Final Technical - Signed Off

Railway Infrastructure Services

Rail Products

Technical Guide

Innovation in rail

www.corusgroup.com

Care has been taken to ensure that this information is accurate, but Tata Steel UK Limited, and its subsidiaries, does not accept responsibility or liability for errors or information which is found to be misleading.

Copyright 2008Tata Steel

Rail Products UK – Rail Sector HQ

Rail SectorPO Box 298YorkYO1 6YH

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UK – Manufacturing Facilities & Commercial

Rail ProductsRail Service CentrePO Box 1Brigg RoadScunthorpe DN16 1BP

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Rail Products2 Avenue du President Kennedy78100 Saint Germain en LayeFrance

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CRP/th/REV4/AUG08

World-class rail products that enhance the performance of railways across the globe

Corus rail, steel sleepers and associated track products are produced in the

UK and France where skilled staff are able to draw on more than a century

of excellence in manufacturing and metallurgy. Corus Rail Products is also

able to exploit the huge bank of railway industry expertise available within

the larger Corus Group, which employs 14,000 engineers and technologists

worldwide.

Corus has supplied rail and track products to customers in more than 85

countries throughout the world. The company’s global reach is matched by

its proven ability to set international standards in manufacturing processes,

product performance and customer service.

Corus employs a team of technical and commercial representatives on every

continent to work closely with customers. In addition, rail experts at Corus

can offer a multitude of solutions for the packaging, transporting, handling

and storage of rails together with technical assistance for the optimization

of in-service performance of rail and track systems.

Corus Rail Products offers one of the widest and most comprehensive rail product ranges in the world.

01 Introduction02 The Corus manufacturing and supply processes08 Finishing, test and inspection10 Despatch11 The Corus product range

Technical Guide

1

The Corus manufacturing and supply processes

£100m investment in rail manufacturing during 2006-7, to create world class rail facilities in France and the UK.

Rail Manufacturing

Corus has 130 years of rail manufacturing experience, both in France and the UK; from the introduction of continuous cast steel and the invention of universal rail rolling to the development of innovative heat treatment processes and low noise rails, they have developed a reputation as a world leader in technological development. The recent £100m investment has transformed rail manufacturing in the UK, building on the Hayange mill’s long-established leading market position.

In 2000, Corus invested £20m in steelmaking and casting at Scunthorpe to produce world-class rail steel. This provided the quality and quantity of bloom required to supply both of Corus’ rail mills, Hayange in France and Workington in the UK. During 2005, Corus worked in close cooperation with key customers in the UK to

understand their future requirements; the strong requirement for longer rail and optimised supply chain logistics from steelmaking to installation in track provided the rationale to develop 120m rail manufacture at Scunthorpe. A major enhancement to the existing Medium Section Mill comprised a new furnace, close coupled seven stand finishing mill train, rotary stamper, hot saw and a cambering & cooling bank. A new service centre was built to carry out all rail finishing operations using the best available technology.

The addition of a welding plant to the Rail Service Centre at Scunthorpe has allowed Corus to provide the UK market with the most complete solution to the customer’s requirements, with 108m rail welded into 216m strings that are delivered to track with a single movement.

Corus Rail’s Hayange manufacturing plant in north east France provides world class rail solutions to western

Europe and across the globe, and the location provides an ideal hub for delivery worldwide, with excellent rail, road and river links. Heat-treated products are available with hardness values over 400BnH, and the unique patented process ensures exceptionally low residual stress levels. Hayange pioneered universal rolling to ensure the dimensional consistency that is essential for high-speed track; when SNCF broke the world train speed record on the new TGV Est line in April 2007, it was on Hayange rail.

Corus Manufacturing Philosophy

The Corus manufacturing philosophy is built on the principle that all activities must be undertaken in a safe and healthy way and with due regard for the environment. The company is committed to developing a culture of Continuous Improvement based on lean principles. Strategy deployment cascades through all levels of every business to ensure that business strategies are aligned to corporate objectives and that every employee understands not only what the business is trying to achieve, but also how they can contribute to the achievement of these objectives. The promotion of a common set of goals helps the business to harness the full potential of its manpower resource.

Customer Requirements

The railway industry needs to make rapid progress to ensure that it can meet the challenges for higher traffic volumes, heavier axle loads and higher speeds; track trials of new rail grades in a range of track conditions, from heavy haul to high-speed, are demonstrating the value of a harder rail and the opportunity to improve contact fatigue performance. At Corus we work closely with our

customers to fully understand future requirements; the partnership approach adopted with key customers helps to ensure that investment in product and plant development is aligned to their needs. A leadership role in the European project Innotrack is an example of how Corus is working closely with the major railways of Europe including SNCF, Network Rail and Deutsche Bahn to establish the performance of new rail grades and support structures, and to optimise logistics options.

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Technical Guide

Corus manufacturing andsupply processes

The Corus commitment to product quality is evident in our world-class steel manufacturing process; this philosophy extends to the rolling and finishing of rail products and to the well-proven process for delivering products to the exacting requirements of customers worldwide.

This commitment has been emphasized by the recent investment at the rail manufacturing sites at Scunthorpe (UK) and Hayange (France) totalling over £100 millions. This has further strengthened our steelmaking capability by increasing production flexibility to meet changing volume demands, and has also improved logistics by providing rails and steel sleepers closer to the market.

Steel making

The Technology

Scunthorpe, in north-east England, boasts one of Corus’ major steel plants. The manufacture of rails at this site adds to an already wide range of products including plates, structural sections, special profiles, semis and wire rod; this diverse product range at a single site provides a huge flexibility in steelmaking operations and associated competitive advantages, which is reflected in a record production of 4.5 million tonnes against a rated capacity of 3.8 million tonnes. Although the generic plant and process route for the manufacture of rail steels is very similar among all the major manufacturers, consistent quality can only be achieved through robust practices and process control techniques that depend on experience and a commitment to continuous improvement.

The Process

Hot liquid iron with low levels of residual elements provides ideal feedstock for the manufacture of today’s rail steel, essential for the increasing duty conditions on modern railways. At Corus, the manufacture of quality rail steel starts by reducing this high quality iron ore in blast furnaces, followed by the associated post treatment of the liquid iron through desulphurisation units.

The liquid iron is further refined in one of three 300 tonne oxygen steelmaking converters through controlled oxidation of carbon and other elements in charged hot metal and scrap. The precise control of the entire steelmaking operation relies on sophisticated computer models and a wide variety of intelligent process control equipment. These systems allow the process to be closely monitored by highly skilled operators; the refined steel is then ready for tapping into ladles for the next stage of manufacture.

The desired steel chemistry is achieved through careful addition of alloying elements, and close control of the deoxidation process ensures a very high level of steel cleanness and absence of oxide inclusions that, in the past, have been the cause of “Tache Ovale” type defects.

The secondary steelmaking operations at Scunthorpe are focused on three ladle metallurgical furnaces (LMF) and two RH degassers. The LMF, equipped with electromagnetic stirring as well as facilities for the precise addition of alloying materials, ensures the control of steel chemistry to consistent and narrow bands. Temperature control is also an important function of this stage of steelmaking as it ensures low levels of central segregation in the cast bloom.

The maximum vacuum achieved and the time spent at this vacuum are two of the essential process control requirements for the RH recirculating degassers, which reduce the hydrogen content of the steel to well beyond the maximum stated in international specifications. However, if lower levels of hydrogen are required by the customer, further dehydrogenisation is achieved through controlled slow cooling of the cast blooms in specially constructed units, the results of which have been verified through modelling and measurements.

The introduction of continuously cast feedstock for the manufacture of rails in the mid 1970s has been one of most influential single developments in enhancing the integrity of rails in track. Rails manufactured from continuously cast feedstock on a rolling mill equipped with modern NDT inspection facilities have eliminated the classic “Tache Ovale” defects that were a major cause of rail failures from ingot feedstock; however, further developments in continuous casting technology have been necessary to consistently achieve a bloom with minimum levels of

segregation and free of hinge, side and corner cracks. The recent investment to enhance the Scunthorpe casters was aimed at these objectives, and incorporates mould electromagnetic stirring and dynamic spray control. Various bloom cross sections are produced by the continuous casters but the two most common for rail manufacture are 355mm x 305mm and 330mm x 254mm.

The manufacture of rail steel blooms is closely controlled at each stage through appropriate sampling and analysis of steel chemistry and other product quality attributes; this regular testing, coupled with stringent product identification and tracking, ensures that quality is guaranteed.

The Benefits

The manufacture of a rail steel bloom requires a robust tracking and process control system to promote continuous improvement through intelligent analysis of the interdependence of process parameters and product quality. The sophisticated and tightly-controlled steelmaking process, when combined with the precise rolling techniques employed at the two Corus Rail mills, results in homogeneous mechanical properties over the full length of the rail, ensuring consistent and reliable in-service performance.

Technical Guide

54

Corus’ bloom suppliers operate quality management systems certified to ISO 9001 and ISO 14001. They also work to detailed specifications to ensure adherence to rail standards.

Rolling

The microstructure obtained on all the treated rails consists of 100% ultra fine pearlite with no transition zone. Because of this process, the hardness values decrease very slowly with depth, resulting in minimal plastic deformation and reduced wear under significant axle loads. The high values achieved for elongation and reduction of area assure optimum resistance to deformation and brittle failure.

The above Corus heat treatment process produces rails that do not require roller straightening after heat treatment, and the residual stresses measured on the rails in their delivery condition are of an extremely low level. The resulting state of compression significantly reduces the

risk of failure initiation and growth at the point within the rail where the loading is at its highest. This is a major benefit on the foot of the rail, where low residual stresses reduce the risk of fatigue failure associated with a corrosion pit and there is no reliable method of inspecting the foot in service. The compressive stresses in the rail head may also offer benefits in delaying the growth of rolling contact fatigue (RCF) cracks. Transversely, the residual stresses are negative everywhere, with a mean value of -55 MPa, -50 MPa and -5 MPa in the head, the web and the base respectively.

The Benefits

The substantial capacity, flexibility •and process consistency offered by Corus rolling mills enables the production of a wide variety of rail and sleeper sections to high quality standards.The hardening processes are so •efficient that, even at a depth of 20mm below the running surface, a hardness of 365HB is achieved – a feature that results in exceptional in-service life of Corus heat-treated rail sections.

The Technology

Corus’ rolling mills at Scunthorpe in the UK and Hayange in France utilise modern process technology to achieve outstanding results. Computer modelling and computer-controlled heating and cooling processes utilise novel roll pass design and modern process technology.

The Process

Blooms are reheated in a natural gas-fired furnace. Computer modelling and control of the reheating process result in tight control of rolling temperatures and ensure consistent product dimensions and surface quality. On leaving the furnace, blooms are descaled using high-pressure water jets.

The rolling process is undertaken using reversing stands to achieve the initial bloom reduction. There are up to nine passes in a bloom-sizing mill to adjust the section for entry into the intermediate mill, where another three passes are made. At Scunthorpe, the 7 stand universal finishing train ensures tight dimensional control to the final section. Surface quality is controlled using high pressure water descaling to remove secondary scale prior to entry, as well as within within the finishing train to ensure a high standard of surface finish for all rolled products.

The universal rail rolling process was perfected by Corus at Hayange. Traditional rolling-in passes on two-high reversing roughing mills obtain a symmetrical blank. The blank is then subject to a succession of passes in universal stands. Each of the universal passes is followed by an edging pass to control the expansion of the head and the foot. The last rolling pass is designed to give the section its precise and final dimensions and is undertaken in a semi-universal finishing stand. During the final rolling pass, relief branding is applied on the rail web. This carries information such as the rail profile, grade of steel and year of manufacture. After leaving the finishing stand, identification marks unique to each hot sawn rail are stamped automatically at regular intervals along the length of each rail. The hot stamping mark provides full product traceability back through the manufacturing process, linking product attribute data to manufacturing parameters.

Rolled profiles are hot cut to standard lengths, ready for final processing. At the same time, samples are taken for assessment of profile and analysis of mechanical and chemical properties. After hot sawing, rails are transferred to cooling banks where they cool to an ambient temperature. Rails are pre-cambered before cooling to compensate

for the natural curvature, that occurs during cooling.

Steel sleepers are also manufactured in Scunthorpe. The rolling process is similar; however, these products are hot sheared into multiple lengths before being cooled and stacked ready for further processing.

Rails are heat treated to improve wear and rolling contact fatigue resistance to enhance life. The heat treatment process employed at Corus, Hayange, involvescontrolled heating and cooling of the full cross section of the rail.

At the Hayange plant, the rails after natural cooling are straightened in both planes. They are then heated in excess of 900ºC using inductors; the novelty of this process is that the entire rail section is heated above the pearlite to austenite transformation temperature. The rails are then cooled using a computer controlled system to refine the microstructure and increase the hardness of the rail head up to 420HB. Compressed air from a set of nozzles positioned around the rail makes it possible to control the cooling of both the head and base in such a way that the rails do not require further straightening. This process allows the delivery of rails with optimised residual stresses, and guarantees no opening of the rail web during the saw cut test.

Rolling

Conditions Longitudinal stresses (MPa) measured by strain gauges - typical values

Saw cut test(mm)

Head Web Foot

Standard grade Natural cooling before straightening 30 -20 30 +0.2

Natural cooling after straightening 140/180 -110/-160 190/220 +1.5/+1.8

Corus Heat treatment Off line heat treatment without straightening -86 +41 -30 -1.5

Residual stresses vs. straightening conditions

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Technical Guide

7

Finishing, test and inspection

The Technology

Ongoing investment in modern test and inspection equipment plays a major role in ensuring that Corus’ rail products are of a consistently high quality. Laser, eddy-current and ultrasonic technologies are utilised alongside conventional testing methods to provide evidence that products meet the specified requirements.

The Process – Finishing

Rail straightening is undertaken using computer-synchronised straightening machines to produce ultra-straight and ultra-flat rails. The primary straightener acts in the vertical plane and the secondary straightener acts in the horizontal plane with the rollers mounted onto conical spindles to eliminate eccentricity. Rails are cut to the customer’s ordered length by sawing at ambient temperature and are drilled, if required. Sawing and drilling are carried out on high-speed combined machines, which ensure that the tightest length and hole diameter/hole location tolerances can be achieved.

Roller straightening has only a limited effect on rail ends. Rail ends are checked in both lateral and vertical planes by a combination of laser beams and straight edges. This check is combined with hydraulic presses, and guides the operator during the process.

Corus is the UK’s market leader in the field of rail welding and is responsible for the development of the patented ‘Invisible Weld’ Narrow Heat Affected Zone welds. The company's welding facilities are co-located with the Rail Service Centre at Scunthorpe, where highly-qualified welding technicians produce rails in lengths up to 216 metres. The flash butt welding process uses the resistance welding method to create a weld made purely of parent material. State-of-the-art scanning equipment is used to ensure all welded rail lengths meet specification.

For sleeper finishing, hot rolled sleeper blanks are despatched in short blank lengths (sheared at Corus) or long multiple lengths, which are subsequently cut prior to finishing. Sleepers are finished using several processes including cold forming to produce the tilt angle and spade end shape. Fasteners are then attached and sleepers are then stacked and strapped in bundles ready for storage and despatch – each identified to show exactly when and where they were produced.

The Process – Test and Inspection

The development of high-speed trains means that rail straightness is a crucial factor governing performance of the rail in track. Corus uses state-of-the

art laser technology to measure the flatness and straightness of rails.

A wave meter is used, and is composed of a series of laser rangefinders measuring flatness of the rail running surface and a second series of laser rangefinders measuring flatness on the side of the rail head. The position of the sensors has been calculated so as to measure all the specified variations in straightness. Signals are processed automatically to obtain the equivalent results obtained using a sliding straight edge, the lengths of which are stipulated in the standards (3 metres; 1.5 metres and 2 metres in Europe). Different signal processing programs are used to check straightness in accordance with the order specification.

Eddy current testing is used to identify any surface defects that exceed specification limits. The test equipment comprises electromagnetic coils, which induce eddy currents in the rail. The amplitude and form of the eddy-currents depend on the surface condition of the test surface thus allowing surface defects to be detected.

Based on the 60kg profile the in-line ultrasonic testing equipment inspects more than 90 per cent of the rail head and more than 60 per cent of the rail web and the central part of the foot. Ultrasonic testing detects internal defects such as inclusions, which can have an adverse effect on in-service rail life. Coverage of the profile is achieved by means of seven probes for the head, up to six probes in the web and two or three on the foot.

Defects detected by the in-line test are inspected manually using portable ultrasonic testing equipment in order to confirm the presence of a genuine defect. A test report is established and

archived for each rail. Calibration is carried out regularly on artificial defects machined into ‘calibration rails’.

A range of acceptance tests is undertaken to customer specification – and in the presence of a customer representative if required.

These tests include tensile and hardness, decarburisation measurements, segregation checks and steel cleanness assessments. Testing is carried out at the Corus manufacturing sites – ensuring quick availability of results after the product has been rolled.

At the final stage of manufacture, full profile and full rail surface quality inspection is undertaken. This final inspection includes dimensional checks using calibrated profile gauges including the cold profile gauge. A check for rail end twist can also be made using gauges.

The cold profile gauge installed in the NDT lines is a continuous dimensional measurement device, which is an excellent rail dimensional control improvement tool. The process principle is based on optical sectioning. Five lasers project their beams on the rail, itself monitored by seventeen cameras directed at 45° with respect to the axis of the product under inspection. The computer program processes the pictures provided by the cameras, standardises them and then puts them together to recreate the full straight section of the rail.

The large number of laser sources and cameras is necessary for the wide range of profiles to be inspected, the same technique is used irrespective of whether they are symmetrical or asymmetrical, for switches and crossings or tramways (grooved rails), and nearly forty dimensions are measured and computed.

The Benefits

The quality finishing process •ensures that all Corus products are manufactured to the highest standard, suitable for a range of environments including high speed, heavy haul, mixed traffic systems, urban environments and industrial applications.In addition to post-production tests, •thorough inspection is undertaken throughout the manufacturing process, including profile dimension and hot surface quality checks. The inspection results are used to make any appropriate adjustments to production processes and ensure that Corus rail products are of the highest quality and meet customer requirements.

In keeping with its reputation for innovation, Corus is at the forefront of rail inspection technology.

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Technical Guide

9

Despatch

The Technology

When the manufacturing process is complete, Corus’ team of logistics experts comes into its own – ensuring the safe and cost-effective delivery of products to customers across Europe and around the world. Once again, Corus utilises the best in modern technology – from special handling equipment to purpose-designed rail wagons – to ensure the integrity of its products in transit.

The Process

Following final inspection, rails are loaded for despatch directly onto wagons using special handling equipment. The rails may be loaded either as loose rails, ‘head up bundles’ or ‘nested bundles’, banded together. The loading operations are carried out using the unique section specific Camlok system, electro-magnets or clamps.

The Corus mills at Hayange and Scunthorpe have substantial experience of delivery by rail to UK, French and other European customers. Hayange lies at the heart of the efficient railway and waterway networks that guarantee rapid access to the majority of European destinations – and beyond – via the port of Antwerp. A private branch line at Hayange links directly to the public rail marshalling yard at Ebange and the river port of Illange. Each location is within 10km of the Corus mill. In the UK, Corus

utilises efficient rail and road links to the major northern English ports of Teesside, Immingham and Liverpool. Road and rail links to the Channel Tunnel allow rapid delivery to mainland Europe.

Corus has extensive experience of river transport for the delivery of rail products. The waterway route via the canalised Moselle and Rhine remains the most competitive transport channel and it is possible to deliver 80m rails by river to Antwerp using modern, specially adapted vessels. In addition, Corus has efficient handling facilities for loading the river craft.

For marine transport, Corus at Scunthorpe has various shipping options to choose from. The nearby port of Flixborough Wharf is capable of handling vessels up to 4,000 tonnes, and for heavier shipments the port of Immingham can accommodate vessels up to 25,000 tonnes. Both ports are rail connected. Overseas export orders from Hayange usually transit via the port of Antwerp, which offers regular departures to numerous destinations including the United States and the Far East. Corus has extensive experience in direct handling and marine transport of long rails (73m) to European destinations.

The UK can also utilise road transport for rail lengths under 28m; this is undertaken by a fleet of road lorries. HIAB facilities are available for offloading rails at work sites and where access is difficult.

Long welded rail delivery from Scunthorpe is undertaken by rail, utilising special trains equipped to handle and offload rail up to 216m long. The rail can be offloaded directly at the work site, with shorter rail lengths transported on a fleet of purpose-designed rail wagons. Corus’ specially designed fleet of trains allows for complete control of the supply chain and gives JIT ability on key high profile work sites.

Thanks to its expertise in rail coating and corrosion protection, Corus can deliver rail that is protected against corrosive marine environment during transportation and storage.

The Benefits

Corus’ proven and efficient product •despatch process means that delivery costs are reduced and the risk of rail damage during handling and transit is minimised.In order to provide an improved •response to customers’ requirements for quality and reliability, Corus has a fully developed acceptance and monitoring system at the port of Antwerp.

In addition to producing rail for its high-speed network, Corus worked with SNCF in France to develop dedicated transport methods for delivery of the rail. The result was a fleet of special rail wagons, allowing rails of up to 80m to be carried over a large proportion of the continental network. Corus was the first company to successfully transport 120m rail across Europe.

The Corus product rangeCorus was the first company in Europe to manufacture rail for high-speed lines – its rail manufactured for SNCF in France included the East line of the high-speed network where a TGV train broke the world speed record in April 2007, reaching a speed of 574.8km/h (356mph).

for high-speed networks

Requirement:Commercial operating speeds on these networks range from 150km/h to more than 300km/h. Lines are mainly composed of straight stretches and large radius curves that are generally considerably greater than 4,000 m. Track is based on rail sections of 50 to 60kg/m, usually of non heat-treated steel grade with a hardness ranging from 200 to 300HB. In order to reduce the dynamic loads, the axle load is limited to 17 tonnes for high-speed trains. Detection of high-speed trains by track circuit is a major element in rail safety and has implications for the quality of the rails used.

Corus Products:With its world-class rail straightening and testing facilities at both Scunthorpe and Hayange, Corus has been able to give full support to the development of high-speed networks. Corus rails have been used by SNCF for its high-speed lines in France since 1980 and Corus has equipped more than 1,500km of new line where trains run at commercial speeds of 270 to 320km/h.

The development of Corus rail steel manufacturing processes has improved the in-service fatigue life of rails through its facilities. Further reduction in the incidence of rolling contact fatigue has been achieved through the judicious use of newly developed rail steels and an appropriate rail grinding strategy.

In order to guarantee perfect electrical contact between train wheels and rails in zones with low traffic, Corus has developed Sogenox™ where the upper part of the head is covered by a layer of stainless steel which prevents any rusting. The stainless steel is deposited by welding a steel strip on the face of the bloom, with the result that the head of the rail at the end of the rolling has a stainless steel thickness greater than 1mm on the running surface and the active sides of the rail head. Re-heating, rolling, finishing and inspections are realised according to the usual process and following the current specifications.

This process can be applied to all profiles of symmetrical railway rails and switch rails rolled by Corus.

Rail

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Technical Guide

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for heavy haul networks

Requirement:These rails are used by trains with very high axle loads (25 to 35 tonnes) or where the cumulative amount of loads transported is substantial (around 100 to 150 MGT/yr). The routes may be diverse and the terrain crossed frequently, requiring the construction of tight radius curves of less than 200m. In order to increase wear resistance and improve fatigue life, high strength rail grades are recommended.

Corus Products:Corus offers heat-treated rail with optimised residual stresses. Roller straightening is undertaken following heat treatment in most major heat treated rail manufacturing processes in use today. This operation induces tensile stresses in the railhead and foot seen as an opening of the web during the saw-cut test This produces a risk of sudden longitudinal fracture of the core during service.

The Corus hardening process allows hardened rails to be delivered without roller straightening. The rails produced by this process are characterised by longitudinal compressive stresses at the railhead and foot and vertical compressive stresses in the web. During the web saw-cut test, closure is always observed and is a guarantee against catastrophic longitudinal fracture of the web.

Sections up to 70kg/m can be treated and hardnesses of between 350 and 420HB can be achieved. It is important to note that Corus heat-treated rails are being used in other applications and not exclusively in the heavy haul environment.

In addition to heat-treated rails, Corus supplies naturally hard grades with a hardness of 300 – 340HB which offer a good combination of fatigue and wear resistance for tangent and shallow curved track.

Corus rail is used in heavy haul networks across five continents.

for mixed traffic networks

Requirement:Mixed traffic networks cover tracks where the commercial operating speed is usually lower than 150km/h and where freight trains (up to 25t axle load) and passenger trains share the same line. The types of lines are extremely varied – from long straight stretches across plains to very tight alpine curves. The track gauge may be standard (1435mm), wide (1524mm) or narrow (1067mm). A wide range of rail sections and steel grades are required in order to meet the constraints of existing structures and specific operating conditions.

Corus Products:Corus has a wide and comprehensive product portfolio and is able to offer a full range of rail profiles and steel grades to meet the requirements for mixed traffic applications.

For rails used in aggressive environments such as tunnels or at level crossings, Corus can supply coated rails for longer in-service life. Corus coated rail products include Coreprotec.

Silent Track™ has been developed by Corus as an ecomonic solution to meet European noise legislation. Silent Track™ is a noise reduction system using sound absorbers applied on the web and upper part of the foot of rails. Its use avoids the need for costly construction of noise abatement walls.

Corus also has significant experience in producing rails and special sections for switches and crossings. The product range includes sections adapted to the requirements of different types of track and is produced in the same grades as for Vignole rails and also in a naturally hard and particularly resilient grade named R 260 Cr.

Rail continued

for urban networks and mass transit schemes

Requirement:Increasing urbanisation and traffic congestion, coupled with growing environmental awareness, has encouraged the use of tramways and metro systems worldwide. Tramways in the heart of towns require special rails with U-shaped profiles, which can be set flush into the roadway. These rails are often cambered to very tight curves (15m – 25m) and must demonstrate a high degree of wear resistance. Track noise reduction is a major imperative and, because of access difficulties, rails must also be easily weldable.

Corus Products:There is no single rail solution to the multiplicity of conditions on urban networks and mass transit schemes. Corus offers a wide range of products that have been utilised on a large number of urban schemes across the globe. These include a choice of 13 different grooved rail profiles developed for the urban market. Corus is also able to work with customers to meet non-standard requirements for grooved rail.

As a result of close involvement in the redevelopment of tramways in France, Corus is able to demonstrate the highest levels of accuracy for tramway profile dimensions – particularly rail asymmetry and web-head offset.

Another development from Corus is the novel (patented) process for in-situ weld restoration of worn grooved rails involving deposition of relatively thick layers of an austenitic stainless composition to increase wear resistance and extend life further.

for industrial settings

Requirement:Rail for industrial applications includes track laid on a temporary or semi-permanent basis in plantations, forests or quarries. These systems are generally intended to be portable and comprise light rail sections. Other industrial uses range from permanent tracks serving large industrial sites to small, specialised tracks. Traffic often includes high axle loads or high traffic intensity. Site layout constraints may result in very tight curves or steep gradients.

Corus Products:Reliable product quality is essential to cater for the varied and often less than optimal service conditions. For industrial track, Corus uses prime steel, rolled using proven techniques to ensure the highest product quality is achieved.

Corus also supplies track for cranes - including mobile, semi-mobile and overhead travelling cranes – and for specialised applications such as ship-launching equipment.

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Technical Guide

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High speed and mixed traffic systems

Specification Grade Chemical composition % by mass Mechanical properties

C Si Mn P S Cr Al V H2 (ppm)

Rm (MPa)

Elong -ation (%)

BHNHardness Centre line

Rm (KSI)

UIC 860-O 700 0.40/0.60 0.05/0.35 0.80/1.25 ≤0.050 ≤0.050 680/830 ≥14

900A 0.60/0.80 0.10/0.50 0.80/1.30 ≤0.040 ≤0.040 880/1030 ≥10

900B 0.55/0.75 0.10/0.50 1.30/1.70 ≤0.040 ≤0.040 880/1030 ≥10

EN 13674-1 R 200 0.40/0.60 0.15/0.58 0.70/1.20 ≤0.035 0.008/0.035 ≤0.15 ≤0.004 ≤0.030 ≤3.0 ≥680 ≥14 200/240

R 220 0.50/0.60 0.20/0.60 1.00/1.25 ≤0.025 0.008/0.025 ≤0.15 ≤0.004 ≤0.030 ≤3.0 ≥770 ≥12 220/260

R 260 0.62/0.80 0.15/0.58 0.70/1.20 ≤0.025 0.008/0.025 ≤0.15 ≤0.004 ≤0.030 ≤2.5 ≥880 ≥10 260/300

R 260Mn 0.55/0.75 0.15/0.60 1.30/1.70 ≤0.025 0.008/0.025 ≤0.15 ≤0.004 ≤0.030 ≤2.5 ≥880 ≥10 260/300

EN 13674-2 R 260Cr 0.40/0.60 020/0.45 1.20/1.60 ≤0.025 0.008/0.025 0.40/0.60 ≤0.004 ≤0.060 ≤2.5 ≥880 ≥10 260/300

Urban transport


C Si Mn P S Cr Al VH2 (ppm)

Rm (MPa)

Elong -ation (%)


Rm (KSI)

EN 14811:2006 R200G 0.40/0.60 0.15/0.58 0.70/1.20 ≤0.035 ≤0.035 ≤0.15 ≤0.004 ≤3.0 ≥680 ≥14 200/240

R220G 0.50/0.65 0.15/0.58 1.00/1.25 ≤0.025 ≤0.025 ≤0.15 ≤0.004 ≤3.0 ≥780 ≥12 220/260

R260G 0.63/0.82 0.15/0.58 0.70/1.20 ≤0.025 ≤0.025 ≤0.15 ≤0.004 ≤2.5 ≥880 ≥10 260/300

Corus Rail 700V 0.20/0.30 0.20/0.30 1.20/1.50 ≤0.025 ≤0.025 0.10/0.16 ≤3.0 685/853 ≥14

900V 0.41/0.51 0.20/0.30 1.10/1.40 ≤0.025 ≤0.025 0.10/0.15 ≤2.5 ≥885 ≥10

Customer E 24-2NE* ≤0.17 ≤0.045 ≤0.045 ≥ 0.02 340/460 (1) ≥28

300** 0.040/0.06 0.25/0.45 ≤0.025 ≤0.020 ≥300 Resistance < 14 µΩ. cm

* piste, ** conductor rail (1) Re ³ 235 Mpa and KCV at +20°C > 35 J/cm²

Steel sleepers

EN 10025 S275 0.16/0.22 0.20/0.49 0.60/0.90 ≤0.040 0.010/0.025 ≤0.004 400/510 ≥20

This list is indicative of the profiles produced at Corus, however other profiles can be requested.

CEN Design Rail Sections

Specification 36E2(prev S40)

39E1 (prev 80 A)

45E1 (prev 90 A)

46E1 (prev SBB1)

46E2 (prev U33)

49E1 (prev DIN S49)

Head crown Single radius mm • •

Double radius mm 200/60 300/80 200/60 300/80

Gauge corner Radius J=mm 13 13 13 13

J=7/16in. •

J=1/2in •

Head width Taper 1:20 • • Parallel 1:20 1:17.2

Fishing tapers Upper & lower 1:2.75 • •

Upper Fishing taper 1:3 1:4 1:3 1:3

Upper fillet Radius mm 7 6/30 7 7

Double 5/16 & 7/8in. • •

Web Parallel Yes Yes Yes Centre portion only

Radius mm 80/120

Face radius M=20” • •

Double tapered foot • •

Lower fillet Radius mm 7 6/30 7 7

Radius L= 1/2in 1/2in.

Lower Fishing taper 1:3 1:4 1:3 1:3

Outer Flange taper 1:10 1:4 1:10 1:7.81

Rail height A in. 5 1/4 5 5/8 mm 128 133.35 142.88 145 145 149

Foot width B in. 4 5/8 5

mm 115 117.47 127.00 125 134 125

Head width C in. 2 1/2 2 5/8

mm 60 63.50 66.67 65 62 67

Web thickness D in. 33/64 35/64

mm 13 13.10 13.89 14 15 14

Head area in.2 3.52 4.01

mm2 1989 2270 2590 2543 2510 2982

Web area in.2 1.56 1.78

mm2 866 1007 1147 1192 1121 1106

Foot area in.2 2.77 3.11

mm2 1806 1789 2008 2147 2263 2204

Total area in.2 7.85 8.90

mm2 4661 5065 5745 5882 5894 6292

Section weight lb/yd 80.15 90.91

kg/m 36.59 39.76 45.10 46.17 46.27 49.39

Moment of inertia lxx in.4 28.9 37.6

cm4 1020 1205 1564 1641.1 1642.7 1816

Section modulus zxx in.3 10.8 13.1

cm3 151 177 215 217 213 240.3

Distance of neutral axis

from top of rail

in. 2.67 2.87

mm 67.68 67.89 72.79 75.65 77.14 75.59

Moment of inertia Iyy in.4 5.3 6.8

cm4 203 220 285 298.2 329.3 319.1

Section modulus Zyy in.3 2.3 2.7

cm3 35 37 45 47.7 49.1 51

Rail ProfilesSteel Grades

Heavy haul tracks


C Si Mn P S Cr Al V H2 (ppm)

Rm (MPa)

Elong -ation (%)


Rm (KSI)

Arema Standard 0.74/0.84 0.10/0.60 0.75/1.25 ≤0.020 ≤0.020 ≤0.25 ≤0.10 ≤0.10 ≥98 ≥10 ≥300 143

Low alloy

Standard 0.72/0.82 0.10/0.50 0.80/1.10 ≤0.020 ≤0.020 0.25/0.40 ≤0.005 ≤0.10

Intermediate 0.72/0.82 0.10/1.00 0.70/1.25 ≤0.020 ≤0.020 0.40/0.70 ≤0.005 ≤0.10 ≥1015 ≥8 ≥325 147

High Strength 0.74/0.84 0.10/0.60 0.75/1.25 ≤0.020 ≤0.020 ≤0.25 ≤0.10 ≤0.10 ≥1180 ≥10 370/410 171

Low alloy

High Strength 0.72/0.82 0.10/1.00 0.70/1.25 ≤0.020 ≤0.020 0.40/0.70 ≤0.005 ≤0.10 ≥1180 ≥10 370/410

UIC 860-O 1100 0.60/0.82 0.30/0.90 0.80/1.30 ≤0.030 0.008/0.035 0.80/1.30 ≥1080 ≥9 157

EN 13674-1 R 320Cr 0.60/0.80 0.50/1.10 0.80/1.20 ≤0.020 0.008/0.025 0.80/1.20 ≤0.004 ≤0.18 ≤ 2.5 ≥1080 ≥9 320/360 157

R 350HT 0.72/0.80 0.15/0.58 0.70/1.20 ≤0.020 0.008/0.025 ≤0.15 ≤0.004 ≤0.03 ≤ 2.5 ≥1175 ≥9 350/390 170

R 350LHT 0.72/0.80 0.15/0.58 0.70/1.20 ≤0.020 0.008/0.025 ≤0.30 ≤0.004 ≤0.03 ≤ 2.5 ≥1175 ≥9 370/410 170

Corus Rail MHH 0.72/0.82 0.40/0.80 0.80/1.10 ≤0.020 ≤0.20 0.40/0.60 ≤0.004 ≤2.0 ≥1280 ≥12 381/408 186

14 15

Technical Guide


Specification 50E1 (prev U50E)

50E2 (prev 50 EB-T)

50E3 (prev BV50)

50E5 (prev UNI50)

50E6 (prev U50)

Head crown Single radius mm 400

Double radius mm 200/60 300/80 300/80 200/60

Gauge corner Radius J=mm 13 13 13 14 13

Head width Taper 1:20 1:20 1:20 1:16 1:20

Upper Fishing taper 1:3 1:3 1:3 1:3 1:3

Upper fillet Radius mm 12 8/30.81 7 7 12

Web Parallel Yes Yes Centre portion only Yes

Radius mm 450 80/120

Lower fillet Radius mm 12 8/30.81 7 7 12

Lower Fishing taper 1:3 1:3 1:3 1:3 1:3

Outer Flange taper 1:10 1:8 1:8.31 1:8 1:10

Rail height A mm 153 151 155 148 153

Foot width B mm 134 140 133 135 140

Head width C mm 65 72 70 67 65

Web thickness D mm 15.5 15 14 14 15.5

Head area mm2 2745 2608 2836 2946 2745

Web area mm2 1273 1279 1295 1106 1273

Foot area mm2 2397 2478 2240 2310 2465

Total area mm2 6416 6365 6371 6362 6484

Section weight kg/m 50.37 49.97 50.02 49.9 50.9

Moment of inertia lxx cm4 1987.8 1988.8 2057.8 1844 2017.8

Section modulus zxx cm3 246.7 248.5 259.5 242.1 248.3


from top of rail mm 80.56 80.04 79.3 76.15 81.26

Moment of inertia Iyy cm4 365 408.4 351.3 362.4 396.8

Section modulus Zyy cm3 54.5 58.3 52.8 53.7 56.7


Specification 52E1 (prev 52RATP)

54E1 (prev UIC54)

54E2 (prev UIC54E)

54E3 (prev DIN S54)

Head crown Single radius mm 350

Double radius mm 300/80 300/80 300/80

Gauge corner Radius J=mm 12 13 13 13

Head width Taper Parallel 1:20 1:20 1:17.2

Upper Fishing taper 1:2 1:2.75 1:2.75 1:3

Upper fillet Radius mm 12 8/22 8/22 16

Web Parallel

Radius mm 400/600 508 508 500

Lower fillet Radius mm 12 16 16 16

Lower Fishing taper 1:2 1:2.75 1:2.75 1:3

Outer Flange taper 1:10 1:10 1:10 1:7.81

Rail height A mm 150 159 161 154

Foot width B mm 150 140 125 125

Head width C mm 65 70 67.01 67

Web thickness D mm 15 16 16 16

Head area mm2 2959 2901 2942 3223

Web area mm2 1102 1486 1486 1338

Foot area mm2 2583 2590 2428 2391

Total area mm2 6643 6977 6856 6952

Section weight kg/m 52.15 54.77 53.82 54.57

Moment of inertia lxx cm4 1970.9 2337.9 2307 2074

Section modulus zxx cm3 247.1 278.7 276.4 262.8


from top of rail mm 79.76 83.87 83.47 78.93

Moment of inertia Iyy cm4 434.2 419.2 341.5 354.8

Section modulus Zyy cm3 57.9 59.9 54.6 56.8

16

Technical Guide

17


Specification 55E1 (prev U55)

56E1 (prev BR113A)

60E1 (prev UIC60)

60E2 (prev UIC60)

Head crown Single radius mm

Double radius mm 200/60 305/80 300/80 200/70

Gauge corner Radius J=mm 13 12.7 13 8/16

Head width Taper 1:20 1:20 1:20 1:20

Upper Fishing taper 1:3 1:2.75 1:2.75 1:2.75

Upper fillet Radius mm 12 8 7/35 7/35

Web Parallel Yes Yes Centre portion only Centre portion only

Radius mm 120 120/120

Lower fillet Radius mm 12 15 7/35 7/35

Lower Fishing taper 1:3 1:2.75 1:2.75 1:2.75

Outer Flange taper 1:10 1:10 1:14 1:14

Rail height A mm 155 158.75 172 172

Foot width B mm 134 140 150 150

Head width C mm 62 69.85 72 72

Web thickness D mm 19 20 16.5 16.5

Head area mm2 2897 2860 3084

Web area mm2 1465 1712 1730

Foot area mm2 2775 2597 2856

Total area mm2 7137 7169 7670 7648

Section weight kg/m 56.03 56.3 60.21 60.03

Moment of inertia lxx cm4 2150.4 2321 3038.3 3021.5

Section modulus zxx cm3 255.2 275.5 333.6 330.8


from top of rail mm 84.26 84.24 91.08 91.33

Moment of inertia Iyy cm4 418.4 421.6 512.3 500.5

Section modulus Zyy cm3 62.4 60.2 68.3 68.1

A.S.C.E. Design Rail Sections

Specification A.S.C.E. 75 A.S.C.E. 80 A.S.C.E. 85 A.S.C.E. 90

Head crown Single radius 12 in • •

Double radius 300 & 80mm

Gauge corner Radius J= 5/16 in. • •

Radius J= 13mm

Head width Parallel • •

1:20 taper

Fishing tapers Upper & lower 13°=1:4.3 • •

Upper & lower 1:2.75

Fillet radii Upper & lower 1/4 in. • •

Upper mm

Lower mm

Foot Double tapered

Outer taper

Web Fully radiused M=12” Rad. • •

Fully radiused M= 508mm Rad.

Upper & lower radii 120mm

Centre parallel

Rail height A in. 4 13/16 5

mm 122.24 127.00 131.76 142.88

Foot width B in. 4 13/16 5

mm 122.24 127.00 131.76 130.18


mm 62.71 63.50 65.09 65.09


mm 13.49 13.89 14.29 14.29


mm2 1981 2129

Web area in.2 1.54 1.64

mm2 996 1059


mm2 1756 1890


mm2 4733 5078


kg/m 37.18 39.86 42.2 44.65


cm4 954 1101 1255.8 1610.8

Section modulus Zxx in.3 9.11 10.09

cm3 149 165

Distance of neutral axis in. 2.51 2.62

from top of rail mm 63.9 66.59


cm4 226 259 288.7


cm3 37 41

18

Technical Guide

19

A.R.E.M.A. Designs

Specification 100RE 115RE 119RE 132RE 136RE 141RE (prev 141AB)

Head crown Single radius 14 in.

Double radii 10in. & 1 1/4in. 10 in. & 10 in. & • • 8 in. &

1 1/2 in. 1 1/2 in. 1 3/4 in.

Gauge corner Radius J= 3/8 in. • • •

Radius J= 9/16mm • • •

Head width Taper 1:40 • • • •

1:16 1:11.4

Fishing tapers Upper & lower 1:4 • • • • •

Upper 1:3, lower 1:4 •

Upper fillet radii Single 3/8 in. •

Double 3/4 in. & 3 in. rad. • •

Double 5/16 in. & 3/4 in. rad. • • •

Double 7/16 in. & 3/4 in. rad.

Web Face radius M in. 14 14 14 8 & 16 8 & 20 8 & 20

Lower fillet L radius 3/4 in. 5/8in. • • 7/8in. • •

Rail height A in. 6 6 5/8 6 13/16 7 1/8 7 5/16 7 7/16

mm 152.40 168.27 173.04 180.97 185.74 188.91

Foot width B in. 5 3/8 5 1/2 5 1/2 6 6 6

mm 136.52 139.70 139.70 152.40 152.40 152.40

Head width C in. 2 11/16 2 23/32 2 21/32 3 2 15/16 3 1/16

mm 68.26 69.06 67.47 76.20 74.61 77.79

Web thickness D in. 9/16 5/8 5/8 21/32 11/16 11/16

mm 14.29 15.87 15.87 16.67 17.46 17.46

Head area in.2 3.80 3.92 4.31 4.43 4.82 5.37

mm2 2450 2524 2770 2855 3099 3465

Web area in.2 2.21 3.04 3.04 3.61 3.64 3.55

mm2 1428 1961 1961 2332 2347 2290

Foot area in.2 3.90 4.29 4.29 4.87 4.87 4.87

mm2 2518 2770 2770 3142 3142 3142

Total area in.2 9.91 11.25 11.64 12.91 13.33 13.80

mm2 6396 7256 7510 8329 8600 8903

Section weight lb/yd 101.21 114.68 118.67 131.66 135.88 140.70

kg/m 50.21 56.89 58.87 65.31 67.40 69.79

Moment of inertia lxx in.4 48.40 65.90 71.40 87.90 94.20 100.44

cm4 2015 2743 2972 3659 3921 4181

Section modulus Zxx in.3 14.87 18.10 19.40 22.40 23.70 25.24

cm3 244 297 318 367 388 414

Distance of neutral axis in. 3.26 3.63 3.69 3.92 3.97 3.97

from top of rail mm 82.78 92.20 93.73 99.57 100.83 100.85

Moment of inertia Iyy in.4 9.29 10.73 10.84 14.40 14.44 14.91

cm4 387 447 451 599 601 621

Section modulus Zyy in.3 3.44 3.90 3.94 4.79 4.82 4.97

cm3 56 64 65 78 79 81

Various Rail Sections

Specification 100CP 122CB 124JK 136RE10 136RE14 136CN 136JK 136OP

Head crown Single radius mm 355.6 4in.

Double radii 254/31.75 203.2/44.45 254/31.75 355.6/31.75

Triple radii

Gauge corner Radius J= in. 9/16in.

Radius J= 13mm 14.29 9.63 9.53/14.29 14.29 14.29 14.29

Head width Taper 1:20 1:16 1:20 1:40 1:40 1:40 1:40

Upper Fishing taper 1:3 1:4 1:2.75 1:4 1:4 1:4 1:4

Upper fillet Radius in. 5/16 in. & 3/4 in

mm 9.53 19.05 19.05 19.05 19.05 7.74

Web Parallel

Parallel in. 8/20in.

Radius mm 355.6 76.2/355.6 203.2/506 203.2/508

Radius M mm 355.6 203.2

Lower fillet Radius in. 3/4 in.

mm 15.88 19.05 19.05 19.05 19.05 19.05

Lower Fishing taper 1:3 1:4 1:13.703 1:4 1:4 1:4 1:4

Outer Flange taper 1:10

Rail height A in. 7 11/32

mm 153.99 172.24 174.63 185.74 185.74 186.53 185.74 185.74

Foot width B in. 6

mm 136.53 152.4 139.7 152.4 152.4 152.40 152.4 152.4

Head width C in. 2 15/16

mm 65.6 72.53 73.48 74.61 74.61 74.61 73.48 74.01

Web thickness D in. 11/16

mm 14.29 16.67 15.88 17.46 17.46 17.46 17.46 17.46

Head area in.2 4.86

mm2 3136

Web area in.2 3.64

mm2 2347

Foot area in.2 4.87

mm2 3142

Total area mm2 6478 7748 7831 8593 8632 8625

Section weight lb/yd 136.49

kg/m 50.85 60.74 61.39 67.36 67.66 67.62 67.33 67.17

Moment of inertia in.4 94.88

lxx cm4 2064.4 3065.1 3164.1 3920.9 3954.2 3949.6 3916 3910.3

Section modulus in.3 23.79

Zxx cm3 247 331.5 343.5 388.4 393.3 389.8

Distance of neutral in. 3.99

axis from top of rail mm 83.57 92.46 92.11 100.84 100.45 101.31

Moment of inertia in.4 14.47

Iyy cm4 386.3 528.9 483.8 601 603.5 604.8 602.7 600.4

Section modulus in.3 4.82

Zyy cm3 56.6 69.4 69.3 79 79.3 79.4

20

Technical Guide

21

India 52

305 & 80

•

•

1:2.75

8 & 22.5

381 & 381

13

1:2.75

1:6

156

136

67

15.5

2882

1334

2367

6583

51.68

2105

260

80.89

354

52


Specification

Head crown Single radius mm

Double radii mm

Gauge corner Radius J= in.

Radius J= 13mm

Head Parallel

Upper Fishing taper

Upper fillet Radius in.

mm

Web Parallel

Face radii in.

mm

Lower fillet Radius in.

mm

Lower Fishing taper

Outer Flange taper

Rail height A in.

mm

Foot width B in.

mm

Head width C in.

mm

Web thickness D in.

mm

Head area in.2

mm2

Web area in.2

mm2

Foot area in.2

mm2

Total area in.2

mm2

Section weight lb/yd

kg/m

Moment of inertia lxx in.4

cm4

Section modulus Zxx in.3

cm3

Distance of neutral axis in.

from top of rail mm

Moment of inertia Iyy in.4

cm4

Section modulus Zyy in.3

cm3

Ethiopia UNI 36 (MOD)

200 & 29

12

•

1:2

9

•

9

1:2

1:5.56

130

106

60

14

2084

882

1705

4671

36.67

1031

155

66.48

164

31

30kg/m

Flat

9

•

1:4

7.8

706

7.8

1:4

1:15

125.5

106

56

11

1723

898

1231

3852

30.24

839.1

132

62.1

133.4

25.17

36kg

128

115

58.27

13

36.54

1019.7

R43

300

13

1:3

5 & 10

350

15

1:3

1:6

140

114

70

14.5

2422

1214

2042

5678

44.57

1479

206

71.65

257

45

R65

500/80

15

1:20

1:4

7/15

370/400

25

1:4

180

150

73

18

8264

64.87

3543.1

359

98.7

570.1

76

CHN 50

(prev R50-50 CH China)

300

13

Parallel

1:4

5/12

350

20

1:4

152

132

70

15.5

6560

51.50

2026.6

249.4

81.27

374.9

56.8

CHN 60 (prev China 60)

300/80

13

1:20

1:3

8 & 25

400

20

1:3

1:9

176

150

73

16.5

2902

1979

2864

7745

60.80

3217

339

94.77

524

70

Australia 60kg/m

300/100

15

1:20

1:4

20

300

20

1:4

170

146

70

16.5

3009

1974

2752

7735

60.72

2935

370

90.65

490

67.1


22

Technical Guide

23

British Standard ‘A’ Designs

Specification 60A 90AM 90R

Head crown Single radius 12 in • 9

Double radii 12” & P=3 1/8in.

Gauge corner radius J=3/8in. •

J=7/16in.

J=1/2in. 1/2

Head side taper 1:20 •

Fishing tapers Upper & lower 1:2.75 • 1:3/1:6

Upper fillet radii Double 5/16 & 7/8in. •

Single 8mm 3/8

Web Face radius M=20” •

Parallel •

Lower web radius 15

Lower fillet radius L= 3/8in. 3/8

Double tapered foot • Single

Rail height A in. 4 1/2 5 5/8

mm 114.30 142.88 142.88

Foot width B in. 4 5/16 5 3/8

mm 109.54 127 136.53


mm 57.15 67.17 66.67


mm 11.11 13.89 13.89


mm2 1698 2433

Web area in.2 1.12 1.88

mm2 725 1213


mm2 1477 2024


mm2 3900 5670


kg/m 30.62 44.91 44.51


cm4 696 1549.7 1584

Section modulus Zxx in.3 7.2 12.9

cm3 117 212

Distance of neutral axis in. 2.34 2.94



cm4 150 279 333


cm3 27 49

Special Rail Sections for Switches and Crossings

Specification 50E6A1 (prev Incli- ned U60)

50E2T1 (prev 63T)

54E1A3 (prev 54D)

60E1A4 (prev 60D)

60E1A5 (prev 60 D 40)

60E1T2 (prev A74)

60E2A2 (prev Zu60 E2-40)

Head crown Double radii 300 & 80mm 200 & 60 • • • • •

Single radius mm

Gauge corner Radius J= 13mm • 13 13 13 13 13

Head width Taper 1:20 • • • •

Parallel

Upper Fishing taper 1:2.75 1:3 1:3 1:2.75 1:2.75 1:2.75 1:2.75 1:2.75

Web Parallel web • • • • • Centre only •

Radius mm 120/120

Fillet radii Upper and lower mm 12 16 16 12 12 16 19

Lower Fishing taper 1:2.75 1:3 1:3 1:2.75 1:2.75 1:2.75 1:2.75

Short flange taper 1:10 1:8 1:12 1:13 1:13 1:14 1:4

Long flange taper 1:10 1:8 1:17 1:17 1:17 1:14 1:17

Inclination to vertical 1:20

Rail height A mm 155 151 129 142 142 172 134

Foot width Short/long mm 78/70 70/70 60/85 65/85 65/85 75/75 55/85

(B) total mm 148 140 145 150 150 150 140

Head width C mm 65 72 70 72 72 72 72

Web thickness D 8/8 15/15 16.25/16.25 16.25/16.25 16.25/16.25 15/15 28/16

mm 16 30 32.5 32.5 32.5 30 44

Head area mm2 2742 2608 3403 3100 3116 3307 3362

Web area mm2 1314 2532 1802 2015 2015 2919 2654

Foot area mm2 2847 2882 3545 3780 3780 3231 3258

Total area mm2 6906 80.19 87.41 8895 8911 9460 9274

Section weight kg/m 54.21 62.95 68.62 69.83 69.95 74.24 72.8

Moment of inertia lxx cm4 2213 2171 1552.5 2025.8 2035.7 3304 1716.3

Section modulus zxx cm3 259 263 210 250.4 252.1 355.1 227.7


from top of rail mm 85.3 82.5 73.92 80.9 80.75 93.1 75.35

Moment of inertia Iyy cm4 497 482 772.5 764.4 764.3 615.7 739

Section modulus Zyy cm3 65 69 96 93.6 93.7 82.1 89.9

24

Technical Guide

25

Other Rail and Track Sections

Specification 33C1 (prev Check Rail U69)

Bull Head Rail BS95RBH

Head crown Single radius mm 12in.

Double radii mm

Gauge corner Radius J= in. 1/2in.

Radius J= mm 13mm

Head width Parallel head •

Upper Fishing taper 1:2.75 •

Upper fillet Radii 1/4in.

Parallel web •

Lower Fillet radius 1/4in.

Lower Fishing taper 1:2.75 •

Outer Flange taper 1:10

Foot base single radius 12in.

Rail height A in. 5 23/32

mm 93 145.26

Foot width B in. 2 3/4 mm 40 69.85

Head width C in. 2 3/4 mm 80 69.85

Web thickness D in. 3/4 mm 20 19.05

Head area in.2 4.48

mm2 2846 2891

Web area in.2 1.98

mm2 765 1275

Foot area in.2 2.84

mm2 589 1830

Total area in.2 9.29

mm2 4202 5996

Section weight lb/yd 94.88

kg/m 32.99 47.07

Moment of inertia lxx in.4 35.03

cm4 297 1458

Section modulus Zxx in.3 11.5

cm3 51.8 188

Distance of neutral axis in. 2.67


Moment of inertia Iyy in.4 4.1

cm4 219 171

Section modulus Zyy in.3 2.98

cm3 44.4 49

Conductor/Electric Contact Rails

Specification Section No. 75 Section No. 74TW Section T52

Head crown Single radius 380mm 610 •

Gauge corner Radius J= mm 6.5 7 3

Head width Parallel • • •

Upper Fishing taper 1:4.3 1:4.9

Upper fillet Radius 6.5 7

Web Parallel web • •

Lower fillet Radius 6.5 7

Lower Fishing taper 1:4.3 1:4.9

Rail height A mm 103.5 138 100.5

Foot width B mm 124 140 44

Head width C mm 105 89 101

Web thickness D mm 70 22.5 46

Head area mm2 3960 3867 3874

Web area mm2 2477 1185 2790

Foot area mm2 3053 4525

Total area mm2 9489 9576 6664

Section weight kg/m 74.49 75.18 52.31

Moment of inertia lxx cm4 972.3 2164 540.8

Section modulus zxx cm3 184 286 89.6


from top of rail mm 52.72 75.78 40.18

Moment of inertia Iyy cm4 773.9 892 374.3

Section modulus Zyy cm3 124.8 127 68.1

26

Technical Guide

27

Grooved Rails

Specification 46G1 (prev SEi60G)

55G1 (prev 35GP)

55G2 (prev 41GP)

59R1 (prev Ri59)

59R2 (prev Ri59N)

60R1 (prev Ri60)

60R2 (prev Ri60N)

62R1 (prev Np4aM)

62R2 (prev NP4aS)

68G1 (prev SEi70G)

Rail height A mm 150 152.5 152.5 180 180 180 180 180 180 200

Foot width B mm 140 141.5 141.5 180 180 180 180 180 180 180

Head width C mm 125 111.8 116.8 113 113 113 113 116 116 146

Web thickness D mm 11 13 13 12 12 12 12 12 12 13

Guage corner radius mm 13 10 10 10 13 10 13 10 13 13

Total area mm2 5814 6978 7049 7515 7414 7721 7611 7945 7886 8699

Section weight kg/m 45.64 54.78 55.33 59.00 58.20 60.60 59.75 62.37 61.91 68.29

Groove width mm 60 36 41 42 42 35.98 36.35 34.44 33.98 70

Groove depth mm 45 45.9 45.9 47 47 47 47 63 63 47

Special Grooved Sections

Specification G51 35GP13 35GPu 41GP13 41GPi 41GPu

Rail height A mm 152 152.5 152.5 152.5 152.5 152.5

Foot width B mm 149 141.5 141.5 141.5 141.5 141.5

Head width C mm 126 111.8 110.6 116.8 115.6 115.6

Web thickness D mm 12 13 13 13 13 13

Guage corner radius mm 9 13 13 13 13 13

Total area mm2 6470 6969 6837 7041 6890 6911

Section weight kg/m 50.79 54.71 53.67 55.27 54.09 54.25

Groove width mm 61.5 34.34 36 39.33 41 41

Groove depth mm 45 45.89 45.9 45.9 45.9 45.9

Track Running Rails

Specification Piste Matra Piste RATP

Rail height A mm 250 230

Head width C mm 120 140

Section weight kg/m 62.85 68.33

Steel sleepers

Steel sleepers have been used throughout the world for decades and Corus has been producing them for more than 80 years.

The traditional sleeper range embraces the needs of railways operating in arduous environments and with difficult conditions for track building. For European higher speed applications, Corus has developed new products which respond to the conditions of modern track for both high-speed trains and under heavy loads. Corus’ experience in the manufacture of fatigue-resistant products has been applied with care to its range of advanced steel sleepers. The principles of design for the modern range of steel sleepers were established through joint research and in-track testing with customers. This combines the virtues of fatigue resistant rail seat design, low section height, optimised section properties and spade options for different stability requirements depending on track design and duty. Lightweight, dimensionally more accurate and more resistant to overload than wooden or concrete sleepers, the design and manufacture of Corus sleepers is subject to a rigorous programme of testing and evaluation.

Corus sleepers can be used with a range of fasteners including Vossloh and Nabla type systems and the recently adopted Pandrol Fastclip.

The success of steel sleepers is due to the large number of benefits they offer compared with other sleeper types. These include:

Installation savingsTime and cost savings due to a reduced ballast requirement.•Simplified logistics resulting from sleeper stackability and •low weight.Unique design ensuring compatibility with mechanised track •laying methods.

Improved performance and through-life economicsLong spade ends for good lateral stability during passage of •traffic.Spade designs with dynamic stability features.•Well distributed load which reduces ballast pressure.•Less tamping required during sleeper life.•

Environmental benefitsCorus steel sleepers are recyclable and reusable.•Reduced ballast requirement.•No problems of chemical leaching (as can happen with •timber sleepers).

All Corus steel sleepers are manufactured from the 3 basic trough rolled sections.

Sleeper data

Section IDPrinciple dimensions

202 436 600

Rail seat thickness mm 7.5/1.2 11.8 14.25

Rail seat width mm 160 168 168

Leg thickness mm 6.75 7.125 7.6

Section width B mm 240 260 280.5

Section height A mm 82.5 100.75 115.25

Section properties

Moment of Inertia Ixx cm4 200 452.79 655

Section modulus cm3 34.4 65.85 81.3

Height of neutral

axis from base mm 58.1 68.76 80.5

Plate weight kg/m 22.1 31.69 39.53

Section 202 Section 436 Section 600

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Technical Guide

29

Final Technical - Signed Off

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