Holding on tight: keeping the elements of track in place is a challenging job, but fastener suppliers are offering new, improved products to meet this challenge

Railway Track and Structures, June, 2003 by Tom Judge

As trains grow heavier and speeds grow higher, new track elements have to be developed, and fasteners have to ensure that everything continues to hold together. Developing new and better fasteners to work in the strenuous railroad environment is an ongoing campaign.

AirBoss: New generation

"AirBoss has designed and is now testing our next generation of fastening system that will allow all of the components to be pre-installed on concrete ties," said Bob Magnuson, president, AirBoss Railway Products, Inc. "Our 'Universal System' consists of improved clips, pads and insulators that can be installed on concrete ties at the factory and shipped to the job site ready for rail. Clip installation that secures the rail can be completed with existing machines, reducing the time and investment that would be required to take advantage of the potential cost savings associated with a tie-captive system. Significant improvements have been incorporated in the new system, which was developed from customer requests and laboratory investigations."

The Universal Fastening System is currently scheduled for test installations on both Union Pacific and BNSF this Summer.

AirBoss is currently working with UP and BNSF under multi-year fastening supply agreements that provide the AirBoss fastening system to concrete tie installation sites.

"Our Clip-Captive Shoulder is the current shoulder of choice utilized by both railroads for their concrete tie installations," Magnuson said.

ATP: Egg fasteners

"Our HK EGG deserves to be called the King Kong Egg," said Bill Osler, general manager, Advanced Track Products, Inc. "These fasteners are fully-tested and installation is about 50 percent complete on East Rail, a Hong Kong light-rail project. This is a totally-new design created specifically for East Rail's 20-ton axle loads. Performance has been truly outstanding, and it validates the capability of ATP's design team. After meeting the specification requirement of six million cycles in a load test, it was requested that we continue to 10 million to determine the extent of reserve durability. After 10 million cycles, there was still no sign of distress. Subsequent testing documented that fastener characteristics before and after 10 million cycles were little different, which is remarkable. The fasteners were designed for UIC60 but can be easily altered for 115 RE and axle loads less than 20 tons, suitable for light-rail and commuter rail service.

Another product redesigned for the East Rail project's 20-ton axle loads is similar to ATP's Loadmaster design concept, with loads cushioned by rubber in compression. This item also successfully passed a six-million-cycle fatigue test with no signs of distress. Designed for UIC60, the item can also be adapted for 115 RE suitable for light-rail and commuter rail service.

NorFast: Cleated plate

NorFast continues to offer a ductile cast-iron plate with a patented cleat base and large (16-inch x 8-inch) footprint. This cleated plate restricts gauge widening and prevents spike shearing off by reducing the lateral loads on screw spikes. NorFast tie plates also prevent rail rollover and are available for 5.5-inch and 6.0-inch rail bases at this time. In addition, NorFast's delivery of pre-assembled plates and Double-J Rod Clips can save time and labor during installation. The company is working closely with four manufacturers of equipment for the application and removal of its pre-assembled system to reduce the labor in the field.

"Our pre-assembled plates deliver better and faster clip installation, and rail change out, without the need for complete removal of the clips from the plate," said Jerome Hines, vice president, sales and marketing. NorFast has introduced a joint plate and a series of inserts for standard, glued and poly-bonded joint bars. The joint plate works in conjunction with NorFast clip retainers and Double-J Rod Clips.

"Also, we are working on a new design for a concrete fastening system that will help to greatly reduce or eliminate tie seat abrasion, which is one of the main reasons the heavy-haul railroads are moving or have moved away from concrete ties," Hines said.

The company decreased its clip manufacturing from three facilities to one strategic location for better quality control.

Pandrol: New systems

"We have been busy the past few years developing new track fastening systems to meet the specific needs of our railroad and transit customers," said Dennis Wilcox, Pandrol USA's vice president of sales.

"For our railroad customers, the patented Pandrol SAFE-LOK III system has a totally redesigned fastener that comes pre-assembled with all components in place on the tie, ready for rail installation. The Pandrol SAFELOK III system is now in track in a number of demanding locations and is performing at or above expectations. The SAFELOK III system provides all of the benefits of the SAFELOK fastener, plus the benefits of a captive system.

"We have also developed a new, patented system for wood ties that is ready for track installation this year. The Pandrol VICTOR system uses a standard AREMA tie plate, a Pandrol shoulder, a unique, patented manufacturing process, and can be used with a Pandrol SAFELOK III, 'e'-clip or FASTCLIP. We are excited about the new system because it provides railroads with a tie plate with a large bearing area, while enabling them to use the Pandrol fastener they prefer. In addition, we are going to provide a VICTOR system with a rail block option design to virtually eliminate rail rollover."