welded shall be
known;
• the two rail sections (including sidewear, rail depth etc.) shall be compatible;
• the condition of the rail ends shall be acceptable. If there are any obvious rail
end defects, then the rail ends shall be cut back and re-checked for defects
or a replacement rail obtained;
• the characteristics of the sleepers immediately adjacent to the joint shall be
acceptable;
• the correct welding portion shall be available;
• there shall not be any unacceptable cracks present at adjacent bolt or bond
holes.

7.3
Welded Joints of any kind shall not be made when the following are present in
either of the rails to be welded:

• rail gall (whether caused by chairs, baseplates, clips or housings)

wheelburns, squats or other defects within 100mm from the nearest edge to
the end of the rail to be welded;
• bolt hole or bond hole, bond attachment or bond scar within 30mm of the
nearest edge to the end of the rail to be welded.

7.4
Welded Joints of any kind shall not be less than:

• 4.5m from a bolted joint, an Insulated Joint, another Welded Joint (see
exception below) or an adjustment switch tip;
• 4.5m from the end of a longitudinal timber or other direct fastened bridge
deck (or at the mid point where the timber is less than 4.5m long).

EXCEPTION: It shall be permissible to reduce the above minimum distance of

4.5m when necessary provided that the rail is supported by at
least three sound sleepers and that it has been approved by
Railtrack.

7.5
For each Alumino-thermic Weld the identity of the welder shall be recorded.

7.6 Inspection of Welded Joints

7.6.1
A competent person, other than the welder who completed the weld, shall carry
out an inspection of all new Alumino-thermic Welds within one month of
installation. It shall be permissible for Railtrack to authorise an exception to the
time limit at defined locations where access requires special arrangements.

For each Alumino-thermic Weld the identity of the person inspecting the weld
shall be recorded.

7.6.2
Railtrack shall ensure that welds having defects are recorded, assessed and
appropriate action taken.

7.7 Minimum Actions

The minimum actions to be taken upon the discovery of a broken weld in a
running line are given in GC/RT5019.

The minimum actions to be taken upon the discovery of a cracked or otherwise

defective weld shall be specified by Railtrack.

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8 Temporary Rail
Clamping Systems
8.1 Temporary Rail Clamping Systems
8.1.1
It shall be permissible to fit a Temporary Rail Clamping System to rail joints or
rail defects provided that:

• the clamping system has been type-approved by Railtrack;

• the clamping system has been fitted in accordance with the manufacturer’s
instruction and any Railtrack requirements.

The maximum speed permitted over a rail joint fitted with a temporary clamping
system shall not exceed 20mph, except that a maximum speed of up to 50mph
shall be permissible provided that all of the following apply:

• the clamping system has been approved for use around a rail joint at a
specified speed of up to 50mph;
• both rail ends have been sawn or disc cut;
• the gap between the rail ends is maintained at ≤ 10mm;
• the head and running edge are co-planar.
• the ballast beneath the two adjacent sleepers on each side of the joint are
well packed and of equal consolidation;
• either the temporary joint is removed after 7 days or the clamps are tightened
or checked for tightness during each visual track inspection.

The maximum speed permitted over a rail joint fitted with temporary clamped
fishplates shall be reduced to 20 mph if any of the above conditions is not met.

In addition to the above the maximum speed permitted over a rail joint fitted with
a temporary clamping system shall be further reduced to 5mph if the gap
between the rail ends is between 50mm and 75mm and the line shall be blocked
if the gap exceeds 75mm.

The maximum speed permitted over a rail defect fitted with a Temporary Rail
Clamping System is specified in GC/RT5019.

8.1.2
It shall be permissible to fit approved Temporary Rail Clamping Systems around
a broken rail. For the conditions of use in such circumstances see GC/RT5019.

8.1.3
A Temporary Rail Clamping System is not designed for prolonged running and
every effort shall be made to effect a permanent repair as soon as reasonably
practicable.

8.2 Emergency Bridging Pieces

It shall be permissible to fit bridging pieces to rail breaks. Bridging systems shall
be approved by Railtrack.

The maximum speed permitted over bridging pieces shall be 5mph (see also
GC/RT5019).

8.3
Reference shall be made to GO/RT3087 "Working Instructions for AC Electrified
Lines” in respect of fitting bridging pieces and / or emergency clamped fishplates
on AC electrified lines.

9 Rail Joint
Straightening
9.1
When the profile of rail joints is required to be improved, it shall be permissible
for this to be carried out by rail joint straightening. Rail joint straightening shall
not be carried out on AMS rail.
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9.2
Fishplated Joints and Welded Joints shall only be straightened using Railtrack
approved equipment and a Railtrack approved process. The minimum
requirements for this process are as follows:

• 1 metre either side of the joint shall be ultrasonically tested a nominal 14

days prior to and following the straightening operation;
• any joint with a defect within 1 metre shall not be straightened;
• all wlded joints which are to be straightened shall be verified by a competent
person as suitable for straightening (see GO/RT3260);
• SmW welds shall not be straightened.

9.3 Records
Records of all straightening work undertaken shall be kept until the rail is
replaced.

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Appendix A

MINIMUM ACTION TO BE TAKEN

UPON THE DISCOVERY OF FLAME CUT HOLES
IN RAILS IN A RUNNING LINE

RAIL STEEL MINIMUM ACTION

Normal Grade Group Impose 20mph ESR, fit emergency

clamped fishplates if possible, and change
rail within 36 hours.

Higher Grade Rail Steels Block the line until the rail is changed.

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Appendix B

MINIMUM ACTION TO BE TAKEN UPON THE DISCOVERY OF

BROKEN OR CRACKED FISHPLATES
IN A RUNNING LINE

DEFECT MINIMUM ACTION

Both broken fishplates at a Fishplated IMPOSE 5mph and fit Temporary Rail Clamping
Joint System. (After fitting, Clause 4.8.2 applies)

One broken fishplate at a Fishplated IMPOSE 20mph ESR. Replace both fishplates
Joint within 24 hours.

One or both cracked fishplates at a Replace both fishplates within 24 hours

Fishplated Joint

Notes:

1 The above is the minimum action . The situation at any particular joint must be
reviewed by a competent person and if necessary more restrictive conditions applied.

2 These minimum actions apply to all types of fishplates between all rail sections.

3 Where there is any doubt as to the ability of the two sleepers either side of the joint to
hold the rail(s) to line, level and gauge where the fishplates are broken, then it will be
necessary to either (a) provide additional or alternative support to the rails or (b) block
the line until the fishplates are changed and the defective sleepers are replaced. This
is especially important where the track is supported on concrete sleepers.

4 All other components used in the affected joint(s), e.g. insulating liners, (shells) must
be replaced at the time the fishplates are changed.

5 Where present, the joint in the opposite rail must be complete, well supported and with
intact fishplates to enable trains to be passed over the joint. If both joints have broken
fishplates then the line shall be blocked until the fishplates are replaced.

6 The cause of the broken or cracked fishplates shall be investigated and where causes
are identified action must be taken to prevent a recurrence.

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References
GC/RT5010 Track Standards Manual - Section 7: Track Systems

GC/RT5019 Track Standards Manual - Section 2: Rails

GO/RT3260 Competence Management for Safety Critical Work

GM/RT1087 Persons Working On or Near AC Electrified Lines

GC/RT5011 Track Standards Manual - Section 9; Switch & Crossing Systems

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