BS EN 13674-1

BRITISH STANDARD
BS EN 13674-1:2003Incorporating Corrigendum No. 1
Railway applications — Track — Rail —

Part 1: Vignole railway rails 46 kg/m and above

The European Standard EN 13674-1:2003 has the status of a British Standard

ICS 45.080

��

BS EN 13674-1:2003

This British Standard, was published under the authority of the Standards Policy and Strategy Committee on 3 October 2003

© BSI 30 July 2004

ISBN 0 580 42726 9

National forewordThis British Standard is the official English language version of EN 13674-1:2003. It partially supersedes BS 11:1985 which will be amended accordingly.BS EN 13674-1:2003 applies to all new installations of Vignole (flat bottom) rail sections of 46 kg/m and above. Other Vignole rails of 27 kg/m and above, switch and crossing rails and check rails will be covered by other parts of BS EN 13674 when they are published.BS 11:1985 will be declared obsolescent following the publication of the other parts of BS EN 13674. This will be done in order to facilitate repairs and maintenance of existing track conforming to and unique to BS 11:1985.The UK participation in its preparation was entrusted to Technical Committee RAE/2, Railway track components, which has the responsibility to:

A list of organizations represented on this committee can be obtained on request to its secretary.Additional informationIn this standard rail grades are based on hardness whereas in BS 11 they are based on tensile strength. The approximate equivalence is shown as follows.

In BS 11, rail sections are identified by a number which is the approximate mass per a unit length of rails in lb/yd. An approximate conversion to kg/m can be made by multiplying the value in lb/yd by 0,49.NOTE The term “Vignole rail” is in common use elsewhere in Europe. It is derived from the name of Charles Blacker Vignoles, an early railway engineer who promoted the use of flat bottom rail.

The textual error set out below was discovered when the English language version of EN 13674-1 was adopted as the national standard. It has been reported to CEN/TC 256/SC 1 in a proposal to amend the text of the European standard.

— Table 5a) column headed “running surface” to be changed to “Sulfur content”.The permitted range of sulfur content is shown as a percentage by mass in Table 5a) in the column incorrectly headed as “running surface”.Cross-referencesThe British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online.

— aid enquirers to understand the text;— present to the responsible international/European committee any enquiries

on the interpretation, or proposals for change, and keep the UK interests informed;

— monitor related international and European developments and promulgate them in the UK.

BS EN 13674-1 grade BS 11 gradeR220 NormalR260 Wear resisting AR260Mn Wear resisting B

This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application.Compliance with a British Standard does not of itself confer immunity from legal obligations.

Summary of pagesThis document comprises a front cover, an inside front cover, the EN title page, pages 2 to 106, an inside back cover and a back cover.
The BSI copyright notice displayed in this document indicates when the document was last issued.
Amendments issued since publication

Amd. No. Date Comments

15298Corrigendum No. 1

30 July 2004 Changes to national foreword

EUROPEAN STANDARD

NORME EUROPÉENNE

EUROPÄISCHE NORM

EN 13674-1

September 2003

ICS 45.080

English version

Railway applications - Track - Rail - Part 1: Vignole railway rails46 kg/m and above

Applications ferroviaires - Voie - Rails - Partie 1: Railsvignole de masse supérieure ou égale à 46 kg/m

Bahnanwendungen - Oberbau - Schienen - Teil 1:Vignolschienen ab 46 kg/m

This European Standard was approved by CEN on 28 February 2003.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the officialversions.

CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and UnitedKingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATIONC OM ITÉ EUR OP ÉEN DE NOR M ALIS AT IONEUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2003 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.

Ref. No. EN 13674-1:2003 E

EN 13674-1:2003 (E)

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Contents

Page

Foreword....................................................................................................................... ...............................................4

Introduction ................................................................................................................... ..............................................5

1 Scope ......................................................................................................................... .....................................7

2 Normative references .......................................................................................................... ..........................7

3 Terms and definitions......................................................................................................... ...........................7

4 Information to be supplied by the purchaser................................................................................... ...........8

5 Steel grades.................................................................................................................. ..................................9

6 Profile drawings/properties/mass .............................................................................................. ..................9

7 Manufacture................................................................................................................... .................................97.1 Product integrity ........................................................................................................... .................................97.1.1 Factory production control ................................................................................................ ...........................97.1.2 Best practice manufacture................................................................................................. .........................107.2 Blooms ...................................................................................................................... ....................................107.3 Rails....................................................................................................................... ........................................107.4 Identification.............................................................................................................. ...................................107.4.1 Branding .................................................................................................................. .....................................107.4.2 Hot stamping .............................................................................................................. ..................................117.4.3 Cold stamping ............................................................................................................. .................................117.4.4 Other identification ...................................................................................................... ................................11

8 Qualifying tests .............................................................................................................. ..............................128.1 Procedure ................................................................................................................... ..................................128.2 Fracture toughness (KIc) .............................................................................................................................128.2.1 Test pieces and test methods.............................................................................................. .......................128.2.2 Qualifying criteria ....................................................................................................... .................................128.3 Fatigue crack growth rate ................................................................................................... ........................138.3.1 Test method............................................................................................................... ...................................138.3.2 Test pieces............................................................................................................... .....................................138.3.3 Number of tests and test conditions ....................................................................................... ..................138.3.4 Qualifying criteria ....................................................................................................... .................................138.4 Fatigue test ................................................................................................................ ...................................138.4.1 Test method............................................................................................................... ...................................138.4.2 Test pieces............................................................................................................... .....................................148.4.3 Number of tests and test conditions ....................................................................................... ..................148.4.4 Qualifying criteria ....................................................................................................... .................................148.5 Residual stress in rail foot ................................................................................................ ..........................148.5.1 Test method............................................................................................................... ...................................148.5.2 Test pieces............................................................................................................... .....................................148.5.3 Measurements.............................................................................................................. ................................148.5.4 Qualifying criteria ....................................................................................................... .................................148.6 Variation of centre line running surface hardness of heat treated rails ................................................148.7 Tensile strength and elongation............................................................................................. ....................158.8 Segregation ................................................................................................................. .................................158.9 Other qualifying requirements............................................................................................... .....................16

9 Acceptance tests .............................................................................................................. ...........................169.1 Laboratory tests ............................................................................................................ ...............................169.1.1 General................................................................................................................... .......................................169.1.2 Chemical composition...................................................................................................... ...........................169.1.3 Microstructure............................................................................................................ ..................................20

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9.1.4 Decarburisation........................................................................................................... .................................219.1.5 Oxide cleanness........................................................................................................... ................................219.1.6 Sulfur prints............................................................................................................. .....................................219.1.7 Hardness.................................................................................................................. .....................................229.1.8 Tensile tests ............................................................................................................. ....................................229.1.9 Retest procedures ......................................................................................................... ..............................239.2 Dimension tolerances........................................................................................................ ..........................239.2.1 Profile ................................................................................................................... .........................................239.2.2 Straightness, surface flatness and twist .................................................................................. .................249.2.3 Cutting and drilling ...................................................................................................... ................................279.3 Gauges...................................................................................................................... ....................................279.4 Inspection requirements/tolerances for internal quality and surface quality .......................................279.4.1 Ultrasonic test requirements .............................................................................................. ........................279.4.2 Surface quality ........................................................................................................... ..................................29

Annex A (normative) Rail profiles ................................................................................................................ ...........44

Annex B (normative) Standard test method for the determination of the plane strain fracturetoughness ( KIc) of rails ..................................................................................................................... ..........68

Annex C (normative) Method for the determination of rail foot surface longitudinal residual stresses .........74

Annex D (normative) Limiting sulfur prints ....................................................................................................... .....77

Annex E (normative) Profile and drilling gauges.................................................................................................. .91

Annex F (informative) Comparison of steel designations referred to in this standard compared tothose in EN 10027-1 and EN 10027-2 ............................................................................................. ..........104

Annex ZA (informative) Clauses of this European Standard addressing essential requirements or otherprovisions of EU Directives. ................................................................................................... ..................105

Bibliography ................................................................................................................... .........................................106

EN 13674-1:2003 (E)

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Foreword

This document (EN 13674-1:2003) has been prepared by Technical Committee CEN/TC 256 “Railwayapplications”, the secretariat of which is held by DIN.

This European Standard shall be given the status of a national standard, either by publication of an identical text orby endorsement, at the latest by March 2004, and conflicting national standards shall be withdrawn at the latest byMarch 2004.

This document has been prepared under a mandate given to CEN by the European Commission and the EuropeanFree Trade Association, and supports essential requirements of EU Directive(s).

For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document.

This part of EN 13674 is the first of a series of standards for rails.

Railway applications – Track:

� Part 1: Vignole railway rails 46 kg/m and above

� Part 2: Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above

� Part 3: Check rails

� Part 4: Vignole railway rails from 27 kg/m to, but excluding 46 kg/m

Other standards planned for publication include the following:

� Special purpose rail – Part 1:Grooved and associated construction.

� Flash butt welding of new rails R220 and R260 grade rails in a fixed plant.

� Flash butt welding of new R260Mn and R350HT grade rails in a fixed plant.

� Flash butt welding of new R220 and R260 grade rails by mobile welding machines at sites other than at a fixedplant.

� Flash butt welding of R220 and R260 grade reusable rails.

� Flash butt welding in association with crossing construction.

� Approval of aluminothermic welding processes.

� Tests for qualification of aluminothermic welders, approval of contractors and acceptance of welds.

� Restoration of rails by electric arc welding.

Annexes A, B, C, D and E are normative. Annex F is informative.

This document includes a Bibliography.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the followingcountries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal,Slovakia, Spain, Sweden, Switzerland and the United Kingdom.

EN 13674-1:2003 (E)

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Introduction

This Introduction provides an explanation of the concepts, and reasoning used in the production of this standard.Its inclusion also ensures that during future revisions restrictions are removed as technology progresses and tohold them where it has not, thus ensuring continued safety as new producers, products and technologies areintroduced.

The most commonly used standards of the world for the supply of railway rails have been reviewed during thepreparation of this standard. However, modern rail production technology and the requirements of high speedrailways within the Community have demanded a completely new look at the philosophy and content of this part ofEN 13674.

Whenever possible this part of EN 13674 is performance based, recognises the European Quality System standardEN ISO 9001 and requires manufacturers to offer the latest proven technology to consistently satisfy thedemanding quality of the required product.

This part of EN 13674 has two major divisions:

1) qualifying tests;

2) acceptance tests.

The qualifying tests introduce a number of performance requirements not previously seen in national orinternational standards. They also include typical results from relevant acceptance tests.

Rail grading is based on hardness rather than tensile strength.

The acceptance tests have been designed to control those characteristics of the rail steel and rail that are ofrelevance to the production of high quality rails and the demands of the railway.

The steel grades covered by this part of EN 13674 reflect trends in railway usage and heat treated rails areincluded. The standard includes rail profiles for Vignole rails having a linear mass 46 kg/m and above.

To ensure the supply of high quality rails, some restrictions on production processes have been imposed.

The standard supersedes other standards covered by the scope and applies to all procurements falling inside therequirements of the European Procurement Directive (93/38/EEC of 14th June 1993). In addition CEN required,where possible, a performance based standard, taking into account safety implications and at the same timeaddressing modern production technology and the requirements of high-speed railways. As a result of the Directiveit was recognised that there would be few opportunities (and these would have to be for transparent safetyconsiderations) for derogation from the standard to operate between the user and the manufacturer.

The standard reflects this change in philosophy from the traditional content of rail standards. A review wasundertaken of the most commonly used rail standards of the world. All relevant aspects important to both user andmanufacturer were considered with the aim of ensuring that all of the content had specific usefulness andrelevance. For example rail grading and much of the standard has been based on hardness rather than tensilestrength. Whilst the two are directly related, hardness is very quick and cheap to carry out and provides morerelevant guidance to the user particularly where properties vary in different parts of the profile.

Since many rail manufacturers would have not previously carried out proving trials, the standard includes aprerequisite for all manufacturers to prove conformity against a set of qualifying test criteria at the time of tendering.The Qualifying tests include all “normal” acceptance test results plus new "type-casting" features such as fracturetoughness, fatigue and residual stress. To provide users with the necessary confidence, acceptance limits havebeen based on results from rail known to have performed well in demanding track installations.

One aspect of the standard which is a complete break from tradition is the inclusion of quality assurance andinspection clause as part of product integrity.

EN 13674-1:2003 (E)

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In order that quality management systems are consistent across all manufacturers and that users have the bestassurance for the consistency of required product quality on this safety critical component of the track, this railstandard recommends that the manufacturers' quality assurance systems are at least equivalent to therequirements of EN ISO 9001. The inclusion of this requirement also reduces the need to incorporate detailedmethod and calibration descriptions on items such as normal chemical composition determination and the need todefine more extensive testing.

Ideally, manufacturing techniques should not be referenced in a product standard. However, some rail attributesare either not known in an exact manner or are not measurable with satisfactory statistical significance. In suchcases best practice manufacturing techniques have been included as a last resort. The equipment specified is thatwhich gives the best probability of achieving the required product for use in track. In the future new technology canadd to, but preferably will reduce or delete such items.

Examples of areas where the technological state of the art renders the standard less than complete include:

� oxide/oxygen relationships;

� hydrogen test techniques;

� roller straightening effects on residual stresses;

� roller straightening effects on contact scrub;

� measurement and effect of residual stresses throughout the rail.

EN 13674-1:2003 (E)

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1 Scope

This European Standard specifies Vignole railway rails of 46 kg/m and greater linear mass, for general and highspeed railway track usage.

Seven pearlitic steel grades are specified covering a hardness range of 200 to 390 HBW and include non heattreated carbon manganese steels; non heat treated alloy steels; and heat treated carbon manganese and low alloysteels.

There are 21 rail profiles specified in this Standard.

Two classes of rail straightness are specified, differing in requirements for straightness, surface flatness and crownprofile. Two classes of profile tolerances are specified.

2 Normative references

This European Standard incorporates by dated or undated reference, provisions from other publications. Thesenormative references are cited at the appropriate places in the text, and the publications are listed hereafter. Fordated references, subsequent amendments to or revisions of any of these publications apply to this EuropeanStandard only when incorporated in it by amendment or revision. For undated references the latest edition of thepublication referred to applies (including amendments).

EN 10002-1, Metallic materials - Tensile testing - Part 1: Method of test at ambient temperature.

EN 10163-1, Delivery requirements for surface condition of hot rolled steel plates, wide flats and sections - Part 1:General requirements.

EN 10276-1, Chemical analysis of ferrous materials - Determination of oxygen in steel and iron – Part 1: Samplingand preparation of steel samples for oxygen determination

EN ISO 6506-1, Metallic materials – Brinell hardness test – Part 1: Test method (ISO 6506-1:1999).

ISO 1099:1975, Metals - Axial load fatigue testing.

ISO 4968:1979, Steel - Macrographic examination by sulfur print (Baumann method).

BS 6835-1:1988, Method for determination of the rate of fatigue crack growth in metallic materials - Fatigue crackgrowth rates of above 10-8 m per cycle.

DIN 50602:1985, Microscopic examination of special steels using standard diagrams to assess the content ofnon-metallic inclusions.

ASTM E399:1991, Standard test method for plane strain fracture toughness of metallic materials.

3 Terms and definitions

For the purposes of this European Standard, the following terms and definitions apply.

3.1heatone liquid steel melt tapped out of a converter or electric arc furnace which includes after continuous casting agiven number of blooms relating to the weight of the heat and the extension of the mixing zone. In the case ofsequence casting the blooms belonging to the mixing zone should be clearly defined.

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3.2sequenceany number of heats, of the same steel grade, which undergo continuous casting in tundishes. Tundishes can beused in parallel if the caster has many strands.

3.3heat treated railrail that has undergone accelerated cooling from austenitizing temperature during the metallurgical transformationperiod

3.4re-heated railall rolled rail that has undergone re-austenitization for heat treatment purposes

3.5mill heat treated railheat treated rail that has not undergone re-austenitization after rolling

3.6rolling processprocess between the blooms leaving the heating furnace and exiting the finishing pass

3.7isothermal treatment processprocess whereby blooms are held for a period of time at an elevated temperature for diminishing the hydrogencontent

NOTE 1 For maximum efficiency this is as near to (but below) the pearlite to austenite transformation temperature as ispractically possible.

NOTE 2 This process is sometimes referred to as sub critical diffusion annealing.

3.8qualifying testsspecial tests and criteria which are relevant to some aspects of the service performance of rails. Acceptance testsalso form part of the qualifying tests.

3.9acceptance teststests carried out as part of the process and product control system, normally on a heat, sequence or tonnage basis

4 Information to be supplied by the purchaser

The purchaser shall provide the supplier with the following information at the time of tender or order:

a) the rail profile (see annex A);

b) the steel grade (see clause 5);

c) the profiles class, ‘X’ or ‘Y’ (see 9.2.1);

d) the straightness class ‘A’ or ‘B’ of rail as specified in 9.2.2;

e) the lengths of rail (see 9.2.3 and Table 10);

f) undrilled or drilled rail ends to take fish bolts, and location and dimensions of holes when required (see 9.2.3);

g) any special treatments to be applied to bolt holes;

h) tolerances for bolt holes to which special processes are to be applied;

EN 13674-1:2003 (E)

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i) paint code requirements (see 7.4.4).

5 Steel grades

The seven steel grades are given in Table 1. The five hardness ranges of the steel grades shall conform to thosegiven in Table 1.

The steel grade designations referred to in this standard are compared to those in EN 10027-1 and EN 10027-2 ininformative annex F.

Table 1 — Steel grades

Grade a Hardness range(HBW)

Description Branding lines

Carbon – manganese No branding linesR200 200 to 240 (C-Mn)

Non heat treatedCarbon – manganese _______

R220 220 to 260 (C-Mn)Non heat treatedCarbon – manganese ____

R260 260 to 300 (C-Mn) _______Non heat treatedCarbon – manganese _______

R260Mn 260 to 300 (C-Mn) _______Non heat treatedAlloy (1 %Cr) _______

_______R320Cr 320 to 360 Non heat treated _______

Carbon – manganese ______

R350HT 350 to 390 b (C-Mn) _______ ________Heat treated

R350LHT 350 to 390 b Low alloy, heat treated ______

_______ _____________

a See Table 5 for chemical composition/mechanical properties.

b See Table 7 for hardness requirements.

6 Profile drawings/properties/mass

Rail profiles, dimensions, properties and linear masses are given in annex A. The tolerances of certain dimensionsshall be as given in Table 8. All other quantities are informative only.

NOTE Linear masses have been calculated based on the density of steel of 7850 kg/m3.

7 Manufacture

7.1 Product integrity

7.1.1 Factory production control

All Vignole rails shall be produced under a comprehensive system of factory production control which shall ensureconfidence in the conformity of the finished product. The system shall address this European Standard to ensurethat the finished products consistently comply with requirements to achieve the product integrity necessary toprovide assurance of product safety in track.

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Manufacturers shall demonstrate continuing compliance, including documented evidence, with the factoryproduction control system required.

Manufacturers having a factory production control system which complies with EN ISO 9001 are recognised assatisfying the minimum requirements specified by this clause.

7.1.2 Best practice manufacture

The product shall be manufactured to the best practices as specified in 7.1.

NOTE This is to ensure that the rail attributes, described in the introduction, which are not known in an exact manner or arenot practically measurable, achieve the required high level of product integrity in track.

7.2 Blooms

Blooms made from basic oxygen steel or electric arc furnace steel that has been secondary ladle arc refined,vacuum degassed and continuously cast, shall be used for the manufacture of rails.

7.3 Rails

7.3.1 The manufacturer shall operate a procedure for the effective removal of scale during the rolling andstraightening processes.

7.3.2 The cross-sectional area of the rail shall not exceed one ninth that of the bloom from which the rail is rolled.

7.3.3 Rail straightening shall be by a two stage roller straightening process which straightens the rail about its XXand YY axes as defined in the rail profiles shown in annex A. End deviations or a localised deviation on the rail maybe corrected using pressing.

NOTE Other mandatory processes are described in the relevant clauses within the standard.

7.4 Identification

7.4.1 Branding

Brand marks shall be rolled in relief on one side and in the middle of the web (see annex A) of each rail at leastonce every 4 m. The brand marks on the rails shall be clearly legible and shall be 20 mm to 25 mm high, raisedbetween 0,6 mm and 1,3 mm.

The branding line(s) to denote grade shall be 50 mm in length for the long branding line and 25 mm in length forthe short branding line.

The brand marks shall include:

a) the identification of the mill;

b) the steel grade as shown in Table 1;

c) the last two figures of the year of manufacture;

d) the rail profile identification as shown in annex A.

EXAMPLE

___ROLLING MILL _______ 96 60 E 1

(60 E 1 profile rail rolled 1996 and 260 HBW carbon-manganese rail steel grade).

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___ROLLING MILL _______ _______ 96 60 E 1

(60 E 1 profile rail rolled 1996 and 350 HBW heat treated carbon-manganese rail steel grade).

7.4.2 Hot stamping

In addition to the branding requirements of 7.4.1 each rail shall be identified by a numerical and/or alphabeticalcode system, hot stamped on the non-branded side of the rail web by machine and each rail shall be hot stampedat least once every 5 m.

If hot stamping every 5 m is not practical, the identity of the rail shall be applied by hot stamping or rotary burn nearthe end of the rail.

NOTE Subsequent cutting could result in more than one rail length having the same identity.

The figures and letters used shall be clearly legible and shall be 16 mm high. The stamped characters shall have aflat or radius face (1 mm to 1,5 mm wide) with bevels on each side. The letters and numbers shall be on a 10�angle from vertical and shall have rounded corners. The stamping shall be between 0,5 mm and 1,5 mm in depthalong the centre of the web. The design shall be as shown in Figure 1.

Figure 1 — Design of letters and numbers on a 10° angle for rail stamps

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 bloom within the strand;

c) the position of the rail in the bloom (A, B ... Y).

In the event of identification marks having been removed, omitted or requiring alteration, re-identification of suchmarks shall be made by rotary burr.

7.4.3 Cold stamping

Cold stamping shall only be used on the cut face of the rail within the central portion of the head, at the request ofthe purchaser.

7.4.4 Other identification

Rails of straightness class A shall be identified with a green mark and the position of the green mark is to bespecified by the purchaser. The steel grade may additionally be identified using paint. The purchaser shall specifythe colour and position of the paint application.

EN 13674-1:2003 (E)

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8 Qualifying tests

8.1 Procedure

8.1.1 The manufacturer shall describe any bloom slow cooling or isothermal treatment process used todemonstrate compliance with the requirements of 9.1.2.2.

8.1.2 All qualifying tests as specified in 8.2 to 8.9 shall be undertaken at least once every five years and as aresult of any significant production process change for all grades, with the exception of 8.7.1, where predictiveequation approval is carried out on an ongoing basis. In addition the residual stress test shall be carried out on allavailable grades every 2 years.

The manufacturer shall only carry out testing on the 60 E 1 profile or the heaviest section produced.

All rail grades and profiles supplied shall conform to the qualifying criteria in accordance with 8.2 to 8.9.

The results for the grades to be supplied shall be provided at the time of tendering.

In the event of a manufacturer not having produced the rail grade prior to the tender enquiry he shall have theoption of carrying out such tests on the first available sequence. When the qualifying criteria have been compliedwith, compliance with the standard is demonstrated and consequently the manufacturer is qualified.

8.1.3 The samples in accordance with 8.1.4 and 8.1.5 shall be removed from finished roller straightened rails.These samples shall not be subject to any further mechanical or thermal treatment (other than the treatment ofageing of the tensile test pieces as described in 9.1.8.3).

8.1.4 Test pieces for fracture toughness, fatigue crack growth rate and fatigue tests (see 8.2, 8.3 and 8.4respectively) shall be taken from 3 sample rails at least 3 m from the cut ends of the rail. Sample rails shall be fromdifferent heats and different strands.

8.1.5 For residual stress tests (see 8.5) there shall be 6 sample rails and the test pieces shall be taken at least3 m in from each rail end.

8.1.6 All tests should be carried out by a laboratory that operates an approved and audited quality assurancesystem conforming to requirements at least equivalent to EN ISO 9001.

8.1.7 The purchaser shall have access to all test records, calibrations and calculations that contribute to the finalresults.

8.1.8 All test results shall be reported to the purchaser.

8.2 Fracture toughness (KIc)

8.2.1 Test pieces and test methods

Tests shall be performed in accordance with annex B.

8.2.2 Qualifying criteria

The value of K1c shall comply with Table 2.

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Table 2 — Minimum single and minimum mean values of KIc

Steel gradeMinimum single value

KIc (MPa m1/2)

Minimum Mean

KIc (MPa m1/2)

R200 and R220 30 35

R260 and R260Mn 26 29

R320Cr 24 26

R350HT 30 32

R350LHT 26 29

NOTE In some circumstances *Qk values can be used for the purpose of qualification - see B.6.

8.3 Fatigue crack growth rate

8.3.1 Test method

Tests shall be carried out in accordance with the general requirements of BS 6835-1.

8.3.2 Test pieces

A three point bend, single edge notch test piece, of the dimensions and location within the rail shown in Figure 2shall be used.

8.3.3 Number of tests and test conditions

A minimum of 3 tests from each sample rail shall be performed under the following conditions:

� test temperature shall be within the range + 15 �C to + 25 �C;

� R = 0,5 (R = minimum cyclic load/maximum cyclic load);

� 3 point bend test piece loading span shall be 4 W (see Figure 2);

� cyclic loading frequency shall be within the range 15 Hz to 40 Hz;

� environment - laboratory air.


Fatigue crack growth rates (m/Gc) shall not exceed the values given in Table 3.

Table 3 — Fatigue crack growth rates

Steel grades � K = 10 MPa m½ � K = 13,5 MPa m½

All grades except R200 and R320Cr 17 m/Gc 55 m/Gc

8.4 Fatigue test

8.4.1 Test method

Constant amplitude fatigue tests shall be carried out in accordance with ISO 1099.

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8.4.2 Test pieces

The test pieces shall be machined from the sample rail as shown in Figure 3.

8.4.3 Number of tests and test conditions

A minimum of 3 test pieces shall be tested from each sample rail under the following conditions:

� test temperature shall be within the range + 15 �C to + 25 �C;

� control variable shall be axial strain amplitude;

� the strain cycle shall be symmetrical about the initial, zero load.


For a total strain amplitude of 0,00135, the life of each specimen shall be greater than 5 � 106 cycles.

NOTE Life is defined as the complete separation of the specimen.

8.5 Residual stress in rail foot

8.5.1 Test method

The residual stresses in the rail foot shall be determined in accordance with annex C.

8.5.2 Test pieces

Each of the 6 test pieces from the rail section shall be 1 m in length and shall be taken from rails as described in8.1.3 and 8.1.5.

NOTE Only a small part of the test piece will be destroyed for the purpose of measuring residual stress; the remaindercan be used for other qualifying approval tests.

8.5.3 Measurements

Longitudinal residual stress determinations shall be made on the rail foot of each of the 6 test pieces described in8.5.2. The location of the measurements is shown in Figure C.1.

If data are available for straightness class A rails then class B rails of the same profile need not be tested.


The maximum longitudinal residual stress in the foot shall be 250 MPa for all steel grades.

8.6 Variation of centre line running surface hardness of heat treated rails

This clause only applies to heat treated rails.

For the longest length of rail produced by the manufacturer, a one metre length of rail shall be taken from each endand at 20 m intervals from one end of the rail. These shall be hardness tested (HBW) in accordance withEN ISO 6506-1 along their length at 25 mm intervals on the centreline of the running surface after 0,5 mm hasbeen ground away. The hardness results shall be no more than � 15 HBW from the mean result obtained.

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8.7 Tensile strength and elongation

8.7.1 Predictive equations relating chemical composition to tensile strength and elongation shall be calculatedusing multiple regression analysis for all non heat treated rails produced. The following procedure shall be carriedout:

� development of a predictive equation;

� confirmation of the predictive equation;

� periodic updating of the predictive equation;

� corrective action.

8.7.2 Manufacturers shall calculate, using multiple regression analysis for all naturally hard steel gradesproduced, predictive equations relating chemical composition to tensile strength and elongation. Eachmanufacturer shall derive its own predictive equations.

The predictive equations shall be produced from a minimum number of 100 heats and a maximum number of200 heats.

The equations shall be created by carrying out one valid tensile test per heat. Tensile tests shall be carried out inaccordance with 9.1.8.2 and 9.1.8.3.

The predictive equations shall produce results which are within a scatter band governed by the following limits:

tensile strength : 12,5 MPa (1 standard error);

elongation : 1,0 % (1 standard error).

8.7.3 The results of the predictive equations shall be compared with experimentally determined tensile strengthand elongation results as described in 9.1.8. This comparison will be achieved by carrying out one valid tensile testevery 2 000 tonnes or at least every tenth heat.

The experimental results shall be within plus or minus 25 MPa tensile strength and plus or minus 2 % elongation ofthose obtained from the predictive equations.

8.7.4 The results of the experimental tensile strength and elongation tests obtained from 8.7.3 shall be used toupdate the predictive equations. These results shall be accumulated and the equations updated annually. Theupdated equations shall be based on the last 200 results.

8.7.5 If results from the predictive equations or the experimental results are outside the limits set in 8.7.2 and8.7.3 then actions a), b) and c) and when necessary action d) shall be taken:

a) the manufacturer shall carry out an investigation;

b) the problem will be resolved by the manufacturer taking appropriate corrective action;

c) the manufacturer shall report the findings of a) and b) to the purchaser;

d) if the problem cannot be resolved to the satisfaction of the purchaser, the manufacturer or potentialmanufacturer shall have failed the approval requirements as specified in 8.1.1. If the physical tests themselvesare within the requirements of Table 5 a) the product is satisfactory.

8.8 Segregation

Full section transverse test pieces shall be sulfur printed in accordance with ISO 4968. For this purpose rail sulfurprints shall be taken from each strand from the beginning of every heat, excluding the mixing zone, for five heats.

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The samples shall be assessed and classified according to the limiting figures of annex D. For the process to beaccepted, all samples shall be classified as acceptable.

8.9 Other qualifying requirements

In addition to the results of the tests described in 8.2 to 8.8 inclusive the manufacturer shall provide a complete setof results for the acceptance tests described in 9.1. Samples for these tests shall be taken from the rails used forthe qualifying tests as described in 8.1.3.

9 Acceptance tests

9.1 Laboratory tests

9.1.1 General

Laboratory tests shall be performed, during production, at frequencies as stipulated in Table 4. Results for eachlaboratory test shall comply with the limiting values shown in Table 5. Additional information and other acceptancetests not covered by Table 5 shall comply with the requirements of 9.1.2 to 9.1.8 inclusive. All rails supplied shallmeet the requirements of clauses 8 and 9.

9.1.2 Chemical composition

9.1.2.1 General

The liquid chemical composition shall be determined for each heat. When the solid chemical composition ischecked, this shall be carried out at the position of the tensile test piece. Liquid and solid chemical compositionshall conform to the requirements of Table 5 a).

9.1.2.2 Hydrogen

The hydrogen content of the liquid steel shall be measured by determining pressure of hydrogen in the steel usingan on-line immersion probe system.

At least two liquid samples shall be taken from the first heat of any sequence using a new tundish and one fromeach of the remaining heats and analysed for hydrogen content (see Table 4). The first sample from the first heat ina sequence shall be taken from the tundish at the time of the maximum hydrogen concentration.

The heats shall be assessed for hydrogen content in accordance with Table 6.

The blooms from group 1 heats shall be deemed to be satisfactory.

The blooms from group 2 heats shall be slowly cooled or isothermally treated and all heats shall be tested in the railform.

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Table 4 — Testing frequency

Relevant Steel gradesTest on

subclause R200, R220, R260, R260Mn, R320Cr R350HT, R350LHT

Chemical composition 9.1.2 One per heat One per heat

Hydrogen 9.1.2.2 One per heat (two from first heat in sequence) One per heat (two from first heat in sequence)

Total oxygen 9.1.2.3 One per sequence a One per sequence a

Microstructure 9.1.3 Not required for grades 200, 220 and 260 One per 50 tonnes of re-heated a,c

One per 1000 tonnes or part thereof for grades 260 Mnand 320 Cr

One per 100 tonnes of mill heat treated a,c

Decarburisation 9.1.4 One per 1000 tonnes or part thereof a,b One per 500 tonnes of re-heated and mill heat

treated a,c

Oxide cleanness 9.1.5 One per sequence a,b One per sequence a,b or c

Sulfur print 9.1.6 One per 500 tonnes or part thereof a,b One per 500 tonnes or part thereof a,b or c

Hardness 9.1.7 One per heat a,b One per 50 tonnes of re-heated a,c

One per 100 tonnes of mill heat treated a,c

Tensile 8.7 & 9.1.8 One calculation per heat/one per 2 000 tonnes a,b One per 1 000 tonnes a,c

a Samples shall be taken at random but only rails from blooms outside the mixing zone between heats when continuously cast in sequence.

b Samples shall be cut after rolling.

c Samples shall be cut from heat treated rails.

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Table 5 a) — Chemical composition/mechanical properties

% By mass10-4% ppm

max. by massRm

min.min.

elongASteel sample

gradeC Si Mn P

max

runningsurface c

Cr Almax.

Vmax.

Nmax.

Oa Hb MPa %

Centre line

R200 Liquid 0,40/0,60 0,15/0,58 0,70/1,20 0,035 0,008/0,035 0,15 max 0,004 0,030 0,009 20 3,0

Solid 0,38/0,62 0,13/0,60 0,65/1,25 0,040 0,008/0,040 0,15 max 0,004 0,030 0,010 20 3,0 680 14 200/240

R220 Liquid 0,50/0,60 0,20/0,60 1,00/1,25 0,025 0,008/0,025 0,15 max 0,004 0,030 0,008 20 3,0

Solid 0,50/0,60 0,20/0,60 1,00/1,25 0,025 0,008/0,025 0,15 max 0,004 0,030 0,008 20 3,0 770 12 220/260

R260 Liquid 0,62/0,80 0,15/0,58 0,70/1,20 0,025 0,008/0,025 0,15 max 0,004 0,030 0,009 20 2,5

Solid 0,60/0,82 0,13/0,60 0,65/1,25 0,030 0,008/0,030 0,15 max 0,004 0,030 0,010 20 2,5 880 10 260/300

R260 Liquid 0,55/0,75 0,15/0,60 1,30/1,70 0,025 0,008/0,025 0,15 max 0,004 0,030 0,009 20 2,5

Mn

Solid 0,53/0,77 0,13/0,62 1,25/1,75 0,030 0,008/0,030 0,15 max 0,004 0,030 0,010 20 2,5 880 10 260/300

R320 Liquid 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 0,009 20 2,5

Cr

Solid 0,58/0,82 0,48/1,12 0,75/1,25 0,025 0,008/0,030 0,75/1,25 0,004 0,20 0,010 20 2,5 1080 9 320/360

R350 Liquid 0,72/0,80 0,15/0,58 0,70/1,20 0,020 0,008/0,025 0,15 max 0,004 0,030 0,009 20 2,5

HT

Solid 0,70/0,82 0,13/0,60 0,65/1,25 0,025 0,008/0,030 0,15 max 0,004 0,030 0,010 20 2,5 1175 9 350/390

R350 Liquid 0,72/0,80 0,15/0,58 0,70/1,20 0,020 0,008/0,025 0,30 max 0,004 0,030 0,009 20 2,5

LHT

Solid 0,70/0,82 0,13/0,60 0,65/1,25 0,025 0,008/0,030 0,30 max 0,004 0,030 0,010 20 2,5 1175 9 350/390

a See 9.1.2.3.

b See 9.1.2.2.

c See Figure 10.

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Table 5 b) — Maximum residual elements

All values in M by mass

Mo Ni Cu Sn Sb Ti Nb Cu & 10 Sn Others

R200, R220, R260, R260Mn 0,02 0,10 0,15 0,030 0,020 0,025 0,01 0,35 0,35 (Cr + Mo + Ni + Cu + V)

R320Cr 0,02 0,10 0,15 0,030 0,020 0,025 0,01 0,35 0,16 (Ni + Cu)

R350HT 0,02 0,10 0,15 0,030 0,020 0,025 0.04 0,35 0,25 (Cr + Mo + Ni + Cu + V)

R350LHT 0,02 0,10 0,15 0,030 0,020 0,025 0,04 0,35 0,20 (Mo + Ni + Cu + V)

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Table 6 — Hydrogen content of heats

Heats Hydrogen content 10-4 % (ppm)

Steel grades R200 and R220 All other steel grades

Group 1 � 3,0 � 2,5

Group 2 � 3,0 � 2,5

If the hydrogen contents of the first samples of a first heat or the heat sample of a second or further heat do notcomply with the requirements of Table 5 a) then the blooms made before those samples are taken shall be slowlycooled or isothermally treated. This applies also to all blooms made before the hydrogen content eventually complieswith the requirements in Table 5 a) shall be slowly cooled or isothermally treated.

When testing of rails is required rail samples shall be taken at the hot saw at a frequency of one per heat at random.However on the first heat in a sequence, the rail sample shall be from the last part of a first bloom teemed on anystrand. Hydrogen determination shall be carried out on samples taken from the centre of the rail head.

If any test result fails to meet the requirements stated in Table 5 a) the heat shall be rejected.

9.1.2.3 Determination of total oxygen content

9.1.2.3.1 General

Total oxygen content shall be determined in the liquid steel, following solidification of the sample, or from the solid railhead, in the positions shown in Figure 4, and at the frequency shown in Table 4.

For orders in excess of 5 000 tonnes at least 95 % of heats shall have a total oxygen content of less than 20 ppm. Nomore than 5 % of heats shall have a total oxygen content of up to 30 ppm. Heats with a total oxygen content greaterthan 30 ppm shall be rejected.

For orders less than 5 000 tonnes, only one sample with total oxygen greater than 20 ppm, but less than 30 ppm, isallowed. Heats with total oxygen greater than 30 ppm shall be rejected. Any heats with total oxygen above 20 ppmshall require that all subsequent heats be tested until values below 20 ppm are achieved.

9.1.2.3.2 Preparation of the sample

The thickness of the transverse rail slice shall be 4 mm.

Samples shall be prepared in accordance with EN 10276-1.

9.1.2.3.3 Measurement

The measurement of oxygen shall be made using an automatic machine.

9.1.3 Microstructure

9.1.3.1 General

Microstructures shall be determined at a magnification of x 500.

The microstructure shall be verified for R260Mn, R320Cr and heat treated rails in accordance with the requirements ofTable 4.

The testing position in the rail head shall be as shown in Figure 5.

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9.1.3.2 Grades R200, R220

The microstructure shall be a mixture of pearlite and grain boundary ferrite. There shall be no martensite, bainite orgrain boundary cementite.

9.1.3.3 Grade R260, R260Mn

The microstructure shall be pearlitic but grain boundary ferrite may occur in these grades. The maximum grainboundary ferrite permitted is shown in Figure 6. There shall be no martensite, bainite or grain boundary cementite.

9.1.3.4 Grade R320Cr

The microstructure shall be fully pearlitic with no martensite, bainite or grain boundary cementite.

9.1.3.5 Grades R350HT, R350LHT

The microstructure shall be pearlitic with no martensite, bainite or grain boundary cementite. The maximum grainboundary ferrite permitted is shown in Figure 6.

9.1.4 Decarburisation

No closed ferrite network shall be observed below 0,5 mm depth measured anywhere on the rail head surface. Thedecarburisation depth will be assessed by means of a hardness test at a frequency shown in Table 4. After aminimum of preparation of the rail surface (polishing) a hardness test according to the method indicated in 9.1.7 willbe performed in three points. None of the results of hardness obtained shall be lower than the minimum valuespecified of the grade, reduced by 7HBW (example : 253HBW for grade R260).

Photomicrographs showing the depth of decarburisation allowed are shown in Figure 7 and Figure 8 defines the railhead surface for decarburisation checks.

9.1.5 Oxide cleanness

Samples shall be prepared and assessed in accordance with DIN 50602. For orders less than 5 000 tonnes, only onesample with a K3 greater than 10 and less than 20 is allowed. Samples shall be taken from one of the last blooms ofthe last heat of the sequence but from each sample 2 specimens shall be tested.

The following limits shall apply.

Total index 10 � K3 � 20 for a maximum of 5 % of samples.

K3 � 10 for a minimum of 95 % of samples.

The testing position in the rail head is shown in Figure 9.

9.1.6 Sulfur prints

Sulfur prints of transverse rail sections shall be prepared in accordance with ISO 4968 at the frequency shown inTable 4.

All samples, including those intended for repeat test, shall be taken from outside the mixing zones of the heat. Whenpart or all of an adjacent heat has been withdrawn due to non-conformance, tests shall be made in the mixing zonesto determine the first conforming blooms.

The sulfur prints shall conform to the requirements of annex D.

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9.1.7 Hardness

Brinell hardness tests shall be carried out in accordance with EN ISO 6506-1 at the frequency shown in Table 4. Thetest conditions shall be as follows:

� tungsten carbide ball;

� ball diameter 2,5 mm;

� load 1,839 kN;

� period of application 15 s.

Other measurement techniques, for example Rockwell or Vickers hardness testing, may be used, but in case ofdispute Brinell hardness testing in accordance with EN ISO 6506-1 shall be used.

The hardness values measured shall meet the requirements given in Table 7 for the relevant grade.

In the case of the heat treated grades the mean value of position 2 shall be greater than the value of position3 + 0,4 [(mean value of position 1) minus (value of position 3)]. Also the difference between any of the three position1 s shall be no more than 30 HBW. The testing positions are shown in Figure 10.

The hardness on the centre line of the head crown shall not vary by more than 30 HBW on any individual rail.

For the steel grades R200, R220, R260, R260Mn and R320Cr the hardness shall only be tested for position RS. Forheat treated rails hardness shall be tested in accordance with the positions shown in Figure 10.

0,5 mm shall be ground from the running surface before a hardness impression is made.

Table 7 — Hardness testing positions and requirements

Rail Steel GradePosition

R200 R220 R260 R260Mn R320Cr R350HT R350LHT

Hardness (HBW)

RS a 200-240 220-260 260-300 260-300 320-360 350-390 b 350-390 b

1 340 min 340 min

2 331 min 331 min

3 321 min 321 min

4 340 min 340 min

a RS = Point on the centre line running surface.

b If the hardness exceeds 390HBW, the rail is acceptable provided the microstructure is confirmed to be pearlitic, and thehardness does not exceed 405 HBW.

9.1.8 Tensile tests

9.1.8.1 Steel grades R200, R220, R260, R260Mn, R320Cr

For rail steel grades R200, R220, R260, R260Mn and R320Cr the tensile strength and elongation shall be determinedby the predictive equation described in 8.7.2.

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If a manufacturer is temporarily unqualified, or if limited production quantities prevent qualification, then tensile testingshall be one per heat.

The values determined by the predictive equation shall not be less than those quoted in Table 5 a).

9.1.8.2 Steel grades R350HT and R350LHT

For rail steel grades R350HT and R350LHT tensile tests shall be carried out at a frequency given in Table 4. Testsamples shall be removed from the rail as shown in Figure 5. Results obtained shall comply with the values given inTable 5.

9.1.8.3 Method of test

The manufacturer shall determine the tensile properties in accordance with EN 10002-1 using a round tensile testpiece with the dimensions as follows:

� diameter 10 mm;

� original cross-sectional area 78,5 mm2;

� original gauge length 50 mm;

� minimum parallel length 55 mm.

Before testing the tensile test pieces should be at a temperature of 200 �C for up to 6 h. In the case of dispute, beforetesting the tensile test pieces should be at a temperature of 200 �C for 6 h.

9.1.9 Retest procedures

If any test fails to meet the requirements of 9.1.2 to 9.1.8 (but excluding hydrogen) then two tests shall be performedon samples from rails in close proximity to the original. Should either retest fail then rails shall be progressively testeduntil acceptable material is found. The failed material shall be rejected or in the case of heat treated material re-treated and tested. For hydrogen and oxygen testing refer to the 9.1.2.2 and 9.1.2.3 respectively.

If the results of an investigation under 8.7.5 or the qualification procedure, or the predictive equation indicate thatcertain rails are out of specification, then acceptance of such rails shall be based on experimental tensile test results.The minimum values in Table 5 shall apply in such cases.

9.2 Dimension tolerances

9.2.1 Profile

The nominal dimensions of the rail profile (see annex A) and the actual dimensions anywhere on any rail shall notdiffer by more than the tolerances given in Table 8.

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Table 8 — Profile tolerances

* Reference points(see Figure E.1)

Profile class (dimensions in mm) Gaugefigure

number

(see annex E)

X Y

Height of rail a *H

� 165 mm � 0,5 + 0,5

- 1,0 E.3

� 165 mm � 0,6 + 0,6

- 1,1

Crown profile *C

Class A straightness + 0,6 + 0,6

- 0,3 - 0,3 E.4

Class B straightness � 0,6 � 0,6

Width of rail head *WH � 0,5 + 0,6 E.5

- 0,5

Rail asymmetry *As � 1,2 � 1,2 E.6,E.7

Inclination of fishing surfaces

(on the basis of 14 mm parallel

to the inclined theoretical fishing � 0,35 � 0,35 E.8

surfaces) b *IF

Height of fishing *HF

� 165 � 0,5 � 0,5 E.8

� 165 � 0,6 � 0,6

Web thickness *WT + 1,0 + 1,0 E.9

- 0,5 - 0,5

Width of rail foot *WF � 1,0 + 1,5 E.10

- 1,0

Foot toe thickness *TF + 0,75 + 0,75 E.11

- 0,5 - 0,5

Foot base concavity 0,3 max 0,3 max

a The total height variation over any rail length shall not be greater than 1 mm for rails � 165 mm and 1,2 mm forrails � 165 mm.

b The maximum fishing tolerance on the head and on the foot is 0,35 mm but the total tolerance allowed is also ± 0,35 mm.

9.2.2 Straightness, surface flatness and twist

Flatness testing of the body shall be performed automatically.

Tolerances for straightness, surface flatness and twist shall meet the requirements given in Table 9. Rejected railsmay be subject to only one roller re-straightening.

In cases of dispute on the results of the automatic technique, rail flatness shall be verified using a straight edge asshown in Table 9.

When measuring sidesweep the rail shall be stood vertically on a suitable support that allows the rail to beunrestrained. If a measurement technique other than that given above is used, only the above shall be used in thecase of dispute.

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Table 9 — Straightness, surface flatness and twist tolerances

Key1 Overlap2 Body3 Whole rail4 End “E

Key1 V and H. Location of flatness measurements2 The position of H is nominally 5 mm - 10 mm below the gaugecorner on the side of the head

Class B Class Ad L d L

� 0,4 mm 3 m c � 0,3 mm 3 m c

and andVertical flatness V� 0,3 mm 1 m c � 0,2 mm 1 m c

BODY a

Horizontal flatness H � 0,6 mm 1,5 m c� 0,45 mm 1,5 m c

b

End “E” 1,5 m 2 m� 0,5 mm 1,5 m � 0,4 mm 2 m

and

and� 0,3 mm 1 m d

and

Vertical straightness

e � 0,2 mm e � 0,2 mm

b

If e > 0 F � �� 0,6 mm 2 m

and

ENDS a

Horizontal straightness � 0,7 mm 1,5 m� 0,4 mm 1 m d

b

"to be continued"

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Table 9 (concluded)

Class B Class Ad L d L

OVERLAP aLength of overlap 1,5 m 2 m

Vertical flatness V � 0,4 mm 1,5 m c � 0,3 mm 2 m c

Horizontal flatness H � 0,6 mm 1,5 m c� 0,6 mm 2 m c

b

WHOLE RAILUpsweep and downsweep 10 mm e 10 mm e

Side sweep Curve radius R > 1500 m Curve radius R > 1500 mTwist See Figures 11 and 12 See Figures 11 and 12

NOTE It is unlikely that the manufacturer can supply rails � 54 kg/m for class A tolerances.

a Automatic measurement equipment shall measure as much of the rail as possible but, at least the body. If the whole rail satisfies the body specifications, then measurement of end and overlap is notmandatory.

b Automatic measurement techniques are complex and are therefore difficult to define but the finished rail flatness shall be capable of being verified by straight edge as shown in the above drawings.

c 95 % of delivered rails shall be within limits specified, with 5 % of rails allowed outside the tolerances by 0,1 mm.

d Reference L sliding over end E.

e The ends of the rails shall not be up more than 10 mm when the rail is on its foot or on its head when standing on an inspection bed.

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9.2.3 Cutting and drilling

The size and location of drilled holes, the squareness of rail ends and rail lengths shall be within the tolerancesgiven in Table 10.

Drilled holes and rail ends shall be deburred. For holes that are to be subject to special treatments the tolerancesshall be in accordance with 4.h).

9.3 Gauges

The gauges required for manufacture are as shown in annex E.

If other measurement techniques than those given in annex E are used, only those in annex E shall be used in caseof dispute.

9.4 Inspection requirements/tolerances for internal quality and surface quality

9.4.1 Ultrasonic test requirements

9.4.1.1 All rails shall be ultrasonically tested by a continuous process ensuring that the entire rail length andspecified cross-sectional area are inspected.

9.4.1.2 The minimum cross-sectional area examined by the ultrasonic technique shall be:

� at least 70 % of the head;

� at least 60 % of the web;

� the area of the foot to be tested shall be as shown in Figure 16.

By convention these areas are based on projecting the nominal crystal size of the probe. The head shall be testedfrom both sides and from the running surface.

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Table 10 — Drilling and cutting tolerances

Number Dimensionalrequirement

Tolerance

1 Drilling Diameter� 30 mm � 0,5 mm� 30 mm � 0,7 mm

Centring and positioning The horizontal position of the holes is checked using a gauge as shown in Figure E.12 which has a stop designed to come intoof the holes vertically and contact with the end of the rail and pins designed to enter the holes.horizontally The diameter of the pins for horizontal and vertical clearances is smaller than the diameter of the holes by:

- 1,0 mm for holes less than or equal to 30 mm in diameter;- 1,4 mm for holes greater than 30 mm in diameter;- the distances between the centre lines of the pins and the stop are equal to the nominal distances from the centre line of the holes to theend of the rail;- the gauge pins shall be able to enter the holes at the same time while the stop is touching the end of the rail.The vertical centring of the holes can be checked using a gauge as shown in Figure E.13.The side of the hole, left or right, is determined by proceeding from the side with the relief markings.

2 Squareness of ends 0,6 mm in any direction

3 Length a

- both ends drilled� 24 m � 3 mm� 24 m � 40 m � 4 mm- other (undrilled or oneend drilled)

� 1 mm/per metre of rail(max. � 30 mm on any rail)For special purpose undrilled rails the length tolerance is � 6 mm up to 24 m and � 10 mm for � 24 m rail.

a The given rail lengths apply for + 15 �C. Measurements made at other temperatures are to be corrected to take into account expansion or contraction of the rail.

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9.4.1.3 The sensitivity levels of the automatic equipment used shall be a minimum 4dB greater than the levelrequired to detect the artificial defects described in 9.4.1.4. An echo giving a possible defect indication shall bere-tested, using an increased sensitivity of 6dB in place of 4dB.

Rails giving signals over the threshold in the rail using the increased sensitivity shall be rejected or cut back toremove the defective portion.

The system shall incorporate continuous monitoring of interface and intermediate echo signals.

9.4.1.4 There shall be a calibration rail for each profile ultrasonically tested and the positions of the artificialdefects are given for the rail head, web and foot of the 60 E 1 profile in Figures 13, 14, and 15 respectively.Calibration rails for other profiles shall be based upon the 60 E 1 calibration rail and detailed drawings shall be madeavailable to the purchaser.

Other methods of calibration may be used but these methods shall be equivalent to that described above.

The calibration rail shall be used to test the equipment at production speed at the beginning and once every 8 h oftesting a particular profile.

9.4.2 Surface quality

9.4.2.1 General

All rails shall be visually or automatically inspected on all faces for surface imperfections. In addition, the undersideof the rail foot shall be inspected automatically in accordance with 9.4.2.6. All rails shall comply with the criteriadefined at 9.4.2.2 and 9.4.2.3. Assessment and dressing of imperfections shall be in accordance with 9.4.2.5.

9.4.2.2 Hot marks, protrusions and seams

All protrusions on the running surface or the underside of the foot shall be dressed. Any protrusions affecting the fitof the fishplate at less than 1 m from the extremity of the delivered rail shall be dressed to shape.

The depth of hot marks and seams, as defined in EN 10163-1, shall not exceed:

� 0,35 mm for the running surface;

� 0,5 mm for the rest of the rail.

In the case of longitudinal guide marks, there shall be a maximum of two, to the depth limits specified, at any pointalong the length of the rail but no more than one of these shall be on the rail running surface. Recurring guide marksalong the same axis are accepted as a single guide mark.

The maximum width of guide marks shall be 4 mm. The width to depth ratio of allowable guide marks shall be aminimum 3:1.

In the case of hot formed marks originating from the vicinity of the mill rolls, those which are recurrent along thesame axis, at a distance equal to the roll circumference, shall be accepted as a single mark. They can be removedby dressing except those marks on the rail crown where a maximum of 3 per 40 m is allowed.

9.4.2.3 Cold marks

Cold marks are longitudinal or transverse cold formed scratches.

The discontinuity depth shall be not larger than:

� 0,3 mm for the rail running surface and underside of foot;

� 0,5 mm for the rest of rail.

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NOTE It is difficult, or impossible to detect in track fatigue cracks initiating and propagating from the underside of the foot;therefore all practicable efforts should be made to avoid cold transverse marks in this area.

9.4.2.4 Surface microstructural damage

Any sign of surface microstructural damage resulting in martensite or white phase shall be dressed or the railrejected. The dressed area shall be proved by suitable hardness testing. The hardness shall not be more than50 HBW greater than the surrounding material.

9.4.2.5 Proving and dressing of surface imperfections

If the imperfection depth cannot be measured it shall be investigated by depth proving, and subsequently dressed tothe criteria below, using a rotary burr, lamellar flap tool or grinding belt, providing the rail microstructure is notaffected by the operation and the work is contour blended.

The depth of dressing shall be not larger than:

� 0,35 mm for the rail running surface;

� 0,5 mm for the rest of rail.

No more than three defects within a length of 10 m of rail and, over the whole length, a maximum of one defect per10 m rail length shall be dressed or proved. After dressing profile tolerances shall be in accordance with Table 8 andflatness tolerances shall be in accordance with Table 9.

9.4.2.6 Automatic foot inspection

The rail shall be automatically inspected on the underside of the foot along its entire length.

The equipment used shall be able to detect artificial imperfections with sizes as shown in Table 11. The artificialimperfections shall have a tolerance of � 0,1 mm.

Table 11 — Dimensions of test imperfections

Depth (mm) Length (mm) Width (mm)

1,0 20 0,5

1,5 10 0,5

An edge loss for the automatic technique is permitted for the extreme 5 mm of the flat portion of the foot width ateach side.

A suitable test rail containing artificial imperfections requires to be run every 8 h.

EN 13674-1:2003 (E)

31

Dimensions in millimetres

Key

1 Notch machined into this face

2 Section through rail head

3 Letter ‘H’ to be stamped on end face of test piece as shown

Figure 2 — Location and dimensions of fatigue crack growth test pieces

EN 13674-1:2003 (E)

32

All dimensions in millimetres

Intersecting point of the R 13 and R 80 radii (60 E 1 section)

Location of the centre of the test piece

Key

1 Screw threads (both ends) to be concentric with Ø A within 0,005 mm. Different forms (without threaded heads of test pieces)may also be used.

2 Cylindrical within 0,005 mm

3 Centre drilla 26 mm radius shall run tangential with gauge diameter (datum dia’A’) without undercutting or leaving a shoulderb General tolerance to be � 0,2 mm unless otherwise statedc Specimen to be identified on each end

Figure 3 — Specimen for determining fatigue initiation life

EN 13674-1:2003 (E)

33


Figure 4 — Sampling positions in rail for total oxygen determination


Key

Intersecting point of the R 13 and R 80 radii (60 E 1 section)

Location at the centre of the tensile test piece

Area to be checked for microstructure

Figure 5 — Location of tensile test piece and microstructure checks

EN 13674-1:2003 (E)

34

Photomicrograph x 500

Figure 6 — Photomicrograph and diagram showing maximum allowable ferrite at the grain boundaries forgrades other than R200 and R220

EN 13674-1:2003 (E)

35

� Surface of rail

� Limit of continuous ferrite network. This example showsdecarburisation to a depth of 0,28 mm

Grades R200 and R220

�� Surface of rail

�� Limit of continuous ferrite network. This example showsdecarburisation to a depth of 0,25 mm

All grades other than R200 and R220

Figure 7 — Photomicrographs (x 100) showing depth of decarburisation allowed on the rail wear surface

EN 13674-1:2003 (E)

36

Key

1 Decarburisation limits apply to this part of rail head

Figure 8 — Range of extent of rail head surface for decarburisation checks

EN 13674-1:2003 (E)

37


Key

1 Face to be examined

Figure 9 — Oxide cleanness sampling position in rail head

EN 13674-1:2003 (E)

38


Key

1,2,3 and 4 Location of hardness testing (see Table 7)

� exact intersecting points of the radii

Figure 10 — Hardness testing positions

Dimension in millimetres

NOTE If the rail shows evidence of twist being laid head up on an inspection bed, it will be checked by inserting feelergauges between the base of the rail and the rail skid nearest the rail end. If the gap exceeds 2,5 mm the rail is rejected.

Figure 11 — Whole rail twist

EN 13674-1:2003 (E)

39

Key1 Cross section 1 m away from the rail end

2 Gauge

3 Cross section at the rail end

NOTE 1 If the rotational twist in the end metre of the rail exceeds 0,2� as measured by the gauge illustrated above the rail isrejected.

NOTE 2 The relative twist between the cross-sections at the rail ends, and the cross-sections 1 m away from each end,should not exceed 0,0035 � c. The following measurements should be made with a specific gauge (1 m long), on each rail end,using as measuring references, points on the under surface of the foot following the measuring procedures below.

(*) : diameter of contact surfaces: 20 mm.

Foot widthb (mm)

Distance between contacts(*) c (mm)

b � 130 90130 � b � 150 110

b � 150 130

Figure 12 — Rail end twist

EN 13674-1:2003 (E)

40

NOTE 1 Both flat bottomed holes are 2 mm diameter and 15 mm deep.

NOTE 2 Flat bottomed holes A and C are 8o � 1o from B and D below.

Figure 13 a)

NOTE 1 Both flat bottomed holes are 2 mm diameter and 15 mm deep.

NOTE 2 Flat bottomed holes B and D are 90o to opposite

Figure 13 b)

EN 13674-1:2003 (E)

41

Figure 13 c)

Key

1 Two mm diameter through hole

Figure 13 — Location of artificial defects in rail head of 60 E 1 profile

All dimensions in millimetres measured from the centre line

EN 13674-1:2003 (E)

42

Key

1 Centreline of web

NOTE 1 Flat bottomed holes are 2 mm diameter drilled to centre line of web.

NOTE 2 Flat bottomed holes are allowed to be ± 10o from horizontal.

Figure 14 — Location of artificial defects in rail web of 60 E 1 profile

EN 13674-1:2003 (E)

43

Key

1 Two mm diameter through hole

Figure 15 — Location of artificial defect in rail foot of 60 E 1 profile

Key

1 Area to be tested

Figure 16 — Area to be tested in rail foot of 60 E 1 profile

EN 13674-1:2003 (E)

44

Annex A(normative)

Rail profiles

The rail profiles listed are new designated and accurately dimensioned profiles developed from the previous lessaccurately dimensioned profiles listed. Table A.2 and Figure A.22 define the transition references.

Table A.1 — List of profiles and previous rail profiles

Figure No Profile Previous profile

A.1 46 E 1 SBB I

A.2 46 E 2 U33

A.3 46 E 3 NP 46

A.4 46 E 4 46 UNI

A.5 49 E 1 DIN S49

A.6 49 E 2 S49 T

A.7 49 E 3 DIN 549 b

A.8 49 E 4 HUSH 113lb/54 Kg

A.9 50 E 1 U50E

A.10 50 E 2 50EB-T

A.11 50 E 3 BV 50

A.12 50 E 4 UIC 50

A.13 50 E 5 50 UNI

A.14 50 E 6 U 50

A.15 52 E 1 52 RATP

A.16 54 E 1 UIC 54

A.17 54 E 2 UIC 54 E

A.18 54 E 3 DIN S54

A.19 55 E 1 U55

A.20 56 E 1 BS 113lb BR Variant

A.21 60 E 1 UIC 60

EN 13674-1:2003 (E)

45


Key

1 Centre line of branding

Cross-sectional area : 58,82 cm2

Mass per metre : 46,17 kg/mMoment of inertia x-x axis : 1641,1 cm4

Section modulus - Head : 217 cm3

Section modulus - Base : 236,6 cm3

Moment of inertia y-y axis : 298,2 cm4

Section modulus y-y axis : 47,7 cm3

Indicative dimensions : A = 18,881 mmB = 43,881 mm

Figure A.1 — Rail profile 46 E 1

EN 13674-1:2003 (E)

46


Key




Section modulus - Head : 213 cm3






EN 13674-1:2003 (E)

47


Key




Section modulus - Head : 224,2 cm3






EN 13674-1:2003 (E)

48


Key



Mass per metre : 46,9 kg/mMoment of inertia x-x axis : 1688 cm4





Indicative dimensions : A = 38,378 mm


EN 13674-1:2003 (E)

49


Key










EN 13674-1:2003 (E)

50


Key










EN 13674-1:2003 (E)

51


Key










EN 13674-1:2003 (E)

52


Key










EN 13674-1:2003 (E)

53


Key






Moment of inertia y-y axis : 365 cm4




EN 13674-1:2003 (E)

54


Key










EN 13674-1:2003 (E)

55


Key










EN 13674-1:2003 (E)

56


R 3

R 2

0

R 15

R 2

1:8,01

X X

75

,1 t

o R

50

87

5,3

6 t

o X

-X a

xis

65

,3

70

BA

125

R 2

2

Y

Y

49

,4

14

,1

15

2

10

1:2

0

1

1:2,75

15

,5

R 3

28

15

1:2,75

R 3

R 13

R 8

0

R 3

00

R 8

R 508

R 508

CLR 508

LC

Key










EN 13674-1:2003 (E)

57


Key










EN 13674-1:2003 (E)

58


Key










EN 13674-1:2003 (E)

59


Key










EN 13674-1:2003 (E)

60


Key










EN 13674-1:2003 (E)

61


Key










EN 13674-1:2003 (E)

62


Key










EN 13674-1:2003 (E)

63


Key





Section modulus - Base : 304 cm3





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64


Key










EN 13674-1:2003 (E)

65


Key










EN

136

74-1

:200

3 (E

)

66

Tab

le A

.2 —

Rai

l tra

nsiti

on r

efer

ence

s (s

ee F

igur

e A

.22)

Rai

l pro

file

Ref

.46

E1

46E

246

E3

46E

449

E1

49E

249

E3

49E

450

E1

50E

250

E3

50E

450

E5

50E

652

E1

54E

154

E2

54E

355

E1

56E

160

E1

143

,88

40,5

953

,76

38,3

846

,84

40,4

747

,03

50,8

743

,84

52,0

549

,98

49,7

340

,47

43,8

442

,46

49,7

346

,31

46,8

440

,59

51,2

352

,05

265

,00

62,0

073

,72

65,0

067

,00

67,0

067

,00

70,0

065

,00

72,0

070

,00

70,0

067

,00

65,0

065

,00

70,0

067

,01

67,0

062

,00

69,8

572

,00

b14

,30

13,4

214

,18

13,7

514

,00

13,6

214

,00

14,7

513

,58

14,3

014

,23

14,1

013

,62

13,5

812

,62

14,1

013

,85

14,0

013

,42

14,5

314

,30

b112

,77

12,1

511

,86

13,2

811

,92

13,1

111

,80

11,8

912

,13

12,0

012

,01

12,0

413

,11

12,1

311

,98

12,0

412

,08

11,9

212

,15

11,6

112

,00

h198

,18

94,5

398

,13

99,7

194

,56

94,5

894

,55

58,7

310

0,05

103,

4910

4,35

101,

7394

,45

100,

0593

,52

107,

7510

7,16

93,9

095

,24

107,

3611

8,57

h281

,95

79,1

981

,34

81,0

379

,02

79,0

279

,02

44,8

586

,64

88,4

188

,99

88,3

279

,02

86,6

477

,99

92,2

592

,25

83,2

082

,80

92,1

610

1,50

h374

,47

65,9

172

,27

71,9

368

,40

68,4

068

,40

15,1

963

,87

78,2

276

,90

57,3

368

,40

63,8

757

,85

66,0

466

,04

54,5

860

,04

70,5

487

,06

l153

,99

32,3

850

,73

58,9

933

,13

33,1

333

,13

32,9

232

,13

30,5

431

,40

33,0

832

,74

32,1

323

,81

35,9

234

,97

32,1

332

,21

33,0

136

,61

l27,

284,

796,

815,

487,

067,

067,

0610

,53

8,21

6,61

7,19

11,4

97,

068,

218,

0012

,02

12,0

212

,41

8,21

9,87

8,25

l33,

130

2,39

1,71

2,41

2,41

2,41

00

1,54

2,44

1,67

2,41

01,

391,

541,

541,

520

03,

20

u124

,74

23,2

029

,79

25,8

426

,55

26,6

126

,54

22,9

924

,52

27,9

327

,65

26,5

326

,61

24,5

222

,24

26,0

325

,36

23,5

721

,50

23,9

226

,83

u26,

524,

796,

544,

635,

995,

995,

997,

208,

216,

615,

7811

,25

5,99

8,21

6,98

7,30

7,30

11,1

88,

215,

278,

25

u32,

320

2,16

0,85

1,32

1,32

1,32

--

1,54

1,01

0,26

1,32

00,

360,

690,

690,

240

03,

20

EN 13674-1:2003 (E)

67

Key

� Transition point 0,01 mm

Figure A.22 — Principal rail transition references

EN 13674-1:2003 (E)

68

Annex B(normative)

Standard test method for the determination of the plane strain fracturetoughness ( KIc) of rails

B.1 Test methods

This test shall be performed in accordance with the requirements of ASTM E399 except where superseded by therequirements specified in this part of EN 13674. The requirements specified in this part of the EN 13674 apply onlyto the determination of plane strain fracture toughness of railway rail steels covered by the definitions andrequirements of this standard.

B.2 Test pieces

B.2.1 The location of the test piece in the rail’s transverse section is shown in Figure B.1.

B.2.2 The thickness “B” of all test pieces shall be 25 mm. For any rail head transverse profile the test piece width“W” shall be the maximum achievable of the following dimensions:

40 mm;

45 mm;

50 mm.

B.3 Number of tests

A minimum of 5 tests from each sample shall be performed.

B.4 Test conditions 1)

B.4.1 Fatigue pre-cracking shall be carried out in the temperature range + 15 �C to + 25 �C using a stress ratio inthe range � 0 � + 0,1. Fatigue pre-cracking shall be carried out at a cyclic frequency in the range 15 Hz to 120 Hz.The final crack length to test piece width ratio shall be in the range 0,45 to 0,55 and during the last 1,25 mm ofcrack growth Kmax shall not exceed MPa m1/2.

B.4.2 The single edge notched bend test piece shall be loaded under displacement control using three pointbending with a loading span (S) equal to four times the test piece width (W).

B.4.3 Tests shall be performed at a test temperature of - 20 �C � 2 �C. Test piece temperature shall be measuredusing a beadless thermocouple spot welded to the test piece at the location shown in Figure B.2.

1) It is recommended that the chevron notch in ASTM E399 is used to avoid crack front curvature problems.

EN 13674-1:2003 (E)

69

B.5 Analysis of test data

B.5.1 The calculation of KQ shall be in accordance with ASTM E399. The checks made to establish whether thisvalue is a valid KIc shall be in accordance with ASTM E399 except for the requirements of B.5.2 to B.5.6.

B.5.2 Pmax/PQ shall be less than 1,10 for force-crack mouth opening curves where pop-in does not occur beforethe intersection of the curve with the 95 % secant. There shall be no Pmax/PQ criterion for other types of curve.

B.5.3 The linearity of force-crack mouth opening curves Ia, Ib, IIa and III (see Figure B.3) shall be checked in thefollowing manner.

Measure the distance (v1) between the tangent OA and the force-crack mouth opening curve at a constant force of0,8 PQ. Measure the distance (v) between the tangent OA and the force-crack mouth opening curve at a constant

force of PQ. For a test result to be valid v1 � 0,25 v.

B.5.4 The linearity of force - crack mouth opening curves IIb and IIc (see Figure B.3) shall be checked in thefollowing manner.

Measure the distance between the tangent OA and the force - crack mouth opening curve at constant forces of0,8 PQ and PQ recording these values as v1 * and v* respectively.

Measure the crack mouth opening values arising from all “pop-ins” that occur up to PQ; this is done by measuringthe horizontal distance travelled along the crack mouth opening axis between the start and finish of each “pop-in”.Sum the values for “pop-ins” occurring below 0,8 PQ and for those occurring between 0,8 PQ and PQ recording

them as � v1pi and � vpi respectively.

For a test result to be valid [v1 *- � v1pi] � 0,25 [v* - (� vpi + � v1pi)]

B.5.5 The linearity criterion cannot be applied to force - crack mouth opening curve IV.

B.5.6 For all force - crack mouth opening curves the KQ value shall be subjected to the validity check that the test

piece thickness (B) and crack length (a) are equal to, or greater than, the value of 2,5 (KQ/Rp0,2)2, where Rp0,2 is the

0,2 % proof stress at the fracture test temperature of - 20 �C.

B.6 Reporting of results

All measurements required to calculate the test result and to show that the test conditions were as specified in thetest procedure shall be recorded.

All results shall be reported as either KIc values *QK values or KQ values; where *

QK values are those KQ values

which failed the validity criteria due only to one or more of the following:

1) Pmax/PQ > 1,1;

2) Exceedence of the 2,5 (KQ/Rp0,2)2 criterion;

3) Crack mouth opening displacement - force relationship.

The mean and standard deviation of both KIC and *QK results shall be recorded. For each grade of rail tested these

results shall be included in a table giving the following information.

EN 13674-1:2003 (E)

70

Steel 0,2 % Mean Number of Sample Mean Number SampleGrade Proof KIC KIC standard KQ of KQ standard

Stress at (MPa m1/2) results deviation results deviation

- 20 �C (MPa m1/2) (MPa m1/2) (MPa m1/2)MPa

The value to be used for the acceptance criteria is that of the mean KIC and shall be based on a minimum of fiveKIC values.

When five KIC values have not been obtained any *QK values shall be included with any KIC values in the mean

value to be used for the acceptance criteria. In this event the number of test results shall be at least ten.

All values of KIC and *QK shall be above the minimum value specified in Table 2..

EN 13674-1:2003 (E)

71


Key

1 Notch machined in this face

2 Section through rail head

3 Letter ‘H’ to be stamped on end face of test piece as shown

B = 25

W = see B.2.2

For all other test piece proportions

see ASTM E399

Figure B.1 — Location and section of fracture toughness test pieces

EN 13674-1:2003 (E)

72


Key

1 Notch

2 Thermocouple to be placed in the shaded zone

3 Fatigue crack tip

Figure B.2 — Location of thermocouple on fracture toughness specimens

EN 13674-1:2003 (E)

73

Key

1 Force, P

2 Crack mouth opening displacement (v)

Key

1 Force, P

2 Crack mouth opening displacement (v)’

Figure B.3 — Force - Crack mouth opening curves

EN 13674-1:2003 (E)

74

Annex C(normative)

Method for the determination of rail foot surface longitudinal residualstresses

C.1 Procedure

Residual stresses shall be estimated by first attaching an electrical strain gauge on the rail foot surface. Thesurface to which the gauge is attached shall be progressively isolated from the rail and the relaxed strains shallthen be used to estimate the stresses which have been relieved whilst the original residual stresses are taken to bethose values but with a change of sign.

C.2 Strain gauges and their location

Electrical strain gauges of the encapsulated type shall be used, 3 mm in length with a gauge factor accuracy ofbetter than � 1 %.

The strain gauge shall be attached to the surface of the rail foot in order to measure longitudinal strain at thepositions as shown in Figure C.1. The surface of the rail foot shall be prepared and the strain gauge shall beattached, in accordance with the recommendations of the strain gauge manufacturer.

Any surface preparation shall not itself result in a change of the residual stresses in the rail foot.

NOTE The strain gauge should be located at the centre of the 1 m length of the sample rail set aside for this work.

Readings shall be taken from the strain gauges. While cooling the rails to maintain a constant temperature, twosaw cuts shall be made to remove a 20 mm thick slice from the centre of the rail length (Figure C.2). A second setof measurements shall be taken.

The residual stresses shall be calculated from the differences between the first and second sets of relieved strainsby multiplying by 2,07 � 105 MPa.

EN 13674-1:2003 (E)

75

Key

1 Strain gauge

Figure C.1 — Location of strain gauge to measure rail foot surface longitudinal residual stresses

EN 13674-1:2003 (E)

76


Key

1 Centreline

2 Saw cut

3 Strain gauge

4 Rail foot

Figure C.2 — Slice removed from the rail

EN 13674-1:2003 (E)

77

Annex D(normative)

Limiting sulfur prints

The limiting sulfur prints presented in this annex are summarised in Table D.1.

Table D.1 — Limiting sulfur prints

Figure Limiting sulfur print Classification

D.1 Perfect Acceptable

D.2 Small negative and positive segregation Acceptable

D.3 Negative segregation in the web Acceptable

D.4 Small positive segregation Acceptable

D.5 Dendritic structure Acceptable

D.6 Spotty segregation over the total cross section Acceptable

D.7 Negative segregation-zone arising from electromagnetic stirring Acceptable

D.8 Negative rim Not acceptable

D.9 Positive segregation from internal hot cracks in the blooms See Figure D.9

D.10 Subsurface pin holes Not acceptable

D.11 Double positive segregation in the web Not acceptable

D.12 Central web segregation extending into head and/or base Not acceptable

D.13 Scheme of sulfur prints of rails rolled from continuously cast blooms See Figure D.13

EN 13674-1:2003 (E)

78

Classification: acceptable

Figure D.1 — Perfect sulfur print

EN 13674-1:2003 (E)

79


Figure D.2 — Small negative and positive segregation

EN 13674-1:2003 (E)

80


Figure D.3 — Negative segregation in the web

EN 13674-1:2003 (E)

81


Figure D.4 — Small positive segregation

EN 13674-1:2003 (E)

82


Figure D.5 — Dendritic structure

EN 13674-1:2003 (E)

83


Figure D.6 — Spotty segregation over the total cross-section

EN 13674-1:2003 (E)

84


Figure D.7 — Negative segregation - zone arising from electromagnetic stirring

EN 13674-1:2003 (E)

85

Classification: not acceptable

Figure D.8 — Negative rim

EN 13674-1:2003 (E)

86

Classification: acceptable for crack length � 5 mm for not heat treated and � 3 mm for heat treated materials

acceptable for added length of single cracks � 10 mm

Figure D.9 — Positive segregation from internal hot cracks in blooms

EN 13674-1:2003 (E)

87


Figure D.10 — Subsurface pin holes

EN 13674-1:2003 (E)

88


Figure D.11 — Double positive segregation in the web

EN 13674-1:2003 (E)

89


Figure D.12 — Central web segregation extending into head and/or base

EN 13674-1:2003 (E)

90

X m

axX

max

Classification: Central web segregation extending into head and/or base not acceptable exceeding the followingthreshold values X max:

Profile: max. acceptable extension x46E1 to 54 E3 15 mmAll other profiles Not specified

Figure D.13 — Schematic diagram defining extent of allowable web segregation

EN 13674-1:2003 (E)

91

Annex E(normative)

Profile and drilling gauges

The gauges for manufacture as specified in 9.3 are shown in the figures which are summarised in Table E.1.

Table E.1 — Summary of figures

Figure E.1 Datum references for tolerances

Figure E.2 Datum references for decision

Figure E.3 Height of rail

Figure E.4 Crown profile

Figure E.5 Width or rail head

Figure E.6 and E.7 Asymmetry

Figure E.8 Fishing height HF and inclination IF

Figure E.9 Web thickness

Figure E.10 Width of rail foot

Figure E.11 Foot toe thickness

Figure E.12 and E.13 Drilling gauges

EN 13674-1:2003 (E)

92

Figure E.1 — Datum references for tolerances (see Table 8 and Figure A.22)

EN 13674-1:2003 (E)

93

Datum Reference Figure No.0 - Height - must not + must pass E.30 - Crown profile - must + must not pass the wedge E.41 - Width of rail head - must not + must touch E.52 - Rail asymmetry - must not + must touch E.6, E.73 - Inclination of fishing surfaces E.8

4, 5 - Height of fishplating - must + must not touch E.85 - Web thickness - must not + must pass E.9

4,5 - Thickness of rail foot E.11- - must not touch the web + must touch the web E.11

6 - Width of rail foot - must not + must pass E.10

Figure E.2 — Datum references for decision

EN 13674-1:2003 (E)

94

Figure E.3 – Height of rail

EN 13674-1:2003 (E)

95

Key

1 Maximum width of rail head tolerance

2 Theoretical profile

3 Step gauge to check the table shape

4 Thickness 10

Figure E.4 — Crown profile

EN 13674-1:2003 (E)

96

Figure E.5 — Width of rail head

EN 13674-1:2003 (E)

97

Figure E.6 — Rail asymmetry

EN 13674-1:2003 (E)

98

Figure E.7 — Rail asymmetry

EN 13674-1:2003 (E)

99

Key

1 and 2 Marks engraved 14 mm apart to indicate measuring points

3 h3 = theoretical

4 HF = theoretical

X1, X2, X3, X4: gap between rail and gauge measured with a feeler gauge

Points X1 and X2, maximum difference 0,35 mmPoints X3 and X4, maximum difference 0,35 mmMaximum total difference when added together - 0,35 mm

Figure E.8 — Fishing height and inclination

EN 13674-1:2003 (E)

100

Figure E.9 — Web thickness

Figure E.10 — Width of rail foot

EN 13674-1:2003 (E)

101

Key

1 Maximum

2 Minimum

3 Width of foot/2

4 Tolerance

Figure E.11 — Foot toe thickness

EN 13674-1:2003 (E)

102

Key

WT Web thickness

Figure E.12 — Gauge for checking distance between holes and rail end and hole diameter

EN 13674-1:2003 (E)

103

Key

WT Web thickness

Z Distance between centre of the hole and base of the rail

Figure E.13 — Gauge for checking distance between holes and base of rail

EN 13674-1:2003 (E)

104

Annex F(informative)

Comparison of steel designations referred to in this standard compared tothose in EN 10027-1 and EN 10027-2

Steel grade in this standard Steel name according to EN 10027-1 Steel number according to EN 10027-2R200 R200 1.0521R220 R220 1.0524R260 R260 1.0623

R260Mn R260Mn 1.0624R320Cr R320Cr 1.0915R350HT R350G1HT 1.0631

R350LHT R350G2HT 1.0632

EN 13674-1:2003 (E)

105

Annex ZA(informative)

Clauses of this European Standard addressing essential requirements orother provisions of EU Directives.

This European Standard has been prepared under a mandate given to CEN by the European Commission and theEuropean Free Trade Association and supports essential requirements of EU Directive.

Council Directive 96/48/EC of 23 July 1996 on the Interoperability of the trans-European high speed railsystem

Compliance with this Standard provides one means of conforming with the specific essential requirements of theDirectives concerned and associated EFTA Regulations

WARNING: Other requirements and other EU Directives may be applicable to the products falling within the scopeof this Standard

Relationship between this European Standard and Directive 96/48/EC

Clauses/sub-clauses of thisEuropean Standard

Chapter/§/of TSI rollingSTOCK

Corresponding text,clause/annex of theDirective 96/48/EU

Comments

Chapter 4 – Characterisationof

Chapter II Article 5

the subsystem Points 3a; 3b

clause 4.3 – Specifiedperformance

Annex II point 3

Clause 5 – Steel grades Point 4.3.3 Annex III Clauses 1.1; 1.5 Only the following points:

Table 1: Steel grades and Annex K1 - hardness of the rail

- profile of the rail

Clause 9 – Acceptance tests - linear mass of the rail are

Clause 9.1.7 Hardness considered as relevant tosatisfy the essentialrequirements of theDirective 96/48/EC

Clause 9.2 Dimensiontolerances

Chapter 5 – Interoperability Chapter II Article 5

Clause 9.2.1 Profile Constituents Point 3e, 3f

Clause 5.2 – Description ofthe InteroperabilityConstituents of theInfrastructure Subsystem

Chapter III Article 8

Annex A: Rail profiles Point 5.2.1 – The rail andAnnex K2

EN 13674-1:2003 (E)

106

Bibliography

[1] EN ISO 9001, Quality management systems – Requirements (ISO 9001:2000).

[2] EN 10027-1, Designation systems for steel – Part 1: Steel names, principal symbols.

[3] EN 10027-2, Designation systems for steel – Part 2: Numerical system.

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BS EN 13674-1:2003

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BS EN 13674-1