Engineering Manual

Track

TMC 203

Engineering Manual
TRACK INSPECTION

Version 5.3

Issued April 2013

Reconfirmed 03 July 2019

Owner: Chief Engineer Track

Approved by: Andrew Wilson Authorised by: Malcolm Kerr
Technical Specialist Chief Engineer Track
Wheel/Rail

Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp

UNCONTROLLED WHEN PRINTED Page 1 of 253

RailCorp Engineering Manual — Track
Track Inspection TMC 203

Document control
Revision Date of Approval Summary of change
1 October, 2006 First issue as a RailCorp document. Includes content from
TS 22 000 2 01 SP, C 2009, C 2011, C 2107, C 2430, C
2435, C 2436, C 2437, C 2438, C 2439, C 2440, C 2441,
C 2442, C 2443, C 2444, C 2445, C 2445, C 2447, C 2508,
C 3102, C 3210, C 3215, TS 3102, TS 3655, AP 5134, CSI
018, CSI 025, RC 2411, RC 2436, RC 2442, RC 2508,
Draft RC 4801, RTS 3432, RAP 5108, RAP 5133, RAP
5134, RAP 5135, RAP 5138, RAP 5139, RAP 5140, RAP
5141, RAP 5142, RAP 5701, CTN 01/05, CTN 01/07, CTN
01/11, CTN 02/01, CTN 02/07, CTN 03/01, CTN 04/01,
CTN 04/04, CTN 04/07, CTN 04/09, CTN 04/10, CTN
04/11, CTN 04/15, CTN 04/25, CTN 04/27, CTN 05/12,
CTN 05/15, CTN 05/18, CTN 06/04, CTN 06/06, CTN
06/08.
2 April, 2007 Additional reference; Minor corrections; inclusion of CME
accountabilities for LXing sighting points; clarification of
requirements for attendance on Track Recording Car;
Inclusion of CME accountabilities for review of Defect
Management System; Removal of requirement to have
Maintain Points & Crossing Competency to certify turnouts
after examination; Minor change to competency for
Swingnose crossing examination; Correction of alignment
measurement; Clarification of measurement of line;
additional explanation of checkrail effectiveness; additional
explanation of rail dimensions; Changes to BOS numbers;
addition of 8m line measurement; addition of 47kg
corrosion limits and correction of others; Addition of
information on dealing with false readings; Minor
correction; inclusion of requirements of CTN 06/05;
Changes to ballast deficiency table; Additional information
about dealing with fixed points; Additional requirements for
checking obstructions to sighting distances; Minor
corrections; additional guidance on measuring dip at
crossings; inclusion of VAE Expansion switches; additional
guidance of assessment of manual point lever
effectiveness; revision of slip examination procedure;
addition of VAE Swingnose examination procedures;
addition of requirements to check tip of swingnose with
switch tip gauge; inclusion of content of CTN 05/20.
3 October, 2007 Minor change to references, Addition of rounding of
measurements; addition of initial review requirements for
tight gauge, Minor change (emphasis) in Table 12), Minor
change to Figure 31
4 May, 2008 C2-1.1 – Inclusion of requirements for Integrated Walking;
C2-2.1 – additional requirement for Team Managers to
report non-attendance on Track Recording runs; C5-3 –
Addition of Absolute Superelevation limit; C5-4 – Correction
of error in Rail Wear table; C7-3.1 – Additional patrol
procedure for Ancillary lines; C7-4.1 Additional issues for
Engine Patrol; C9-2 – Add check of movement of Friction
Buffer Stops; C11-2 – Add check of movement of Friction
Buffer Stops; C11-9 – Wording change to clarify
maintenance limits; C19-2 – Clarification of measurement
conventions for platform clearances; C19-3 – Correction of

© Rail Corporation Page 2 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Revision Date of Approval Summary of change

error on measurement interval; C19-4 inclusion of
requirement to measure at 50m intervals on curves;
Correction of errors in Figure 32; C23-3 – Addition of check
of line of open switch; Form STW 1 - Minor change to
clarify response requirement
4.1 December, 2008 Chapter 1 - Minor Correction to out-of–course inspections;
Chapter 2 - Additional requirements for notification of staff
not attending Track Recording runs; Additional defects in
C5-8 Insulated joints; Addition of explanation of Manual
Trackstab adjustments in C13-1.1; Inclusion of additional
requirements in C16-1.1 for checking around insulated joint
keys; C23-17.2.2 added measurement of splice rail
opening for VAE Swing Nose crossings; Form Clear 2 ­
Minor addition for clarification; Form STW 1 - Minor change
to clarify response requirement
4.2 May, 2009 Complete document – Format Change; Section C2-1.2
Addition of requirement to provide a “route plan” for each
Mechanised Patrol; C7-3 – Change to Track Magnets
Health Warning to reflect reduced danger to pacemakers;
addition of inspection and response requirements from
TMC 521 Level Crossings Manual; C7-5.2 - Addition of
definitions of Critical Trackwork and Critical locations for
Mechanised Track Patrol Detailed Review; C9-2 – Change
to Track Magnets Health Warning C9-2 and C9-3 – addition
of inspection and response requirements from TMC 521
Level Crossings Manual; C11-7 – Change to Track
Magnets Health Warning; C12-5.1 – Added limit on
distance between creep control marks; C12-6 – addition of
anchoring on concrete structures; C20-4 and C20-5 –
addition of inspection and response requirements from
TMC 521 Level Crossings Manual; Section C23-10 ­
Change to Figure 55 to clarify slope of landing area
4.3 December, 2009 Various - Changes to titles; C2-1.1 - add CME
responsibilities for nomination of sidings for examination;
C5-1 – New section on Mandatory Limits and responses
and guidelines; limits and responses categorised into
mandatory and guidelines; New section C5-15 - Siding
limits and responses; C7-3.1 (10) Additional information
regarding switch defects from CTN 09/06; C11-1 – Addition
of information from CTN 09/01; C20-4 - Added requirement
to measure flare opening; Form LX 1 - Added
measurement of guard rail flare
4.4 July, 2010 C1-4 – Additional references; C2-2.1 – Addition of
requirements for AK Car Operator to report non-attendance
by civil maintenance representatives and report Emergency
defects to IOC; New heading C4-10.1 – “Measurement in
crossings; new section C4-10.2 “Switch measurement”; C5­
2 – clarification of application of limits to speed bands; C5-1
to C5-14 – Change XPT to passenger in speed headings;
Sect C5-13.2 – correction of typo; changes to LXing limits
to match TMC 521; C6-1.3.2, C6-1.4.2, C6-1.5.2 – Minor
change to wording for clarity; C-[Link] – Added
requirement to slow Hi-rail patrol over Level Crossings to
conduct examination; C9-2 – Addition of reference to TMC
404, Addition of Boundary signs; C11-2 – Addition of
Boundary signs; C12-5.3 - Addition of advisory maximum

© Rail Corporation Page 3 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Revision Date of Approval Summary of change

length between Alignment measurements; C13-1 –
Addition of formulae from which Table 12 values are
derived; C20-1, C20-4 - Change terminology from "check
rail" to "guard rail"; Form LX 1 - Change terminology from
"flangeway effectiveness" to "guard rail effectiveness"
4.5 February, 2011 C4-1 – Additional detail on use of metallic objects - from
CTN 10/13; C9-2.6 Inclusion of check for damage from rail
bond welds; C11 - Inclusion of inspection of switch pad
protectors in siding turnouts (includes content from CTN
10/16); C12 - Correction of error in creep example page 5;
C14 - Changes to reflect use of ultrasonic depth gauge to
measure rail foot thickness; and change in measuring
intervals; addition of requirement to complete NIL return if
no defects are found; Form 2, Form WTSA 1, Form
WTSA 2, Form WTSA 3, Form WTSA 4, Form Rail 1, Form
Rail 2, Form Rail 3, Form Rail 4, Form Clear 1, Form
Clear 2, Form LX 1, Form Drain 1 and Form STW 6 ­
Inclusion of examiner’s name
4.6 August, 2011 C2-1.3 and C2-1.4 – addition of requirements for IOC to
call out staff for emergency examinations; Competencies
updated to current National competencies; C7-3.1 added
check for untested aluminothermic welds (flouro pink
marking); C14-1 – added reference to additional rail wear
gauges. Inclusion of new rail wear angle gauge and
procedures for use; C18-3 – New section on examination of
resilient baseplates; C20-4 – added diagram explaining
flangeway width and guardrail effectiveness measurement;
5.0 June 2012 C2-1.1 clarification in “For Clearance Examination” allowing
the exemption for all clearances >KE+300mm not just track
centres; C2-2.1 Addition of requirement for CME to
manage assessment of areas where track recording car
has flat lined and guidelines for assessment;. C3 Removal
of requirement for Check & Repair Track Geometry for Post
Irregularity examinations, Certify plain track after track
examination, Certify turnouts & special trackwork after track
examination; C5-1 Changes to Mandatory Limits and
Responses. Clarification of guideline actions.C5-2 Change
to response table for inspection response to P3 defects.C5­
3 Changes to “Response to Base Operating Conditions”.
Note to allow 20/20 speed column to be used when
assessing BOCS limits on 25kph turnout roads. C5-5.2
New rail wear limit table including some changes to limits
and notes on actions. C5-10.2 New guidelines for insulator
and pad wear on concrete sleepers. C5-11.2 Further
Information for assessing ballast defects. Changes to
guideline priorities for excess ballast.C5-12 Changes to
Turnout Defect Limits and Responses for: Gauge through
crossing, Checkrail flangeway width. C5-12.1.3 Clarification
of where to take checkrail effectiveness and crossing
gauge measurements. C5-12.2.2 Changes to limits and
responses for: Gauge at switch tip, switch slope, switch tip
height, switch component condition, checkrail bolts, housed
points. C5-13 Changes to level crossing defect table. C5­
15 Changes to Siding Limits and responses; C6-1 –
Clarification of assessment & correction requirements for
track geometry.6-1.2. Changes to correction of tight gauge.
C6-1.3 Short twist. Changes to AK chord lengths and

© Rail Corporation Page 4 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Revision Date of Approval Summary of change

inspection requirements, C6-1.4 Long Twist. Changes to
AK chord lengths and inspection requirements, C6-1.5 Top.
Changes to AK chord lengths and inspection requirements,
C6-1.7 Changes to AK chord lengths and inspection
requirements; C11-10 changes to action to be taken
section.; C11-9 Changes to siding maintenance limits.
(table 8) some acceptance limits that are contained in
TMC203 “Track Geometry Manual” and TMC251 “Turnout
Manual” and were contradictory to the limits in those
manuals have been removed and referenced to the
appropriate manual; C11-10 Reference made to use 20
kph main line limits for defects not found in the siding
BOC’s; C12-5.3 Updated to include reference to “revised
alignment” on new WTSA forms; C12-7 Changed from
“report worst ballast loss in 500mts section” to “report all
ballast loss in 500mts section; Added extra information on
reporting ballast, foul ballast and pumping track on new
WTSA forms; Note inserted to highlight the need to record
and report to CME severe bog holes where sleepers are
not supported and ballast is not in contact with sleeper;
C12-8 Updated misalignment triggers to include detail on
how to record on new WTSA form. Removed the need to
collect some information that is now not required during
field inspection; C13-1 Changes to table 13 to comply with
new WTSA software. Correction of Table 11 to remove
500m jointed which is not applicable; C13-6. Updated
information on entering all ballast loss into analysis to
comply with new WTSA software; C13-7. Updated
disturbance information to allow the use of the lower % loss
for time based or tonnage for both primary and secondary;
Clarification in where to access disturbance records and
information; Updated generally to reflect changes in the
software replacing references to TrackStab. Table 13
changes to reflect changed capabilities in the new WTSA
software; C16-2 Note added to clarify recording of
Insulated joints that require supplementary patrol. Note
added to refer Insulated joints with severe spark gap
erosion to signals staff so bonding can be checked; C18-2
Instruction on what to examine in concrete sleeper
inspection; C23-4 Updated to include instruction on where
to measure checkrail effectiveness to ensure uniformity due
to different crossing nose profiles. Removed the
requirement to also measure gauge at the back legs of the
crossing. Removed the requirement to measure flangeway
depth and clearance at either end of the checkrail; C26 ­
Clarification of retention period for inspection records to
separate from State Records requirements; Form 2 ­
Addition of how found and who found information; Form
WTSA 2 - Added new WTSA field sheet; Form Rail 3 ­
Added priority column to form; Form STW 1 - Removed old
tolerances for crossing measurement. Removal of “bolts
torque applied”. Added question on type of crossing
(manganese Y/N). Added question on switch type when
using switch tip gauge. Requirement to record all twist
defects.
5.1 July 2012 C5-12.2.2 correction of typo in table instances of “>5mm”
should be “<5mm” relating to switch tip width.

© Rail Corporation Page 5 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Revision Date of Approval Summary of change

5.2 August, 2012 C5-12.2.2 Correction of typo in table under Housed Points
Flangeway Clearance (mm), “>49” changed to “>50” &
“<39” changed to “≤ 39”
5.3 April, 2013 Changes detailed in summary table below

Summary of changes from previous version

Summary of change Section

Control changes Document

Deleted individual forms from TOC Control

Reformatted to new template – Page numbering converted to continuous numbering. All

Separate document control on individual chapters removed

Addition of TOC Manual as a reference C1-4

Changes to management requirements for clearance examination and review to C2-1.1

reflect changes in responsibilities for clearance assessment.
Inclusion of infringing speed signs and equipment attached to tunnel walls in locations
to be listed by CME for clearance examination

Change to operating limits for general condition of sleepers C5-10.1

Change to operating limits for checkrail flangeway depth in crossings C5-12.2.1

Item 14 – Inclusion of reference to TOC Manual as location of permant speed signs C9-2

Minor change to clarify influence of reconditioning and ULX works on stability loss C13-7
Clarification on the use of tonneage information for determining track stability loss due
to track disturbance

Rewrite to include TORFMA units and content of FM BCNT 20121126 Inspection C17
procedures

Complete chapter revision to reflect changes in responsibilities for clearance C19

assessment and introduction of visual Inspection of platform clearances

Added inspection of steel in-bearers C23-6.1.3

Added Index to forms Appendix 1

Form Clear 2 – changes to reflect changed examination requirements
Form Rail 4 - Alterations to include TORFMA inspection
Form Rail 5 – New form for lubrication inspection

© Rail Corporation Page 6 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Contents
Chapter 1 General ......................................................................................................................12
C1-1 Purpose ................................................................................................................................12
C1-2 Context .................................................................................................................................12
C1-3 How to read the manual .......................................................................................................12
C1-4 References ...........................................................................................................................13
C1-5 Introduction ...........................................................................................................................13
Chapter 2 Management Requirements ....................................................................................15
C2-1 Track Examination................................................................................................................15
C2-2 Track Recording ...................................................................................................................22
C2-3 Recording and Reporting of Defect Detection and Removal ...............................................23
C2-4 Management & Reporting of Welded Track Stability Assessment.......................................25
C2-5 Management of Operating Limits and Responses ...............................................................27
C2-6 Management of District Waivers ..........................................................................................27
Chapter 3 Competencies...........................................................................................................28
Chapter 4 Methods of Measurement ........................................................................................29
C4-1 Use of Non Metallic Tapes ...................................................................................................29
C4-2 Gauge ...................................................................................................................................29
C4-3 Cross Level/Superelevation..................................................................................................30
C4-4 Alignment..............................................................................................................................31
C4-5 Line .......................................................................................................................................31
C4-6 Rail Level ..............................................................................................................................33
C4-7 Rail Top ................................................................................................................................33
C4-8 Clearance to Structures........................................................................................................33
C4-9 Track Centres .......................................................................................................................34
C4-10 Turnouts and Special Trackwork..........................................................................................34
C4-11 Measuring Rail Dimensions..................................................................................................36
Chapter 5 Defect Limits and Responses .................................................................................37
C5-1 Mandatory Limits and Responses ........................................................................................37
C5-2 Standard Defect Categories and Responses .......................................................................37
C5-3 Response to Base Operating Conditions .............................................................................38
C5-4 Track Geometry Defects.......................................................................................................39
C5-5 Rail Wear Defects.................................................................................................................40
C5-6 Rail Surface Condition Defects ............................................................................................41
C5-7 Rail Lubricator Defects .........................................................................................................42
C5-8 Rail Joint Defects..................................................................................................................42
C5-9 Insulated Rail Joints Defects ................................................................................................43
C5-10 Sleeper Condition Defects....................................................................................................45
C5-11 Ballast Defects......................................................................................................................46
C5-12 Turnouts and Special Trackwork Defects.............................................................................49
C5-13 Level Crossings Defects.......................................................................................................56
C5-14 Transit Space Defects ..........................................................................................................56
C5-15 Siding Limits and Responses ...............................................................................................58

© Rail Corporation Page 7 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 6 Assessment of Base Operating Conditions ..........................................................61

C6-1 Track Geometry....................................................................................................................61
C6-2 Rail Wear..............................................................................................................................66
C6-3 Rail Condition .......................................................................................................................69
C6-4 Sleepers................................................................................................................................69
C6-5 Ballast ...................................................................................................................................70
C6-6 Turnouts................................................................................................................................70
C6-7 Level Crossings ....................................................................................................................73
C6-8 Transit Space .......................................................................................................................73
Chapter 7 Track Patrol...............................................................................................................75
C7-1 Patrol Methods .....................................................................................................................75
C7-2 Examination Requirements ..................................................................................................75
C7-3 Walking and Hi-Rail Patrol Procedures ................................................................................78
C7-4 Engine Patrol Procedures.....................................................................................................85
C7-5 Mechanised Track Patrol Procedure ....................................................................................88
C7-6 Supplementary Patrol Procedure .........................................................................................90
C7-7 Adjacent Track Patrol Procedures........................................................................................91
C7-8 Night Patrol Procedures .......................................................................................................91
C7-9 Wet Weather Patrol ..............................................................................................................92
C7-10 Heat Patrol............................................................................................................................93
Chapter 8 Front of Train Examination .....................................................................................94
C8-1 Examination Requirements ..................................................................................................94
C8-2 Examination Procedure ........................................................................................................94
C8-3 Action to be Taken................................................................................................................94
Chapter 9 Detailed Walking Examination ................................................................................95
C9-1 Examination Requirements ..................................................................................................95
C9-2 Examination Procedure ........................................................................................................95
C9-3 Action to be Taken..............................................................................................................101
Chapter 10 Post Irregularity Examination ...............................................................................103
C10-1 Examination Procedure ......................................................................................................103
C10-2 Action to be Taken..............................................................................................................103
Chapter 11 Siding Inspection ...................................................................................................104
C11-1 Track Patrol in Sidings........................................................................................................104
C11-2 Detailed Walking Examination of Plain Track in Sidings....................................................104
C11-3 Inspection of Turnouts in Sidings .......................................................................................105
C11-4 Inspection of Clearances in Sidings ...................................................................................105
C11-5 Inspection of Sleepers in Sidings .......................................................................................105
C11-6 Inspection of Drainage in Sidings.......................................................................................105
C11-7 Inspection of Track Magnets ..............................................................................................105
C11-8 Yard and Siding Categories................................................................................................106
C11-9 Siding Maintenance Requirements ....................................................................................106
C11-10 Action to be Taken..............................................................................................................107
Chapter 12 Track Stability Measurement ................................................................................108
C12-1 Special Infrastructure Situations.........................................................................................108
C12-2 Preparation for Measurement.............................................................................................108

© Rail Corporation Page 8 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

C12-3 Measurement Procedure ....................................................................................................108

C12-4 Measuring Rail Gaps ..........................................................................................................108
C12-5 Measuring Rail Adjustment in CWR ...................................................................................109
C12-6 Rail Anchor Examination ....................................................................................................117
C12-7 Ballast Examination ............................................................................................................119
C12-8 Misalignment Triggers ........................................................................................................121
C12-9 Inspection for Old Welds at Fixed Points ...........................................................................122
C12-10 Ties and Painted Rails........................................................................................................122
C12-11 Guidelines for the Assessment of Crossing Loops ............................................................122
Chapter 13 Welded Track Stability Analysis ...........................................................................124
C13-1 Rail Adjustment - Long Welded Rail...................................................................................124
C13-2 Rail Adjustment - Continuous Welded Rail ........................................................................130
C13-3 Assessment of Bunching Points and Fixed Points .............................................................134
C13-4 Rail Adjustment - Winter Deficiencies ................................................................................136
C13-5 Stability Loss - Anchors ......................................................................................................136
C13-6 Stability Loss - Ballast ........................................................................................................136
C13-7 Stability Loss - Track Disturbances ....................................................................................137
C13-8 Stability Loss - Track Condition ..........................................................................................139
C13-9 Stability Loss - Preliminary Result ......................................................................................140
C13-10 Location Factor in WTSA Analysis .....................................................................................140
C13-11 Primary Analysis Final Result.............................................................................................141
C13-12 Stability Limits.....................................................................................................................141
C13-13 Secondary Analysis ............................................................................................................141
C13-14 Additional Tools ..................................................................................................................142
C13-15 Action to be Taken..............................................................................................................143
C13-16 Control of the Correction Process ......................................................................................143
C13-17 Non Standard Welded Track - Priorities for Corrective Action ...........................................143
Chapter 14 Rail Wear and Condition Examination .................................................................144
C14-1 Rail Wear Examination .......................................................................................................144
C14-2 Rail Condition Examination ................................................................................................148
C14-3 Rail Corrosion Examination ................................................................................................148
Chapter 15 Examination of Mechanical Joints .......................................................................151
C15-1 Examination Procedure ......................................................................................................151
C15-2 Action to be Taken..............................................................................................................152
Chapter 16 Examination of Insulated Joints ...........................................................................153
C16-1 Examination Procedure ......................................................................................................153
C16-2 Action to be Taken..............................................................................................................156
Chapter 17 Examination of rail lubricators .............................................................................157
C17-1 Examination procedure - (mechanical plunger type lubricators) ........................................157
C17-2 Examination procedure - TORFMA/GFL units (electronic control electric pump type) ......157
C17-3 Lubrication Distribution Test (Finger Wipe Test)................................................................163
C17-4 Action to be taken...............................................................................................................163
C17-5 Fault detection ....................................................................................................................163
C17-6 Fault investigation...............................................................................................................166

© Rail Corporation Page 9 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 18 Sleeper Inspection .................................................................................................170

C18-1 Timber Sleeper Inspection..................................................................................................170
C18-2 Concrete Sleeper Inspection ..............................................................................................171
C18-3 Resilient Baseplate Inspection ...........................................................................................171
C18-4 Definition of Condition ........................................................................................................174
C18-5 Action to be Taken..............................................................................................................175
Chapter 19 Clearance Examination..........................................................................................176
C19-1 Inspection Procedure..........................................................................................................176
C19-2 Detailed Inspection of Clearance to Platforms ...................................................................176
C19-3 Civil Maintenance Engineer and Team Manager review....................................................180
C19-4 Mid Cycle Visual Inspection of Clearance to Platforms......................................................180
C19-5 Inspection of Clearance to Structures ................................................................................180
C19-6 Inspection of Track Centres................................................................................................180
C19-7 Inspection of Track Centres at Clearance Points ...............................................................183
C19-8 Inspection of Rail Level ......................................................................................................185
C19-9 Action to be Taken..............................................................................................................185
Chapter 20 Level Crossing Examination .................................................................................186
C20-1 Examination Requirements ................................................................................................186
C20-2 Crossing Types...................................................................................................................186
C20-3 Equipment...........................................................................................................................186
C20-4 Examination Procedure ......................................................................................................186
C20-5 Action to be Taken..............................................................................................................188
Chapter 21 Special Track Inspection Issues...........................................................................189
C21-1 Hot Weather Inspection Issues ..........................................................................................189
Chapter 22 Track Recording .....................................................................................................191
C22-1 Field Duties Prior to Track Recording ................................................................................191
C22-2 Action required During Recordings ....................................................................................191
C22-3 Distribution of Recording Graphs .......................................................................................191
C22-4 Defect Examination & Repair .............................................................................................192
C22-5 Missing Inspections ............................................................................................................192
C22-6 Track Recording Analysis...................................................................................................192
Chapter 23 Turnout & Special Trackwork Examination .........................................................193
C23-1 Examination Requirements ................................................................................................193
C23-2 Equipment...........................................................................................................................193
C23-3 Switch Examination ............................................................................................................193
C23-4 Crossing and Checkrail Examination .................................................................................199
C23-5 Gauge & Superelevation ....................................................................................................201
C23-6 Bearer Condition.................................................................................................................202
C23-7 General Condition...............................................................................................................204
C23-8 For Supplementary Patrol...................................................................................................204
C23-9 Action to be Taken..............................................................................................................205
C23-10 Catchpoints Examination....................................................................................................205
C23-11 Housed Points Examination ...............................................................................................206
C23-12 Switch Examination Olympic Park......................................................................................209
C23-13 Expansion Switch Examination ..........................................................................................210

© Rail Corporation Page 10 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

C23-14 Switch Lever Examination ..................................................................................................213

C23-15 Diamond Examination ........................................................................................................214
C23-16 Single and Double Slip Examination ..................................................................................216
C23-17 Swingnose Crossing Inspections .......................................................................................217
C23-18 Special Tangential Turnout Examination Requirements ....................................................223
Chapter 24 Drainage Examination............................................................................................225
C24-1 Examination Requirements ................................................................................................225
C24-2 Examination Procedure ......................................................................................................225
C24-3 Action to be Taken..............................................................................................................226
C24-4 Assessment of Condition....................................................................................................226
Chapter 25 Track Inspections by CME and Team Manager...................................................228
Chapter 26 Records ...................................................................................................................229
Appendix 1 Examination forms .................................................................................................230
Form Index............................................................................................................................................230

© Rail Corporation Page 11 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 1 General
C1-1 Purpose
This manual provides requirements, processes and guidelines for the inspection of track
and for the response to track defects. It includes all inspections undertaken during track
examination, track recording and special inspections.

C1-2 Context
This manual is part of RailCorp's engineering standards and procedures publications.
More specifically, it is part of the Civil Engineering suite that comprises standards,
installation and maintenance manuals and specifications.

To assure the on-going safety of the track and to effectively manage the repair of
condition and replacement of components, RailCorp carries out a schedule of
inspections.

The schedule of inspections and their frequencies are detailed in RailCorp engineering
standard ESC 100 - Civil Technical Maintenance Plan. Each inspection in the Civil
Technical Maintenance Plan references a Service Schedule.

Track Service Schedules which provide a summary of the elements of the inspection, are
contained in TMC 101 - Track and Right of Way Service Schedules. Each Service
Schedule references a Manual.

This manual contains requirements, process and guidelines for the management of track
assets and for carrying out examination activities. It also provides operating limits against
which the condition of track is measured, and mandatory actions required when limits are
reached.

The manual is written for the persons undertaking installation and maintenance activities.

It also contains management requirements for Civil Maintenance Engineers and Team
Managers needing to know what they are required to do to manage track inspection
activities on their area.

C1-3 How to read the manual

The best way to find information in the manual is to look at the Table of Contents starting
on page 7. Ask yourself what job you are doing? The Table of Contents is written to
reflect work activities.

When you read the information, you will not need to refer to RailCorp Engineering
standards. Any requirements from standards have been included in the sections of the
manual and shown like this:

Extract from RailCorp Standard ESC 220.

− Rails longer than 220m
− Rails longer than 27.4m with resilient fastenings more than 1 in 3 (unless the
rails have been correctly adjusted in accordance with requirements for CWR)

Reference is however made to other Manuals.

© Rail Corporation Page 12 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C1-4 References
C1-4.1 Australian and International Standards
Nil

C1-4.2 RailCorp Documents

ESC 100 – Civil Technical Maintenance Plan
ESC 220 – Rail and Rail Joints
TMC 001 – Civil Technical Competencies and Engineering Authority
TMC 101 – Track and Right of Way Service Schedules
TMC 211 – Track Geometry and Stability
TMC 215 – Transit Space – (Not Yet Published)
TMC 221 – Rail Installation & Repair
TMC 223 – Rail Adjustment
TMC 224 – Rail Defects & Testing
TMC 225 – Rail Grinding
TMC 226 – Rail Defects Handbook
TMC 231 – Sleepers & Fastenings
TMC 404 – Recognising Geotechnical Problems
TMC 521 – Level Crossing Manual
SPC 201 – Measurement Gauges
OS 001 IM – Train Operating Conditions (TOC) Manual

C1-5 Introduction
To assure the on-going safety of the track and to effectively manage the repair of
condition and replacement of components, RailCorp carries out a schedule of
inspections. Each inspection targets identified aspects of track and is carried out at a
frequency that has been established through analysis and experience to identify signs of
the track wearing out or varying from design. These inspections allow RailCorp staff to
program repairs whilst the track is still safe for normal operation.

The inspections include:

Track Patrol
A visual inspection of the track either by Walking, Hi-rail vehicle at slow speed, Engine
Patrol or Mechanised Track Patrol vehicle. .

The patrollers look for signs that the track is deteriorating, particularly where immediate
action is required to maintain track safety. This involves looking for obstructions, track
geometry defects, broken rails, signs of earthworks or drainage failure and the visibility
and security of track signage. Detailed inspection is undertaken during the patrol when
visual signs are identified.

Patrol staff will take action to protect the track (stop or slow down trains) if bad defects
are found.

© Rail Corporation Page 13 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Detailed Walking Examination

A walking inspection of track is conducted to view the track behaviour in detail. This
inspection provides information on the condition of all aspects of the track and its
components.

Engine Inspection
An inspection is conducted from the cab of a train to assess the effect of track condition
on the ride comfort of trains. Some types of track geometry variations are best found by
this inspection. The inspection is also an opportunity for track staff to find out from train
crew areas that drivers consider need attention.

Detailed Examinations
Specific elements of track are examined, measured and recorded at scheduled intervals.
The elements include turnouts, insulated rail joints, rails, lubrication, level crossings,
drainage and clearance to structures beside and above the track.

The examinations form an important part of the process of measuring condition,

assessing performance and determining how quickly the different parts of the track are
wearing out. The extent and timing of repair and replacement is determined from the
information recorded.

Track Geometry Recording Car

The rail mounted recording car (commonly known as the AK car) operate on RailCorp
lines at scheduled intervals. They record the condition of the track geometry, compare it
to established standards and provide real time information to track staff of locations
where maintenance work is required to correct variations in rail level, alignment and
gauge. The recording software also applies statistical techniques to assess the overall
condition in comparison to standards and other locations on the RailCorp network.

Misalignment Prevention
When rail track heats up in extreme Summer temperatures it will misalign (also known as
a buckle) if it is not properly controlled. Track in NSW is designed to resist buckling at
high temperatures by maintaining the right amount of rail in track, stopping the rail from
moving and bunching up and providing resistance to the sideways movement that occurs
when track buckles. To provide assurance that the design conditions are maintained
during the summer period track stability examination, analysis and correction is
conducted between August and October each year.

This involves inspection of rail adjustment, ballast profile and condition, fastening
condition and areas of potential concern, analysis of contribution of these factors to the
overall stability and programmed, prioritised improvement at identified locations.

Heat Patrol
o
During the hotter months of the year, when temperatures reach 38 C, staff conduct
patrols of the track to detect early signs of instability leading to misalignments. These
patrols are normally conducted by hi-rail or the front of a train so that track can be
inspected in a short period of time in the hottest part of the day.

Out of Course Inspections

In addition to the programmed inspections mentioned above, RailCorp staff conduct
special inspections of track in periods of extreme rainfall and flooding, bushfires and at
locations where track conditions warrant more frequent monitoring, to provide assurance
of the on-going safety of the infrastructure.

© Rail Corporation Page 14 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 2 Management Requirements

RailCorp has in place a Defect Management System for the track defects. The system
includes periodic and 'on-event' examination of track for geometry and condition,
recording of defects, limits and mandatory responses to the occurrence of defects and
management of their removal.

Management requirements for the Defect Management System are detailed below

C2-1 Track Examination

C2-1.1 Civil Maintenance Engineer
Civil Maintenance Engineers must establish systems to ensure:
1. Cyclic examinations are undertaken at the minimum frequencies established in
ESC 100 – Civil Technical Maintenance Plan.
These are the minimum frequencies. At locations where obvious deterioration
occurs at higher rates due to such factors as curvature, usage, axle load or speed,
more frequent inspections should be scheduled. These additional inspections may
be reduced in scope to address only those parts of the inspection affected by the
additional factors.
2. 'On event' examinations are undertaken when the initiating event occurs.
3. Any increase in the frequency of any examinations required to suit local conditions is
established and recorded.
4. Monitor the effectiveness of the patrol regime.
5. Take action to require additional patrols where circumstances require.
6. The frequency and details of any special examination required in addition to those
specified is established and recorded.
7. A Length Examination Schedule detailing the mode, frequency and timing of all
planned examinations, is established and recorded.
8. The position responsible for the examination of each length is nominated.
9. Staff undertaking examination tasks have the required competencies.
10. Where persons carry out any part of the track examination system but have not
achieved all the required competencies ensure that such persons are competent to
perform the particular examinations required.
11. Team Managers are fully meeting their responsibilities in relation to the Track
Examination System.
12. Necessary reports to the Senior Management are correctly supplied.

For Integrated Track Patrol

To implement "Integrated Track Patrol" for plain track, turnouts and special trackwork in
their district, the Civil Maintenance Engineer must:
1. Assess plain track, turnouts and special trackwork in accordance with the
applicability requirements documented in ESC 100 – Civil Technical Maintenance
Plan. Document nonconforming locations where applicability requirements are not
met.
2. Review nonconforming locations to include those that can be managed by
implementing Supplementary Patrols as prescribed under the “Integrated Track
Patrol Regime” in ESC 100.

© Rail Corporation Page 15 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. Where geotechnical examination at a specific location is assigned to track patrol,

arrange for the geotechnical condition is to be reviewed by the Principal
Geotechnical Engineer to determine whether the condition can be managed by this
new regime and, if required, develop and implement additional examination of the
geotechnical risk location.
4. Identify and assess the risk at locations in the clearance register or with potential to
breach Base Operating Clearance Standards. Develop and implement a
management plan where required.
5. Establish methods to manage any lockspike degradation or failure. (Indicators may
be lockspike throat wear, sleeper plate movement, gauge widening, usually in sharp
curves, wet areas or tunnels).
6. Manage any other tasks that are not requirements of the track patrol service
schedules, but are packaged with track patrol for convenience.
To implement "Integrated Track Patrol" for plain track, turnouts and special trackwork on
Ancillary lines in their district, the Civil Maintenance Engineer must:
1. In consultation with the Maintenance Team Manager, list all ancillary lines and
determine whether the ancillary line meets applicability requirements documented in
ESC 100 – Civil Technical Maintenance Plan.
2. Consider each ancillary line individually.
3. If in doubt, physically examine.
4. Consider defect history from TES examinations and AK car examination.
5. Assess potential for rapid deterioration or failure.
Note: Special emphasis should be focussed on managing the risks of spread road,
track geometry defects, broken plates and bolts that have the potential to cause
derailment.

On the basis of the assessment above the Civil Maintenance Engineer may implement
the "Integrated Track Patrol" regime on applicable lengths, inclusive of additional
examinations to manage nonconforming locations.

The Civil Maintenance Engineer must:

1. Program the appropriate combination of Walking Patrol, Hirail Patrol, Mechanised
Track Patrol, Engine Patrol and Supplementary Patrol, to comply with the
requirements of ESC 100 – Civil Technical Maintenance Plan, TMC 101 – Track
Service Schedules and other requirements of this Manual.
2. Keep a local record of the program that demonstrates that the programmed tasks
meet these requirements.

For Mechanised Track Patrol

1. Ensure rail view cameras are used to assess rail continuity where MTP track and
easement imagery cannot be captured due to low light conditions.
2. Where MTP is being considered, assess the lighting in each dive and tunnel
structure jointly with the Manager Track Recording. Where both MTP imagery and
Engine Patrol is ineffective, additional walking patrols must be conducted. The
district should consider whether it is cost effective to provide suitable lighting at
these specific locations.

For Integrated Walking Patrol

Where the requirements for the implementation of "Integrated Track Patrol" have been
met, Integrated Walking may be introduced for plain track, turnouts and special trackwork
in the following circumstances:
1. The Mechanised Track Patrol vehicle is available to meet the inspection schedule.

© Rail Corporation Page 16 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

2. Walking Patrols are conducted on each track separately

In addition the Civil Maintenance Engineer must:

1. Carry out a review of tasks and time required for the 90 day walk and allocate
appropriate time to conduct the examination.
2. Since track is inspected less frequently, assess current repair strategies and adjust
where required to ensure defects are managed appropriately. The practice of
frequently inspecting defects (and not removing them) may need to change for some
types of defects. For example, replace loose chair studs and checkrail bolts when
found to avoid accumulation of loose studs and loss in redundancy.
3. Emphasise with patrol staff the following changed requirements:
∼ For single rail traction return sections and sections without track circuits, patrol
staff to be extra vigilant on detecting a bang or similar indication of a
discontinuity from EP (on engine and MTP vehicle), particularly looking for
unexpected discontinuities. These should be followed up with inspection of the
location by foot.
∼ look for indications of lock spike failure and worn rail plate holes.
∼ when Ancillary Lines are patrolled, check mainline turnouts connected to the
Ancillary Line for loose or broken chairs and bearer fasteners.
4. Arrange for alternate examination methods for discrete locations as follows:
∼ At locations such as level crossings, guard rails, glued insulated joints and
turnouts alternate signals circuit paths may result in doubtful detection of rail
breaks by track circuits. At these discrete locations it is practical to compensate
by MTP rail view camera imagery review.
∼ If MTP identifies a potential problem with ballast covering fastenings, arrange a
follow up walking inspection to determine an appropriate response.
∼ For specific locations where there is potential for track movement near
structures or where narrowing of centres may occur, develop and manage
appropriate control measures. One possible method includes the use of
centreline marking and follow up examination to monitor for movement. In
combination with track stability examinations and track clearance inspections
this would provide sufficient control.
Where Variations to Patrol Methods Have Been Approved:
1. For Night Patrols, provide patrol staff a schedule of any known hazard locations
outside the immediate area of the track surrounds so they can direct special
attention to those locations.
2. Civil Maintenance Engineers may approve the use of Engine Patrols to replace a
single standard patrol opportunity lost due to strike/ loss of possession, subject to
the following additional requirements:
∼ Individual patrol requirements must be reviewed by the Civil Maintenance
Engineer for the patrol area.
∼ The Civil Maintenance Engineer must keep a written record of the use of engine
patrols including, date, locations patrolled by engine, last normal patrol date,
and special inspections or patrol methods used.
∼ The Civil Maintenance Engineer must forward written advice of these details to
the Chief Engineer Track within 24 hrs.

For Siding Examination

1. Ensure all RailCorp sidings are nominated for examination
2. Ensure the RailCorp portion of private sidings are nominated for examination

© Rail Corporation Page 17 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

For Rail Wear and Condition

1. Ensure arrangements are in place to conduct visual examination of all vertical split
head rail defects in daylight, if the defect has been found at night and full
requirements for inspection cannot be carried out.

For Examination of Similar Flexure Turnouts

1. Determine that default TMP examination of 6 months may be varied based on the
actual wear experienced on the high rail stockrail. (See Section C23-1.)

For Sleeper Condition

1. Ensure that locations where Pandrol ties have been used at less than 1 in 2 on
backcanted dogspiked track are assessed. If any problems are being experienced
with clips breaking corrective action must be taken.

For Clearance Examination

1. Provide examination staff with:
For Platform and structure clearance
∼ A list of structures known to be within a lateral clearance of 2500mm of the track
centre line. On curves of ≤ 800m radius, the limit for recording is to be
increased to 3000mm to allow for the vehicle displacement and the effect of
superelevation.
∼ The design clearance for each of those structures in the form of:
- A form “Clear 1” that contains the location of each measurement point and
the design horizontal, vertical clearance and superelevation at each, at
maximum intervals of 10 metres.
- If the structure has no survey information then the form will list the
horizontal and vertical clearance at both ends of the structure and at 10m
intervals.
∼ If the information is not yet available in this form then provide the design
clearance for each of those structures. In the form of:
- The kilometrage of the Sydney and country ends of each structure.
- The clearance to the gauge face of the nearest rail at both ends of the
structure and at 10m intervals.
- The designed superelevation at each clearance measurement point and
whether the structure is convex or concave.
For track centre examination.
∼ The design track centres for each measurement location in the form of:
- A form ‘Clear 2” which has details of each measurement location and
design track centres and superelevation for each length.
Locations must be at the nearest survey mark to the tangent points on
straights. If the straight is more than 250m long, take intermediate locations
at not more than 250m intervals. On curves the locations must be at
maximum intervals of 50m.
∼ If the information is not yet available in this form then provide the design track
centres and superelevations for each length:
At approved clearance infringement locations
∼ Written advice detailing the required clearances, examination frequency, special
actions, etc. at locations where there is an approved infringement of the
structure gauge. This includes:
- Locations where permanent speed signs have been located closer to the
track than Kinematic Envelope +200.
- Locations in tunnels where cables and supporting equipment have been

© Rail Corporation Page 18 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

installed closer to the track than Kinematic Envelope +200.

At restricted vertical clearance locations
∼ Locations of special survey plaques at structures with restricted clearances
together with the necessary instructions, detailing restrictions on track lifts and
additional monitoring.
For non electrified lines
∼ A list of structures on non -electrified lines, where the vertical clearance is less
than 5000mm (5250mm for curved track) within 2135mm of either side of the
track centre line.
For Clearance points
∼ Details of designed lateral clearances at clearance points.
∼ A list of locations where clearance examination is not necessary. This occurs
where the design clearance for the appropriate rolling stock on the particular
line exceed the minimum track design clearance by 300mm or more.
Note Civil maintenance Engineers may determine that clearance examination is not
necessary in certain locations. This occurs where the design clearance for the
appropriate rolling stock on the particular line exceed the minimum track design
clearance by 300mm or more.
2. Review Clearance Examination.
∼ Review all Platform, Structure and Track Centre clearance examination sheets
for clearances outside of tolerance detailed in Chapter 19.
∼ Confer with the Team Manager for the area and plan for the rectification of
locations that fall outside of tolerance or ensure other controls are in place.
∼ Ensure areas outside of tolerance and agreed actions and or controls are
recorded into a defect management system.
For Track Stability
1. Determine locations, in addition to curves and tangent points, where alignment
measurement is required.
2. Be satisfied that welded track is maintained for maximum stability during the summer
period.
3. Ensure that Team Leaders undertake Heat Patrols when required.
4. Be satisfied that air temperatures are being monitored and WOLO requirements
have been implemented when warranted.

For Level Crossing Examination

1. Arrange for the assessment of sighting distances at level crossings with passive
control in accordance with RailCorp Engineering Manual TMC 521 - Level Crossing
Manual.
2. Arrange for permanent marks to be painted on rails at the S2 and S3 sighting points
assessed in (1) above.
3. Arrange for marking of the location on the road approach of the S1 sighting point.

C2-1.2 Team Managers

1. Team Managers are accountable for the satisfactory completion of track
examinations in their area. This includes:
∼ Ensuring the satisfactory completion of the mandatory examinations and any
additional track examinations required.
∼ Ensuring that persons carrying out examinations (or parts of examinations) are
competent to do so.

© Rail Corporation Page 19 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Spot checking of track conditions and comparison with examination records for
accuracy of measurement, recording and assessment of action taken in
response to the information observed and recorded.
∼ Undertaking pre-summer inspections of their area (See Chapter 21).
∼ Ensuring the Team Leader obtains the necessary reports in relation to the
following activities which may affect the performance of the track:
- examinations of the Length by Track Recording Cars,
- examination of Bridges, and
- other necessary reports related to the Length.
∼ Providing assistance to Track Examination staff where required.
∼ Referring matters beyond the resources of the area to the Civil Maintenance
Engineer.
∼ Providing track examination staff with the technical information and tools
required for the various examinations.
∼ Ensuring the work or protection identified to maintain a safe track is
satisfactorily implemented.
2. Where Integrated Track Patrol is implemented on a length, Team Managers must:
∼ Provide a “route plan” for each Mechanised Patrol which shows the critical
1 2
trackwork and any critical locations to be examined. The plan should be
adjusted to include any critical outstanding defects and any additional critical
locations found during earlier patrols or during engine patrols.
∼ Manage the nomination of locations that require Supplementary Patrol.
Check Examination forms from Detailed Walking, Timber Sleeper Inspection,
Inspection of Insulated Joints and Turnout Examination for locations nominated
for Supplementary Patrol.
Check with Rail Flaw Detection Operators and receive Weekly Defect Summary
Reports for heeled switches with strong crack predictors nominated for
Supplementary Patrol.
∼ Enter locations and details of components, defects or conditions requiring
Supplementary Patrol into Teams3.
Teams3 entry
In the Proposed Action drop down box select Supplementary Patrol. (In
addition to the normal method of recording the defect)
On Patrol when additional examinations are required, generate a list by
filtering the Supplementary Patrol action in the Proposed Action column. Use
the function print filtered defects then choose track inspection report to
produce a list of all conditions requiring supplementary examination.

1 Critical Turnouts, diamonds, junctions, catchpoints, expansion switches, GIJs or mechanical joints and
trackwork any other special track features. Note that GIJs in concrete sleepered track that are well
supported and not subject to high impacts such as from end batter may be exempted from the
critical trackwork category.
2 Critical Any locations where there are known or suspected track condition problems such as poor tie
locations condition, outstanding geometry defects, pumping bridge ends and any locations found on
engine patrols that require more detailed checking

© Rail Corporation Page 20 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. The Team Manager is to check the following:

∼ A minimum of 5% of each Team Leader's inspection sheets per month.
∼ The actual progress of each Team Leader in line with the schedule each month.
∼ A minimum of 5% of all jobs carried out by either the Team Leader or the
maintenance team.
4. Team Managers are to record the details of checks and inspections made in a note
book or diary which must be kept up to date and available for personal reference and
examination by the Civil Maintenance Engineer.
5. Team Managers are to ensure that track conditions affecting equipment at
interlocked points as detected and notified by signalling staff on Form 2 Weekly
Defect Summary Report are entered in Teams3 and dealt with in the same way as
any track defect. Team Managers may review priorities in line with other track
defects.
Signalling staff are required to record sufficient information on the form so that track
staff can accurately locate the site and assess the priority of the defect. The
"ACTION TAKEN, PROPOSED OR REQUESTED" column is used by signalling staff
to explain the problem and includes a target date for repair.

C2-1.3 Team Leader

The Team Leader is responsible for:
1. The completion of track examinations in accordance with the schedule.
2. Personally carrying out the required examinations or delegating (where necessary)
examinations to competent staff.
3. Fully explaining to staff delegated to carry out track examinations their duties and
responsibilities and ensuring these examinations are satisfactorily completed.
4. Reporting to the Team Manager all matters beyond the resources of Team Leader
and any other reports required.
5. Taking action in response to faults identified during track examinations which could
include immediate action to stop or slow down trains to maintain a safe track.
6. Arranging additional track examinations whenever there is any reason to suspect
that the safety of the Length may be affected.
This circumstance will arise during periods of extremely hot weather, extremely cold
weather, severe storms, prolonged wet weather, snow, flood or fire or any other
reasonable reason.
Additional examinations may also be required as a result of "call outs" based on
reports from train drivers or the public.
Whilst notification of such events will, normally, be provided by the Infrastructure
Operations Centre, Team Leaders should use their own initiative to contact the IOC
to establish whether an examination is required.
7. Maintaining up to date records of all examinations on the appropriate forms.

C2-1.4 Infrastructure Operations Centre

Track staff may need to undertake out-of-course examinations of track infrastructure.
These may be required during periods of extremely hot weather, extremely cold weather,
severe storms, prolonged wet weather, snow, flood or fire or any other reasonable
reason, or they may be considered necessary as a result of reports from train drivers or
the public
In circumstances where emergency examinations of track are required, IOC staff will take
appropriate action to contact staff in the affected locations and arrange for the inspections
to be undertaken.

© Rail Corporation Page 21 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C2-2 Track Recording

C2-2.1 Summary of Responsibilities
Manager Track Recording
1. The Manager Track Recording is responsible for:
∼ Programming and operation of the Track Recording Car.
∼ Completeness and accuracy of recording.
∼ Provision of a printed Emergency Defect list.
Civil Maintenance Engineer
1. Civil Maintenance Engineers must ensure that a system is in place to:
∼ Monitor the frequency of track recording on all tracks on their area.
∼ Check that all kilometre posts are correctly located and visible to car crews prior
to recording runs.
∼ Take action to address late or non testing.
∼ Manage attendance of field staff on recording runs.
∼ Provide clear instructions concerning the distribution of the defect list and
graphs at the end of the run when Team Managers are rostered on other than
their own Length.
∼ Manage the removal of defects.
∼ Manage the assessment of track condition.
∼ Manage the recording and reporting of defect control and track condition.
∼ Maintain track safety whilst defects remain in track.
2. Determine the method and arrange inspection of track geometry for crossing loops
and other areas (including flat line locations) that have been missed in the Track
Recording run. Track that has not been recorded can be assessed by a combination
of methods. The methods used will be determined by the track configuration (plain
track or turnout etc), general track condition, sleeper type and the frequency of
missed previous runs. Options include:
∼ Evaluate the ride of a train over the section.
∼ Detailed walking examination of the missed section.
∼ Review all uncorrected defects from previous run.
∼ Review previous graphs for defect growth patterns.
∼ Manual measurement of potential defects.
∼ Use of a track measurement trolley.
∼ Using MTP recording if available to determine and evaluate top and twist
defects.
3. Provide clear instructions concerning the distribution of the defect list and graphs at
the end of the run when Team Managers are rostered
4. Give high priority to their attendance on Track Recording runs. Whilst it may be
difficult, it is to be expected that Civil Maintenance Engineers should ride over all
track of consequence at least annually or conduct a detailed review of recording
graphs.
5. Maintain a record of track with condition indices exceeding the limits in (3) below,
assessment of the locations and planned remedial actions.

© Rail Corporation Page 22 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Team Manager
1. The Team Manager is responsible for:
∼ Attending recording runs (when required).
∼ Inspection and removal of defects.
∼ Recording and reporting of defect removal.
∼ Monitoring and ensuring the safety of outstanding defects.
2. Team Managers must accompany all track recording runs. It is acceptable to roster
Team Managers to cover multiple track lengths, but each Team Manager should ride
over all his/her track at least annually.
If Team Managers are rostered to attend a track recording run, but are unable to
attend for whatever reason, they must contact the Infrastructure Operations Centre
(IOC) as soon as possible, so that alternative arrangements can be made.
3. Assess any significant track sections (over 50m) including turnout areas, but
excluding turnouts, reported with condition indices exceeding:
∼ Track surface > 45
∼ TCI >70
4. Plan rectification work needed to raise the section to the required standards. Priority
will depend on track speed.
5. Forward details of the work required and a proposed plan of rectification to the Civil
Maintenance Engineer within four weeks of the run.
Team Leaders
1. Team Leaders should accompany the car of their track Length when possible. Since
they will normally be “on the ground” during recording runs to assess any defects
found, this may not always be possible.
RailCorp AK Car Operator
If at any time during the recording run no civil maintenance representative is in
attendance the AK Operator must contact IOC to arrange for alternative staff. In the
event of an Emergency defect and no civil staff are present, the AK operator must re­
contact IOC and advise of the defect detected. IOC must then contact the appropriate
civil representative to determine the correct action.
Infrastructure Operations Centre
If no one is accompanying the car the Infrastructure Operations Centre operator will:
1. Make arrangements for an alternative RailCorp employee to attend the track
recording run
2. Make an IFMS incident report.
3. If an emergency defect is detected by the track recording vehicle, the IOC will
immediately investigate the defect. The IOC in discussion with the track staff will
determine what action is necessary based on the size of the defect and any facts the
AK Car staff can shed such as ride quality experience by them at the time the defect
was detected.

C2-3 Recording and Reporting of Defect Detection and Removal

All track defects that are detected MUST be recorded in an identifiable Defect
Management System. Multiple systems are not precluded.

An auditable trail must exist for all actionable defects from detection/notification to
investigation, assessment, repair programming, repair action and certification.

© Rail Corporation Page 23 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

The ‘System’ must include, as a minimum, the following details:

− Defect
− Type
− Size
− Location (line, track and kilometres)
− Date found
− Source of information
− Action required (includes investigation, assessment, repair)
− Programmed action date (includes investigation, assessment, repair)
− Repair action
− Repair date
− Repair agency
− Review of performance
Civil Maintenance Engineers must:
1. Ensure that the Defect Management System is satisfactorily managed by the Team
Manager.
2. Monitor the level of track defects, assess the impact on track performance and take
appropriate action.
3. Review records and defects for trend identification at least annually. The outcomes
must be considered in the development of district maintenance strategies and Asset
Management Plans.
At any time the Civil Maintenance Engineer must be able to demonstrate, through the
Defect Management System, current status of all defects recordable on the system.

C2-3.1 Use of Electronic Systems

Electronic systems may be used to record and manage defects.

RailCorp's Teams3 recording system is approved for use.

Where electronic systems are used the requirement within this manual for reports to be
signed does not apply as long as there is certification that examinations have been
carried out in accordance with the requirements of the manual and the defect has been
entered into a Defect Management System. Similarly, reports in the formats detailed in
the manual do not need to be reproduced as long as the information required in the report
is contained within the electronic system.

C2-3.2 Source of Information

Defect Management Systems will contain defects from the following formal examination
and reporting systems:
− Track Examination System
− Track Patrol
− Other Examinations (actionable defects)
− Welded Track Stability Priority 1
− Rail Flaw Detection System
− Track Geometry Recording Car Examination
− Reports from train drivers

© Rail Corporation Page 24 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

− Field Inspections by Supervising Officers

− All track defects affecting signalling reliability at interlocked points as found by
signalling staff (eg rail movement affecting points detection, A & B timber problems
etc).

C2-4 Management & Reporting of Welded Track Stability Assessment

Civil Maintenance Engineer
Each Civil Maintenance Engineer must:
1. Establish programs to measure welded track stability prior to the summer season,
and, where it has been identified that curve pull-ins are a problem, prior to winter
works programs.
2. Ensure that all staff involved in measurement have appropriate tools - thermometers,
gap gauges, alignment survey data etc. and that all tools are checked and
calibrated.
3. Ensure that all staff involved in measurement are aware of requirements for
consistency in measuring and recording and have copies of measurement
procedures.
4. Establish programs to analyse welded track stability prior to the summer season,
including.
∼ Analysis software tested and/or readied for use
∼ Technical staff appropriately schooled in use of the software, data entry and
checking of information
5. Establish a recording system to monitor progress of measurement, analysis and
removal of Priority 1 stability locations.
6. Monitor the recording system regularly to verify accuracy.
7. Ensure analysis is completed and additional analysis of bunching points is carried
out.
8. Determine locations where analysis and assessment of lengths <500m is to be used.
It is appropriate to assess anomalous sections ie where there is a section that has
an adjustment that is uncharacteristic of the average result for the normal 500m
section.
9. Have systems in place to ensure that any area where adjustment control has been
found to be lost is classified as non-standard track.
10. Have systems in place to ensure that non-standard track is dealt with as a Priority 1
stability defect. Where track which is non-standard due to loss of adjustment control,
has other stability problems such as ballast deficiency, poor ballast condition or
recent disturbance then the repair/protection requirement MUST be treated with
additional urgency.
11. Ensure that any errors in welding during the year are considered in the track stability
analysis process.
12. Arrange detailed Secondary analysis of all Priority 1 locations to determine
appropriate corrective action.
13. Arrange check of track alignment on sharp curves that:
∼ Have a history of winter pull-in (check in mid to late November)
∼ Have been disturbed by resleepering/ resurfacing etc (check in mid to late
November or one week after the activity whichever is the later)
∼ Appear to have pulled in from visual inspection on track patrol (check when
observed).
WTSA inspections are normally carried out in July – September each year. Curves

© Rail Corporation Page 25 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

may pull in after initial measurements are taken. Curves may also pull in after track
resurfacing, resleepering etc has occurred.
14. Arrange alternative centre line marking of curves if the initial track position is
established ie when the track is resurfaced or measured for WTSA.
Instruct track patrollers to check for track movement during routine patrols.
15. Review WTSA if curves have pulled in significantly.
16. Establish programs to correct identified priority locations.
∼ Verify competent staff and other resources are available.
∼ Field staff to be given refresher training in corrective techniques - track
adjustment, ballasting etc, where required.
∼ Strategies in place for dealing with fire bans eg equipment for fire fighting
available and staff briefed.
17. Provide Weekly Reports to the Chief Engineer Track (commencing at a time
specified each year by the Chief Engineer Track but generally early September)
detailing progress in measurement, analysis of track and correction of WTSA
priorities. The reports are detailed in Form WTSA 4.
18. Establish contingency planning to prevent the occurrence of, or moderate the impact
of, misalignments.
∼ What if it gets hot before analysis complete? Identify areas likely to be critical,
recently disturbed track, areas with history of problems or gross ballast
deficiencies. Determine strategies to be used eg early WOLO, heat speeds etc.
∼ Dealing with priorities identified but not corrected. How are these managed?
Determine strategies to be used eg early WOLO, heat speeds. Management
system must deal with a moving target
19. Establish programs to provide protection at locations of suspected instability during
hot weather.
20. Implement special protective actions (including speed restrictions) when:

% Stability loss due to track disturbance and ballast Air temperature

deficiencies ONLY
0
55% 25 C
0
40% 30 C
Other appropriate actions should be determined in accordance with local factors.
21. Ensure arrangements are in place for liaison with visiting teams for compliance to
WTSA requirements.
22. Brief patrol staff on monitoring track in summer eg disturbance, damage, loss of
profile, heat wriggles.
23. Arrange staff seminars to reinforce work methods to be used for work in hot weather
and to gain commitment for action plans.

Team Managers
The Team Manager will:
1. Check completed track stability field measurement sheets for obvious errors and
anomalies.
2. Carry out some random checks of the measurements to satisfy themselves of the
accuracy of the field sheets.

© Rail Corporation Page 26 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C2-5 Management of Operating Limits and Responses

The Civil Maintenance Engineer is the minimum level of authority permitted to issue the
authority to operate at speeds other than default speed over non-complying track
conditions detailed in Chapter 5.

C2-6 Management of District Waivers

C2-6.1 Risk Assessment Guidelines for Ballast on Track
C2-6.1.1 Detailed Walking or Special Sleeper Inspection
At any locations where detailed walking or a sleeper inspection is incomplete due to
ballast on track inhibiting the inspection of fastenings and sleepers, and for which the
inspection becomes overdue and outside of allowable tolerances, a District Waiver may
be issued by the Civil Maintenance Engineer for the sleeper/ fastening component of the
inspection, subject to the following:
1. A risk assessment must be carried out which includes consideration of
∼ Track geometry/ formation/ drainage
∼ Track recording car information
∼ Defect records
∼ Sleeper condition records
∼ Knowledge of inspection staff
2. Where a detailed examination of ties has been carried out within the last 12 months
and the results show the track is tied for 5 years - then the district waiver can extend
full completion of the detailed walking or special sleeper inspection for 12 months
from the last detailed inspection, or six months from the scheduled inspection
whichever is the longer.
3. Where a detailed examination of ties has been carried out within the last 12 months
and the results show the track is only tied for 12months – then the district waiver can
extend full completion of the detailed walking or special sleeper inspection for a
maximum of three months but in any case not more than 9 months from the detailed
sleeper inspection.
4. Where tie condition is unknown or does not meet the above then no extension of the
inspections may be granted at district level beyond that permitted in the specified
tolerances for the inspections excepting that – where the tolerance has already been
exceeded (or will be exceeded within 28 days) then an emergency waiver may
issued permitting an extension of a maximum of 28 days to allow time for further
investigations and or correction and or additional waivers from a higher authority and
provided that: - a speed restriction is imposed to reduce the track speed by 25% or
10kph whichever gives the lower speed.
5. Notwithstanding any of the above, where evidence of gauge widening becomes
apparent immediate action is to be taken to inspect the track sufficient to establish its
gauge security.

C2-6.1.2 Track Patrol

No special risk assessment is required to address ballast on track for the track patrol
inspection. It is noted that Track Patrol must register as a defect any location with ballast
on the track that inhibits visibility of sleepers and fastenings.

© Rail Corporation Page 27 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 3 Competencies
NOTE: These competencies may enable activities to be carried out in other manuals.
For a comprehensive list of all activities that are covered by a given competency see
Engineering Manual TMC 001 - Civil Technical Competencies and Engineering Authority.

To carry out this work You need these competencies

Walking patrol TLIB3100A - Visually inspect track infrastructure
Hi-rail patrol TLIB3100A - Visually inspect track infrastructure
Engine patrol TLIB3100A - Visually inspect track infrastructure
Mechanised Track Patrol TLIB3100A - Visually inspect track infrastructure
(Engine patrol)
Mechanised Track Patrol Track Examination AND Training in Video Track
-Detailed Review Competencies Examination and associated
requirements of Mechanised
Track Patrol
Supplementary patrol TLIB3100A - Visually inspect track infrastructure
Wet Weather patrol TLIB3100A - Visually inspect track infrastructure
Heat patrol TLIB3100A - Visually inspect track infrastructure
Night patrol TLIB3100A - Visually inspect track infrastructure
Front of train examination TLIB3100A - Visually inspect track infrastructure
Track Examination TLIB3100A - Visually AND TLIB3099A ­
inspect track infrastructure Examine track
infrastructure
Track Examination includes the following activities:
Detailed Walking, Welded Track Stability Examination, Welded Track Stability Analysis, Siding
Examination, Track Recording Car Examination, Track Clearances Examination, Track Centres
Examination, Rail Wear and Condition Examination, Visual Examination of VSH Rail Defects, Rail
Corrosion Examination, Examination of Insulated Joints, Examination of Mechanical Joints,
Examination of Rail Lubricators, Detailed Tie Examination, Ballast Examination, Examination of
Special Track Layouts, Special Turnout Examination, Special Switch Timber Examination,
Inspection of Crossing Condition, Visual Examination of High Rail Tangential Switches, Wear
Examination of High Rail Tangential Switches, Expansion switch examination, Operational
Examination of Expansion switch, Surface Drainage Examination, Sub-Surface Drainage
Examination
Swingnose crossing Track Examination AND Training in
inspections Competencies Swingnose crossing
inspection
Post Irregularity Track Examination Competencies
examinations
Certify plain track after Track Examination Competencies
track examination
Certify turnouts & special Track Examination Competencies
trackwork after track
examination
Check Rail Lubricators TLIS2012A - Install and service rail lubrication equipment
prior to operation of rail
flaw detection vehicles
Service Rail Lubricators TLIS2012A - Install and service rail lubrication equipment

© Rail Corporation Page 28 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 4 Methods of Measurement

C4-1 Use of Non Metallic Tapes
Using metallic tapes can result in electrocution or track circuit failures.

Some of the safety risks include:

− Electrocution from overhead wiring and high voltage lines and making contact
between rails and overhead wiring structures.
− Small electric shocks from track circuit voltages.
Some of the reliability risks include:
− Signal failures due to short circuit across the track.
− Signal failure due to short circuit across insulated joints (both open track and
turnouts).
− Tripping of trains at line speed.
DO NOT use Steel tapes, metal reinforced linen tapes and long steel rules when taking
measurements:
− Between rails of same or different tracks.
− Near live exposed electrical equipment.
− Between rail and overhead wiring structures.
− Between OHW structures and fencing or metallic troughing.
Only use non-conducting tapes and sticks that have been electrically tested, approved
and branded, when working around electrical equipment.

If you have to use metallic objects, conduct an assessment of the potential risks (both for
safety and reliability) involved.

You must consider whether the equipment that they are using may form a conductive
bridge between the rail and any adjacent metallic structure (including other rails). There
are many items of equipment that could be at issue; for example, a spirit level, track bar
or grinding bar. Even a steel gap gauge could form a short circuit across an insulated
joint. Adjacent conductive equipment could include, steel bridge columns, bridge girders,
metal structures supporting platforms or metal edging on platforms.

C4-2 Gauge
Gauge is measured 16mm below the top of the rail.

Where gauge variation is suspected:

1. Check gauge at 2m intervals with an accurate gauge board and record details of
measurements.
The rails must be bearing against the outside holding device before measurement.
When assessing Tight gauge, flow is to be included. When assessing wide gauge
use the gauge point as reference excluding flow. The principle is that the worst
potential case needs to be measured. Rail flow provides the worst scenario for tight
gauge. When measuring wide gauge, any flow lip may detach at any time, meaning
that the gauge point will become the widest point.

© Rail Corporation Page 29 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

WARNING
There are two types of measuring board available:
One type has straight lugs that sit against the rail flow. The second type has a
machined lug that measures at the gauge point under the rail flow.
When flow is present this could result in measurement differences of up to ~5mm
between the two boards.

To measure the rail gauge using an accurate Gauge Board:

1. Place the Gauge Board across the rails at right angles. Allow the spring-loaded end
to rest tightly against the gauge face of the rail.
2. Read the measurement of the gauge from the scale provided on the board.
3. Assess any rail play that is evident and add this to the static gauge as measured.
This will ensure that the gauge as measured accurately reflects the true loaded
gauge at the location.
To check for rail play:
1. Examine the upper surface of the tie. If there is any evidence of the sleeper plates
moving then the gauge may not be secure.
2. Additional rail play can arise due to:
∼ Movement between rail foot and edge of plate or fastening.
∼ Movement between lockspike and plate.
Such possible movements need to be considered in the assessment of gauge and
gauge security. Areas where rapid failure is possible must have urgent action taken
to secure the track against potential spread even if the actual measured gauge falls
within allowable tolerances.

C4-3 Cross Level/Superelevation

Measure cross level and superelevation with an accurate standard track combination
gauge and level. Other devices may be used to determine cross level, but their accuracy
should be determined by comparison with an accurate standard combination track gauge
and level.

Where cross-level variation is suspected:

1. Check and record cross-level values at 2m intervals.
2. Calculate the variation value between each 2m interval and at 14m intervals.
3. Obvious weak spots such as joints should be separately measured and assessed.
To measure cross level and using an accurate gauge and cross level board:
1. Check that the board is correctly calibrated. A correctly calibrated board should
measure an opposite reading when reversed 180 degrees in the same location. Eg
+15 and –15.
2. Use the correct datum rail. This is the down rail on tangent track and the low rail on
curves.
3. Place the board across the rails at right angles ensuing both ends sit securely on the
top of the rail head.
4. Turn the superelevation dial until the bubble is centred.
5. Record the measurement as displayed on the board insuring that they are recorded
as + or -.

© Rail Corporation Page 30 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C4-4 Alignment
Measure alignment to survey marks from the gauge face of the nearest rail.

Using a Measuring Tape and Plumb Bob:

1. Locate the first survey mark in the area that you consider requires measurement.
Check the mark to determine whether the distance of the track alignment Is marked
on it. If it isn’t, you may need to check with the CME's office before you start
measuring.
2. Mark the point on the rail that is square to the survey mark.
To do this accurately, have someone hold one end of your tape measure or string
against the survey mark.
Move the other end backwards and forwards on the rail until you identify the shortest
distance between the survey mark and the rail.
3. Have someone place the zero mark of the tape measure on the survey mark or the
rail (whichever is highest) and hold it there.
4. Drop your plumb bob down on the other mark and extend the tape out to just past
the plumb bob line.
5. With your eye carefully positioned over the top of the plumb bob line, place the tape
next to the line. Move the tape slowly up and down the string until you find the
smallest measurement that lines up with the plumb bob line. This line is the distance
from the survey mark to the rail.
6. Repeat this procedure for all of the survey marks around the curve, or over the
distance that you wish to measure.

C4-5 Line
Measure line of the line rail using stringlining methods.

The outer rail (or high rail) of curves is the line rail. On tangent track, either rail may be
used a s the line rail, but the same rail shall be used throughout the tangent.

Measure offsets in mm to the nearest 1mm. Where the measurement is visually not
exactly to a neat mm, note the + or - error.

Where visible irregularities are evident:

1. Visually locate the central point of the alignment irregularity.
2. Using a 5 metre tape measure, measure off and mark four 2 metre intervals on each
side of the central point of the irregularity. This will produce 8 measurement
intervals about the trouble spot.
3. Number each measurement station. The central point of the irregularity will be
o.
station N 5.
o. o.
4. Stretch an 8m stringline from station N 1 to station N 5, making sure the string is
referenced to the gauge face of the line rail at a point 16mm below the running
surface.
5. Measure and record the distance from the string to the gauge face of the rail (16mm
o.
below the running surface) at station N 3. This is the middle ordinate (or radius)
o.
measurement for station N 3.
o. o.
6. Move the stringline forward and stretch it from station N 2 to station N 6. Measure
o.
and record the middle ordinate (or radius) opposite station N 4.
o. o.
7. Move the stringline forward and stretch it from station N 3 to station N 7. Measure
o.
and record the middle ordinate (or radius) opposite station N 5.
o. o.
8. Move the stringline forward and stretch it from station N 4 to station N 8. Measure

© Rail Corporation Page 31 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

o.
and record the middle ordinate (or radius) opposite station N 6.
o. o.
9. Move the stringline forward once more stretching it from station N 5 to station N 9.
o.
Measure and record the middle ordinate (or radius) opposite station N 7.
o.
10. You will now have mid-ordinate (or radius) measurements from station N 3 to station
o
N 7 (5 measurements).
11. Where alignment irregularities cover a significant length of track, increase the
number of measurement stations. As a general rule, stringlining should cover a
distance of at least 8m either side of any noticeable irregularity in track alignment.
If you use a Radius Rule to measure the mid-ordinate, you can read the radius in metres
directly from the rule. (See Figure 1).

If, however, you use a tape measure to measure the mid-ordinate the reading will be in
mm. You can convert the mid-ordinate value in mm to radius (in m) by using Table 1
below.

Middle Middle Middle

Radius Radius Radius
Ordinate Ordinate Ordinate
mm m mm m mm m
4.0 2,000 19.0 420 42.0 190
5.5 1,500 20.0 400 44.5 180
8.0 1,000 21.0 380 47.0 170
9.0 900 22.0 360 50.0 160
10.0 800 23.5 340 53.5 150
11.5 700 25.0 320 57.0 140
13.5 600 26.5 300 61.5 130
14.5 550 28.5 280 66.5 120
16.0 500 31.0 260 73.0 110
16.5 480 33.5 240 80.0 100
17.5 460 36.5 220 89.0 90
18.0 440 40.0 200 100.0 80
Table 1 – Versine and Radius measurements

As in Table 1, the radius can be calculated for an 8 metre chord using the formula:
8000
R=
V

Where R = Radius of curve in metres

and V = Middle ordinate in millimetres

CURVE
160
180
200
90

240
100

120

140

300

600
400

1000
2000

OFFSET

8m STRING
RADIUS IN METRES

TO FIND RADIUS MEASURE OFFSET FROM RAIL TO CENTRE OF 8m STRING

Figure 1 – Radius rule

© Rail Corporation Page 32 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C4-6 Rail Level

Using a Level Board or string and bubble:
1. Locate the survey mark that you wish to measure from.
2. Put one end of the Level Board (or string) on the survey mark or the rail (whichever
is highest) and have someone hold it there.
3. Hold the other end level and square to the rail.
4. Measure the distance down to the survey mark or the rail (whichever is lowest) with
a tape measure remembering to keep the Level Board (or string) level.
5. When you are measuring rail level, the lower rail is the datum rail. If you have
measured the higher rail with the process listed above, you should now measure the
difference in cross level or superelevation of the two rails. This measurement must
be subtracted from your rail level measurement, to give the level of the datum rail
above or below the survey mark.

C4-7 Rail Top

Measure longitudinal level with a chord of specified length. Take the measurement at the
centre of the head.

Where visible irregularities are evident:

1. Visually locate the central point of the rail top irregularity. This will often be a joint.
2. Using a 5m tape measure, measure off and mark two 3 metre stations on each sides
of the central point of the irregularity. This will produce 4 measurement intervals
about the trouble spot.
3. Number each measurement station. The central point of the irregularity will be
o.
station N 3.
o. o.
4. Stretch a 6m stringline from station N 1 to station N 3, making sure the stringline
contacts the running surface in the middle of the rail head at each end of the
stringline.
5. Measure and record the distance from the string to the middle of the rail head at
o.
station N 2.
o. o.
6. Move the stringline forward and stretch it from station N 2 to station N 4. Measure
o.
and record the middle ordinate opposite station N 3.
o. o.
7. Move the stringline forward once more stretching it from station N 3 to station N 5.
o.
Measure and record the middle ordinate opposite station N 4.
8. Where top irregularities cover a significant length of track, increase the number of
measurement stations. As a general rule, stringlining should cover a distance of at
least 6m either side of any noticeable irregularity in rail top.

C4-8 Clearance to Structures

Using a Measuring Tape and Plumb Bob:
1. Locate the survey mark that you wish to measure from.
2. Mark the point on the near rail that is square to the survey mark.
To do this accurately, have someone hold one end of your tape measure or string
against the survey mark.
Move the other end backwards and forwards on the rail until you identify the shortest
distance between the survey mark and the rail.
3. Have someone place the zero mark of the tape measure on the survey mark or the
rail (whichever is highest) and hold it there.

© Rail Corporation Page 33 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

4. Drop your plumb bob down on the other mark and extend the tape out to just past
the plumb bob line.
5. With your eye carefully positioned over the top of the plumb bob line, place the tape
next to the line. Move the tape slowly up and down the string until you find the
smallest measurement that lines up with the plumb bob line. This line is the distance
from the survey mark to the rail.
6. Record this measurement.
7. Repeat this procedure for all of the survey marks over the distance that you wish to
measure.
8. To determine the distance to the track centreline, add 718mm (half of a gauge
measurement) to the measurement on the scale.

C4-9 Track Centres

Using a non-conductive tape measure (e.g. cloth, fibreglass):
1. Measure the distance from the gauge face of one rail of one track to the gauge face
of the corresponding rail on the adjacent track
2. DO NOT measure adjacent rails of two adjacent tracks.

C4-10 Turnouts and Special Trackwork

C4-10.1 Measurement in Crossings
Flangeway width is the distance between the gauge side of a running rail and the guard
face of a check rail or the guard face of a wing rail, measured 16mm below the top of the
rail.

Flange way depth is the height of the running surface of the rail above the top of the
blocks at checkrails and in ‘V’ and ‘K’ crossings.

Checkrail effectiveness is the distance from the guard face of checkrail to the gauge face
of the nose of crossing, measured square to the running rail at the nose of the crossing.

Gauge Checkrail
Crossing
Flangeway Checkrail Effectiveness Flangeway
Xing R R
Point Running
rail
Gauge Line
Checkrail

Figure 2 – Measurements in turnouts

C4-10.2 Switch Measurement

Measurement of switch tips for acceptance or during track examination involves the
measurement of switch tip width, depth of top of switch below top of stock rail and switch
angle. The measurements are taken as explained in Figure 3 below. Note that the
acceptance and operating limits apply to conventional, undercut and tangential switches.

© Rail Corporation Page 34 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Width

Height

Switch Angle

Figure 3 – Measurement of switch tip profile

These measurements are difficult to take accurately, particularly switch tip width and
angle. Use the Switch Tip Profile Gauge detailed in SPC 201 and demonstrated in
Figure 4 and in Section C23-3.

Conventional switch Undercut switch

Tangential switch
Figure 4 – Using profile gauge to measure of switch tip profile

© Rail Corporation Page 35 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C4-11 Measuring Rail Dimensions

The measurement points shown in Figure 6 and Figure 5 are used for assessment of rail
wear and corrosion.

Measurement Point Detail

A Rail head height – measured 16mm in from side of head
B Rail head width – measured 16mm down from top of head
E Rail web thickness – measured at narrowest point
F Rail foot (flange) thickness – measured 16mm in from edge
G Rail foot width – measured edge to edge
Gauge Face Angle Measured at right angles to the plane of the sleeper
Table 2 – Rail measurement points

B Gauge Face Angle

16
Sleeper
A Gauge
Face

16
Ballast

E
Figure 5 – Gauge face angle

16 16

F F
G

Figure 6 – Rail measurement locations

© Rail Corporation Page 36 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 5 Defect Limits and Responses

C5-1 Mandatory Limits and Responses
Since the initial publication of these limits in October 2006, in order to limit the potential
impact on reliability until the effectiveness of the new limits have been proven by trial,
inspection staff were authorised by Engineering Waiver to follow current directions for the
assessment and correction of track geometry and condition defects.

Following a review of the effectiveness of the Base Operating standards some parts of
this chapter are now mandatory and default inspection assessment and repair responses
must be applied

These sections are listed in Table 3 below and detailed in the following pages:

C5-4.1 Track Geometry Defects ALL

C5-6.1 Rail Surface Condition PART Rail Corrosion
Defects
C5-7.1 Rail Lubricator Defects ALL
C5-10.1 Sleeper Condition ALL
Defects
C5-12.1 Turnouts and Special PART Switch rail throat opening
Trackwork Defects
Switch Rail Open Throw
Heel block condition and vertical support
Check Rail Effectiveness
Bearer Condition
Table 3 – Mandatory limits

The remaining operating limits and responses in this chapter shall be used as Guidelines.

Where limits and responses are provided as guidelines, they are provided as advice but
priorities can be altered after consideration of the cause, component condition and growth
potential of the defect and its potential to effect safety and/or reliability.

C5-2 Standard Defect Categories and Responses

All defects are categorised in one of six standard defect categories as follows

Inspect and verify

Response Category Action
response
Prior to passage of next Prior to passage of next
Emergency 1 (E1)
train train
Within 2 hrs or before the Within 24 hrs
Emergency 2 (E2) next train, whichever is the
greater
Priority 1 (P1) Within 24 hrs Within 7 days
Priority 2 (P2) Within 7 days Within 28 days
Priority 3 (P3) Within 28 days Program for repair
Normal (N) Nil Routine inspection

© Rail Corporation Page 37 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C5-3 Response to Base Operating Conditions

1. Do not impose speed restriction immediately.
2. Inspect defect within the time period shown for Response category or as directed in
Chapter 6 Assessment of Base Operating Conditions.
3. If you cannot inspect within the time period shown, a speed restriction must be
applied to reduce the priority of the defect or permission gained from the CME
4. Assess the defect using the assessment guidelines. The purpose of the initial
assessment is to confirm the defect exists and to determine the component condition
and cause of the defect and any potential for rapid failure.
5. If there is potential for rapid failure at the time of assessment then this must be
considered in deciding on the action to be taken. Additional monitoring, more urgent
repair or lower speeds may be required as a result.
6. Once the defect is confirmed it must be placed in a defect management system.
7. If the guidelines allow you to change the response category you may do so. If the
guidelines do not give you options, then within the response period you must
address the defect by one or more of the following :
• Correct the defect
• Do sufficient work on the defect to move it “UP” the table – i.e. its not perfect but its
better – the response time is deferred
• Decrease the speed, moving the defect response to the “LEFT” of the table
• Get permission from the CME for the uncorrected defect to remain.
Example
Short
Track Speed (Normal /Passenger) km/hr
Twist

Manual
20/20 40/40 60/60 80/90 100/115 115/160
2m Correcting “Short Twist”
from 20mm to 16 will allow
<12 N N N N N N you to delay repairs for 28
days
12 –13 N N N N P3 P2
14 - 15 N N N P3 P2 P1
16 N N P3 P2 P1 E2
17 – 18 N P3 P2 P1 E2 E2
19 – 20 P2 P2 P1 E2 E2 E2
21 - 22 P1 P1 E2 E2 E2 E1
Reducing the speed from
23 E2 E2 E2 E2 to 40/40
80/90 E1 will alsoE2
allow you to delay repairs
> 23 E1 E1 E1 forE1
28 days E1 E1

Note. When a defect is found and the track speed lies between two speed bands in the
tables, apply the response for the HIGHER speed band. Exception: If turnout roads are
25kph the 20/20 column can be used

© Rail Corporation Page 38 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Example
A 22mm Short Twist defect is found on a track which has a track speed of 50km/h. The
Mandatory Response is E2, NOT P1
50
Short
Track Speed (Normal /Passenger) km/hr
Twist
Manual
2m 20/20 40/40 60/60 80/90 100/115 115/160

<12 N N N N N N
17 – 18 N P3 P2 P1 E2 E2
19 – 20 P2 P2 P1 E2 E2 E2
21 - 22 P1 P1 E2 E2 E2 E1
23 E2 E2 E2 E2 E1 E2
> 23 E1 E1 E1 E1 E1 E1

C5-4 Track Geometry Defects

C5-4.1 Mandatory Limits
Track Geometry
Short Twist Track Speed (Normal / Passenger) km/hr
Wide Tight
Gauge gauge 2.7m
2m 20/20 40/40 60/60 80/90 100/115 115/160
DO NOT USE
<21 <10 <16 <12 N N N N N N
21 – 22 10 16 – 18 12 –13 N N N N P3 P2
23 – 26 11 - 12 19 – 21 14 - 15 N N N P3 P2 P1
27 – 28 13 – 14 22 – 23 16 N N P3 P2 P1 E2
29 – 30 15 – 16 24 – 25 17 – 18 N P3 P2 P1 E2 E2
31 – 32 17 26 – 27 19 – 20 P2 P2 P1 E2 E2 E2
33 – 34 18 28 – 29 21 - 22 P1 P1 E2 E2 E2 E1
35 – 37 19 – 20 30 – 31 23 E2 E2 E2 E2 E1 E1
>37 >20 >31 > 23 E1 E1 E1 E1 E1 E1
Long Twist Track Speed (Normal / Passenger) km/hr
Not in a Transition In a Transition
13.2m 14m 13.2m 14m 20/20 40/40 60/60 80/90 100/115 115/160
DO NOT USE DO NOT USE
<29 <31 <32 <34 N N N N N N
29 – 33 31 – 35 32 – 36 34 – 38 N N N N P3 P2
34 – 38 36 – 40 37 – 41 39 – 43 N N N P3 P2 P1
39 – 43 41 – 46 42 – 46 44 – 49 N N P3 P2 P1 E2
44 – 49 47 – 52 47 – 52 50 – 55 N P3 P2 P1 E2 E2
50 – 56 53 – 59 53 – 59 56 – 62 P2 P2 P1 E2 E2 E2
57 – 60 60 – 64 60 – 63 63 – 66 P1 P1 E2 E2 E2 E1
61 – 66 65 – 70 64 – 69 67 – 72 E2 E2 E2 E2 E1 E1
>66 >70 >69 >72 E1 E1 E1 E1 E1 E1

© Rail Corporation Page 39 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Top Line Track Speed (Normal / Passenger) km/hr

Cross Variation from
Level Design
1.8m/ 10m Variation
6m from 10m 20/20 40/40 60/60 80/90 100/115 115/160
DO NOT
USE Design DO NOT 8m
USE
<15 0 - 16 <36 <15 <13 N N N N N N
15 – 18 17 - 20 36 – 40 15 – 18 13 – 15 N N N N P3 P2
19 – 21 21 - 24 41 – 50 19 – 24 16 – 20 N N N P3 P2 P1
22 – 24 25 - 27 51 – 55 25 – 34 21 – 29 N N P3 P2 P1 E2
25 – 27 28 - 30 56 – 60 35 – 45 30 – 39 N P3 P2 P1 E2 E2
28 – 29 31 - 32 61 – 66 46 – 55 40 – 48 P2 P2 P1 E2 E2 E2
30 – 31 33 - 34 67 – 71 56 – 60 49 – 52 P1 P1 E2 E2 E2 E1
32 – 37 35 - 40 72 – 75 61 – 63 53 – 54 E2 E2 E2 E2 E1 E1
>37 > 40 >75 >63 >54 E1 E1 E1 E1 E1 E1
Absolute Superelevation Track Speed (Normal / Passenger) km/hr
Actual Cross Level Measurement 20/20 40/40 60/60 80/90 100/115 115/160
>170 E1 E1 E1 E1 E1 E1

C5-4.2 Guidelines
Nil

C5-5 Rail Wear Defects

C5-5.1 Mandatory Limits
When a reportable limit (as shown in the guidelines below) is reached the Civil
Maintenance Engineer is to be notified. Action is to be taken to enable rerailing prior to
reaching condemning limits. This must consider: the head loss compared to max
permitted; the impact of surface condition; if 53kg/m rail is involved the potential for
Vertical Split Head defects.

If condemning limits are exceeded the Chief Engineer Track is to be notified.

C5-5.2 Guidelines
Rail Wear
Axle Sleeper Rail Curve Wear Tangent Wear Head Loss Max %
Load type kg/m head width “B” Head depth “A” Curve radius
Max
Report­ Report
Condemn Condemn 200-300 300-400 500-600 >600
able -able
23t All 47 48 52 26 30 33% 33% 33% 33%
25t All 53 48 54 26 32 33% 33% 33% 33%
Passenger 53 46 54 24 32 38% 38% 38% 38%
25t Timber 60SC 46 52 26 32 40% 40% 43% 43%
25t Timber 60HH 46 52 26 32 40% 44% 48% 52%
25t Concrete 60SC 46 52 24 32 40% 47% 52% 55%

30t Concrete 60HH 48 52 26 32 47% 51% 58% 60%

25t Concrete 60HH 46 52 24 32 60% 60% 60% 60%

Response P1 P3 P1 P3 P1 P1 P1 P1

CME’s should also regularly review head loss limits using the AK rail profile system.

© Rail Corporation Page 40 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Track Speed (Normal / Passenger) km/hr

Rail Wear Angle
20/20 40/40 60/60 80/90 100/115 115/160
0
< 24 N N N N N N
0 0
24 - 26 P3 P3 P3 P3 P3 P3
0
≥ 26 P2 P2 P1 P1 E2 E2

C5-6 Rail Surface Condition Defects

C5-6.1 Mandatory Limits
Rail Surface Condition
Rail Corrosion Track Speed (Normal / Passenger) km/hr

60 53 47
Web Foot Web Foot Web Foot 20/20 40/40 60/60 80/90 100/115 115/160

E F G E F G E F G

17 14 146 15 13 146 14 13 127 As new dimensions

>15 >10 >139 >13 >10 >139 >12 >10 >120 N N N N N N
13-15 6-10 130-139 11-13 6-10 130-139 10-12 6-10 115-120 P3 P3 P3 P3 P3 P3
<13 <6 <130 <11 <6 <130 <10 <6 <115 P1 P1 P1 P1 P1 P1

C5-6.2 Guidelines
Rail Surface Condition
Track Speed (Normal / Passenger) km/hr
Fish Scaling; Spalling Rail Contact fatigue
20/20 40/40 60/60 80/90 100/115 115/160
No surface cracking in No visible cracking on rail
N N N N N N
gauge corner or on rail head head
Fish Scaling present:
Gauge Corner, and N N N P3 P3 P3
Top of rail head
Minor Spalling Present: Cracks visible
Gauge Corner, and P3 P3 P3 P2 P2 P2
Top of rail head
Significant Spalling Present: Cracks 1mm deep or TDS
Gauge Corner, and potentially hidden during P2 P2 P2 P1 P1 P1
Top of rail head ultrasonic testing
TDM potentially hidden
P1 P1 E2 E2 E2 E2
during ultrasonic testing
TDL potentially hidden
E2 E1 E1 E1 E1 E1
during ultrasonic testing

Surface Track Speed (Normal / Passenger) km/hr

Wheel Burns Notches
Squats 20/20 40/40 60/60 80/90 100/115 115/160
No Wheel Burns TBD TBD N N N N N N
Indents or Head Flow Visible TBD TBD P3 P3 P3 P2 P2 P2
Indents 1mm or signs of TBD TBD P2 P2 P2 P1 P1 P1
minor ballast disturbance
Indents 2mm or ballast TBD TBD
disturbance or minor track P1 P1 E2 E2 E2 E2
geometry deterioration

© Rail Corporation Page 41 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C5-7 Rail Lubricator Defects

C5-7.1 Mandatory Limits
Rail Lubrication
Reservoir level Indicator arm out 300 (Full) Full no action
out 0 Empty - fill
Blade Height (below top of rail Should be Adjust if required
head) P&M 20-23mm
RTE25 15-20mm
holes Open OK
Closed Replace blade
Wear Replace Blade
Pump Brackets Damaged Replace
Pump Body Damaged Replace
Moved down Adjust Height
Plunger height Head contamination ­ Should be Adjust plunger
Too much P&M 2-3mm
Rail dry - Too little RTE25 1-3mm
Bolts Loose Tighten

C5-7.2 Guidelines
Nil

C5-8 Rail Joint Defects

C5-8.1 Mandatory Limits
Nil

C5-8.2 Guidelines
Rail Joints
Fishplate Cracks ((includes broken and cracked plates Track Speed (Normal / Passenger) km/hr
at insulated joints) 20/20 40/40 60/60 80/90 100/115 115/160
No visible crack in either fishplate N N N N N N
Visible crack in 1 fishplate - other location P2 P2 P2 P2 P2 P2
Visible crack in 1 fishplate - bottom of fishplate P2 P2 P1 P1 P1 P1
Visible crack in both fishplates - other location P2 P2 P1 P1 P1 P1
Visible crack in both fishplates - bottom of fishplate P1 P1 E2 E2 E2 E2
1 fishplate broken, other with no crack P1 P1 E2 E2 E2 E2
1 fishplate broken, other with visible crack E2 E2 E1 E1 E1 E1
Both fishplates broken E2 E1 E1 E1 E1 E1
Track Speed (Normal / Passenger) km/hr
Sleeper Support at Fish-Plated Joint
20/20 40/40 60/60 80/90 100/115 115/160
Effective joint support N N N N N N
Pumping joint, < 10mm N N N P3 P3 P3
10 - 12mm joint movement P3 P3 P3 P2 P2 P2
>12mm joint movement P2 P2 P2 P1 P1 P1
Track Speed (Normal / Passenger) km/hr
Rail Joint Adjustment at Fish-Plated Joint
20/20 40/40 60/60 80/90 100/115 115/160
Effective fish bolts / swaged fastenings N N N N N N
fish bolts / swaged fastenings Visibly bent N N N P3 P3 P3
fish bolts / swaged fastenings Bent > 5mm P3 P3 P3 P2 P2 P2
Joint Gaps 15 - 20mm P3 P3 P3 P2 P2 P2
Joint Gaps 20 - 30mm P2 P2 P2 P1 P1 P1
Joint Gaps > 30mm P1 P1 P1 E2 E2 E2

© Rail Corporation Page 42 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Rail Joints
Ineffective Fish Bolts and Swage Fastenings at Fish- Track Speed (Normal / Passenger) km/hr
Plated Joint 20/20 40/40 60/60 80/90 100/115 115/160
No ineffective fastenings N N N N N N
2 on each side effective P1 P1 P1 P1 P1 P1
1, 2 or 3 effective on 1 side, and 1 on the other side P1 E2 E2 E2 E2 E2
0 effective on 1 side and 2 or 3 on other side P1 E2 E2 E2 E2 E2
0 effective on 1 side and 0 or 1 on other side E2 E1 E1 E1 E1 E1

Loose Fish Bolts and Swage Fastenings at Fish-Plated Track Speed (Normal / Passenger) km/hr
Joint 20/20 40/40 60/60 80/90 100/115 115/160
No loose fastenings N N N N N N
2 on each side remaining tight P3 P3 P3 P3 P3 P3
2 or 3 loose on 1 side, and 1 tight on the other side P3 P2 P2 P2 P2 P2
1 on each side remaining tight P2 P1 P1 P1 P1 P1
0 effective on 1 side and 1 on other side, but with sufficient
E2 E2 E2 E2 E2 E2
integrity to provide lateral and vertical support
All bolts loose, vertical and lateral support lost E1 E1 E1 E1 E1 E1
Track Speed (Normal / Passenger) km/hr
Rail End Condition at Fish-Plated Joint
20/20 40/40 60/60 80/90 100/115 115/160
Gauge face misalignment <1mm N N N N N N
Gauge face misalignment 1 to 3mm P2 P1 P1 P1 P1 P1
Gauge face misalignment > 3mm P1 E2 E2 E2 E2 E2
Track Speed (Normal / Passenger) km/hr
Rail End Condition at Fish-Plated Joint
20/20 40/40 60/60 80/90 100/115 115/160
Rail ends not battered N N N N N N
Dip 3 - 4mm and / or Gauge face flow 3 - 5mm P3 P3 P3 P2 P2 P2
Dip > 4mm and / or Gauge face flow > 5mm P2 P2 P2 P1 P1 P1

C5-9 Insulated Rail Joints Defects

C5-9.1 Mandatory Limits
Nil

C5-9.2 Guidelines
Insulated Rail Joints
Track Speed (Normal / Passenger) km/hr
Loss or failure of insulation material - Mechanical & Glued
20/20 40/40 60/60 80/90 100/115 115/160
No insulation material failure N N N N N N
Insulation material visibly cracked or disintegrated P2 P1 P1 P1 P1 P1
Components fail to insulate (generally causing signal failure) E2 E1 E1 E1 E1 E1

© Rail Corporation Page 43 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Insulated Rail Joints

Mechanical & Glued Track Speed (Normal / Passenger) km/hr
Metal 20/20 40/40 60/60 80/90 100/115 115/160
Rail head conductors,
Rail head flow
wear/damage metal particles,
across joint ­
around the key brake dust about
joint
No head flow No visible damage No contamination N N N N N N
Flow on either rail Visible damage
with potential to
provide < 6mm
gap (mechanical), P3 P3 P3 P2 P2 P2
or < 4mm gap
(glued) between
rail ends
Visible about joint P3 P3 P2 P2 P1 P1
Flow on either rail Excessive
with potential to damage that could
provide < 4mm short the key in
gap (mechanical), future P2 P2 P2 P1 P1 P1
or < 3mm gap
(glued) between
rail ends
Continuous or
nearly continuous
across key or P1 P1 E2 E2 E2 E2
between joint bar
and rail
Joint Gap Joint Gap Track Speed (Normal / Passenger) km/hr
Adhesive Failure
Movement ­ Movement ­
- Glued 20/20 40/40 60/60 80/90 100/115 115/160
Mechanical Glued
No joint closing No joint closing / No failure
N N N N N N
opening
Insulation key Visible gap or sign Evidence of
being squeezed of movement failure:
out; rust stain between
Joint pulling apart fishplate & rail
- visible gap at minor movement P3 P3 P2 P2 P2 P2
insulation key between plate and
rail (normally
between joint and
1st hole)
Gap between rails Movement > 1 Movement
< 6mm; mm between plate and
Joint pulling apart rail evident under
- bent bolts load
P2 P2 P1 P1 P1 P1
Movement
between plate and
rail extending
beyond 1st hole
Track Speed (Normal / Passenger) km/hr
Partial Insulation Failure - Glued
20/20 40/40 60/60 80/90 100/115 115/160
No evidence of failure N N N N N N
Insulation test fails for 1 plate to rail combination
P1 P1 P1 P1 P1 P1
(Failure of both would give a signal failure)
Track Speed (Normal / Passenger) km/hr
Ineffective Drainage around Joint - Mechanical and Glued
20/20 40/40 60/60 80/90 100/115 115/160
No ineffective drainage N N N N N N
Water lying in joint vicinity P2 P2 P1 P1 P1 P1
Water contacting foot of rail near joint P1 P1 E2 E2 E2 E2

© Rail Corporation Page 44 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C5-10 Sleeper Condition Defects

C5-10.1 Mandatory Limits
Sleeper condition
Consecutive Missing
Spacing (mm) Track Speed (Normal / Passenger) km/hr
Sleepers
Not at Not at
At a Joint At a Joint 20/20 40/40 60/60 80/90 100/115 115/160
joint joint

Nil Nil < 900 < 700 N N N N N N

1 900 - 1200 700 - 900 P2 P2 P1 P1 P1 P1
2 1 1200 - 1500 900 - 1200 P1 P1 E2 E2 E2 E2
>2 >1 ≥1500 ≥1200 E2 E2 E1 E1 E1 E1
Clusters of Consecutive Ineffective
Track Speed (Normal / Passenger) km/hr
Sleepers
Tangents & Well tied
Curves
Curves 20/20 40/40 60/60 80/90 100/115 115/160
R<1000m
R>1000m

0-2 (only at 0-1 (only at ≥5 years

isolated isolated N N N N N N
locations) locations)
3 2 ≥1 year P3 P3 P3 P3 P3 P3
4 3 ≥28 days P2 P2 P2 P2 P2 P2
5 4 Not securely
P1 P1 E2 E2 E2 E2
tied
>5 >4 Not securely
E2 E2 E1 E1 E1 E1
tied
General Condition Description – Timber Sleepers Track Speed (Normal / Passenger) km/hr
Moderat
Wide Sharp
e
Tangent Well tied 20/20 40/40 60/60 80/90 100/115 115/160
Curves
s& Curves
400≤ R ≤
Curves R R < 400
1000m
>1000m
> 65% > 65% > 65% ≥5 years
N N N N N N
good good good
35 to 45 to 50 to ≥1 year
65% 65% 65% P3 P3 P3 P3 P3 P3
effective effective effective

≥28 days P2 P2 P2 P2 P2 P2
NA Not securely
See Clusters of Consecutive Ineffective Sleepers (above)
tied
1. Where % of sleepers is referenced, this should be determined over a minimum of 20 sleepers.
2. Sleepers that are relied upon to be effective to meet the criteria for consecutive ineffective sleepers must have sufficient strength
and remaining life to remain effective for the life specified in the general condition category.
Ineffective Timber Sleepers at Joints Track Speed (Normal / Passenger) km/hr
Tangents &
Curves
Curves Well tied 20/20 40/40 60/60 80/90 100/115 115/160
R<1000m
R>1000m

0 0 ≥5 years N N N N N N
1 ≥1 year P3 P3 P3 P3 P3 P3
1 ≥28 days P2 P2 P2 P2 P2 P2

© Rail Corporation Page 45 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Sleeper condition
>1 >1 Not securely
P1 P1 E1 E1 E1 E1
tied

Rail Movement relative to sleeper, including effect of Track Speed (Normal / Passenger) km/hr
rail roll
20/20 40/40 60/60 80/90 100/115 115/160
Horizontal Vertical
0 - 5 mm 0 - 2 mm N N N N N N
6 - 8 mm N N N P3 P3 P3
9 - 10 mm 3 - 4 mm P3 P3 P3 P2 P2 P2
11 - 12 mm 5 - 6 mm P2 P2 P2 P1 P1 P1
> 12 mm > 6 mm P1 P1 P1 E2 E2 E2

C5-10.2 Guidelines
Concrete sleeper component condition
Track Speed (Normal / Passenger) km/hr

20/20 40/40 60/60 80/90 100/115 115/160

Squeezed out missing or failed insulators P3 P3 P3 P3 P3 P3
Severely worn sleeper pads P3 P3 P3 P3 P3 P3

Note. To prevent damage to sleepers & the rail foot insulators and pads that have failed
on a faceshould be replaced within a nominal period of 6 months.

C5-11 Ballast Defects

C5-11.1 Mandatory Limits
Nil

C5-11.2 Guidelines
When assessing ballast deficiency the main consideration should be the potential for the
loss to affect track geometry.

WTSA should be used during the summer period to assist in deciding on priority. New
ballast deficiencies in summer especially on recently disturbed track pose significant
misalignment risk.

In winter ballast deficiencies on curves increase the risk of curve pull in.

Consider the location of the deficiency e.g High rail shoulder is more critical in summer
than low rail shoulder.

Consider other problems at the location that make the situation worse. e.g, Pumping
track.

© Rail Corporation Page 46 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Ballast Deficiency R<400m

Ballast Required (t/20m) Track Speed (Normal / Passenger) km/hr
Shoulder Profile Crib Profile Combined Profile
20/20 40/40 60/60 80/90 100/115 115/160
Timber Concrete Timber Concrete Timber Concrete

1 1-2 1 1-2 2-3 2-4 N N N N/A N/A N/A

2 3 2 3 4 6 N N P3 N/A N/A N/A
3 4 N P3 P3 N/A N/A N/A
5 4 P3 P3 P3 N/A N/A N/A
4-5 3-4 5-6 6 8 P3 P3 P2 N/A N/A N/A
6-7 8 10 P3 P2 P2 N/A N/A N/A
5-6 P3 P2 P1 N/A N/A N/A
6-7 ≥8 ≥7 10 12 P2 P2 P1 N/A N/A N/A
≥8 ≥7 12 14 P2 P1 P1 N/A N/A N/A
14 P1 P1 P1 N/A N/A N/A
≥16 P1 P1 E2 N/A N/A N/A
≥16 P1 E2 E2 N/A N/A N/A

Ballast Deficiency R>400m

Ballast Required (t/20m) Track Speed (Normal / Passenger) km/hr
Shoulder Profile Crib Profile Combined Profile
20/20 40/40 60/60 80/90 100/115 115/160
Timber Concrete Timber Concrete Timber Concrete
1 1-2 1 1-2 2 2-4 N N N N N N
3 N N N N P3 P3
2 2 3 4 6 N N N P3 P3 P3
4 N N P3 P3 P3 P3
3 3 4 8 P3 P3 P3 P3 P3 P3
5 6 P3 P3 P3 P3 P2 P2
4-5 4-5 5-6 8 10 P3 P3 P3 P2 P2 P2
6-7 10 12 P3 P3 P2 P2 P1 P1
6-7 ≥6 12 P3 P2 P2 P1 P1 P1
≥8 ≥7 P2 P2 P2 P1 P1 P1
14 P2 P2 P1 P1 P1 P1
≥8 14 P2 P1 P1 P1 P1 P1
16 P2 P1 P1 E2 E2 E2
≥16 P1 P1 E2 E2 E2 E2

© Rail Corporation Page 47 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Excess Ballast (all track)

Track Speed (Normal / Passenger) km/hr
Ballast Profile
20/20 40/40 60/60 80/90 100/115 115/160
Profile as specified N N N N N N
Surplus ballast in excess of specified profile exists P3 P3 P3 P3 P3 P3
Potential to interfere with correct function of track or
signalling components.
Potential to interfere with operations. P2 P2 P2 P2 P2 P2
Note. If practical remove offending ballast at the time of
inspection.
Prevents proper detailed inspection of track or signal CME CME CME CME CME CME
components Risk Risk Risk Risk Risk Risk
assess assess assess assess assess assess
ment ment ment ment ment ment
and and and and and and
local local local local local local
waiver waiver waiver waiver waiver waiver

Poor Drainage and / or Ballast Condition

Track Speed (Normal / Passenger) km/hr
Ballast Profile
20/20 40/40 60/60 80/90 100/115 115/160
Minimal fines in ballast N N N N N N
Fines in ballast, visible contamination on surface of ballast N N N P3 P3 P3
Ballast fouled by fines and debris P3 P3 P3 P2 P2 P2
Ballast fills with water during rain
Ballast Visible foul and unable to maintain track within
geometry maintenance limits lower than P1
Repetition of alignment defects to P1 at same location
Saturated contaminants visible after rain
Ballast visibly pumping and unable to maintain track within
geometry maintenance limits lower than E2
Sleeper flexing or ballast voids completely filled with
P2 P2 P2 P1 P1 P1
contaminants
Repetition of track geometry defects E2, E1 at same
location
Repetition of alignment defects to E2 at same location

© Rail Corporation Page 48 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C5-12 Turnouts and Special Trackwork Defects

C5-12.1 Mandatory Limits
C5-12.1.1 Switches and Stockrails

Switches
Apply to Conventional and Tangential turnouts (unless shown otherwise)
Switch rail throat Switch Rail Open Track Speed (Normal / Passenger) km/hr
opening (mm) Throw (mm)
Back of Switch Rail to Switch Rail Toe to Stock
20/20 40/40 60/60 80/90 100/115 115/160
Stock Rail Rail
Conventional ONLY
45 – 50 95 – 100 N N N N N N
42 – 45 90 – 94 N N N N P3 P3
40 – 41 86 – 89 N N P3 P3 P2 P2
37 – 39 P3 P3 P2 P2 P1 P1
82 – 85 P3 P3 P2 P1 P1 E2
35 – 36 P2 P2 P1 P1 E2 E2
80 – 81 P2 P1 P1 E2 E2 E1
< 35 E2 E2 E2 E2 E1 E1
< 80 E2 E2 E1 E1 E1 E1
Track Speed (Normal / Passenger) km/hr
Heel block condition and vertical support
20/20 40/40 60/60 80/90 100/115 115/160
Conventional Turnouts with fixed heels
Cracked P2 P2 P2 P2 P1 P1
Vertical movement of switch tip is evident
Broken but still effective P2 P2 P1 P1 P1 P1
> 2mm horizontal and > 4 mm vertical movement of
switch tip
Missing / Broken and ineffective E2 E2 E2 E1 E1 E1

C5-12.1.2 Bearers
Apply to Conventional and Tangential turnouts (unless shown otherwise)
Bearer Condition Track Speed (Normal / Passenger) km/hr

Cluster of Consecutive
Well tied 20/20 40/40 60/60 80/90 100/115 115/160
Ineffective Bearers
0-1 ≥5 years N N N N N N
2 ≥1 year P3 P3 P3 P3 P3 P3
3 ≥28 days P2 P2 P2 P2 P1 P1
4-5 Not securely tied P1 P1 E2 E2 E2 E2
>5 Not securely tied E2 E2 E1 E1 E1 E1

Ineffective Bearers Track Speed (Normal / Passenger) km/hr

R > 350m: R < 350m 20/20 40/40 60/60 80/90 100/115 115/160
1 in 6 1 in 7 N N N N N N
1 in 5 1 in 6 N N N P3 P3 P3
1 in 4 1 in 5 P3 P3 P3 P2 P2 P2
1 in 3 1 in 4 P2 P2 P2 P1 P1 P1
1 in 2 1 in 3 P1 P1 P1 E2 E2 E2

© Rail Corporation Page 49 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Track Speed (Normal /XPT) km/hr

Failed concrete bearers
20/20 40/40 60/60 80/90 100/115 115/160
0 N N N N N N
1 P2 P1 P1 P1 P1 P1
2 P1 E2 E2 E2 E2 E2

C5-12.1.3 Crossings

Crossings
Apply to Conventional and Tangential turnouts
Track Speed (Normal / Passenger) km/hr
Check Rail Effectiveness (mm)
20/20 40/40 60/60 80/90 100/115 115/160
V Crossing K Crossing
≥ 1400 ≥ 1397 E2 E1 E1 E1 E1 E1
1398 – <1400 1396 – <1397 P2 P2 P1 P1 E2 E2
1396 – <1398 1395 – <1396 P3 P3 P2 P2 P1 P1
1389 – <1396 1389 – <1395 N N N N N N
1386 – <1389 1387 – <1389 N N N N P3 P3
1384 – <1386 1385 – <1387 P3 P3 P2 P2 P1 P1
1382 – <1384 1382 – <1385 P2 P2 P1 P1 E2 E2
<1382 <1382 E2 E1 E1 E1 E1 E1

Note. Checkrail effectiveness and gauge measurements at “V” &”K” crossings should be
taken at a point just behind (nominally 150mm) the point of the crossing to ensure that
varying crossing nose shapes do not effect consistency of measurement. For “K”
crossings this point may have to be further away to allow the measuring board to be
square to the measurement point.

Note. Where there is evidence of wheel wear on the gauge face of the crossing nose
despite satisfactory checkrail effectiveness measurements this could indicate movement
under load. If this is the case then the potential rail play should be assessed and
incorporated into static measurements to determine priority.

C5-12.2 Guidelines
C5-12.2.1 Crossings

Crossings
Gauge through Crossing (mm) Track Speed (Normal / Passenger) km/hr

20/20 40/40 60/60 80/90 100/115 115/160

V Crossing K Crossing
≥ 1444 ≥ 1439 E2 E2 E1 E1 E1 E1
1442 – < 1444 1438 – < 1439 P2 P2 P1 P1 E2 E2
1440 – < 1442 1437 – < 1438 P3 P3 P2 P2 P2 P2
1431 – <1440 1432 – < 1437 N N N N N N
1430 – < 1431 1431 – < 1432 P3 P3 P2 P2 P1 P1
1428 – < 1430 1430 – < 1431 P2 P2 P1 P1 E2 E2
< 1428 mm < 1430 mm E2 E2 E1 E1 E1 E1

© Rail Corporation Page 50 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Crossings
Track Speed (Normal / Passenger) km/hr
Check Rail Flangeway Width (mm)
20/20 40/40 60/60 80/90 100/115 115/160
> 50 P1 P1 P1 P1 E2 E2
49 - 50 P3 P3 P2 P2 P1 P1
39 – 48 N N N N N N
<39 P3 P3 P2 P2 P1 P1
P1 P1 P1 P1 E2 E2
< 38

Track Speed (Normal / Passenger) km/hr

Check rail flangeway depth (mm)
20/20 40/40 60/60 80/90 100/115 115/160
> 45 N N N N N N
42 - 45 P3 P3 P3 P3 P3 P3
40 - 41 P3 P2 P2 P2 P2 P2
38 - 40 P2 P1 P1 P1 P1 P1
35 - 37 P1 E2 E2 E2 E2 E2
<35 E2 E1 E1 E1 E1 E1
Track Speed (Normal / Passenger) km/hr
Crossings - Vertical wear (mm)

20/20 40/40 60/60 80/90 100/115 115/160

Crossing nose Wing rail
<3 <5 N N N N N N
3–4 5–8 P3 P3 P3 P3 P2 P2
5–6 9 – 10 P2 P2 P1 P1 P1 P1
>6 > 10 P1 P1 E2 E2 E2 E2
Track Speed (Normal / Passenger) km/hr
Check rail Height of above rail (mm)
20/20 40/40 60/60 80/90 100/115 115/160
0 – 25 N N N N N N
26 – 28 N N N P3 P3 P3
29 – 30 P3 P3 P3 P2 P2 P2
30 – 31 P2 P2 P2 P1 P1 P1
32 – 37 P1 P1 P1 E2 E2 E2
> 37 E2 E2 E2 E1 E1 E1

Cracks in Cast Crossing nose- gauge Track Speed (Normal / Passenger) km/hr
face wear - unworn
Crossings 20/20 40/40 60/60 80/90 100/115 115/160
nose remaining (mm)
Non-critical ≥2 N N P3 P3 P3 P3
Critical <2
Manganese - Fine P3 P3 P2 P2 P2 P2
surface cracks visible
Fully (not affecting the <1
running surface)
P2 P2 P1 P1 E2 E2
Manganese - Elongated
cracks
No unworn nose P1 E2 E2 E2 E1 E1
Fully (affecting the
E2 E2 E2 E2 E1 E1
running surface)
Metal flow on crossing nose causing lip Track Speed (Normal / Passenger) km/hr
(mm) 20/20 40/40 60/60 80/90 100/115 115/160
0-1 N N N N P3 P3
1 to 2 P3 P3 P2 P2 P2 P2
>2 P2 P2 P1 P1 P1 P1
Crossing Nose Break Track Speed (Normal / Passenger) km/hr
Width of Break within transfer length (mm) 20/20 40/40 60/60 80/90 100/115 115/160
12 - 15 N N N N P3 P3

© Rail Corporation Page 51 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Crossings
15 - 20 P3 P3 P3 P3 P2 P2
20 - 25 P2 P2 P1 P1 P1 P1
>25 P1 P1 E2 E2 E2 E2
Track Speed (Normal / Passenger) km/hr
Check rail bolts
20/20 40/40 60/60 80/90 100/115 115/160
Loose P2 P2 P2 P2 P2 P2
1 Missing / Ineffective P2 P2 P1 P1 P1 P1
2 Missing / Ineffective P1 P1 E2 E2 E2 E2
≥3 Missing / Ineffective E2 E1 E1 E1 E1 E1
Track Speed (Normal / Passenger) km/hr
Swing nose clearance (mm)
20/20 40/40 60/60 80/90 100/115 115/160
1 N N N N N N
> 1 to 2 P2 P2 P1 P1 P1 P1
>2 P1 P1 E2 E2 E2 E2
Track Speed (Normal / Passenger) km/hr
Diamond Crossing

Variation from design (mm)

20/20 40/40 60/60 80/90 100/115 115/160
Theoretical
Diagonal Diagonal
Crossing
Length ­ Width
Point
0-6 0-2 0-5 N N N N N N
> 6 to 12 > 2 to 3 > 5 - 15 P3 P3 P3 P2 P2 P2
> 12 >3 > 15 P2 P2 P2 P1 P1 P1

C5-12.2.2 Switches and Stockrails

Note. Limits below apply to manual turnout examination only. Tight gauge applies to the
switch tip only. Wide gauge applies to the machined section of the switch. Otherwise
gauge limits are as per plain track limits.

Switches
Apply to Conventional and Tangential turnouts
Tight Gauge Wide Gauge in Turnouts Track Speed (Normal / Passenger) km/hr
at Switch (mm)
Tip With curve
No curve wear 20/20 40/40 60/60 80/90 100/115 115/160
(mm) wear
1-4 0-5 0-5 N N N N N N
5-6 6 - 10 6 - 10 N N N N P3 P3
7-8 N N P3 P3 P3 P3
9 - 10 11 - 20 11 - 15 P3 P3 P2 P2 P2 P2
11 - 12 P2 P2 P1 P1 P1 P1
21 - 25 16 - 20 P1 P1 P1 P1 E2 E2
>12 >25 >20 E2 E2 E2 E2 E1 E1

© Rail Corporation Page 52 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Switches
Track Speed (Normal / Passenger) km/hr
Switch face slope
20/20 40/40 60/60 80/90 100/115 115/160
Conventional facing switch for gauge face of switch
passes switch tip gauge N N N N N N
Marginal failure with no more than 1mm variation between P1 E2 E2 E2 E2 E2
top and bottom of gauge
Marginal failure with more than 1mm variation between E1 E1 E1 E1 E1 E1
top and bottom of gauge
With 20km/hr may be reclassified as E2 if no evidence of
switch being hit or part climbed by wheel
Notes. * For trailing switches consideration must be given to possible facing movements.
For tangential switches guidance for switch face slope is given in Section C23-12.
Track Speed (Normal / Passenger) km/hr
Switch tip height (mm)

Conventional Tangential 20/20 40/40 60/60 80/90 100/115 115/160

Facing Undercut
Meets switch tip gauge
N N N N N N
height and width
Fails switch tip height no P3 P3 P3 P3 P3 P3
more than
-3mm but width 2mm
narrower than gauge
-5mm but width 4m
narrower than gauge
see Figure 7
Fails switch tip height no Sits high of machined P2 P2 P2 P2 P2 P2
more than section of stockrail
-4mm but width 2mm
narrower than gauge
-6mm but width 4m
narrower than gauge
see Figure 7
Failing the above E2 E2 E2 E2 E2 E2

Switch Width at Tip Side wear on nose Track Speed (Normal / Passenger) km/hr
of switch
(mm)
(mm) 20/20 40/40 60/60 80/90 100/115 115/160
Conventional ONLY
Complies with switch tip And wheel wear mark
N N N N N N
gauge (≤4mm). >5mm from nose tip
Complies with switch tip wheel wear mark <5mm
P3 P3 P2 P2 P2 P2
gauge (≤4mm). from nose tip
Fails switch tip gauge. wheel wear mark >5mm
P2 P2 P1 P1 P1 P1
(width >4 to 6mm) from nose tip
Fails switch tip gauge. Wheel wear mark<5mm
(width >4 to 6mm) from nose tip but no
impact visible on switch tip
>6 Wheel wear mark<5mm
from nose tip but no P1 P1 E2 E2 E2 E2
impact visible on switch tip
>4mm and Any signs of wheel impact E2 E1 E1 E1 E1 E1
on the switch tip
Note. Switch tip height and width applies to facing movements only. For trailing switches
consideration must be given to possible facing movements.

© Rail Corporation Page 53 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

amount narrower
than gauge
Width height
variation with
decreasing
width amount
higher
than
gauge

Enlargement showing allowance

for switch which is narrower.
Switch tip gauge width indicator
is 4mm.

Figure 7 switch tip gauge showing allowance for narrower switch if above height

Stock Rail Creep at Switch Opening Track Speed (Normal / Passenger) km/hr
Switch (mm) (mm)
trailing and facing Conventional and 20/20 40/40 60/60 80/90 100/115 115/160
points Tangential
Turnouts
0 to 2 0 to 1 N N N N N N
> 2 to 4 N N P3 P3 P3 P3
1 to 2 P3 P3 P3 P3 P2 P2
> 4 to 6 P3 P3 P2 P2 P2 P2
2 to 3 P2 P2 P2 P2 P1 P1
>6 P2 P2 P1 P1 P1 P1
> 3 Trailing Movements P2 P1 P1 P1 P1 P1
> 3 Facing Movements P1 E2 E2 E2 E2 E2
Switch Component condition Track Speed (Normal / Passenger) km/hr

Rail Brace / Chair Switch bearing Stops 20/20 40/40 60/60 80/90 100/115 115/160
Cracked / loose Cracked / loose.
Rail braces visibly moving, Note. If potential to cause P3 P3 P3 P3 P3 P3
bolts or fastenings not signal failure repair
tight immediately
1 only Broken / Ineffective 1 only Missing / Ineffective
P3 P3 P3 P3 P3 P3

2 consecutive Missing /
2 consecutive Broken /
Ineffective P2 P2 P1 P1 P1 P1
Ineffective

> 2 consecutive Missing /

> 2 consecutive Broken /
Ineffective P1 P1 E2 E2 E1 E1
Ineffective

Switch Blade Switch Blade Track Speed (Normal / Passenger) km/hr

Vertical Support Vertical Support
Vertical clearance to Switch tip movement 20/20 40/40 60/60 80/90 100/115 115/160
track plates on A & B under load.
Timbers (mm) (Heel block pumping)
0 to 1 No movement N N N N N N
2 to3 P3 P3 P3 P3 P3 P3
Vertical movement is
P3 P3 P2 P2 P2 P2
evident 3-6 mm
>3 P2 P2 P2 P2 P2 P2
Vertical movement is
P2 P2 P1 P1 P1 P1
evident >6 mm

© Rail Corporation Page 54 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Switch Blade Head Mating Surface fit with Track Speed (Normal / Passenger) km/hr
Stock Rail at the switch tip. (mm)
20/20 40/40 60/60 80/90 100/115 115/160
non interlocked Interlocked
0 to 1 0 to 1 N N N N N N
2 > 1 to 2 P3 P3 P2 P2 P2 P2
> 2 trailing P2 P2 P1 P1 P1 P1
> 2 facing > 2 trailing and facing P1 P1 E2 E2 E2 E2
Track Speed (Normal / Passenger) km/hr
Housed Points

Vertical
Height of Clearance
Flare at
Housing Width of between 20/20 40/40 60/60 80/90 100/115 115/160
end of
above Housing Switch Tip
Housing
Stockrail (mm) and
(mm)
(mm) Housing
(mm)
25 -31 152 102-100 3 N N N N N N
32 – 33 Note 1. Note 2. Note 3 P3 P3 P2 P2 P2 P2
34 – 35 P2 P2 P1 P1 P1 P1
36 – 37 80 - 90 P1 P1 E2 E2 E2 E2
≥38 <80 E1 E1 E1 E1 E1 E1

Track Speed (Normal / Passenger) km/hr

Housed Points Flangeway Clearance (mm)
20/20 40/40 60/60 80/90 100/115 115/160
>50 P1 P1 E2 E2 E2 E2
48 - 50 P3 P3 P2 P2 P1 P1
41 – 47 N N N N N N
40-41 P3 P3 P2 P2 P1 P1
P1 P1 P1 P1 E2 E2
≤ 39

Note: 1 The width of housing is limited by the shimming adjustment available (about 10mm).
Once the housing has worn to about 140mm it will need to be replaced. Urgency will be
determined by the flangeway clearance.

Note: 2 The impact of the wheels on the flare should be assessed and a priority given based on
this. Normally the flare will “wear in” to give minimal impact. Care should be taken when
shimming the housing not to create an impact point on the flared ends.

Note: 3 The 3mm clearance allows free movement of the switch. Speed restrictions will not have
any impact on this clearance. The minimum priority set should be P2. More urgent
attention may be required if point operation is affected.

Note: 4. The requirements for switch blade clearances for non-interlocked points are not normally
applicable for main line turnouts. The limits for sidings should be used if required see
(Section C5-15)

C5-12.2.3 Switch Tension.

The requirements for switch tension for manually operated points are not normally
applicable for main line turnouts. The limits for sidings should be used if required (see
Section C5-15).

© Rail Corporation Page 55 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C5-13 Level Crossings Defects

C5-13.1 Mandatory Limits
Nil

C5-13.2 Guidelines
Level Crossings
Guard Rail Track Speed (Normal / Passenger) km/hr
Effectiveness Flangeway
Wide Gauge
Clearance
(mm) to Gauge face of 115/16
Opposite rail (mm) 20/20 40/40 60/60 80/90 100/115
0
(mm)
0 – 10 1,375 - 1,380 > 55 N N N N N N
>1,380 - 1,385 P3 P3 P3 P3 P2 P2
11 - 15 >1,385 - 1,390 P3 P3 P2 P2 P2 P2
≤55 P3 P3 P2 P2 P1 P1
> 15 (20 if due >1,390 P2 P2 P2 P2 P1 P1
to curve wear)
> 20 (25 if due Evidence of Evidence of P2 P2 P1 P1 P1 P1
to curve wear) wheels striking end wheels striking
of checkrail / end of guard
flangeway material rail / flangeway
material
* Untapered steel guard rails must be recorded as defects and reported to the Civil Maintenance Engineer

C5-14 Transit Space Defects

C5-14.1 Mandatory Limits
Nil

C5-14.2 Guidelines
Transit Space
Track Speed (Normal / Passenger) km/hr
Clearances - other than at Platforms

Clearance beyond Kinematic Envelope (mm)

Lateral 20/20 40/40 60/60 80/90 100/115 115/160
Vertical
(includes Track Centres)
Approved Approved
Temporary Temporary
Infringement Infringement
> 200 Approved > 100 Approved
N N N N N N
clearances clearances
> 125-200 N N P3 P3 P3 P3
> 100-125 > 75 - 100 P3 P3 P3 P2 P2 P2
> 50-100 Approved > 50 - 75 Approved
Clearance Clearance
less 25, if less 25, if P2 P2 P2 P1 P1 P1
clearances clearances
> 50 > 50
0 - 50 0 - 50 0 - 50 0 - 50 P1 P1 P1 E2 E2 E2
<0 <0 <0 <0 E2 E2 E1 E1 E1 E1

© Rail Corporation Page 56 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Transit Space
Track Speed (Normal / Passenger) km/hr
Platform Clearances

Variation from design (mm)

Reduction in clearance Increase in clearance ­

Towards platform Away from platform
straight curves straight curves
See Section C19-2
Track Speed (Normal / Passenger) km/hr
Platform Height

Height of Platform above Actual Rail Level (mm)

Standard Access Level Access Platforms
Platforms
See Section C19-2
Track alignment and superelevation Track Speed (Normal / Passenger) km/hr
relative to design for Overhead Wiring 20/20 40/40 60/60 80/90 100/115 115/160
2 x super PLUS 1 x alignment < 30 mm N N N N N N
2 x super PLUS 1 x alignment = 30 to < 40 mm N N N P3 P3 P3
2 x super PLUS 1 x alignment = 40 to < 50 mm P3 P3 P3 P2 P2 P2
2 x super PLUS 1 x alignment = 50 to < 60 mm P2 P2 P2 P1 P1 P1
2 x super PLUS 1 x alignment > 60 mm P1 P1 P1 E2 E2 E2
Track Speed (Normal / Passenger) km/hr
Track Position relative to OHW

Rail Level relative to design

20/20 40/40 60/60 80/90 100/115 115/160
Unrestricted areas in Restricted Height
Areas
TBD TBD

Track Position relative to OHW Track Speed (Normal / Passenger) km/hr

Superelevation variation 20/20 40/40 60/60 80/90 100/115 115/160
Alignment to survey
from design
TBD TBD

© Rail Corporation Page 57 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C5-15 Siding Limits and Responses

C5-15.1 Mandatory Limits
Nil

C5-15.2 Guidelines
C5-15.2.1 Geometry
Track Geometry
Twist Gauge Siding Category
Super Top
(Var from Wide
(6m chord) Short Long Focal
design) mm mm Tight
(2m) (14m) Secondary Primary Points or
mm see note mm
mm mm
1 Signalled

≤ 40 ≤ 25 ≤ 17 ≤ 40 ≤ 22 ≤ 12 N N N

16 - 20 16 - 20 41 - 46 N N P3
21 - 25 21 - 25 18 - 20 47 - 52 23 - 26 13- 14 N P3 P3
26 – 40 26 - 27 26 – 28 11 - 15 P3 P3 P3
41 - 60 28 - 30 53 – 59 29 – 30 15 – 16 P3 P3 P2
61 – 66 31 - 32 60 – 64 31 – 32 17 P3 P2 P2
67 – 71 33 - 34 21 - 22 65 – 70 33 – 34 18 P2 P1 P1
72 – 75 35 - 40 23 65 – 70 35 – 37 19 – 20 P1 E2 E2
>75 > 40 > 23 >70 >37 >20 E2 E1 E1

Note 1. Assessment of wide gauge should also include thorough examination of

fastening, ties and rail foot condition. Higher priorities and more urgent action
should be considered regardless of the actual measured gauge when potential
for spread road is evident. Ballast covering ties and fastenings must be cleared
to enable detailed examination. If detailed examination is not possible the CME
must be informed and a risk assessment carried out to determine action.

C5-15.2.2 Ties Bearers

Ties / Bearers
Clusters of Consecutive Ineffective
Fastenings securing points levers to Focal
Sleepers
A&B timbers. Number of secure Secondary Primary Points or
fastenings
Signalled

<2 4 N N N

3 N N P3

2 N
N P3
(isolated locations)
3 P3 P3 P2
2 P3 P2 P2
4 P2 P2 P1
5 P1 E2 E2
>5 1 or 0 E2 E1 E1

© Rail Corporation Page 58 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C5-15.2.3 Turnouts

Switches
Focal Points
Switch profile Switch tip height Secondary Primary
or Signalled
No spalling or broken Meet mainline switch tip gauge N N N
pieces limits
Minor spalling permissible Minor non-conformance if no switch N N P2
tip contact (because of protection
from switch protectors)
Major chipping switch fails Switch tip sits higher than stockrail P2 P1 E2
switch tip gauge
width/angle
Rod tension on switch at 3mm
opening
(tonne) Switch rods Secondary Primary Focal Points

Thornley Heavy duty

≥ 0.25 ≥ 0.4 Not worn bent or damaged N N N

0.16 - 0.24 0.3 – 0.39 N N P2

0.12 – 0.15 OK if not critical N P2 P1
< 0.12 Bent but still closes P1 E2 E1
Easy to open E1 E1 E1
Secure Points (Book out and clip)

Switch Rail Open Throw (mm)

Switch Rail Toe to Stock Rail Secondary Primary Focal points

Manual levers only
<100 N N N
100-96 N N P3
95-90 P3 P3 P2
89 – 85 P1 P1 E2
< 85 E2 E2 E1

/hr
Heel block condition and vertical support
Focal Points
Secondary Primary
Conventional Turnouts with fixed heels or Signalled
Cracked P3 P3 P2
Vertical movement of switch tip < 2mm is evident
Broken but still effective P2 P2 P1
> 2mm horizontal and > 4 mm vertical movement of switch tip
Missing / Broken and ineffective E2 E2 E2
Heel block vertical support
Focal Points
Heel Bolts Movement of Switch Tip Secondary Primary
(mm) or Signalled

Bolts tight No movement N N N

N N P3
75% Bolts tight Vertical movement is evident P3 P3 P2
>2 horizontal opening; P2 P2
P3
>4 vertical movement

© Rail Corporation Page 59 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Crossings
Checkrail Checkrail
Effectiveness Effectiveness
Secondary Primary Focal Points or Signalled
Tight Wide
1386 1397 N N N

1384 – <1386 1398 – 1400 N P3 P2

1382 – <1384 >1400 P2 P2 P1
<1382 E2 E2 E1

Note. Checkrail effectiveness and gauge measurements at “V” &”K” crossings should be
taken at a point just behind (nominally 150mm) the point of the crossing to insure that
varying crossing nose shapes do not effect consistency of measurement. For “K”
crossings this point may have to be further away to allow the measuring board to be
square to the measurement point.

Note. Where there is evidence of wheel wear on the gauge face of the crossing nose
despite satisfactory checkrail effective measurements this could indicate movement
under load. If this is the case then the potential rail play should be assessed and
incorporated into static measurements to determine priority.

Gauge through crossing Secondary Primary Focal Points or Signalled

Tight Wide

1431 <1442 N N N

1428 – < 1431 1442 – 1444 N P3 P2

1426 – < 1428 >1444 P2 P2 P1

< 1426 E2 E2 E1
Flangeway width Secondary Primary Focal Points/ Signalled
Tight Wide

> 38 <49 N N N

38 – 36 49 – 51 N P3 P2
< 36 >51 P2 P2 P1

C5-15.2.4 Bolts
Bolts should be sufficient to secure each element of the infrastructure.

Missing or loose bolts should be prioritised and replaced/tightened in accordance with

their impact on the infrastructure.

© Rail Corporation Page 60 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 6 Assessment of Base Operating Conditions

C6-1 Track Geometry
The specified inspection responses assume that the defect is initially identified by a track
recording vehicle or by a person without the appropriate competency to inspect and
determine the required action. Under these circumstances, it will be necessary for a
person with track examination competencies to assess the defect within the specified
time and to instigate the required action.

If detected by a person with track examination competencies then assessment must take
place at the time of detection.

The mandatory actions are based on geometry defect considerations only. The condition
of track components or potential for rapid deterioration may require more urgent response
or lower speeds limits until repaired. This is particularly relevant at gauge defects caused
by failure of fastenings.

It should be noted that more restrictive criteria may be imposed due to the application of
other base operating requirements (e.g. overhead wiring or clearance requirements).

Guidance on speed restrictions to be applied is given in the following sections. However

attention should be given to any outstanding defects when carrying out engine
inspections to address rough riding conditions. Additional speed restrictions should be
imposed if rough riding is found.

The Track Recording Car measures defects to 0.1mm. The base operating limits for
geometry are only categorised to the nearest mm. Readings from the Track Recording
Car are to be rounded to the nearest mm. (eg 15.1mm becomes 15mm, 15.5mm
becomes 16mm, 15.6mm becomes 16mm etc)

Note that the track can be inspected prior to the track geometry car run to review
previously identified defects. Defects can be pre-inspected and appopriate action
determined in advance. If the track geometry car simply confirms the pre-inspeciton
findings then no further inspection is required in response to the geometry car finding.

Assessing “False” Track Recording Car Readings

The Track Recording Car may give readings that, on initial examination, appear larger
than expected (e.g. 40mm wide gauge). Action is required to Inspect and verify the
defect in field and, if it is verified as a “false” reading, sign it off as requiring no action.
Field verification is not required if staff on the car confirm that the recording for that
parameter was not valid. In this case the area covered by the invalid recording should be
treated as if it was not recorded. Ludicrous readings e.g. 120mm wide gauge should be
treated as invalid. Some defects can be “field verified” by ride on the car itself as
indicated in the following sections.

When apparent “false” recordings are classified as E1, the mandatory response is
normally “Inspect and Verify before the next train.” Team Managers may extend the
Inspect and Verify response period, if they are satisfied by discussion with the operators
on the car, by observation of the ride of the car, by knowledge of the track and by close
observation of the recording trace, that the defect is a “false” recording. The defect can
only be “signed off” after it has been verified by inspection.

The use of this method requires the Team Manager or their representative to hold Track
Examination competencies and be present on the Track Recording Car during the
recording run.

© Rail Corporation Page 61 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

When assessing defects it should be noted that the Track Recording Car measures the
track under loaded conditions. When field staff locate the defect by static measurements
that are similar to those found by the AK car the defect size located by the car should be
used to determine priority unless otherwise specified in the following assessment
instructions.

Track recording graphs must be reviewed as well as a field examination to determine

“false” recordings.

CME’s and Team Managers should review “false” defects to prevent actual defects from
being dismissed as “false” This can be done by checking current graphs, comparison to
previous graphs or spot checking of “false” defects in the field.

C6-1.1 Wide Gauge

C6-1.1.1 Initial Review
Emergency level defects (E1 and E2) for wide gauge MUST be reviewed as Emergency
Defects.

Arrange an immediate inspection (if necessary call staff out). If there is good reason to
believe the track is secure against further widening (for example it is on concrete
sleepered track) and is no more than 37mm wide then the inspection can be downgraded
to meet the requirements of a Priority 1 (P1) ie within 24hrs.

Inspection

1. Verify the gauge measured including any play available. Wide gauge excludes head
flow.
2. In assessing wide gauge the issues to be considered are:
∼ The track must be well secured against further widening.
∼ The high rail must meet the requirements of the rail wear standard including
gauge face angle.
∼ Gauge variation must not be such as to affect ride (should be seen on the
versine trace on the graphs, by observing the alignment of the high rail or by
observing traffic).
If the above conditions are met then no speed restriction should be required pending
correction. Otherwise a speed restriction in line with the track condition must be
applied.
3. An assessment should be made to determine if there are any locations where gauge
has widened significantly between geometry car inspection runs. This assessment
should be carried out when the full graphical report becomes available. Such
locations are to be the subject of a special inspection using the guidelines above.

C6-1.1.2 Correction
Wide gauge defects are to be corrected in accordance with the standard guidelines.

If, however, the gauge has only been given a Priority (P2) and no problems are found
during the inspection then correction can be deferred and the situation reviewed at the
next geometry car inspection.

C6-1.2 Tight gauge

Tight gauge defects are shown on the defect list as gauge with a minus sign in front eg ­
13mm (note that wide gauge defects are shown without the minus sign).

© Rail Corporation Page 62 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C6-1.2.1 Initial Review

Emergency level defects (E1 and E2) for tight gauge reported by the Track Recording
Car may be reviewed as Priority 1 (P1) defects, ie within 24hrs.

C6-1.2.2 Inspection & Assessment

1. Verify the gauge measured and confirm it is genuine. Tight gauge should include
head flow but temporary narrow gauge due to switches not being fully closed (until
the train passes) is not considered to be tight gauge.
2. Assess if there are any infrastructure problems arising from the tight gauge such as
fastenings working loose or rail rolling out under load. An appropriate speed
restriction should be applied if problems with the infrastructure are found.
3. Assess the length over which tight gauge is to be found and whether there are any
signs of vehicle hunting. This can be seen as wear marks on the gauge face of both
rails staggered between rails at intervals of 5m to 20m (from the mark on one rail to
the next mark on the same rail). If evidence of hunting is found the speed of affected
traffic should be restricted to no more than 80kph. Confirm by visual observation of
different types of traffic. Normally only freight vehicles are affected and in most areas
of the metropolitan system there is already a blanket restriction of 80kph for freight
traffic.

C6-1.2.3 Correction
1. Tight gauge is to be corrected in accord with the standard guidelines.
2. If hunting is found then the track should be corrected within 7. If this is not done a
reassessment should take place to ensure that the speed restriction is affective in
stopping hunting. If it is not then a further reduction in speed should be imposed.
Again the defect should be corrected within 7 days or a further review undertaken.
3. Tight gauge 13-14mm on lines with speed greater than 80km/hr which do not exhibit
problems (as detailed above) do not need to be corrected at the P2, P1 or E2
correction timeframe but should be programmed for correction via future rail grinding
programs. As resources permit tight gauge at levels of 11mm to 12mm should also
be corrected.

C6-1.3 Short Twist

Short twist for track geometry defects are determined using a 2m chord on the car.
Defects may be shown as positive or negative. Their absolute value determines their
defect status.

C6-1.3.1 Initial Review

Emergency Level defects (E1 and E2) for short twist are to be reviewed as Emergency
Defects. A check should be made with track geometry car operating staff to ascertain if
the recordings are correct. If they are then the short twist should be the subject of an
immediate assessment. This should consider the deterioration potential of the location if
known. Apply a speed restriction reflecting the size of the defect and the deterioration
potential.

C6-1.3.2 Inspection
Short twist defects are to be inspected in accordance with the standard guidelines.
Where Emergency Level (E1 and E2) defects have already been assessed (eg on the
track recording car) and a speed restriction applied, further inspection within the
inspection response time is not necessary.

© Rail Corporation Page 63 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Verify the twist measured using manual methods (2m chord). In assessing the defect the
issues to be considered are:
− The track geometry under loaded conditions
− The stability of the track and the potential for further deterioration.
− The alignment of the track.
Apply appropriate speed restriction if there is potential for rapid deterioration. It is not
mandatory to place a speed if the defect is assessed as having no potential for rapid
deterioration and is corrected with the standard period allowed for action. Monitoring may
also be required until correction and should be determined by considering the
deterioration potential of the defect.

C6-1.3.3 Correction
Short Twist defects are to be corrected in accord with the standard guidelines.

C6-1.4 Long Twist

Long twist for track geometry defects is determined using a 14m chord on the geometry
car. Defects may be shown as positive or negative. Their absolute value determines
their defect status.

C6-1.4.1 Initial Review

Emergency Level (E1 and E2) defects for long twist are to be reviewed as Emergency
Defects. A check should be made with track geometry car operating staff to ascertain if
the recordings are correct. If they are then a speed restriction of 20kph should be applied.
Correction at least sufficient to reduce the defect below emergency level should be
carried out within 24 hours.

C6-1.4.2 Inspection
Long twist defects are to be inspected in accordance with the standard guidelines.
Where Emergency Level (E1 and E2) defects have already been assessed (eg on the
track recording car) and a speed restriction applied, further inspection within the
inspection response time is not necessary.

Verify the twist measured using manual methods (14m chord). In assessing the defect
the issues to be considered are:
− The track geometry under loaded conditions
− the stability of the track and the potential for further deterioration
− The alignment of the track
− If the twist ramp is mainly due to a designed transition
Where the twist arises predominantly from the inherent design of the transition ramp and
the offending ramp is observably smooth then apply the long twist limits for transitions.
These limits provide an additional allowance of 3mm.

Apply appropriate speed restriction if there is potential for rapid deterioration. It is not
mandatory to place a speed if the defect is assessed as having no potential for rapid
deterioration and is corrected with the standard period allowed for action. Monitoring may
also be required until correction and should be determined by considering the
deterioration potential of the defect.

C6-1.4.3 Correction
Long Twist defects are to be corrected in accordance with the standard guidelines.

© Rail Corporation Page 64 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C6-1.5 Top
Top track geometry defects are determined using a 6m chord. Defects may be shown as
positive or negative. Their absolute value determines their defect status.

C6-1.5.1 Initial Review

Emergency Level (E1 and E2) defects for top are to be reviewed as Emergency Defects.
A check should be made with track geometry car operating staff to ascertain if the
recordings are correct. If they are then top should be the subject of an immediate
assessment. This should consider the deterioration potential of the location if known.
Apply a speed restriction reflecting the size of the defect and the deterioration potential.

C6-1.5.2 Inspection
Top defects are to be inspected in accordance with the standard guidelines. Where
Emergency Level (E1 and E2) defects have already been assessed (eg on the track
recording car) and a speed restriction applied, further inspection within the inspection
response time is not necessary.

Verify the top measured using manual methods (6m chord). In assessing the defect the
issues to be considered are:
− The track geometry under loaded conditions.
− The stability of the track and the potential for further deterioration.
− The presence of other geometry defects and factors affecting the ride of trains.
Apply appropriate speed restriction if there is potential for rapid deterioration. It is not
mandatory to place a speed if the defect is assessed as having no potential for rapid
deterioration and is corrected with the standard period allowed for action. Monitoring may
also be required until correction and should be determined by considering the
deterioration potential of the defect.

C6-1.5.3 Correction
Top defects are to be corrected in accordance with the standard guidelines.

C6-1.6 Superelevation
Track recording car graphs should be assessed for variation from design superelevation.
This should be done in post-analysis. By observation the defect would normally be seen
as a variation from smooth. Where deviations from design superelevation are found
compliance with BOCS is recommended (but check that the calibration on the Track
Geometry Recording Car is not in error).

C6-1.7 Line
Line track geometry defects are determined using a 8m chord measured at mid-ordinate
and comparing the actual versine against the design versine. Defects may be shown as
positive or negative. Their absolute value determines their defect status.

C6-1.7.1 Initial Review

Emergency Level (E1 and E2) defects for line are to be reviewed as Emergency Defects.
The degree of concern will relate directly to the jerk experienced by persons on the track
geometry car (considering the speed of the car). If the defect registered by the track
geometry car is genuine then an immediate speed restriction is recommended in line with
the ride performance. In the absence of such an assessment apply the default speed
restriction limits.

© Rail Corporation Page 65 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C6-1.7.2 Inspection
Line defects are to be inspected in accordance with the standard guidelines. Where
Emergency Level (E1 and E2) defects have already been assessed (eg on the track
recording car) and a speed restriction applied or where the team manager or their
representative on the car has determined that it was a false recording, further inspection
is not necessary.

Verify the line measured by assessing the ride/ dynamic performance of trains either from
a front of train or by observing trains passing over the site at track speed. The
requirement for a speed restriction will depend primarily on this assessment. Line defects
should be re-classified and a revised priority allocated on the basis of this assessment.
In the absence of such an assessment a speed restriction should be applied to bring the
operating speed to no more than the BOCS default speed.

In analysing the cause of the problem and corrective action the defect should be
assessed by manual measurements or by using the data from the track geometry car.

C6-1.7.3 Correction
Line defects may be difficult to correct within short timeframes. Reclassified line defects
are to be corrected with priority based on consideration of the effects of any speed
restriction imposed. All line defects outstanding are to be monitored during routine track
patrol and during scheduled front of engine inspections.

C6-2 Rail Wear

Confirm head losses for P1 and P3 by detailed measurement, excluding head flows, and
make assessment based on detailed head area.

C6-2.1 Relaxation of Condemning Limits

When rail wear (either tangent wear "A" or Curve wear "B" reaches P3 level (formerly
called the Reportable limit) continual review and assessment is required so that rerailing
may be undertaken before the condemning (P1) level is reached.

When rail tangent wear (reduction in head height) on 60kg/m rail reaches P3 level
(formerly called Reportable limit) assess the location and operating conditions to
determine whether rail wear may be permitted beyond the condemning (P1) level.
Assess the total allowable % head loss in accordance with Table 4. Calculate the head
loss from head width and height in accordance with Section C6-2.2.

© Rail Corporation Page 66 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Sleeper Type Axle Load Curvature Condemning limit

(% Head loss)
60 HH 60 SC
Concrete Sleepers 30 Tonne 200 - 300m 47% NA
300 - 400m 51% NA
400 - 600m 58% NA
600m or greater 60% 42%
25 Tonne 200 - 300m 60% 40%
300 - 400m 60% 47%
400 - 600m 60% 52%
600m or greater 60% 55%
Timber Sleepers with 30 Tonne NA NA NA
elastic fastenings
25 Tonne 200 - 300m 41% NA
(In Face)
300 - 400m 44% NA
400 - 600m 48% NA
600m or greater 52% NA
Timber Sleepers with 25 Tonne NA NA NA
dogspikes

Table 4 - Allowable Head Loss on 60kg/m rail

Note 1: NA - no reduction in curve wear limit is allowed.

Note 2: Notwithstanding the % head loss limits above the maximum tangent wear limit
for 60kg rail is for a head depth of 24mm.
Note 3: Once 60kg and 53kg rails reach the P3 level which are limiting wear limits for
potential VSH defect development, the following options are possible in order
extend the limits to the P1 values specified in Section C5-5.2 or for 60kg rail the
head loss values in Table 4:
- Grind the rails to the profiles specified in Engineering Manual TMC 225.
- Ensure that no defects are developing in the rails by taking special care
with the ultrasonic inspection.
C6-2.2 Calculation of Head Loss
Where it is necessary to establish the percentage loss of area of the rail head in 60kg/m
or 53kg/m rail, the following method may be used:

1. Measure the remaining head width and head depth using the method in Section
C14-1.
2. Determine head loss values by referring to Table 5 for 60kg/m rail or Table 6 for
53kg/m rail.
3. More accurate determinations can be made directly using rail profile measuring
systems.

© Rail Corporation Page 67 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Loss of Head Area (%) 60kg/m rail

Remaining
Head Remaining Head Width
Depth
45 48 51 54 57 60 63 66 69
34 47 44 41 38 35 32 30 27 24
33 49 46 43 40 37 34 32 29 27
32 51 48 46 43 40 37 34 31 29
31 53 50 48 46 42 39 37 34 31
30 56 53 50 48 44 42 40 37 34
29 57 54 52 49 46 44 42 39 36
28 59 56 54 51 48 46 44 41 39
27 61 58 56 53 50 48 46 43 41
26 63 60 57 55 52 50 48 45 43
25 62 59 57 55 53 50 48 46
24 63 61 59 56 54 52 50 48
23 65 63 61 59 57 55 52 50
22 67 65 62 60 59 57 54 53
21 65 62 60 58 57 55
20 66 64 62 61 59 57
19 63 61 60
Table 5 - Loss of rail head area (%) 60kg/m rail

Loss of Head Area (%) 53kg/m rail

Remaining
Head Remaining Head Width
Depth
45 48 51 54 57 60 63 66 69
34 39 36 33
33 42 38 35 32 29 26 24
32 44 41 37 34 31 28 26 23 21
31 46 43 40 37 33 30 28 25 23
30 48 45 42 40 36 33 31 28 25
29 50 47 44 42 39 36 33 30 28
28 52 49 46 44 41 38 35 32 30
27 54 51 48 46 43 40 37 34 32
26 56 53 50 48 45 42 40 37 35
25 58 55 52 50 47 44 42 40 37
24 60 57 55 52 49 47 45 43 40
23 63 59 57 54 51 49 48 46 43
22 64 61 59 56 54 52 51 48 46
21 61 58 56 54 53 51 49
20 66 64 62 61 59 57
19 63 61 60
Table 6 - Loss of rail head area (%) 53kg/m rail

© Rail Corporation Page 68 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C6-3 Rail Condition

C6-3.1 Fishplates - (Includes Broken and Cracked Plates at Insulated Joints)
To be determined.

C6-3.2 Sleeper Support at Fish-Plated Joint

To be determined.

C6-3.3 Rail Joint Adjustment at Fish-Plated Joint

Review risk of wheel climb for E1,E2 and P1 (track curvature, horizontal angle at joint,
foulness of joint, joint vertical and lateral integrity).

C6-3.4 Loose or Ineffective Fish Bolts and Swage Fastenings at Fish-Plated

Joint
Assess joint for E1 and E2, restrict or stop trains depending on support conditions, max
speed 20km/h, observe site prior to passage of each train until ineffective bolts are
replaced.

Note: The BOS tables are based on 6 hole fishplates;

C6-3.5 Rail End Condition at Fish-Plated Joint

To be determined.

C6-3.6 Rail Contact Fatigue

To be determined.

C6-3.7 Wheel Burns

Assess E2,P1 and P2 to establish if speed restriction is required to control damage,
Review Rail Maintenance strategy and arrange corrective grinding within 3 months.

C6-3.8 Rail Surface Condition - Fish Scaling and Spalling

Assess P1 and P2 to establish if speed restriction is required to control damage, Review
Rail Maintenance strategy and arrange corrective grinding within 3 months.

C6-3.9 Insulated Rail Joints

To be determined.

C6-4 Sleepers
C6-4.1 Missing Sleepers or Excessive Spacing
Repair within P1 within 7 days unless assessed by Civil Maintenance Engineer in
consideration of current operations or after placement of appropriate operational
restrictions (eg speed, axle load).

C6-4.2 Ineffective Clusters

Assess E1 to establish if continued operation should be permitted dependent on traffic
type, boarded speed, track geometry, local risk factors detailed assessment of sleeper
condition and deterioration potential. Monitor each train until repaired.

Apply immediate speed restriction on E2 to reduce impact dependent on traffic type,

boarded speed, track geometry, local risk factors detailed assessment of sleeper
condition and deterioration potential. Monitor at appropriate interval until repaired.

© Rail Corporation Page 69 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Assess need for speed restriction on P1 and P2 dependent on traffic type, boarded
speed, track geometry, local risk factors, detailed assessment of sleeper condition and
deterioration potential. Monitor weekly until repaired.

C6-4.3 Ineffective Sleepers at Joints

Assess E1 to establish if continued operation should be permitted dependent on traffic
type, boarded speed, track geometry, local risk factors detailed assessment of sleeper
condition and deterioration potential. Monitor each train until repaired.

Assess need for speed restriction on P2 dependent on traffic type, boarded speed, track
geometry, local risk factors, detailed assessment of sleeper condition and deterioration
potential. Monitor each patrol until repaired.

C6-5 Ballast
C6-5.1 Ballast Profile Deficiencies
P1 May be reduced to P2, depending on current and expected weather conditions and
other stability loss factors.

C6-5.2 Excess Ballast, Poor Drainage and / or Ballast Condition

To be determined.

C6-6 Turnouts
The applicability of these requirements may vary depending on whether the turnout is a
conventional or tangential type.

C6-6.1 Tight Track Gauge at Switch Tip

C6-6.1.1 Inspection
The inspection should:

1. Verify the gauge measured and confirm it is genuine. Tight gauge should include
head flow but temporary narrow gauge due to switches not being fully closed (until
the train passes) is not considered to be tight gauge.
2. Assess if there is any infrastructure problems arising from the tight gauge such as
fastenings working loose or rail rolling out under load. An appropriate speed
restriction should be applied if problems with the infrastructure are found.

C6-6.1.2 Correction
See plain track geometry.

C6-6.2 Wide Track Gauge

C6-6.2.1 Inspection
The inspection should:

1. Verify the gauge measured and confirm it is genuine.

2. See plain track geometry.

C6-6.2.2 Correction
1. Monitor in line with deterioration potential.
2. See plain track geometry.

© Rail Corporation Page 70 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C6-6.3 Switch Throat to Stockrail

C6-6.3.1 Correction
Additional action may be required for signalling purposes where the switch rail throat
opening dimension is less than 50mm.

C6-6.4 Switch Rail Toe to Stock Rail

C6-6.4.1 Correction
Additional action may be required for signalling purposes.

C6-6.5 Bearers
Assess E1 to establish if continued operation should be permitted dependent on traffic
type, boarded speed, track geometry, local risk factors detailed assessment of bearer
condition and deterioration potential.

Apply immediate speed restriction to E2 to reduce impact dependent on traffic type,

boarded speed, track geometry, local risk factors detailed assessment of bearer condition
and deterioration potential. Monitor at appropriate interval until repaired.

Consider requirement for speed restriction for P1 and P2 depending on traffic type,
speed, track geometry, local risk factors, detailed assessment of bearer condition and
deterioration potential. Monitor weekly until repaired.

C6-6.6 Component condition

Heel Blocks, Rail Brace / Chair, Switch bearing Stops.

To be determined.

C6-6.7 Switch Blade Damage

To be determined.

C6-6.8 Stock Rail or Switch Rail Gauge Face Wear Angle (Conventional)
To be determined.

C6-6.9 Stock Rail or Switch Rail Gauge Face Wear Angle (Tangential)
To be determined.

C6-6.10 Switch Rail Angle

To be determined.

C6-6.11 Stock Rail Gauge Face Wear

To be determined.

C6-6.12 Switch Tip Height (Conventional)

To be determined.

C6-6.13 Switch Tip Height (Tangential)

To be determined.

C6-6.14 Switch Gauge Corner Radius

To be determined.

© Rail Corporation Page 71 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C6-6.15 Switch Width and Wear at Tip (Conventional)

For P1, E2 and E1, as part of specified inspection determine the cause and risk of
derailment.

C6-6.16 Switch Blade Head Mating Surface Fit With Stock Rail
Report to signalling representative.

C6-6.17 Check Rail Effectiveness

The main effectiveness of the checkrail is its ability to protect the crossing nose. Wheel
contact with the crossing nose is therefore a vital observation to be made during
inspections. Any sign of excessive damage to the crossing nose is reason for
replacement/adjustment of the checkrail regardless of the check rail wear.

C6-6.18 Gauge Through Crossing

To be determined.

C6-6.19 Height of Check Rail

To be determined.

C6-6.20 Check Rail Flangeway Width / Depth

Flangeways should be checked for blockages and cleared where blocked.

These will normally be measured in response to other problems.

C6-6.21 Crossing Nose - Vertical Wear

To be determined.

C6-6.22 Wing Rail - Vertical Wear

To be determined.

C6-6.23 Cracks in Cast Crossings

1. Non critical - means cracks longitudinally or vertically that may eventually cause a
crossing to need repair.
2. Critical - means cracks longitudinally or vertically that may lead to a piece of crossing
eventually lifting or breaking out and affecting the running surface integrity.
3. Fully (not affecting the running surface) - means a crack that runs the full section of
the crossing such that the crossing is in two pieces, all fastenings are secure and
does not impact on the running surface (eg Tang area of crossing).
4. Fully (affecting the running surface) - means a crack that runs the full section of the
crossing such that the crossing is in two pieces and fastening are not secure or the
break affects running surface integrity.
5. Rail Bound Manganese Crossings- elongated cracks - have the potential to develop
into broken rails.
6. For P1, E2 and E1, include assessment of derailment potential within required
inspection and respond accordingly.

C6-6.24 Crossing nose - Gauge Face Wear

To be determined.

© Rail Corporation Page 72 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C6-6.25 Crossing Nose Break

Non critical - means cracks longitudinally or vertically that may eventually cause a
crossing to need repair.

For P1, E2 and E1, include assessment of derailment potential within required inspection
and respond accordingly.

C6-6.26 Check Rail Bolts

1. The end bolts of all checkrails should be effective.
2. Crossing Bolts - assess Individual defects for the effectiveness of the bolts.
Ineffective bolts include missing or broken bolts. Loose bolts should be tightened.
Missing or ineffective bolts should be replaced.

C6-6.27 Swing Nose Clearance

To be determined.

C6-6.28 Diamond Crossover

To be determined.

C6-7 Level Crossings

C6-7.1 Assessment
Where there is evidence of wheels striking end of checkrail material, assess the cause. It
may be due to wide gauge or a reduction in flangeway clearance. In either case the
sleepers and/or fastenings may be ineffective. Look for signs of movement.

Inspect for debris and other material in the flangeway to assess the risk of impact on
wheel flanges (density, strength and level of compaction of debris). Default response is
P1 Priority.

C6-8 Transit Space

C6-8.1 Assessment
The Base Operating limits are the minimum conditions for the passage of Rollingstock
operating under normal operating conditions only. It does not include any extra clearance
between Rollingstock and Infrastructure to allow for any people or objects to protrude
from either vehicle or structure.

It should be noted that more restrictive criteria may be imposed due to the application of
other standards (e.g. overhead wiring or clearance requirements).

Specified inspection responses presuppose the defect is initially identified by track

recording vehicle or by a person without appropriate competency to inspect and
determine the required action. Under these circumstances, it will be necessary for a
competent worker to assess the defect within the specified time and to instigate the
required action.

C6-8.2 Temporary Operational Infringements of Lateral Kinematic Plus

200mm or Vertical Kinematic Plus 100mm
For locations where no clearance waivers are in place and where Operational
Infringements are encountered when the defined lateral safety clearance margin beyond
the appropriate rolling stock outline is reduced below 200mm or when the defined vertical
safety clearance margin beyond the appropriate rolling stock outline is reduced below
100mm. These Operational Infringements are not to be approved to remain permanent.

© Rail Corporation Page 73 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Seek approval from the Civil Maintenance Engineer if the infringement is to remain for a
temporary duration.
Assess hazard for E2, impose restrictions and correct.

Assess risk of further deterioration for P1 and develop an appropriate inspection and
response program.
Assess risk of further deterioration for P2 in clearance and verify response.

Infringements may be caused by a combination of alignment variation from design or

superelevation variation from design.

If there are recent scrape marks or gouges on minimum clearance track to structures,
including platforms, treat the incident as an E2 Priority. In addition, consult with Network
Control if a vehicle is suspected as the cause of the problem.

Speed must be low enough (considering track condition) to ensure there are no
excessive vehicle dynamics;

C6-8.3 Approved Operational Infringements of Less than Kinematic Plus

100mm or of Vertical Kinematic Less than 100mm
For locations where clearance waivers are in place covering permanent Operational
Infringements when the defined safety clearance margin beyond the appropriate rolling
stock outline is reduced below 100mm.

Assess hazard for E2, impose restrictions and correct. Examine maintenance
procedures and modify as appropriate.

Assess risk of further deterioration for P1 and develop an appropriate inspection and
response program. Examine maintenance procedures and modify as appropriate.

Assess risk of further deterioration for P2 in clearance and verify response.

Infringements may be caused by a combination of alignment variation from design or

superelevation variation from design.

Refer to Infringement Authorisation for specific limits and conditions.

If there are recent scrape marks or gouges on minimum clearance track to structures,
including platforms, treat the incident as an E2 defect. In addition, consult with Network
Control if a vehicle is suspected as the cause of the problem.

C6-8.4 Platform Lateral and Vertical Clearance

Assess hazard for E2, impose restrictions and correct. Examine maintenance
procedures and modify as appropriate.

Assess risk of further deterioration for P1 and develop an appropriate inspection and
response program. Examine maintenance procedures and modify as appropriate.

Assess risk of further deterioration for P2 in clearance and verify response.

Consult with Operations where movement is away from platforms for P1 and E2 defects.

C6-8.5 Alignment with Respect to Overhead Wiring

Calculate the sum of the alignment variation (if any) with twice the super variation (if any).

Have the site checked by electrical maintenance staff where the alignment variation
results in a P2, P1 or E2 defect.

© Rail Corporation Page 74 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 7 Track Patrol

Track Patrol is a visual examination of the track and right of way which ensures:
− there are no obstructions to train movements or signalling equipment within (or
potentially within) the structure gauge;
− there is continuity of Rails (i.e. no broken rails or joints, or loose or foul joints);
− there are no imminent failures of track fastenings;
− there are no major track geometry defects (of derailment potential) without suitable
protection;
− there are no major deficiencies in the supporting track structure (resulting from
earthworks, bridges, structures, culverts, etc.);
− that permanent and temporary speed signs are visible to train/track vehicle operators
(are present, facing the right direction, not obscured by trees, graffiti etc.);
− that temporary speed signs have been placed correctly, are accurate (have all the
right plates in the right order and working lights) and, are standing securely.

C7-1 Patrol Methods

Track Patrol in RailCorp is undertaken by a number of methods. These include:
− Walking Patrol (including Adjacent Track Patrol and Night Patrol)
− Hi-rail Patrol (including Night Patrol)
− Engine Patrol
− Mechanised Track Patrol
− Supplementary Patrol
These patrol methods may be applied in combination by Civil Maintenance Engineers in
accordance with criteria detailed in ESC 100 – Civil Technical Maintenance Plan to form
an Integrated Track Patrol regime.

C7-2 Examination Requirements

1. The default patrol method is 'Standard Track Patrol'.
2. Integrated Track Patrol may be implemented by Civil Maintenance Engineers
3. The Chief Engineer Track may approve the substitution of 'Standard Track Patrol' by
Night Patrols and Adjacent Track Patrols.

C7-2.1 Standard Track Patrol

Track Patrols are carried out in daylight hours by walking or by Hi-rail vehicles (where
they are permitted).

C7-2.1.1 Walking Patrol

1. Where a walking patrol is to be carried out, two tracks may be examined by walking
on one track whilst examining both tracks. Where adjacent tracks are separated (eg.
at island platforms) it is not possible to patrol one track from the other and each track
is to be patrolled separately.
2. Alternate the direction of walking patrol so that the tracks are walked over equally.

© Rail Corporation Page 75 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C7-2.1.2 Hi-Rail Patrol

1. Where a track patrol is carried out using a Hi-rail vehicle, the nominal speed is to be
20 kph, however the maximum and average speed of patrol will be determined by
local conditions and will vary from length to length. e.g. Track with known good
sleepers and fastenings may be patrolled at a higher speed than track of poor
sleepers and fastenings.
2. When a track vehicle is used to patrol multiple tracks, each line is to be patrolled
separately.
3. At poor GIJ condition locations that are nominated for Supplementary Patrol, slow
the Hi-Rail vehicle down to a speed necessary to conduct the examination, to
increase the opportunity to detect broken GIJ plates on the field side of rails.
This requirement applies to poor condition GIJ’s in plain track and at the boundaries
of turnouts and special track work.
4. At turnouts and special trackwork, slow the Hi-Rail vehicle down to a speed
necessary to conduct the examination), to increase the opportunity to detect broken
plates and rails. The purpose is to increase visibility from the HiRail cab.
5. At Level Crossings slow the Hi-Rail vehicle down to a speed necessary to conduct
the examination.

C7-2.2 Engine Patrol

Track Patrol may be carried out from the front of an engine instead of by walking or by
track vehicle. This may only occur:
− Where patrol by engine is included in an Integrated Track Patrol regime, OR
− when a patrol opportunity is lost due to strike/ loss of possession etc, a single
standard patrol may be replaced by an Engine Patrol, OR
− to supplement routine patrols such as during special events.
The primary purpose of the patrol by engine is to identify critical hazards or potentially
critical hazards requiring attention in the short term. A secondary purpose is to identify
lower priorities that can be reviewed in more detail in the walking patrol.

Engine Patrols are not Front of Train Examinations and should be undertaken on the
slowest train service. If, however, the fastest and slowest services coincide, the
inspections can be combined.

Any serious safety issues identified must be followed up with a site inspection.

C7-2.3 Mechanised Track Patrols

Mechanised Track Patrols may be used as part of an Integrated Track Patrol regime
approved Civil Maintenance Engineers.

Mechanised Track Patrol utilises a Special Patrol Vehicle (SPV) to allow patrollers to
conduct an Engine Patrol while also recording track imagery utilising various camera
views. The patrol includes a detailed review of the recorded imagery within a 24 hour
period.
1. Track Patrols are to be carried out in daylight hours.
2. The SPV is to have a patroller present conducting an engine patrol observing the
track and noting any locations of concern for immediate action or for further
assessment during the Detailed Review. Patrollers will not normally leave the SPV
during patrols.

© Rail Corporation Page 76 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. Where possible patrollers on the vehicle and conducting the Detailed Review should
be familiar with the territory being examined. Should this not be possible then the
patrollers must be briefed on what to look out for by a patroller familiar with the
territory.
4. Supplementary inspections of any suspect conditions are to be arranged where
required.
5. In the event of a loss of patrol from the SPV, the patrol frequency (including latitude)
detailed in ESC 100 - Civil Technical Maintenance Plan must be maintained. This
can be achieved by obtaining an emergency Walking Patrol or by re-running the
SPV with same day inspection.
6. If next day playback is affected (or for any other failure to meet the maximum patrol
frequency) an emergency inspection of any outstanding Supplementary Patrol
locations is to be carried out that night and a Walking Patrol of the full section
conducted the following day.
7. Where track view and easement view imagery cannot be captured due to low light
conditions, rail view cameras must be used to assess rail continuity.
8. In tunnels and dives lighting may not be effective enough for MTP imagery and
Engine Patrol. In this case additional walking patrols must be conducted.

C7-2.4 Supplementary Patrol

Supplementary Patrol is a site specific Walking Patrol used to patrol locations of identified
poor condition as part of an Integrated Track Patrol regime. It is used in the following
locations:
− Timber sleepered track that is not well tied or providing adequate vertical support.
− Glued Insulated Joints in poor condition with poor geometry, formation failure,
chipped rail ends or evidence of heavy impact (extensive whitened ballast, plates
working loose, or poor sleepers.
− Turnouts & special trackwork in poor condition with flogging joints, joints with poor
lateral support, poor fastenings & bearers at crossing/checkrail, heeled switches with
flogging heels or with strong crack predictors.
− K crossings on curves.
While all examinations provide opportunities to detect conditions requiring additional
examination, the prime examinations for triggering Supplementary Patrol are the Detail
Tie Examination, the Examination of Special Track Layouts, Examination of Insulated
Joints, and Ultrasonic Examination of Turnouts.

C7-2.5 Non Standard Track Patrols

C7-2.5.1 Adjacent Track Patrol
An Adjacent Track Patrol is a daytime inspection in which the track is inspected from an
adjoining track but no more than a distance equivalent to two track widths.

C7-2.5.2 Night Patrol

In the metropolitan area patrol in daylight hours may not be possible in some locations.
In such locations Track Patrol may be routinely carried out at night by using an on-rail
vehicle, provided:
− There is adequate lighting to detect infrastructure defects. Hand torches alone are
generally not considered adequate for this purpose (Note 1). Extra lighting
equipment would normally be fitted to an on-rail vehicle.
− Inspection of plain track may be undertaken by track vehicle, but critical areas such
as turnouts and diamonds are to be examined on foot using extra lighting provided
by the on-rail vehicle.

© Rail Corporation Page 77 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

− inspection of tracks adjacent to the track the on-rail vehicle is on may be undertaken
on-foot using torches and using the additional lighting provided by the vehicle.
− There must be at least one daytime inspection per week of each track. This can be
carried out from the front of an engine. This is required to provide an additional level
of assurance and cover long-sight geometry, right of way and other issues along the
track.
Note 1: Approval may be given by the Chief Engineer Track for the use of torches at
night in detailed patrol inspections of special elements of the track such as turnouts &
crossovers. In these inspections only the area in the immediate vicinity of the torch
needs to be examined (no zonal aspects are considered).

Tunnels and similar areas fitted with permanent lighting may be patrolled in the same
manner as for daylight patrols without any special approval.

C7-3 Walking and Hi-Rail Patrol Procedures

C7-3.1 During the Patrol
1. Examine for obstructions to train movements or signalling equipment within (or
potentially within) the structure gauge. Look for:
∼ Track movement that results in narrowing of track centres, or fouling of
platforms and other structures
∼ Movement of structures
∼ Ballast or rubbish in points or train stops
∼ Visible indications of rail vehicles scraping structures.
∼ Trees or other objects that may fall on the track,
∼ Material or equipment foul of the track.
Watch out for trip arm infringements eg animals, rocks, ballast, sleepers etc.
The trip infringement sits between 400mm and 700mm out from the gauge face and
between 50mm and 300mm above rail height (see Figure 8).

Trip Hazard
Rail Level

Gauge 750mm
Face

Figure 8 - Trip Arm Infringement

2. Examine for obstructions to the wheel path of the train (e.g. in flangeways)
3. Examine rail condition. Look for:
∼ Broken rails, joints, breakaways, and loose or foul joints, fishbolts and
fishplates.
∼ Visual indicators of Vertical Split Head rail defects.
The defect can be identified by a flattening out of the rail head and widening of
the shiny portion of the rail (the contact band) (see Figure 9). Note that other
conditions such as wear patterns on closures, the wheel contact point after a

© Rail Corporation Page 78 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

weld and adverse rail loading can indicate the same change in wear pattern.
This may also be accompanied by rust stains down the web if the cracking has
reached the surface on the underside of the rail head near the web, see
Figure 10.
narrow
contact

Contact band has

widened out for no
apparent reason
(ie not at a weld or
closure)
wide
contact

narrow
contact

Figure 9 – Indications of VSH defect

Rust band
shows crack at
underside of
head
in this case
cracking has
progressed into
web of rail

Figure 10 – Rust band under head of rail

∼ Visible indications of excessive rail wear.

∼ Visual indications of wheel burns.
∼ Visual indications of squats.

© Rail Corporation Page 79 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Squat defects in rails are one of the various types of rail defects.
- They are easily identified visually as they appear as dark shadowy areas
on the crown of the head with an associated widening of the running band
(see Figure 11) and sometimes surface cracking or spalling. Squats are
not, however, reported by the ultrasonic testing vehicle unless they develop
into other defects (which is rare).
- Squats should not be confused with wheelburns or corrugations.
Wheelburns usually occur in pairs whereas squats are normally only
present on one rail. Whilst squats can be cyclic they are not as regular as
corrugations (see Figure 12).
- The defective area seems darkened because of the sub-surface cracking
which typically occurs on the horizontal plane, approximately 3-5mm below
the rail surface, and which causes a depression on the rail surface.

Figure 11 - Medium to large size squat defect

Figure 12 - Periodic squats

© Rail Corporation Page 80 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

4. Examine insulated joints. Areas with the potential to deteriorate rapidly causing
signal failures are the main target, especially the high rail of sharp curves and
mechanical insulated joints with the potential to close up in hot weather. Other
locations may be nominated. Look for:
∼ Rail end flow debris across the key that could short circuit the joint.
∼ Any evidence of cracking or rust stains indicating cracking between the joint gap
and the first bolt hole at the bottom of the plates.
Glued Insulated Joints break in the plates generally between the joint gap and
the first bolt hole. Once one side breaks the other side can break fairly rapidly.
The cracks develop at the bottom of the plate on the outside or the inside
corner. On the outside the cracks are visible but not if they start on the inside of
the plate.
Where overflow of glue inhibits the visual inspection scrape it off to facilitate
examination.
∼ Evidence of movement occurring between the rail and the plate particularly in
the area between the joint gap and the first bolt hole.
∼ Build up of grease, filings wheel scale or other debris across the key that could
short circuit the joint
∼ Squeezed out keys.
∼ Broken, visibly cracked or missing joint insulation material.
5. Examine for untested wire feed or aluminothermic welds (flouro pink marking).
6. Examine for failures of sleepers and fastenings. Look for:
∼ Broken or defective sleepers.
∼ Chemical reagents on the track which could affect concrete ties/slabs.
∼ Obvious indications of wide gauge including:
- irregular horizontal alignment of one rail;
- wear pattern of the rail head approaching the gauge face;
- back canting of rails; lifting of the inside spikes or outside edges of the
sleeper plates planing into the timber;
Problems have been experienced with Pandrol plated ties being used in
dogspiked track with rail backcanting, where the Pandrol clips have broken after
a short time. This is caused by the Pandrol clips bearing the load that would
normally be distributed among a number of sleepers.
∼ Rail play under load; loose outside spikes, movement of the rail between the
inner and outer spikes, movement of the rail and sleeper plate assembly on the
timber.
∼ Missing spikes or resilient fastenings and insulators.
If sleepers and fastenings are not visible during Routine Track Patrol this MUST be
registered in the Defect Control System. The priority for removal depends on the
patroller’s knowledge of the condition of the sleepers.
7. Examine for failure of transoms and broken, missing or loose lockspikes, or plate
play on transoms.
Pay particular attention to bridge ends particularly if there is track pumping in the
adjoining ballasted track. Lockspikes may corrode due to moisture (see Figure 13).
Moisture damage also occurs in the transoms.
If evidence of failure is found, report this to the Team Manager who will arrange a
more detailed inspection to check if other spikes are sheared off (these can be
sheared off below the plate but still appear solid in the plate). If in doubt sample
spikes should be extracted and checked for damage and corrosion.

© Rail Corporation Page 81 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 13 – Corroded lockspike

8. Check track geometry. Look for:

∼ Major defects in top, line, twist or superelevation that could cause a derailment.
∼ Pumping or unstable track.
9. Examine for major deficiencies in supporting track structure. Check for:
∼ signs that embankments or cuttings are slipping.
∼ Signs that under track crossings are settling and causing track geometry
defects.
∼ Signs that excavations close to the track are collapsing.
∼ Obvious defects in track geometry that will indicate that bridges or culverts have
failed.
∼ Erosion of embankments or cutting faces.
10. Examine mainline special layouts. Look for:
∼ Obstructions in points, crossings or flangeways.
∼ Swingnose crossings will not operate properly when there are obstructions or a
build up of material between the point and wing rails. Check that no spillage of
coal, ballast or other product has occurred. All spillage should be removed.
∼ Visibly worn or broken switch noses.
∼ Any arris, notching or cracking on the foot of 53kg/m switches from 1.5m to 3m
back from the tip.
Broken switches can arise from wear on the inside of the switch. The inside of
the switch becomes ragged and notched. The most likely evidence of failure
will be signs of a crack running along the foot and up the web (see Figure 14).
There may be grease on the foot but any cracking on the web should be visible.
The head of the rail will be the last part of the rail to fail.
Particular focus needs to be directed at switches which are heavily used.
Switches that are subject to high lateral loads are more likely to suffer from this
defect. High lateral loads will arise from a well used turnout road or where the
main line switch is on a curve.
This defect condition does not affect 60kg/m switches of either conventional or
undercut design.

© Rail Corporation Page 82 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Defect originating from Rusted area shows

worn notched edge on the where crack has been
inside of the switch present prior to failure

Figure 14 – Switch defect

∼ Switches laying open or pumping heels.

∼ Defective fastenings including chairs, studs or bolts.
NOTE: When undertaking patrol on Ancilary Lines adjacent to main line tracks
on which the Extended Walking Track Patrol regime is operating, inspect any
mainline turnouts that connect to the Ancillary line for loose or broken chairs
and fasteners.
∼ Cracked/broken crossings or checkrails.
∼ Loose/broken crossing or checkrail bolts.
Examine fastenings between raised check rail and the supporting chairs
∼ Damaged crossing nose.
∼ Signs that gauge at crossing is incorrect.
11. Check ballast condition. Look for:
∼ Fouled ballast.
∼ Obvious ballast deficiencies.
12. Check all piped drainage, sump covers, grates, surface drains and inlets of
waterways when visible from the four foot. Look for:
∼ Obviously ineffective drainage.
∼ Evidence of boggy track or locations where water pools.
∼ Blocked culverts or waterways.
∼ Any water ponding in drains.
∼ Any sediment, debris or weeds blocking waterways or inlets to waterways.
∼ Sump cover and grates not in position.
∼ Blocked grates.
∼ Any evidence of track formation, cutting or embankment failure, such as earth
movement, track subsidence or ground cracks.
13. Examine permanent and temporary speed signs. Check that:
∼ Signs are in place, facing the right direction, not obscured by trees, dirt, graffiti
etc.

© Rail Corporation Page 83 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Temporary speed signs are correctly placed before and after the location they
are protecting, have the correct plates in the right order, that the lights are
working and that the signs are standing securely.
14. Check for breaches of fencing, unsecured gates or signs of unauthorised access.
15. Check Level Crossings for major misalignment in panel levels i.e. panel or corner of
panel sitting obviously high. (Note – Defect Limits and Responses for Level
Crossings are documented in TMC 521 – Level Crossing Manual.)

16. Examine the condition of track magnets (where fitted). Note that this examination is
not required on every Patrol
∼ Check Trip gear signage is present and legible.
∼ Check that the complete set of magnets is present on each track.
∼ Arrange replacement of defective signage.
∼ Arrange replacement of missing/damaged magnets.
If any magnets or signs are missing or damaged, they should be identified on the
diagram provided in TMC 231 and reported to the Team Manager for replacement
within 24 hours.

WARNING
A magnetic field occurs around these magnets. Bringing electronic watches or
equipment (Laptops, etc), credit cards/passes etc with magnetic strips to within
300mm of the magnets will result in the data being destroyed irrespective of the
exposure time.
Remove wallets, watches etc before working with the magnets
Staff with pacemakers MUST NOT place pacemakers any closer than 500mm
metres to this equipment.
DO NOT place hearing aids within 125mm of the magnet.

17. Check for ineffective safety barriers.

18. Check for damage to equipment including that of other disciplines.
Pay special attention to the following issues in preparation for and during the Summer
period. Track problems can affect the reliability of Signalling equipment in the summer
period. Problems arise from the movement of steel in the hot weather, from summer
storms and even from ballasting work carried out for WTSA.

1. Anchoring
Anchoring of turnouts and special trackwork is important to prevent the movement of
steel especially where there are non-elastic fastenings. Catchpoint areas are
particularly vulnerable. Anchoring is required within and adjacent to turnouts and
special trackwork. Additional anchors should be considered to prevent movement of
steel.
2. Bolts in Turnouts
Chair bolts must be tight in the switch area of turnouts to resist longitudinal
movement of steelwork (as well as lateral movement and to prevent breakage).
3. Insulated Joint Gap and Clips
Make sure that small movements of the rail are not going to cause shorting, either
from clips too close to fishbolts or from the joint gap where there is rail end flow.
4. Switch Movement and Flow
Check that rail flow on the stockrail will not affect switch or stockrail movement in the
heat. Remove stockrail flow for at least 25mm beyond the switch tip.
Check that there is still travel available for the switch before the end of the stockrail

© Rail Corporation Page 84 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

undercut or joggle. At least 25mm beyond the switch tip should be available for
longitudinal movement.
5. New Ballast
Thick layers of new ballast left in the four foot can cause signal failures from
“sagging track” especially if heavily contaminated with fine dust. New ballast should
be ploughed off. If this can't be done check with signal staff as to whether the track
section involved is sensitive to sagging.
Make sure ballast laid out does not foul signalling equipment especially at points and
trainstops). Also make sure hopper doors are fully shut, not just at the conclusion of
the work but if any turnouts are traversed between ballasting locations. Check point
areas if any spillage is suspected. After possession work, inspect point areas that
could be affected by ballasting work (including with off-track plant).
6. Drainage
Poor drainage can affect turnouts and special trackwork (from pumping track) and
open track where “track sagging” can result. Signal staff can identify vulnerable
locations. Check for evidence of boggy track or locations where water pools. Note
that flogging heels on heeled switches is an area of particular vulnerability.
During colder weather be on the lookout for
− Curve pull-ins & affect on clearances and on OHW in electrified areas.
− Broken bolts in turnouts.
− Insulated joint problems including broken or bent bolts, broken plates or bonding
glue cracking and breaking away from the rail at glued insulated joints.

C7-3.2 Actions
1. Tick the method of patrol and record all examination results on Form 2 "Examination
of Length".
2. Assess any defects found or investigated during a track patrol according to the
"Limits and Responses" tables in Chapter 5. The following are typical actions:
∼ Take appropriate protective action if defects require immediate action, OR
∼ Repair the defect personally.
∼ Include repair action in a work program.
∼ Report the fault to the Team Leader or Team Manager as appropriate.
∼ Monitor the fault during future examinations until further deterioration requires
action.
3. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report".

C7-4 Engine Patrol Procedures

C7-4.1 During the Engine Patrol
The primary purpose of patrol by engine is to identify critical hazards or potentially critical
hazards requiring attention in the short term (those that could cause problems before the
next similar patrol). A secondary purpose is to identify lower priorities that can be
reviewed in more detail in the walking patrol.

The detection of defects from an engine will be more successful if you:

− Focus on critical hazards. i.e. don’t direct attention to low priority matters such as
excess ballast.
− Direct your attention to hazards appropriate to the infrastructure being traversed. e.g.
at crossings look out for badly damaged nose and listen/feel for bad thump.

© Rail Corporation Page 85 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

− Use a variety of senses. e.g. listen for wheels thumping over rail irregularities, the
worse it is the bigger the thump.
− Consider environmental, seasonal and traffic factors. e.g. after high wind there may
be rubbish on track or trees leaning over.
− Bear in mind track history. e.g. look out for known bogholes..
− BE AWARE that some hazards are more critical in some locations than others.
Broken rails and broken joints are more critical in areas with single rail traction return
sections and sections without track circuits than they are in sections in which both
rails carry signal circuits (the circuits will detect broken rails).
Details of each hazard are shown in Table 7.

ENGINE PATROL - HAZARD DETECTION - Where and what to look for

No Hazard Condition/ Detection Comments/ Examples
Location
1. Obstruction to Platforms Visual Appears too close
vehicle
Noise noise of scraping
New work Visual Unstable material or
leaning structures
General Visual/Noise Object strikes train
2. Obstruction to Turnouts Visual Objects in flangeway
wheels
Noise Wheel impact noise
Level Crossing Visual Objects/material in
flangeway
Noise Wheel impact noise
New work Visual Soil, ballast or rocks
Noise Wheel impact noise
3. Train trip General Ride Train trips
4. Broken rail Turnout Visual Visible gap in rail
Noise Impact noise
5. Broken joint Glued joint Visual Visible gap in rail
Noise Impact noise
6. Broken joint Mechanical joint Visual Large gap in rail
or breakaway
Noise Impact noise
7. Loose bolts Crossing or joint. Noise Jingling of loose bolts
8. Track Turnouts Visual Discoloured ballast
geometry
Ride Train dips
Top
General Visual Discoloured ballast
Ride Train dips
Bridge ends Visual ramp at bridge
Ride Train lifts or drops
ULXs Visual Trenching
Ride Train dips
9. Track Turnouts Visual Elbow apparent
geometry
Ride Train jerks
Line
General Visual Elbow apparent
Ride Train jerks

© Rail Corporation Page 86 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

ENGINE PATROL - HAZARD DETECTION - Where and what to look for

No Hazard Condition/ Detection Comments/ Examples
Location
10. Track Excavations Visual Undermining one rail
geometry
Ride Train lurches
Twist/super
General Visual Discoloured ballast
Ride Train lurches
11. Track Boghole Visual Pumping mud evident
geometry
Ride Dip or lurch
Rapid
deterioration
12. Support Excavations Visual Ballast or bank
deficiencies undermined
Ride Dip or lurch
Bridges Visual Obvious dip
Ride Dip or lurch
13. Misalignment. Hot weather Visual Heat wriggle
Ride Lurch
14. Flooding Rain Visual Large scale ponding at
major drainage structures
15. Speed boards Speed boards Visual Boards correctly located
and fitted out
16. Trespassers General Visual Unauthorised persons
Table 7 - Engine Patrol Hazard Detection

C7-4.2 During Walking Patrol

In view of the restrictions in terms of the detail that can be inspected by engine you need
to place additional emphasis during the walking inspection on those hazards not easily
detected by engine. These include:

Plain Track
− cracking of rails and joint plates
− foul joints
− missing or loose bolts
− wheel scale or debris that could cause short circuit of insulated joints
− small wheelburns or squats
− defective ties
− ineffective rail fastenings or other conditions which could cause wide gauge
− small scale track support deficiencies
Turnouts
− obstructions in points, crossings or flangeways
− damaged or open switches or pumping heels
− defective fastenings including chairs, studs or bolts
− cracked, broken crossings or checkrails
− damaged crossing nose
− loose bolts

© Rail Corporation Page 87 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

− gauge at crossing
Right of Way
− damaged fencing or unsecured gates
− signs of unauthorised access

C7-4.3 Actions
1. Tick the method of patrol and record all examination results on Form 2 "Examination
of Length".
2. Assess any defects found or investigated during an Engine Patrol according to the
"Limits and Responses" tables in Chapter 5. The following are typical actions:
∼ Take appropriate protective action if defects require immediate action, OR
∼ Repair the defect personally.
∼ Include repair action in a work program.
∼ Report the fault to the Team Leader or Team Manager as appropriate.
∼ Monitor the fault during future examinations until further deterioration requires
action.
3. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report".

C7-5 Mechanised Track Patrol Procedure

Mechanised Track Patrol utilises a Special Patrol Vehicle (SPV) to conduct a front of
Engine examination while also recording track imagery and a detailed review of the
recorded imagery.

Carry out the Mechanised Track Patrol in accordance with the attached guidelines.

Mechanised Track Patrol involves two specific activities.

C7-5.1 Engine Patrol

1. Conduct Engine Patrol from the SPV using the Engine Patrol procedure in Section
C7-4.
2. Nominate, if required, any locations requiring review immediately after the recording.
These must then be reviewed immediately (not left until the next day).
3. Record defects as "Points of Interest".

C7-5.2 Detailed Review

1. Get a copy of the “route plan” from the Team Manager which shows the “critical
trackwork” and any “critical locations” to be examined.
Note
Critical trackwork turnouts, diamonds, junctions, catchpoints, expansion switches,
GIJs or mechanical joints and any other special track features.
Note that GIJs in concrete sleepered track that are well supported
and not subject to high impacts such as from end batter may be
exempted from the critical trackwork category.
Critical locations any locations where there are known or suspected track condition
problems such as poor tie condition, outstanding geometry defects,
pumping bridge ends and any locations found on engine patrols
that require more detailed checking.
2. Use several different camera configurations for the review.

© Rail Corporation Page 88 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. Inspect all tracks using the “easement view” at a review speed of no more than
60km/hr.
4. Inspect all tracks using the “track view” at a review speed in line with its configuration
and condition. The speed of the detailed “track view” review over critical trackwork
and any critical locations should be slow enough to enable observation of these
areas in detail to the satisfaction of the patrollers. In any case the speed is to be no
greater than walking pace.
5. Use "Rail View" for all areas of low light where track view is not effective.
6. Review the “rail views” for critical trackwork and any critical locations at a slow
enough speed to enable observation of these areas in detail to the satisfaction of the
patrollers but in any case the speed is to be no greater than walking pace. Use the
“rail views” with particular care to check:
∼ the plates and bolts of mechanical and glued joints,
∼ the condition and fitting of switch tips,
∼ the condition of any heel joints present in switches, and
∼ the condition of crossing noses and bolting.
7. Listen to the recorded sound, where practicable, to check for impact/ loose bolts in:­
∼ mechanical and glued joints,
∼ the switch area,
∼ any heel joints present in switches, and
∼ crossings & checkrails.
8. Review Points of Interest Priority 1 and Priority 2 and any review areas nominated by
the Team Manager at a speed and using the views appropriate for the type of defect
condition.
9. Where available, use Rail Check reports as an aid in identification of defects. These
reports should be produced, if possible at an interval of once per week for each
section of track on those weeks where Mechanised Track Patrol replaces Foot
Patrols. The defect reports are to be made available for viewing in the proceeding
week’s AIMS inspection.

C7-5.3 Actions
1. Arrange supplementary on-site inspections, where required, of any suspect
conditions.
2. Tick the method of patrol and record Engine Patrol examination results on Form 2
"Examination of Length".
3. Tick the method of patrol and record Detail Review on Form 2 "Examination of
Length".
4. If the SPV system fails or does not allow "Points of Interest" to be recorded indicate
this in the “Other Inspections” space on Form 2.
5. Assess any defects found or investigated during a Mechanised Track Patrol
according to the "Limits and Responses" tables in Chapter 5.
6. Arrange protection or correction of any serious safety issues identified during either
the Engine Patrol or the Detailed Review.
7. Complete Detail Review and certification by next day (within 24 hours) or a shorter
period where specified in the Track Recording and Certification timetable. In most
cases certification will be the day after the recording.
8. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report". This is done by the person undertaking Detail Review.
9. If the SPV system fails or does not allow "Points of Interest" to be recorded the

© Rail Corporation Page 89 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

person undertaking the Engine Patrol is to enter the defects noted on the Engine
Patrol into Teams3 or List the defects on Form 2 "Weekly Defect Summary Report".

C7-6 Supplementary Patrol Procedure

Use the procedures for Standard Track Patrol in Section C7-3 with the following
variations:
1. Get a Track Inspection Report from your Team Manager before undertaking the
patrol. The Report lists all defects that should be inspected during the patrol.
2. Limit the inspection to the items being examined.

For Supplementary Patrol of Glued Insulated Joints

1. Examine GIJ visually for broken, bent or loose bolts, worn cracked or broken
fishplates.
2. Examine GIJ visually for adjustment problems, joint pulling apart or closing up,
ineffective anchoring.
3. Examine GIJ visually for failure of glue (in glued joints).
4. Examine track 2m either side of GIJ key for sleeper condition, sleeper spacing and
presence of rail fastenings.

For Supplementary Patrol of Turnouts and Special Trackwork

1. Examine for obstructions to train movements or signalling equipment within (or
potentially within) the structure gauge.
2. Examine for obstructions to the wheel path of the train (e.g. in flangeways).
3. Examine for continuity of rails (i.e. no broken rails or joints or breakaways, or loose
or foul joints).
4. Examine for visual indicators of VSH rail defects.
5. Visually examine crossing for signs of changes in gauge, checkrail effectiveness and
flangeway clearances.
6. Visually examine crossing for condition and security of crossing bolts and wear.
7. Visually examine condition and fit of switches including height, tip profile, width, wear
angle and rail creep and fit of the switches relative to the stockrails.
8. Look for rail flow on the gauge face of the stockrail or obstruction between the switch
and stockrail.
9. Visually examine switch area for condition of stockrails, loose studs, loose or
cracked chairs.
10. Visually examine switch area for condition of heel joints - joint pumping, cracked heel
block, loose or missing heel bolts, fouled heel joint, loose spikes under the heel joint,
overtightened bolts.
11. Examine for visual indications of wheel burns and squats in rails.
12. Examine for untested wire feed welds (flouro pink marking) or new untested thermit
welds.
13. Examine for imminent failures of bearers or track fastenings.
14. Examine for major geometry defects or potential derailment locations.
15. Examine for major deficiencies in supporting track structure (resulting from
earthworks, bridges, structures, culverts, etc.)

For Supplementary Patrol of Plain Track

1. Examine for loss in continuity of rails (i.e. broken rails or joints or breakaways, or
loose or foul joints).

© Rail Corporation Page 90 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

2. Examine for visual indicators of VSH rail defects.

3. Examine for visual indications of wheel burns and squats in rails.
4. During colder weather be on the lookout for:
∼ curve pull-ins and effect on clearances and on OHW in electrified areas,
∼ Insulated joint problems including broken or bent bolts, broken plates or
bonding glue cracking and breaking away from the rail at glued insulated joints.
5. Where centre line marking of curves has been undertaken to identify curve pull-in,
check if the track has moved.
6. Examine for untested wire feed welds (fluoro pink marking) or new untested thermit
welds.
7. Examine for imminent failures of sleepers and track fastenings.
8. Examine for major geometry defects or potential derailment locations.
9. Examine for major deficiencies in supporting track structure (resulting from
earthworks, bridges, structures, culverts, etc.)

C7-6.1 Actions
1. Tick the method of patrol and record all examination results on Form 2 "Examination
of Length".
2. Assess any defects found or investigated during a track patrol according to the
"Limits and Responses" tables in Chapter 5. The following are typical actions:
∼ Take appropriate protective action if defects require immediate action, OR
∼ Repair the defect personally.
∼ Include repair action in a work program.
∼ Report the fault to the Team Leader or Team Manager as appropriate.
∼ Monitor the fault during future examinations until further deterioration requires
action.
3. Attach a signed off copy of the Track Inspection Report to the weekly Form 2
Examination of length.
4. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report".

C7-7 Adjacent Track Patrol Procedures

Use the procedures for Standard Track Patrol in Section C7-3.

C7-8 Night Patrol Procedures

Night patrol is intended to fulfil all of the requirements of daytime track patrol covering
what can be observed in a localised area of the track and limited surrounds.
1. Get the schedule of any known hazard locations outside the immediate area of the
track surrounds from the Civil Maintenance Engineer so that you can direct special
attention to those locations.
2. Use the procedure for Standard Track Patrol in Section C7-3.
3. Carry out a supplementary engine inspection in daylight focussing on hazards not
easily observable on night patrol including:
∼ Long-sight track geometry problems such as long slacks or alignment
problems,
∼ Signage visibility,
∼ Drainage problems including water pooling,

© Rail Corporation Page 91 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Embankments and cuttings,

∼ Right of way issues such as fencing, signs of trespass.

C7-8.1 Actions
1. Tick the method of patrol and record all examination results on Form 2 "Examination
of Length".
2. Assess any defects found or investigated during a Night patrol according to the
"Limits and Responses" tables in Chapter 5. The following are typical actions:
∼ Take appropriate protective action if defects require immediate action, OR
∼ Repair the defect personally.
∼ Include repair action in a work program.
∼ Report the fault to the Team Leader or Team Manager as appropriate.
∼ Monitor the fault during future examinations until further deterioration requires
action.
3. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report".

C7-9 Wet Weather Patrol

1. Examine surface drainage systems for general effectiveness, scouring, rockfalls,
ponding.
2. Examine sub drainage systems for general effectiveness, ponding, outlet blockage,
sumps overflowing, pipe rupture.
3. Examine Track and Right of Way for water on/over track, backing-up behind
embankments fences culverts, undertrack pipes or trash racks.
4. Examine Track and Right of Way for debris obstructing culverts, drains, undertrack
pipes or underbridges.
5. Examine Right of Way for potential slips or mud-slides (including ineffective or
damaged retaining walls).
6. Examine Right of Way for soil erosion/land degradation.
7. Examine Right of Way for silt entering waterways or other drainage systems.
8. Examine tunnel drainage systems for effectiveness.
9. Examine flow control, water energy dissipation systems and sedimentation basins
for effectiveness.

C7-9.1 Actions
1. Record all examination results on Form 2 "Examination of Length".
2. Assess any defects found or investigated during a Wet Weather Patrol according to
the "Limits and Responses" tables in Chapter 5. The following are typical actions:
∼ Take appropriate protective action if defects require immediate action, OR
∼ Repair the defect personally.
∼ Include repair action in a work program.
∼ Report the fault to the Team Leader or Team Manager as appropriate.
∼ Monitor the fault during future examinations until further deterioration requires
action.
3. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report".

© Rail Corporation Page 92 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C7-10 Heat Patrol

C7-10.1 Examination Requirements
1. Carry out a Heat Patrol on all timber sleepered welded track when the AIR
temperature reaches or is forecast to reach 38°C. The purpose of the inspection is
to detect signs of misalignments.
2. Carry out the patrol between 1430 and 1800 hours.
3. Carry out the patrol by walking, Hi-rail, or the front (or back) of trains.
C7-10.2 Examination Procedure
1. Examine Track for possible early indications of misalignment; alignment variations or
kicks.
2. Examine Track for locations where ballast profile is not to standard.
3. Examine Track for "trigger points" for misalignment; poor weld or rail alignment; poor
rail profile matching; straight closures in curves; variations in alignment and gauge;
glued insulated joints.
4. Examine Track for locations where track has been disturbed recently and not noted
on Stability Loss List.
5. Pay particular attention to locations known to have a high loss of stability based on
the Welded Track Stability Analysis.
C7-10.3 Actions
1. If a misalignment is found, make arrangements to immediately protect rail traffic.
2. Record all examination results on Form 2 "Examination of Length".
3. Note all locations where there is any indication of potential misalignment and check
the current Welded Track Stability Analysis.
∼ Report the fault to the Team Leader or Team Manager as appropriate.
∼ Monitor the fault during future examinations until further deterioration requires
action.
4. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report".

© Rail Corporation Page 93 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 8 Front of Train Examination

C8-1 Examination Requirements
1. Front of Train Examination is a non specific examination which assists in the
assessment of track by enabling the reaction of trains to the track structure to be
observed (preferably at the maximum allowable speed).
2. Front of Train Examination is to be carried out from the driver's compartment of the
fastest train over the length, if this is practical.

C8-2 Examination Procedure

This inspection is required to check the riding qualities of all tracks as a guide to more
detailed inspection requirements.
1. Examine Train reaction to track condition that may indicate geometry defects (top,
line, twist, superelevation or support deficiencies associated with earthworks or
bridges.
2. Note any rough or irregular riding of the train. Check these locations during normal
walking inspection.
3. Examine Train reaction to track that may indicate the presence of a broken rail or
fastening.
4. Examine placement, visibility and condition of speed signs, whistle boards and the
like.
5. Check for obstructions to drivers visibility of signals, including trees and other
objects.

C8-3 Action to be Taken

1. Tick the method of patrol and record all examination results on Form 2 "Examination
of Length".
2. Assess any defects found or investigated during a Front of train examination
according to the "Limits and Responses" tables in Chapter 5.
3. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report".

© Rail Corporation Page 94 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 9 Detailed Walking Examination

C9-1 Examination Requirements
1. Detailed walking examination of each track Length is a thorough examination of the
components of the track structure and the right of way to ensure that the
components are satisfactory and contribute to a safe railway.
2. Detailed walking examination may be progressively carried out in conjunction with
Walking Track Patrols, provided the required patrol frequency is maintained.
3. Walking track for the purpose of marking sleepers for renewal, turnout examinations,
examination of welded track stability etc. is additional to the requirements of detailed
examination but may be combined with the Detailed Walking Examination provided
the overall requirements of the Detailed Examinations are not overlooked.

C9-2 Examination Procedure

1. Examine Ties for general condition
∼ Are there any defective sleepers? Why? - old age? spike killed? many broken?
∼ What is the urgency for spot renewal — say within 3 months, 6 months, 12
months — will they last to the next PRS pass?
∼ How is the gauge - wide? How much?
∼ Can the sleepers stand re—adzing or reboring?
∼ Is the sleeper splitting?
∼ Is the spacing correct?
∼ Are the sleepers skewed?
∼ Are the sleepers firmly packed?
∼ Are sleepers pumping because of foul ballast?
∼ Are there sufficient good sleepers in the area to guarantee gauge?
∼ On concrete sleepers are the insulators squeezed out and need replacing?
2. Examine Fastenings for general condition including loose, missing or ineffective
fastenings, rail play and evidence of backcanting, locations listed for wide gauge and
where ballast prevents routine examination of fastenings.
Pandrol plated track is not fit and forget. It requires proper inspection and
maintenance.
Warning signs of developing problems may be missed if the fastenings are covered
with ballast or if staff are not aware of danger signs.
On site warning signs can include:
∼ Signs of plate movement on the timber in any direction.
∼ Broken, missing or bent lockspikes.
∼ The shiny contact band on the top of the high rail locally narrowed towards the
gauge face.
∼ Sharpened curvature.
3. Examine Turnouts for condition and fit of geometry and components including
switches, crossings, bearers, fastenings and manual levers (where fitted).
∼ Is the top and line of the main and turnout tracks satisfactory?
∼ Is the gauge correct?
∼ Is there any longitudinal movement?

© Rail Corporation Page 95 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Is there any side movement of the rails and plates showing?

∼ At switches in interlocked turnouts:
- Does it fit the stockrail?
- Is there overflow on the end?
- Has it chipped off in places?
- Is the point sharp and safe? Or is there a blunt ramp which could cause a
derailment?
- Is the foot of the switch worn on the slide chairs?
- Does the switch ride higher or lower than the stock rail?
- Are all the studs firmly in place? Are they correct?
∼ On heeled switches:
- Is the heel loose? Is it foul? Is it pumping? Is it in line?
- Does the point of the switch rise up under load? (Indicating heel may need
lifting and packing.)
∼ Have you observed the switch moving, was it satisfactory?
∼ Has the local Signal Interlocking Representative requested any work? Has it
been done?
∼ At stockrails
- Are they correct to gauge?
- Are they worn below the switch when it is closed?
- Have they got excessive overflow that will result in the switch tip chipping
out from contact with the overflow?
∼ At V and K Crossings
- Is the flangeway clearance correct?
- Is there overflow on gauge side of flangeway?
- Is the gauge correct?
- Is the distance from the checkrail to the crossing nose correct?
- Is the crossing worn? How much?
- Is it saddled or broken?
- Is it correctly packed?
- Is it drained correctly?
- Are the timbers sound? Are they pumping?
- Is the checkrail loose? Clearance?
- Are all bolts tight?
- Has it been built up? when?
- Is it correct hand? Right or left hand point rail?
∼ In General
- What type of chairs?
- Are they cracked or broken?
- Are they worn on top?
- Do they need replacement?
- Are the closure rails securely spiked and correct to gauge?
- Are the bearers in need of renewal? Which ones and length?
- Is the ballast sufficient? If not how much is needed?
- Is the ballast clean?
- Is top and line good through the turnout and on the approaches?
- Are there any insulated joints? If so are they in good order?

© Rail Corporation Page 96 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

- Are normal joints in good order?

- Is the whole turnout welded up? If not should it be welded up?
- Is there an anchor point at each end of turnouts?
4. Examine Track at Friction Buffer Stops.
∼ Has the buffer moved?
∼ Is the slide path clear of ballast and obstacles
5. Examine Level Crossings for geometry, fit and condition of ties, fastenings,
flangeways and crossing surface.
∼ Are level crossing signs okay? Can they be clearly seen by approaching traffic?
In addition look for the following in accordance with TMC 521 – Level Crossings
∼ Visible signs of differential levels in crossing surface between adjacent panels,
or between panels and rail head level or adjacent road surface level
∼ Gaps between panels
∼ Loose end restraint fastenings.
6. Examine Rails for fit, condition and adjustment, rail joints, insulated joints,
lubricators, rail wear, wheel burns and other visible defects and condition of guard
rails (where fitted).
∼ Is there sign of gauge face damage? If so what is the age of the rail and the
section?
∼ Any wheel burns or squats?
∼ Any visible cracks?
∼ Is the rail back-canted?
∼ Is there any pitting of the surfaces - particularly in the fillets under the head? - or
the fillets between web and flange?
∼ Are there visual indicators or VSH rail defects, including flattening out of the rail
head and widening of the shiny portion of the rail (the contact band), or rust
stains down the web?
∼ Is rail wear approaching the limit?
∼ Are there any corrugations?
∼ Are there any signs of surface defects that will need corrective grinding?
∼ check for oxy nicks or molten metal on the rail foot from recent rail bond
welding. Surface damage from rail bond molten metal can be ground out taking
a minimum of 0.5mm below any visible damage. If the rail is oxy nicked it must
be welded out.
∼ Is the rail working between the spikes?
∼ Is the sleeper plate working?
∼ Are the welds in good condition?
∼ Are lubricators working efficiently?
∼ What is the urgency of renewal?
7. Rail Ends
∼ Is there any end-flow?
∼ Is the end battered and/or chipped?
∼ Are bolts loose? Why? Is it because of wear or poor washers?
∼ Are the joint sleepers packed well?
∼ Is the joint in good line and level?

© Rail Corporation Page 97 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Is it adequately drained?
∼ Is it anchored correctly?
∼ Is it in adjustment?
∼ What should be done to improve it?
∼ Are the bolts bent or worn?
∼ Are the spring washers effective?
∼ Is the joint frozen?
∼ Is the rail end bent down?
∼ Are the rails pulling?
∼ Is adjustment necessary?
∼ Is the expansion gap correct? If not, is it tight or wide?
∼ Are the anchors effective?
∼ Are anchors correctly fitted?
∼ Are the sleepers sound?
∼ Have the sleepers moved in the ballast?
∼ Is the sleeper pattern correct?
∼ Is the ballast sufficient?
∼ Is it clean and sharp, or foul?
8. Rail Lubricators
∼ Are the lubricators working properly?
∼ Is there too much grease being pumped out?
∼ Are the lubricator mountings loose?
∼ Is there obvious damage, bent/broken blades?
∼ Is the lubricator delivering grease to the rail head only?
∼ Does the lubricator deliver excessive grease to the rail head?
∼ Are insufficient amounts of grease deposited around gauge faces of outer rails
on curves?
∼ Does the tank need filling?
∼ Are there signs of excessive curve wear; shiny wear marks on the gauge face
and/or steel shavings along the rail foot indicating insufficient lubrication?
∼ Are more lubricators required or do the existing ones need replacing?
9. Examine Drainage for condition including cess drains (particularly in cuttings) and
tunnel drainage systems (where applicable).
∼ Are the cesses clean? Are they adequate?
∼ Are mitre drains clean?
∼ Are top cutting drains clean?
∼ Are cross drains clean?
∼ Any sign of silting or overflow?
∼ Are inlets and outlets of culverts clean?
∼ Is the culvert broken?
∼ Is there any water pooling near toe of embankments?
∼ Is there any stagnant water on the tracks?

© Rail Corporation Page 98 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Is there water running from buildings, roads or gutters? Is it from outside

property?
∼ If so have you investigated and reported it?
∼ Are drainage sumps silted up?
∼ Are the sumps too high? Is water backed up in cesses?
10. Examine Earthworks for condition (particularly in slip sensitive areas). Refer to
Engineering Manual TMC 404- Recognising Geotechnical Problems for guidance.
∼ Are any cutting faces slipping?
∼ Are there any new rockfalls in cesses?
∼ Is any embankment moving? Are there any cracks in the ground?
11. Examine Ballast for condition and profile including fouled ballast, pumping or
unstable track and inadequate ballast profiles.
∼ Is it clean?
∼ Is there sufficient crib and shoulder ballast?
∼ Are turnouts adequately ballasted?
∼ Where is ballast required? (Give kilometrage from and to and quantity?)
∼ Should shoulders be removed and replaced with new ballast?
∼ Should the six-foot be removed and new ballast supplied?
∼ Does the drainage require attending to before ordering new ballast?
12. Examine Right of Way. Look for:
∼ Condition of fencing and gates.
∼ Evidence of vermin.
∼ Evidence of rubbish or redundant material.
∼ Firebreak condition, fire hazard control.
∼ Access roads.
∼ Vegetation fouling or with the potential to foul the track.
∼ Undermining of track or structures.
∼ Condition of access roads - effectiveness of roadway drainage, erosion and
scours, condition of under-road pipes and culverts, vegetation encroachment
and other possible obstructions.
∼ Evidence of noxious plants.
∼ Fire hazards.
∼ Vegetation restricting sighting distances at signals and level crossings, and
trees or shrubs with potential for dislodging material and/or obstructing the
track.
∼ Evidence of unauthorised or uncontrolled access through fencing or gates ­
opportunities for stock to gain access, damaged, corroded, loose or missing
fence panels or components, security at gates; locks, chains and hinges, gates
left open.
∼ Examine condition of insulating fence panels in fences (where fitted).
∼ Examine condition and function of swing-back netting on fences (where fitted).
∼ Examine condition of fence signage (where fitted).

© Rail Corporation Page 99 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

13. Examine Permanent and Temporary Speed Signs and other trackside safety
signs for visibility, security and clearances, including:
∼ Condition of painted surfaces or protective coatings, cleanliness and visibility of
the sign and condition of indicator lamps and batteries (where fitted).
∼ Integrity of the sign mountings, mechanical connections and fastenings or
corrosion of metal components.
∼ Where RailCorp boundary signs exist, examine them for position, security and
visibility. If there is any doubt as to the position of the sign it should be
resurveyed. If there are visible track defects immediately adjacent to the sign
the position of the boundary should be confirmed.
14. Examine Permanent Speed Signs for correctness of position, speed shown, track
indicated etc at least once per year.
The current reference to the location of Permanent Speed Signs is RailCorp
Engineering Manual OS 001 IM “Train Operating Conditions (TOC) Manual”
15. Examine Track geometry
∼ Is there any visual irregularity in the top and line of the track?
∼ Is it in need of attention?
∼ What is the cause, — rail wear? loose fastenings? poor sleepers? poor ballast?
poor drainage? track settling?
∼ Has the cross level been checked with the board?
∼ Are the joints down? If so - why?
∼ Is gauge irregular and causing bad line?
∼ Is top and line poor through turnouts or approaches to them?
∼ What needs to be done immediately?
∼ Is the line poor at the joints? If so - why?
∼ Can it wait until the next tamping program?
16. Monitor Welded Track Performance and note deficiencies in preparation for
annual Track Stability Analysis.
17. Examine Undertrack Structures for conditions effecting track geometry.
∼ Is the waterway clear?
∼ Is top and line good over the bridge?
∼ What is condition of transoms?
∼ On steel bridges are the bed-plates clear of rubbish?
∼ Is water being trapped in any member?
∼ Is there any sign of extensive scouring or undermining?
∼ Are sleepers in need of packing on bridge approaches?
18. Examine Track Magnets for condition and security (where fitted). Note that this
examination is NOT required on every Detailed Walking Examination.
∼ Check that magnets are undamaged and correctly secured to sleepers.
Condition and installation details are documented in Engineering Manual
TMC 231 - Sleepers & Fastenings.
Examine epoxy mounts on concrete sleepers for cracking or separation.
The magnets are ceramic magnets and like all ceramics they are quite brittle
and will easily break, and suffer a loss of magnetic strength, if they suffer a
strong impact. Any sign of strike damage therefore should be a cause for
concern and possible change-out of the magnet.

© Rail Corporation Page 100 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Arrange replacement or repair of damaged fastenings.

∼ Check signs are undamaged and secure.
If any signs are loose they should be made secure.
If any magnets or signs are missing or damaged, they should be identified on
the diagram provided in TMC 231 and reported to the Team Manager for
replacement.
Repairs or replacements are required within 24 hours.

WARNING
A magnetic field occurs around these magnets. Bringing electronic watches or
equipment (Laptops, etc), credit cards/passes etc with magnetic strips to within
300mm of the magnets will result in the data being destroyed irrespective of the
exposure time. Exposures in the 300mm to 600mm range from the magnets will not
result in the data being immediately destroyed, but should also be avoided.
Remove wallets, watches etc before working with the magnets
Staff with pacemakers MUST NOT place pacemakers any closer than 500mm
metres to this equipment.
DO NOT place hearing aids within 125mm of the magnet.

19. Housekeeping
∼ Is there good material about?
∼ Is there re-useable material about? scrap material?
∼ Has all released material been sorted, or is it lying covered with grass?
∼ Is the released material ready for loading?
∼ Are recovered rails correctly branded?
∼ Are there old sleepers about?
∼ Are walkways level?
∼ Is the length tidy?
∼ Are there any tools lying about?
20. New Works
∼ Are there any new works on your section that affect the track? If so, do you
know what they are and who is doing them?
∼ If new work has recently started, is it properly protected?
∼ Are there any major repairs being done by other disciplines that could affect the
track or structures? Is the track properly protected?
21. Track Evaluation Car Reports
∼ Have identified defects been satisfactorily corrected?
∼ What was the cause of the defects?
∼ Will the defect re-occur?
∼ Is any long term action required?

C9-3 Action to be Taken

1. Tick the method of patrol and record all examination results on Form 2 "Examination
of Length".
2. Assess any defects found or investigated during a detailed walking examination
according to the "Limits and Responses" tables in Chapter 5. At Level Crossings
Limits and Resonses are found in TMC 521.

© Rail Corporation Page 101 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. Action any defects found. The following are typical actions:

∼ Take appropriate protective action if defects require immediate action, OR
∼ Repair the defect personally.
∼ Include repair action in a work program.
∼ Report the fault to the Team Leader or Team Manager as appropriate.
∼ Monitor the fault during future examinations until further deterioration requires
action.
4. Enter ALL track defects found into Teams3 or List the defects on Form 2 "Weekly
Defect Summary Report".

© Rail Corporation Page 102 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 10 Post Irregularity Examination

This examination is a detailed visual examination of track and right of way conducted
where there has been a derailment, accident or some other irregular event and there is a
concern that the track may be damaged.

Its purpose is to assess condition and certify the track fit for operation.

C10-1 Examination Procedure

1. Examine Ties and Fastenings for damage including:
∼ Ties for broken or split ties, back-canting, rail play.
∼ Broken or missing rail clips.
∼ Broken or missing dogspikes, lockspikes or anchors.
2. Examine Turnouts for:
∼ Debris or obstructions in switches or crossings.
∼ Loose or broken chairs, studs and bolts.
∼ Damaged switches, checkrails, crossings or bearers.
∼ Damaged point lever or interlocking equipment.
3. Examine Rails, Guard Rails and Joints for:
∼ Cracked/broken, notched, bruised or crippled rail.
∼ Cracked, bent or broken fishplates.
∼ Bent or broken bolts.
∼ Damaged joint insulation.
4. Examine Track for debris or obstructions and damage to:
∼ Structures; bridges, culverts, tunnels, etc.
∼ Rail lubricators.
∼ Fencing.
∼ Drainage systems.
5. Examine Ballast for:
∼ Profile deficiencies.
∼ Disturbance/track stability loss.
6. Examine Track Geometry for top, line, gauge, superelevation and twist defects.
7. Examine Track for:
∼ Reduced clearance to structures, platforms, tracks.
∼ Relationship to overhead wiring (where applicable).

C10-2 Action to be Taken

1. Repair defects (where time and resources are available) or report/arrange corrective
action.
2. Certify track safe for train operations.

© Rail Corporation Page 103 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 11 Siding Inspection

Sidings are examined to meet the requirements of ESC 100 - Civil Technical
Maintenance Plan.

Some inspections are identical to inspections conducted on mainline track. For other
inspections the procedures vary. Where nominated in the TMP and accompanying
Service Schedules, undertake the Siding inspections by following the procedures detailed
below.

Note that where private sidings are involved there is still a section of track maintained by
RailCorp between the privately maintained section and the main line that needs to be
considered as per the relevant interface agreements.

C11-1 Track Patrol in Sidings

Patrol track in sidings in accordance with the procedures in Section C7-3.

Make sure that sleepers and fastenings are visible. Check whether gauge is secure.
Other irregularities of importance include the condition of joints and track geometry
irregularities, especially track twist.

C11-2 Detailed Walking Examination of Plain Track in Sidings

1. Visually inspect plain track to detect indications of:
∼ wide gauge;
∼ top defects;
∼ alignment defects;
∼ track centre or track clearance defects;
∼ ballast deficiencies;
∼ drainage deficiencies.
2. Where geometry defects are suspected, take measurements using the procedures in
Chapter 4.
3. Where visual inspection indicates alignment variation, measure track centre
clearances and clearance to any adjacent structure using the procedures in Chapter
4.
4. Visually inspect plain track for evidence of badly worn rails, foul joints, loose or
broken bolts etc.
5. Examine track at Friction Buffer Stops to check that the buffer has not moved and
that the slide path clear of ballast and obstacles
6. Visually inspect mechanical and insulated joints for condition and effectiveness.
7. Check for broken or ineffective ties, ineffective fastenings, wide gauge, back canted
rails.
Whilst all track fastenings and sleepers should be able to be inspected, it is
particularly important to ensure that any unplated track in critical locations (where
there will be a significant impact on operations) should be kept clear of ballast, dirt or
other material so they can be inspected.
8. Note locations of ballast deficiencies or excesses.
9. Examine Right of Way for condition
Check condition of fencing, vegetation and access roads. Pay special attention to
walkways where shunting staff are required to work.

© Rail Corporation Page 104 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

10. Examine railway signs for condition and security

This includes Permanent Speed signs, Safety signs and Boundary signs.
Where RailCorp boundary signs exist, examine them for position, security and
visibility. If there is any doubt as to the position of the sign it should be resurveyed.
If there are visible track defects immediately adjacent to the sign the position of the
boundary should be confirmed.
11. Examine Permanent Speed signs for correctness of signs (for position, speed
shown, track indicated etc. Note that this examination is not required on every
Detailed Walking Examination.
12. Examine the condition and security of track magnets (where fitted) in accordance
with the procedures in Section C11-7. Note that this examination is not required on
every Detailed Walking Examination.
13. Check condition of siding drainage.
14. Check for scrap or objects fouling track or walkways. etc.

C11-3 Inspection of Turnouts in Sidings

Use the turnout examination procedures in Chapter 23 to examine turnouts in sidings with
the following variations:

1. Visually examine turnouts for switch profile and fit, condition of slide chairs and
studs. Use a switch tip profile gauge to check switches when visible profile
irregularities are detected.
2. Check and adjust, where necessary, manually controlled non-interlocked point
levers.
3. Turnouts that have a crossing rate of 1:8.25, or sharper, should be fitted with switch
pad protectors. Check for signs of wheel flange wear at or near the switch tip. This
will give an indication of severity. If the track in front of the switch is curved the
hazard is elevated. Where this evidence exists, note it for attention.
4. Where a switch pad protector is fitted check of it is worn by inspecting for wheel
flange contact at the switch tip. If there is wheel flange contact on the tip or near to it
the switch pad protector should be replaced (alternatively double sided switch pads
can be rotated if the other side is unworn).

C11-4 Inspection of Clearances in Sidings

Examine clearances to structures in accordance with the procedures in Chapter 4.

C11-5 Inspection of Sleepers in Sidings

Examine the condition of sleepers in accordance with the procedures in Chapter 18.

C11-6 Inspection of Drainage in Sidings

Examine the condition and function of surface and sub-surface drains in accordance with
the procedures in Chapter 24.

This includes open drains, sub surface drainage, pipes and sumps and drainage
structures such as trash racks, sedimentation basins and flow control structures

C11-7 Inspection of Track Magnets

Check Trip gear magnets are correctly secured to sleepers

Examine epoxy mounts on concrete sleepers for cracking or separation.

Arrange replacement or repair of damaged fastenings.

© Rail Corporation Page 105 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

WARNING
A magnetic field occurs around these magnets. Bringing electronic watches or
equipment (Laptops, etc), credit cards/passes etc with magnetic strips to within
300mm of the magnets will result in the data being destroyed irrespective of the
exposure time. Exposures in the 300mm to 600mm range from the magnets will not
result in the data being immediately destroyed, but should also be avoided.
Remove wallets, watches etc before working with the magnets
Staff with pacemakers MUST NOT place pacemakers any closer than 500mm
metres to this equipment.
DO NOT place hearing aids within 125mm of the magnet.

C11-8 Yard and Siding Categories

Four main categories of track have been defined in order to set appropriate examination
and maintenance requirements. These are:

Signalled Track
All turnouts and catchpoints that are interlocked and all rail which passes signalling
current.
− Signalled is intended to refer to main yards. Some minor tracks can be signalled but
still classified at a lesser importance e.g. little used sidings.
Focal Points
Locations at which a number of alternate routes diverge/converge. If not signalled
already, such locations are normally connected to signalled trackwork.
Primary Trackwork
All the areas of the yard where rollingstock passes over regularly.
Secondary Trackwork
Non-critical areas of track infrequently used.

C11-9 Siding Maintenance Requirements

Sidings should be programmed for maintenance or renewal so that track component
condition can be maintained in the condition detailed in Table 8, the track geometry limits
in TMC211 and turnout limits in TMC251.

Siding maintenance requirements

Asset Signalled Focal Points Primary Secondary
Plain Track Defects
Bogholes No bogholes, no pumping track Minor only
allowed
Pumping joints No pumping joints Minor pumping
only allowed
Pumping Heels No pumping heels
Pooling water No pooling water Must not remain
24hrs after rain
Cleanliness & No ballast or material on fastenings, No ballast or Granular, only
corrosion rail foot or sleepers material on permissible if ties/
fastenings, rail foot fastenings
or sleepers except examined 24
LXings monthly
Insulation to earth Not shorted to earthed metalwork
Foul Joint NA ≤ 3mm ≤ 3mm

© Rail Corporation Page 106 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Siding maintenance requirements

Asset Signalled Focal Points Primary Secondary
Crossings
Nose Nose & wings to standard ie build up as required OK as long as
safe
Fabrication Worn chocks & rivets not permissible OK as long as
safe
Plating (turnouts & plain track)
General No non-standard plating Non-standard
plating
permissible if
functionally OK
Oxy-cut No oxycut rails or plates
Slotted Plates No slotted plates Machine slotted
plates only
Inserts No inserts Temporary inserts
only
Switches
Switches Square within NA
8mm
Switch rod bolts Bolts tight
Switch rods Not worn bent or damaged OK if not critical
Insulted Joints
Insulated Joint Gap ≥ 3mm Gap (including potential NA
expansion)
Insulated Joint No contact must be able to arise NA
fouling by even if rail moves longitudinally by
fastenings 10mm
Walkways Clean level even and dry
Table 8 – Siding Maintenance Standards

C11-10 Action to be Taken

1. Record all details on Form 2 "Examination of Length.
2. Assess any defects found or investigated during a Siding examination according to
the "Limits and Responses" table in TMC203 C5-15. When other defects are located
in sidings and are not listed in the siding section in C5-15, Chapter 5 mainline limits
in the 20 kph speed band can be used as a guideline
3. List the defects on Form 2 – " Weekly Defect Summary Report."

© Rail Corporation Page 107 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 12 Track Stability Measurement

This chapter details procedures for the examination of rail adjustment and alignment for
welded track, along with ballast profile and anchors. The results of these examinations
are recorded in the field and later used to calculate the stability of welded track by using
Welded Track Stability Analysis.

The examination is necessary to enable calculations to be made to identify locations of

potential track misalignment and to allow corrective work to be undertaken.

C12-1 Special Infrastructure Situations

Reduced requirements for WTSA measurement and analysis apply at the following
locations.
− Tunnels – no WTSA review is required for track more than 50m inside a tunnel.
− Fixed Track – slab track or transom top bridges - no WTSA review of the fixed track
is required (though the interface with timber could cause a fixed point analysis
requirement).
− Expansion Switches - provide a point of relief for track adjustment variations. If
immediately abutting dogspiked track they can be treated as a joint. On elastic
fastened track they can provide relief from consideration of a fixed point if they occur
at the interface.
− Slow speed loops and refuges - reduced WTSA inspection requirements may be
applied to existing loops and refuges meeting the following requirements:
∼ The Civil Maintenance Engineer must approve each location for which the full
WTSA is to be waived. This is to ensure there are no local peculiarities that
require special consideration.
∼ Loops must be visually inspected and assessed at the same time as the pre-
summer WTSA analysis, and defects prioritised. The basis for the assessment
is provided Section C12-11.
∼ Maximum authorised speed in the loop must be 35 kph or less.

C12-2 Preparation for Measurement

1. Conduct a visual inspection prior to gap measurement to ensure joints are working.
Repair any frozen joints.
2. Check the visibility and condition of survey monuments and plaques. They must be
kept free of ballast and visible at all times for checking purposes. If monuments are
damaged or it is suspected that they have moved or are unreliable, report the matter
so that a check survey can be made by surveyors.

C12-3 Measurement Procedure

1. Carry out the inspections on 500m sections of track, between kilometre and half­
kilometre posts.
2. Record inspection details on Form WTSA 1 when the analysis is completed
manually, and on Form WTSA 2 when computer analysis is to be used.

C12-4 Measuring Rail Gaps

1. Measure the rail temperature at each 500m (kilometre and 0.5 kilometre post) along
the track.
Ensure your rail thermometer is accurate. They should be calibrated annually.
Place the rail thermometer on the shady side of the rail web.

© Rail Corporation Page 108 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

2. Record the temperature reading and kilometrage on the form.

More than one temperature reading may be required if part of the rail is shaded or in
a cutting, to give an average temperature for the rail length.
3. Measure gaps at ALL rail joints for the up and down rails, including mechanical
insulated joints (end post not to be counted as part of gap). DO NOT measure glued
insulated joints or joints within a turnout.
4. The following are non standard track configurations and cannot be measured as
LWR.

Extract from RailCorp Standard ESC 220.

− Rails longer than 220m
− Rails longer than 27.4m with resilient fastenings more than 1 in 3 (unless the
rails have been correctly adjusted in accordance with requirements for CWR)

5. Record gap measurement and kilometrage on the form for each of the Up and Down
rails separately.

C12-4.1 Advice on Gap Measurement

Problems often arise in the measurement of rail gaps, which can, if left uncorrected, give
wrong assessments. Use the following tips to minimise these problems.

C12-4.1.1 Suitable Temperatures

0
In general, 25-35 C is the most suitable range for Gap measurements. This is based on
the normal temperature range of theoretically correct gap measurements, which should
vary between 0 and 12mm.

C12-4.1.2 Large Gaps (>20mm)

Gap gauge goes up to 20mm and bent bolts in joint can increase the size of the gap. If
gaps are larger than 20mm, re-measure the full 500m section at a higher rail
temperature, when the rail gap has reduced by at least 2mm from the original reading.

C12-4.1.3 Zero Gaps

Re-measure the full 500m section at a lower rail temperature, when a minimum gap of
0
2mm occurs. If the rail temperature has cooled by 10 C or more, and there is still no gap,
make arrangements to adjust locally and record measurements. This will correct local rail
compression, which could otherwise result in a misalignment.

C12-4.1.4 Frozen Joints

If a frozen joint is suspected, repeat rail gap measurement at different temperatures to
assess joint movement.

WARNING
0
Zero gaps at rail temperatures less than 35 C are an indication of excess
compressive stress, poor rail adjustment and potential misalignment

C12-5 Measuring Rail Adjustment in CWR

Record the adjustment of CWR using two main indicators:
1. Measurement of rail creep at each creep control reference point.
2. Measurement of track alignment compared to survey information.

C12-5.1 Measuring Rail Creep:

1. Locate the creep control reference points established on both sides of the track at

© Rail Corporation Page 109 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

the km and 0.5km posts or at other locations such as OHW stanchions. If the marks
vary from the standard 500m interval, the analysis will remain valid as long as it is
conducted using the actual distance between measuring points rather than the
default 500m.
2. The maximum length between creep control marks shall be 700m unless approved
by the Chief Engineer Track
3. Record the kilometrage of the creep control reference point (or check the accuracy
of the recorded kilometrage.
4. Locate the punch marks on the outside heads of both rails.
Areas that have been adjusted could have two creep measurements. (one each side
of each creep peg)
Ensure string line is pulled tight and is not “blowing in the wind.”
Ensure string line is not caught on rail, ballast shoulder or any other obstruction
Measure and record the amount of rail creep for each rail on the appropriate form.
Always fill out the form in the down direction, ie. with the Sydney end at the top of
the page.
5. The following are non standard track configurations and cannot be measured as
CWR.

Extract from RailCorp Standard ESC 220.

− Rails longer than 220m which have not been adjusted
− Rails longer than 220m with no creep marks or pegs
− Rails longer than 220m with no alignment information available.

6. On the recording sheet, indicate any rail movement with an arrow pointing UP the
page if the creep is toward Sydney, and DOWN the page if the creep is away from
Sydney.

C12-5.2 Damaged or Missing Creep Pegs/Marks

Damaged or missing creep pegs are useless and must not be used. We are generally
measuring fairly small values of creep so if a creep peg is loose or has been moved only
20mm this is fairly significant.

Report damaged pegs to the Civil Maintenance Engineer for replacement.

For this analysis you should use the greater of 20mm on each rail or the historic rail creep
from previous records.

Damaged pegs should be recorded as Priority 1 defect and fixed immediately when
observed throughout the year and noted for future WTSA reference and/or correction.

© Rail Corporation Page 110 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Recording Tangent Creep (Double Punch Marks)

Sheet shows prior to re-adjustment

Creep Pegs or 0 To 10 String Line

Mast Sydney

0 35 0 10 0
35

Measured Creep
Direction of Creep is indicated by an arrow

Punch marks

Left figure is the Sydney Side

Creep and is measured on
40
Sydney side of Creep peg or mast 20

20 15 40 5
5
15
Down Rail

Right figure is the Country Side

Creep and is measured on Country
side of Creep peg or mast
Up RaiI

500m or selected
creep section

20 20

20 20 20 15
20 15

15
20

To
20 20 20 Country 15 20
20

© Rail Corporation Page 111 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Calculating Amount of Tangent Creep

A - minus figure indicates too much steel & a + plus figure indicates not enough steel

To
Creep Pegs or String Line
Mast Sydney

0 Creep
35 or +35
35mm Creep into section 0mm Creep into or out of section

-15 (+20) - (+35) = -15 (-40) - (0) = -40

20 - 35 = -15 0 - 40 = -40 -40

Creep results Punch marks

20mm Creep out of section 40mm Creep into section

20 or +20 40 or -40

5 or -5
Down Rail

15 or+ 15
15mm Creep into section 5m Creep out of section
Up RaiI

(+20) - (+15) = +5 (+15) - (-5) = +20

+5 20 - 15 = +5 15 + 5 = +20
+20

15 Creep out of section

20mm Creep out of section
20 or +20 15 or +15

20 or +20 20 or +20
20mm Creep into section
20mm Creep into section

(+20) - (+20) = 0 (-15) - (+20) = -35

0 20 - 20 = 0 -15 - 20 = -35
-35

20mm Creep out of section 15mm Creep into section

15 or -15
20 or +20

To
Country

© Rail Corporation Page 112 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C12-5.3 Measuring Track Alignment

1. Measure track alignment every 20m on curves (or as many reference points as
possible, or as determined by the Civil Maintenance Engineer. Measurements
should be no more than 50m apart. No alignment measurement is required on
straights.
Alignment reference points usually consist of:
∼ plaques on platforms, structures, OHWS, or
∼ pegs or pipes in the cess or
∼ monuments in the '6 foot'
When measuring track alignment, ensure:
∼ plumbob is sufficiently heavy to negate any wind.
∼ plumbob is centred directly above the reference mark and not touching it in any
way.
∼ do NOT sit the plumbob in pipe and hold string up.
∼ the tape or measuring bar from the rail to the reference mark or plumbob string
is horizontal.
∼ the tape does not touch the ballast or any other obstruction.

WARNING:
DO NOT use metal tapes near live exposed electrical equipment, between rail
and overhead wiring structures or between OHW structures and fencing or
metallic troughing.

2. Record the distance from the running face of the rail to the reference point on the
appropriate form.
3. If the survey alignment figures are known, calculate and record the difference in the
two readings, the "alignment error" on the form.
Enter a positive number if the curve has moved further from its centre (pushed out),
or a negative number if the curve has moved closer to its centre (pulled in).

WARNING:
Be careful when calculating “alignment error” on curves where the reference
marks are in a different position to normal (eg on the outside of the curve).

4. Some track has deliberately been continuously welded "off design line". If this is the
case and the "off line" position at time of adjustment is known and documented then
it can be considered as an "interim design" and is acceptable. This information will
be recorded in the “revised alignment” column on the WTSA form and if present on
the form should be used when calculating “alignment error”.
5. If, for any reason, the alignment cannot be established note this on the form.

C12-5.4 Damaged or Missing Survey Pegs

Do NOT use measurements from survey pegs that are obviously damaged.

Record damaged or missing survey pegs on the field sheets and report them for
replacement.

Measurements should be no more than 50m apart.

If there are insufficient reliable survey pegs around a curve you will have to treat the track
as non-standard.

© Rail Corporation Page 113 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Mast or Survey Mark

Actual Alignment

Design Alignment

2315 2252 –2315= – 63

2252

2315

2315 – 2252 = – 63 2252

Design Alignment

Actual Alignment

The Alignment Error in these cases are negative (–) as the track moved in
towards the centre of the curve

Figure 15

© Rail Corporation Page 114 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Mast or Survey Mark

Design Alignment

Actual Alignment

2315 2315 – 2252 = + 63

2252

2315

2252 – 2315 = + 63 2252

Actual Alignment

Design Alignment

The Alignment Error in these cases are positive (+) as the track moved out
away from the centre of the curve

Figure 16

© Rail Corporation Page 115 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Mast or Survey Mark

Design Alignment

Actual Alignment

2315 2315 – 2252 = + 63

2252

2315

2315 – 2252 = – 63 2252

Design Alignment

Actual Alignment

This figure shows positive (+) and negative (-) Alignment Errors as one track
moved out away from the centre of the curve and the other moved in toward the
centre of the curve.

Figure 17

© Rail Corporation Page 116 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C12-6 Rail Anchor Examination

1. Check the anchor pattern and number and compare this with the following
requirements:

Extract from RailCorp Standard ESC 220.

− Welded track shall meet the following minimum anchoring requirements.
− Double (or box) anchor every fourth sleeper except at mechanical joints
− Double anchor every second sleeper for a distance of 32 sleepers either
side of mechanical joints, starting at the second sleeper from the joint.
− Basic anchoring is to be so that sleepers are anchored on both sides on
each rail (double or box anchor), except for steep grades as detailed
below.
− On track with a falling grade steeper than 1 in 80 in the direction of
traffic, or at other locations where considered necessary to control rail
creep, the anchoring shall be increased by adding single anchoring each
second sleeper (or on every sleeper, if necessary) throughout the
welded rail length, to prevent rail creep.
Insulated Joints in Welded Track
− At mechanical insulated joints EVERY sleeper is to be double anchored
for a distance of 32 sleepers on each side of the joint.
− Glued Insulated Joints are treated as if they were plain track, and
anchored in the same pattern as the track in which they are placed (eg 1
in 4 when laid in 110m rails or CWR, or every 2nd if within 32 sleepers of
a turnout).
Turnouts
− Double anchor every second sleeper for 32 sleepers (ie a total of 16
anchored sleepers) in front of the switch, commencing from the first
sleeper from the switch.
− Double anchor every second sleeper/timber for 32 sleepers/timbers (ie a
total of 16 anchored sleepers/timbers) behind the crossing, commencing
from the first timber after the crossing that has plain track fastenings.
− Double anchor every second timber on the through rails and turnout rails
between the heel of the switch and the front legs of the crossing.
Diamonds
− Double anchor every second sleeper/timber for 32 sleepers/timbers (ie a
total of 16 anchored sleepers/timbers) behind the crossing, commencing
from the first timber after the crossing that has plain track fastenings.
− Double anchor every second timber between the "V" and "K" crossings.
Catchpoints:
− Double anchor the catchpoint rail every second sleeper for 32 sleepers
(ie a total of 16 anchored sleepers) in front of the switch, commencing
from the first sleeper from the switch.
− Double anchor the catchpoint rail every second sleeper/timber for 32
sleepers/timbers (ie a total of 16 anchored sleepers/timbers) behind the
heel commencing from the first timber after the heel that has plain track
fastenings.

© Rail Corporation Page 117 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Extract from RailCorp Standard ESC 220.

Anchoring of Welded Track on Bridges
Steel openings
Transom top openings with spans <18m
− Standard anchoring for welded rails on open track as detailed above shall
be used on welded rails on these bridges.
Transom top openings with spans ≥18m long but < 80m.
− For a distance of 60m from a bridge end, the track shall be double anchored
on every second sleeper.
− On the bridge the track shall be double anchored to every second transom
for half the span length, commencing at the fixed end.
Ballast top steel openings with spans ≥ 4.27m long but <80m
− Standard anchoring for welded rails on ballasted track shall be used on
welded rails on these bridges.
Transom top or Ballast top steel openings with spans ≥80m
− Between expansion switches the rails are to be double anchored to every
fourth transom.
Concrete and masonry openings
For concrete and other track structures an assessment shall be made of the
expansion requirements of the bridge structure as they affect rails.
Concrete structures with spans < 25m
− Standard anchoring for welded rails on open track as detailed in Section
ESC 220 shall be used on welded rails on these structures.

2. Check the fit of anchors tight up against the sides of sleepers.

3. Check the anchor effectiveness. Are they sprung? Remove a few and test their
spring action by driving them back on. Anchors that require little or no effort to
replace have lost their spring and are ineffective.
4. Check for visible signs of rail creep through the anchors. (Look for marks on the rail
flange indicating movement; anchors on one side of sleeper all drifted away from the
sleeper edge; skewed sleepers; wide/tight rail joints).
5. Where resilient fastenings are used, look for evidence to indicate that rails have
'crept' through the sleepers (Look for marks on the rail flange indicating movement).
6. Record the inspection results each 500 metres.
Tick the "OK" column on the manual form (the Yes/No answers on the computer
form) if the anchoring and fastenings for the 500metre section are satisfactory.
Determine and record the percentage not effective, if anchors and fastenings are not
working properly.

© Rail Corporation Page 118 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

These anchors aren't These anchors are tight

doing anything against the sleeper

7. If any defects are identified, record all defects in the 500metre section in the
appropriate column on the manual form, or the Yes/No and Remarks column of the
computer form, using the following example as a guide:

Type of anchor Condition

Resilient Fastening Good
20% ineffective
Fair Type Anchor Good
Incorrect Pattern
Creep Indications
Ineffective/missing

C12-7 Ballast Examination

1. Identify locations where ballast deficiencies exist; even if they are only a few metres
long - this may be where pedestrians or stock regularly cross the line and destroy
the ballast shoulder or it may be damaged by vehicles or perhaps digging for cables.
Single cribs left bare for signal rodding are normally ignored.
2. Estimate and record all deficiencies on the form, showing Crib or Shoulder
deficiencies in Tonnes per 20 metres. Use Table 9 and Table 10 for guidance.
NOTE: WTSA software calculates stability loss from ballast loss in tonnes/20m. It
cannot, however distinguish between timber and concrete sleepers. For the
purposes of establishing stability loss use the t/20m figures on the RIGHT of Table 9
and Table 10. If you are ordering ballast to remove deficiencies use the t/20m
figures on the LEFT of Table 9 and Table 10.
3. For shoulder ballast deficiencies on curves, indicate whether the deficiency is on the
HIGH or LOW rail by writing H or L next to the tonneage figure eg. 5t/20m(H).
4. Provide details in the comments column including location of ballast deficiencies and
action needed for repair (eg regulator, manual boxing up).
5. Note all areas of foul ballast, poor formation. Record these by ticking the FB column
on the form and providing details in the comments column.
NOTE: where severe bog holes occur and the sleepers are being supported by the
rail and not bearing on the ballast underneath or where the ballast around the
sleeper is not in contact with the edge of the sleeper, notation should be made in the
remarks column and the location reported to the Civil Maintenance Engineer who will
arrange for special assessment and appropriate priority.
6. Note all areas of severe white rounded ballast. Record these by ticking the BR
column on the inspection form and provide details in the comments column.
7. Note any pumping bridge end, pumping joints or pumping sleepers. Record these by
ticking the PJ column on the inspection form and provide details in the comments
column.

© Rail Corporation Page 119 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

NOTE: Severely pumping ridge ends are a significant misalignment risk. If bridge
ends or other locations are pumping to the extent that the ballast is offering little
support then this should be noted in the remarks column so that a further 10% can
be added to the stability loss.

SHOULDER - CONCRETE AND TIMBER SLEEPERS For WTSA

For
SOFTWARE
Ordering Input
Ballast

16t/20m Nil each Side 16t/20m

12t/20m Half Shoulder 12t/20m

one side - Nil
other side
8t/20m Half shoulder 8t/20m
both sides

4t/20m Full Shoulder 4t/20m

one side ­
Half other
side
- Full Shoulder -
both sides

Table 9 - Assessment of Shoulder ballast profile Timber and Concrete sleepers

© Rail Corporation Page 120 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

CRIB - TIMBER SLEEPERS For WTSA

For
SOFTWARE
Ordering Input
Ballast

10t/20m Nil in Crib 10t/20m

5t/20m Half Full Crib 5t/20m

- Full Crib -

CRIBS HEAVY DUTY CONCRETE SLEEPERS (Type 5 & 6)

18t/20m Nil in Crib 10t/20m

9t/20m Half Full Crib 5t/20m

- Full Crib -

CRIBS MEDIUM DUTY CONCRETE SLEEPERS

13t/20m Nil in Crib 10t/20m

7t/20m Half Full Crib 5t/20m

- Full Crib -

Table 10 - Assessment of Crib Ballast Profile Timber and Concrete sleepers

C12-8 Misalignment Triggers

1. Record the location of potential misalignment triggers on the measurement form.
These locations may not show up as a priority in the Welded Track Stability analysis
over 500m.
Misalignment triggers include:
∼ Poor Rail/Weld alignment arising from incorrect crowing, rail end alignment,
poor rail profile matching, straight closures in curves, track alignment (including
gauge) glued insulated joints etc. Record by ticking the SA column.
∼ Rail surface including dipped welds, dipped joints. Record by ticking the SA
column.
∼ Multiple wheel burns and corrugations, etc. Record by ticking the RC column.
NOTE If the corrugations are severe to the extent that they are causing
disturbance to the ballast (severe pumping or white rounded ballast) notation
should be made in the comments column so that an extra 10% can be added to
the final stability loss.

© Rail Corporation Page 121 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Rail bunching at fixed points due to changes in fastener, sleeper or rail type,
bridges, turnouts, level crossings or where welds are caught against sleepers
etc. Record in RB column.

Local bunching point - weld is caught

against sleeper - rail cannot move -
sleeper will generally move with rail

∼ Local disturbances due to undertrack crossings, culverts etc.

∼ Ballast pushed up in crib or deficiency behind sleeper.
∼ Anchor points left on.
∼ Curves less than 400m radius. Tight radius curves have a higher misalignment
risk, particularly if they are continuously welded on dogspiked sleepers.
Particular attention must be paid to these locations to correct any track
instability or potential misalignment triggers.
2. During the field inspection make notes in the remarks column where sleeper
skewing, localised ballast pushing by sleepers, irregular sleeper spacing etc., occur.
3. Take special care to note any small timber sleeper panels in concrete sleepers
(including where adjoining timber or concrete tied turnouts).
4. Identify and record locations requiring special assessment including all previous
misalignment sites and Non Standard Welded Track.
Provide details of all misalignment triggers in the comments column.

C12-9 Inspection for Old Welds at Fixed Points

During the WTSA inspection staff should be on the lookout for old aluminothermic welds
within 70m of any bunching point location. The concern is with old welds where there are
suspicions that the “steel in = steel out” process may not have been used. This would not
include welds installed when the rail was laid.

If suspicious old welds have been identified at a bunching point then check adjustment
either by cutting the rail or by using the VERSE system in accordance with the
procedures in Engineering Manual TMC 223 - Rail Adjustment. If adjustment control
records are available for the welds, the adjustment check is not required.

C12-10 Ties and Painted Rails

Show on the form with arrows, type of ties:- C = concrete, T = timber, and if rails are
painted or not.

C12-11 Guidelines for the Assessment of Crossing Loops

Mandatory assessment of Crossing loops MUST include:
1. Check of ballast profile.
2. Check of rail joints (are they working, are gaps reasonable for the temperature).

© Rail Corporation Page 122 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. Check for signs of:

∼ Creep/bunching.
∼ Sleepers bunched up or skewed.
∼ ballast pushed up in cribs or deficiency behind sleepers.
∼ welds jamming on sleepers or sleeper plates.
4. Check for foul ballast or glassy ballast bed.
5. Check for any location where track is severely weakened by disturbance or ballast
condition.
6. Check for pumping sleepers.
7. If track is not jointed then check:
∼ Have there been any stability problems with the loop in the last 3 years. If YES
then loop must be adjusted.
∼ If there has been any welding in the last 12 months, then check that no steel
has been added (Steel in/Steel out). If there are any concerns regarding
adjustment it has to be checked.
∼ Has track been disturbed eg tamping, PRS.
8. Deficiencies identified MUST be assessed and prioritised considering:
∼ Speed of the crossing loop.
∼ Proximity of main line (will loop be foul of main line if it buckles).

© Rail Corporation Page 123 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 13 Welded Track Stability Analysis

The field information gathered in Welded Track Stability measurement is used to
calculate the amount of "lost Track Stability" for each nominal 500m section of welded
track.

Special procedures are included for adjustment analysis of sections less than 500m.

The following analysis can be carried out manually or by computer using the WTSA
program.

Alignment = Radius
Index Length
Diff.
General
Track
T7 Condition

Calculate Curve Track

Alignment Creep Disturbance
Measurements Average Align.
each curve Temp
Error
Total Rail Anchors
CWR Temperature
Error
Inspection

Tangent T8
Creep T6 Ballast
Creep
Measurements Inspection
Temp. Loss
Error of
Track
Stability R
E
Summer
Track Stability
S
Rail Gap Calculate
Measurements Average Rail Length Analysis U
Average Rail Gaps
L
T
LWR T5
T8
Loss
of
Track Location Factors
Actual Rail Theoretical Stability
Rail Curvature
Temperature Measured
Temp. Grade
Measurements Temperature Secondary
Error Crossovers
Bridges Analysis
Train Braking of
Zones Priority
etc Sections

Figure 18 - Welded Track Stability Analysis process

C13-1 Rail Adjustment - Long Welded Rail

The analysis of rail gaps is based on the information gathered in Chapter 12.

For sections of track less than 500m in length replace Steps 1 - 4 below with the steps in
Section C13-1.2.

© Rail Corporation Page 124 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

1. Calculate the average length of rail for each 500metre section from the number of
rail gaps in section.
Example:
For 5 rail gaps - Average rail length is 100m.
For 4 rail gaps - Average rail length is 125m.
2. Calculate the average rail gap for the 500m section by totalling the length of all gaps
and dividing by the number of rail gaps in that section.
Example:
For 4 gaps with total gap measuring 40mm - the average rail gap is 10mm.
For 10 gaps with total gap measuring 36mm - the average rail gap is 3.6mm.
3. Use Table 11 - Jointed Welded Rail - Gap Analysis to determine from the average
rail length and average rail gap what the Theoretical Measured Temperature for that
500 metre section should have been.
Example:
0
Average rail length = 125m From Table 11, Theoretical Measured Temperature is 32 C
Average gap = 10mm
4. Calculate the Rail Temperature Error.
The Rail Temperature Error for the 500m section will be the difference between the
Actual Measured Rail Temperature and the Theoretical Measured Temperature from
Table 11.
Rail Temp Error = Actual Measured Temp - Theoretical Measured Temp.
If the Rail Temperature Error is a minus number then the effective neutral
temperature for the rail has been reduced by poor adjustment. In other words, there
is likely to be an excess of steel.
Example:
0
Actual measured rail temp = 28 C
0
Theoretical temperature = 32 C
−4 C
0
Rail Temperature Error = 28-32 =
0
Effective Neutral Rail Temperature = 35-4 = 31 C
0
(35 C is the design neutral temperature.)

© Rail Corporation Page 125 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

o
Theoretical Measured Temperature ( C)
No. Gaps Average Rail Gap (mm)
/500m
2 3 4 5 6 7 8 9 10 12 15 20 25
33 (15) 44 42 41 38 35 32 29 27 25 20 8 n.a. n.a.
36 (14) 43 42 40 37 35 33 30 27 25 20 10 n.a. n.a.
38 (13) 43 41 40 37 35 33 30 28 26 21 13 n.a. n.a.
42 (12) 42 41 40 37 35 33 30 29 27 22 16 n.a. n.a.
45 (11) 42 41 39 37 35 33 31 29 27 24 18 n.a. n.a.
AVERAGE RAIL LENGTH (m)

50 (10) 42 40 39 37 35 33 31 30 28 25 19 n.a. n.a.

56 (9) 41 40 38 36 35 34 32 30 29 26 21 14 n.a.
63 (8) 40 39 38 36 35 34 32 30 30 27 23 16 9
71 (7) 39 38 37 36 35 34 33 31 30 28 24 18 12
83 (6) 39 38 37 36 35 34 33 32 31 29 26 21 16
100 (5) 38 37 36 36 35 34 34 33 31 30 27 23 19
125 (4) 37 37 36 36 35 34 34 33 32 31 29 26 22
167 (3) 37 37 36 36 35 34 34 33 33 32 30 28 25
250 (2) 37 36 36 35 35 35 34 34 33 32 31 29 27
500 (1) NA
Table 11 - Jointed Welded Rail - Gap Analysis

5. Determine the loss of track stability from the rail temperature error for LWR using
Table 12 - % Loss of Track Stability.
The values for stability loss in Table 12 are derived from the following formulae:
For Jointed Welded Rail (LWR) % Stability Loss = (-3.3368) * Rail
Temperature Error
For Continuous Welded Rail (CWR) % Stability Loss = (-2.5151) * Rail
Temperature Error
For all positive values of rail temperature error (CWR and JWR) % Stability Loss = 0

© Rail Corporation Page 126 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Loss of Track Stability (% of total stability) (based on single rail only)

Rail Jointed Continuou Rail Jointed Continuou
Temperature Welded s Welded Temperatur Welded s Welded
Error Rail Rail e Error Rail Rail
-1 3 2 -16 53 40
-2 7 5 -17 57 43
-3 10 8 -18 60 45
-4 13 10 -19 63 48
-5 17 13 -20 67 50
-6 20 15 -21 70 53
-7 23 18 -22 73 55
-8 27 20 -23 77 58
-9 30 23 -24 80 60
-10 33 25 -25 84 63
-11 37 28 All positive 0 0
values
-12 40 30
-13 43 33
-14 47 35
-15 50 38
Table 12 - % Loss of Track Stability

6. Record this figure on Form WTSA 3 (for manual analysis) as the result for the
500metre section.
Example:
0
For Rail Temp Error of -40 C
Loss of Track Stability is 13%
7. Repeat the process separately for the Up and Down rail. This will give two separate
results. The Combined Loss of Track Stability due to rail adjustment is the sum of
the separate results.
8. Check the comments column of the measurement sheet to ensure that there were
no frozen joints.
If there were any frozen joints, or joints with a zero gap reading, or a gap reading
which shows the joint is fully open and pulling on the bolts, then the correct
adjustment cannot be calculated. Determine stability loss from Table 13 - Influence
of Non Standard or Special Track Conditions.
9. The following are non standard track configurations and cannot be analysed as
LWR. Analyse them as Non Standard track. (see Table 13)

Extract from RailCorp Standard ESC 220.

− Rails longer than 220m with resilient fastenings more than 1 in 3 (unless
the rails have been correctly adjusted in accordance with requirements
for CWR).
− Rails longer than 27.4m with resilient fastenings more than 1 in 3 (unless
the rails have been correctly adjusted in accordance with requirements
for CWR).

© Rail Corporation Page 127 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Condition Stability Loss WTSA program If Applicable

manually adjust by
Frozen joints , zero gaps 10% each rail Covered by "Adverse Conditions"
gaps fully open & pulling on in JWR screen
bolts
Jointed welded rail on resilient 10% each rail Covered by non-standard
fastenings checkbox in JWR screen. Defaults
>1 in 3 sleepers resilient to priority one when checked.
fastened
No creep pegs Calculate using -20mm When missing is selected in the
(creep into the section) creep box -20 creep is used in the
tangent creep on each rail analysis.
for the tangent creep
component of adjustment(1)
Alignment details for CWR not Calculate using -50mm Covered by WTSA software which
known Average Alignment Error defaults to − 50mm when the
for Curve Creep alignment missing box is ticked
component of adjustment curve creep.
Foul ballast, pumping joints, minimum 10% for Track WTSA software actually adds 10% Secondary analysis
poor formation Disturbance if the Foul ballast or Pumping can reduce final
Joints boxes are ticked regardless stability result if 10%
of whether there is a disturbance of loss for foul ballast is
>10% existing. cumulative with track
disturbance.
Ballast Condition ­ ADD 10% Stability loss to WTSA Software adds 10% if the
rounded/disturbed/ pulverised PRELIMINARY result Ballast Condition box is ticked
Bad ballast disturbance ADD an additional 10% Additional manual adjustment Add 10% to FINAL
(This would be appropriate at manually to the FINAL required Result
pumping bridge ends where Stability loss (this is extra
the sleepers have been to the 10% added to the
flogging and ballast is loose preliminary result)
and providing no support to the
sleepers)
Transom top steel 10% Stability loss to be WTSA software adds 10% when
underbridges without added to PRELIMINARY Bridge factor box is ticked.
expansion switches, with span result
≥40m and with elastic
fastenings
Elbows or sharp alignment in 10% Stability loss to be WTSA software adds 10% when
the rail added to PRELIMINARY the SA box is ticked
result
Concrete sleepered track Stability Improved Built in to infrastructure inputs to
Reduce PRELIMINARY software.
result by 33%
Rail Corrugations causing 10% Stability loss to be WTSA software adds 10% when
vibration of track and may also added to PRELIMINARY the RC box is ticked
be causing degraded ballast result
sufficient to cause track
disturbance
Severe Rail Corrugations, ADD an additional 10% Additional manual adjustment Add 10% to FINAL
causing major disturbance, manually to the FINAL required Result
Stability loss.(this is extra
to the 10% added to the
preliminary result)
Joints are evenly spaced at Stability Improved
intervals of 55m or less and the additional benefit of 50C
joints are working correctly credited to the track
adjustment for each rail in
SECONDARY analysis.

Table 13 - Influence of Non Standard or Special Track Conditions

© Rail Corporation Page 128 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Note 1. Whilst 20mm is the default assumed Tangent Creep, a level in keeping with historic
creep rates is preferable where this is known. This should include consideration of the
length of time since creep control was lost. (eg. 3 years at an average of 5mm/year
would give 15mm)
C13-1.1 WTSA Software Manual Adjustments
The WTSA software program used in RailCorp for the analysis has been updated to
reflect some of the additional factors detailed in Table 13 above.

When undertaking Welded Track Stability Analysis, if any of the non standard conditions
detailed in Table 13 are present in the section being analysed, tick the appropriate
checkboxes in the WTSA Data Entry Screen or manually add the nominated % Stability
Loss to the PRELIMINARY or FINAL result (whichever is appropriate).

C13-1.2 Supplementary Analysis of Track Lengths < 500m

This method allows assessment of track of length less than 500metres. The WTSA
software has been set up to calculate the stability loss due to rail temperature error over
the actual length of each nominated section. When manual calculation is performed the
following may be used to determine the rail temperature error for track of any length. All
of the other processes in WTSA remain the same.

The method is appropriate for use to assess anomalous sections ie where there is a
section that has an adjustment which is uncharacteristic of the average result for the
normal 500metre section. For example:
− All joints closed at one end of a 500metre section.
− Track is totally confined by fixed points and the adjustment is different to the rest of
the 500 metres.
Civil Maintenance Engineers will determine locations where this method of analysis may
be used

1. Calculate the rail temperature error for any rail length by the following formula:
85.5 × (G − 6N)
E = Ta − 35 + where L = length of rail
L
0
E = rail temperature error in C
(-ve means too much steel)
Ta = measured rail temperature
G = total gap[ (ie sum of gaps in mm)
N = number of gaps
Coefficient of linear expansion used = 1.17E-5 mm/mm degree

2. In addition because of the inherent statistical variations involved in using distances

shorter than 500m use the following factor to reduce the apparent excess steel:
0
for 250m or less 1.25 C per rail

for 500m or more nil

500 − L
for 250m to 500m a linear interpolation ie
200

© Rail Corporation Page 129 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Example
for a length of 300 metres, with gaps 5mm, 10mm, 5mm on one rail, at a
0
temperature of 30 C
L = 300
Ta = 30
G = 5+10+5=20
N = 3 gaps
85.5 × (20 − 6 × 3)
hence E = 30 − 35 +
300
= -5+(85.5*2/300)
= -5+0.6
= -4.4
now for 300m the statistical variation factor = (500-300)/200 = 1.0
hence the modified rail temperature error = -4.4+1.0 = -3.4
3. Determine the calculation of stability loss for rail adjustment for each rail from
Section C13-2.3. The remaining WTSA process is unchanged.
Note: The formula is only valid for Standard Welded Track and should not be used for
Non-Standard Track ie 1 gap in 300 metres. The track in such cases should be treated
as Non-Standard Track.

C13-2 Rail Adjustment - Continuous Welded Rail

The analysis of tangent and curve creep is based on the information gathered in Chapter
12.

For sections of track less than 500m in length replace all steps in Section C13-2.1 and
C13-2.2 below with the steps in Section C13-2.4.

C13-2.1 Tangent Creep

1. Calculate the net tangent creep from the recorded measurements of rail creep.
The result is calculated by comparing the amount and direction of the creep at either
end of the track section being analysed. The analysis assumes the rails have been
correctly installed and maintained.
If additional rail has moved into the section then the stress is compressive (−).
If rail has moved out of the section then the stress is tensile (+).
Example 1:
Creep direction
km post -10mm -25-(-10) = -15mm
Additional rail in section
1/2km post -25mm Net tangent creep = -15mm
Example 2:
Creep direction
km post -10mm +25-(-10) = +35mm
Less rail in section
1/2km post +25mm Net tangent creep = +35mm

NOTE: Creep towards Sydney is negative while creep away from Sydney is
positive.
2. Read the equivalent Temperature Error for the 500m section due to the amount of
Tangent Creep from Table 14 - Continuous Welded Rail - Creep Analysis.
Example:
Tangent Creep = -15mm
0
From Table 2 - Temperature Error = - 3 C.

© Rail Corporation Page 130 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

NOTE 1: When the Tangent Creep is negative (-), the Temperature Error is also
negative (-) ie the effective neutral temperature of the rail has been
lowered.
2: When the Tangent Creep is positive (+), the temperature error is positive
(+) ie the effective neutral temperature has been raised.
o
Tangent Creep - CWR - Temperature Errors( C)
Creep Temperature Error Creep Temperature Error
0 0
(mm) ( C) for 500m Section (mm) ( C) for 500m Section
5 1 55 10
10 2 60 11
15 3 65 12
20 4 70 13
25 4 75 14
30 5 80 14
35 6 85 15
40 7 90 16
45 8 95 17
50 9 100 18
Table 14 - Continuous Welded Rail - Creep Analysis

C13-2.2 Curve Creep

Determine the Temperature Error due to Curve Creep for each curve in the 500m section
as follows:

1. Calculate the Curve Alignment Index for each curve or portion of curve in the 500m
section.
Radius
Curve Alignment Index =
Length of Curve in 500m section

This Index can be calculated initially and entered on the field recording sheets for the
section.

© Rail Corporation Page 131 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

o
Curve creep - C.W.R. - Temperature error ( C)
Average Alignment Error (mm)
Alignment
Index 15 25 50 75 100 125 150 175 200
0.6 4 7 14 21 29 36 43 50 57
0.8 3 5 11 16 21 21 32 37 43
1.0 3 4 9 13 17 21 26 30 34
1.2 2 4 7 11 14 18 21 25 29
1.4 2 3 6 9 12 15 18 21 24
1.6 2 3 5 8 11 13 16 19 21
1.8 1 2 5 7 10 12 14 17 19
2.0 1 2 4 6 9 11 13 15 17
2.2 1 2 4 6 8 10 12 14 16
2.4 1 2 4 5 7 9 11 12
2.6 1 2 3 5 7 8 10 12 13
2.8 1 2 3 5 6 8 9 11 12
3.0 1 2 3 4 6 7 9 10 11
3.5 1 1 2 4 5 5 7 9 11
4.0 1 1 2 3 4 5 7 8 9
4.5 1 1 2 3 4 4 5 7 8
5.0 0 1 2 2 3 4 5 6 7
6.0 0 1 1 2 3 3 4 5 6
7.0 0 1 1 2 2 2 3 3 4
8.0 0 0 1 1 2 2 2 3 4
9.0 0 0 1 1 2 2 2 3 4
10.0 0 0 1 1 2 2 2 3 3
11.0 0 0 1 1 2 2 2 2 3
12.0 0 0 1 1 1 2 2 2 2
13.0 0 0 1 1 1 2 2 2 2
14.0 0 0 1 1 1 1 2 2 2
15.0 0 0 1 1 1 1 2 2 2
16.0 0 0 1 1 1 1 2 2 2
17.0 0 0 1 1 1 1 2 2 2
18.0 0 0 0 1 1 1 1 2 2
Table 15 - Continuous welded rail - Curve Creep analysis

© Rail Corporation Page 132 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

2. Calculate the Temperature Error from the effect of movement of the curve in the
500m section using Table 15 - Continuous welded rail - Curve Creep analysis:
Example:
Curve 300m long
Radius 900m
900
Curve Alignment Index = =3
300
Average Alignment Error = −40mm
(where alignment error is taken over the worst 100m, being that which is the greatest
negative or lease positive alignment error)
From Table 15:
Temperature Error = −3 C for 500m section.
0

3. If there is more than one curve, or portions of curves, in the 500m section, add the
Curve Creep results for each curve to give the total Lateral Creep Temperature Error
for the 500m section.

C13-2.3 Loss of Track Stability

1. Calculate the Total Rail Temperature Error for each 500m.

Total Rail Temperature Error = Longitudinal Creep (Tangent) Temperature Error

+ Lateral Movement (Curve Creep) Temperature Error
2. Read the Loss of Track Stability for the Total Rail Temperature Error for CWR from
Table 12 - % Loss of Track Stability.
Example:
Total Rail Temperature Error = Tangent Temperature Error + Curve Temperature Error.
0 0
= -3 C + -3 C
0
= -6 C
From Table 12 - loss of track stability is 15%.
3. Repeat the process separately for the Up and Down rails giving two separate results.
The Total or Combined Track Stability Loss due to rail adjustment in the 500m
section is the sum of the two results.
4. Record the results on Form WTSA 3 (for manual analysis).
5. The following are non standard track configurations and cannot be analysed as
CWR. Analyse them as Non Standard track (see Table 13)

Extract from RailCorp Standard ESC 220.

− Rails longer than 220m that have not been adjusted.
− Rails longer than 220m with no creep marks or pegs.
− Rails longer than 220m with no alignment information available.
− Rails longer than 27.4m with resilient fastenings more than 1 in 3 (unless
the rails have been correctly adjusted in accordance with requirements
for CWR).

6. All non standard welded track is to be treated as a Priority 1.

C13-2.4 Supplementary Analysis of Track Lengths < 500m

This method allows assessment of track of length less than 500metres. Calculation is
available to determine the rail temperature error for CWR track of any length. All of the
other processes in WTSA remain the same.

© Rail Corporation Page 133 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

The method is appropriate for use to assess anomalous sections ie where there is a
section that has an adjustment which is uncharacteristic of the average result for the
normal 500metre section. For example:
− creep into a section is confined to a smaller part of the section by turnouts or more
creep resistant track structure eg dogspike track running into Pandrol track
− track is totally confined by fixed points and the adjustment is different to the rest of
the 500 metres.
Civil Maintenance Engineers will determine locations where this method of analysis may
be used.

C13-2.4.1 Tangent Creep

1. Calculate the rail temperature error due to tangent creep for any rail length by the
following formula:
C t × 85.5
Et =
L where L = length of rail
0
Et = rail temperature error in C due to tangent creep
(-ve means too much steel)
Ct = net tangent creep in mm
(-ve means net creep into section)
-5
Coefficient of linear expansion used = 1.17 X 10 mm/mm degree

Note: If small lengths are being analysed the accuracy of the creep recordings needs
to be very good otherwise the validity of the calculation is overwhelmed by the errors
in measurement.

C13-2.4.2 Curve Creep

1. Calculate the rail temperature error due to curve creep for any rail length by the
following formula:
A × 85.5 × L c
Ec =
L×R where L = length of section to be analysed
Ec = rail temp error in degrees C due to curve creep
(-ve means too much steel)
A = average alignment error in mm
(pullin is considered negative)
Lc = length of curve in m (must be within L)
R = radius in m
-5
Coefficient of linear expansion used = 1.17 X 10 mm/mm. degree

C13-2.4.3 Loss of Track Stability

1. Determine the Total Rail Temperature Error as in Section C13-2.3 using the errors
for Tangent Creep and Curve Creep derived above.
2. Calculate the stability loss for rail adjustment for each rail. The remaining WTSA
process is unchanged.

C13-3 Assessment of Bunching Points and Fixed Points

Bunching points are locations where the steel may bunch up because of differences in
the longitudinal creep behaviour of the track when moving from a weaker track structure
to a stronger tack structure in the direction of travel. Bunching points attract a standard

© Rail Corporation Page 134 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

stability loss of 10% (This can be entered into the WTSA software by ticking the "rail
bunching" checkbox).

Where the amount of bunching is considered to be extreme, then (in addition to the
entering the automatic stability loss) conduct a Fixed Point Analysis. Guidance on when
to consider that the interface requires a fixed point analysis is given in Table 16 below.
The table describes the interface between dogspiked timber sleepered track and various
other configurations; and between elastic fastened timber track and various other
configurations.

from Analysis requirements

INTERFACE Elastic fastened plain
timber track (where
Dogspiked plain timber
there are indications of
track
to creep occurring in rails
or sleepers)
Standard 10% loss plus Standard 10% loss
Concrete sleepered track
Fixed Point Analysis
Turnouts, Crossovers etc Standard 10% loss plus Standard 10% loss
Fixed Point Analysis
Transom top elastic fastened Standard 10% loss plus Standard 10% loss
track or small level crossing Fixed Point Analysis
Substantial solid level crossing Standard 10% loss plus Standard 10% loss plus
Fixed Point Analysis Fixed Point Analysis
Elastic fastened plain timber Standard 10% loss Not applicable
track
Table 16 – Guidelines for Fixed Point analysis

In unusual situations where there is severe creep of rails or fastenings occurring (as
found on some very steep heavy trafficked areas) then Civil Maintenance Engineers
should give special consideration to any additional requirements.

C13-3.1 Fixed Point Analysis

Locations nominated above as requiring fixed point analysis must be the subject of an
additional assessment to review the likely impact on track adjustment. If no assessment
is carried out track adjustment must be calculated assuming that incoming rail creep is
confined to the track between the creep point and the bunching point.

C13-3.2 Treatment of Small Sections Between Fixed Points

Where the length of track between fixed points (eg between turnouts or bridges) is more
than 200m, creep points must be installed and monitored. For lengths up to 1000m,
place a creep point in the centre of the section. For lengths greater than 1000m place
creep points starting 500m from one end.

C13-3.3 Assessment for Fixed Point Analysis

Is the bunching point really a location where steel has been bunching?

Factors to be considered include:

− Creep in the section has been stable for at least 3 years, or has reduced in that time
− Single line track with no particular reason to bunch, as traffic is similar in both
directions.

© Rail Corporation Page 135 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

− Are there indications on sleepers/fastenings that steel has been passing through the
"bunching point".
If it can be established that the location is not actually causing steel to bunch then the
bunching point adjustment calculation is not required. Alternatively, if only some of the
steel is creeping through the bunching point, a reduced level of creep can be used in the
analysis.

C13-3.4 Calculation for Fixed Point Analysis

If the fixed point defines a length that is very short, then the result may be exaggerated by
small errors in measurement of creep. In this case the level of creep should be re­
assessed based on the creep history. If there has been a recent change in the creep
measured, it should be re-measured to confirm.

In any case the calculation should assume that the incoming steel is confined between
the creep point and the bunching point. The minimum length to be used is 165m. If the
adjusted length is less than 165m, use 165m. If greater than 165m then use the actual
length. This is necessary because where the track length is short then the measurement
accuracy will have a misleading effect on the adjustment error calculated.

C13-4 Rail Adjustment - Winter Deficiencies

When the analysis is carried out in Summer/Autumn rail adjustment analysis will indicate
areas of potential breakaways.

For both CWR and JWR track a separate defect is registered for each 500m section
0
which has a Rail Temperature Error in excess of + 8 C and remedial action is to be
programmed before Winter.

C13-5 Stability Loss - Anchors

1. Determine stability loss due to anchor condition using the information from the
examination of anchors in Chapter 12 and using Table 17 - Influence of Anchor
Conditions."

Loss of Track Stability (% of total stability)

Type of Anchor Condition Loss of Stability
Elastic Fastening Good 0%
20% Ineffective 5%
Fair Type Anchor Good 2%
Ineffective / Missing 8%
Table 17 - Influence of Anchor Conditions

2. Record on Form WTSA 3 (for manual analysis) the worst result for each 500m
section as representative of the weakest point in that section.

C13-6 Stability Loss - Ballast

1. Determine stability loss due to ballast profile and condition using the information
from the examination of ballast in Chapter 12 and using Table 18.
2. Add the crib result and the shoulder result to determine the stability loss.

© Rail Corporation Page 136 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Loss of Track Stability (% of total stability)

Crib Shoulder
Ballast % Stability Ballast % Stability Ballast %
required Loss required Loss required Stability
(Tonnes/20m) (Tonnes/20m) (Tonnes/20m) Loss
1 7 7 30 1 5
2 14 8 30 2 10
3 19 9 30 3 14
4 24 10 30 4 17
5 27 11 30 5 19
6 29 12+ 30 6 20
Table 18 - Influence of Ballast Deficiencies 7 20
8+ 20
3. Analyse all ballast loss as reported by field staff. The worst combined result (crib +
shoulder) for the 500m Section, again representing the weakest point in the Section
will be used to determine total stability loss.
4. If any areas have been noted as having foul ballast, poor formation or pumping
joints, add a % loss of Track Stability as indicated in Table 13 to the Ballast
Deficiencies Result.

C13-7 Stability Loss - Track Disturbances

Any track disturbance since last May or planned before April next year must be factored
in to the calculations.
Information on locations of track disturbance should be available on records obtained
from Team Managers, Civil Maintenance Engineers and Asset Engineers.
NOTE. There are two methods of calculating the effect of track disturbance on track
stability loss. Tables 19 & 20 use a time based method while Table 21 uses tonnage. The
lower stability loss % when comparing both methods should be used for both primary and
secondary analysis.
Track Disturbance includes:
− Resleepering (manual or mechanised).
− Resurfacing.
− Ballast cleaning and reconditioning.
− Underline Crossings (ULX)
− Indicate if a Dynamic Track Stabiliser is used.
1. Establish the type, extent and timing of the major work activity.
Table 19 - Influence of Major Track Disturbance indicates loss of track stability for
major track disturbances. Depending upon the timing of major works and the type of
work, variations to the impact on track stability will occur. There is a "look-ahead"
period in the assessment, which is carried out in August/September to ensure that
account is taken of works scheduled for the summer ahead. These are more
significant than those during the past months even though the critical situation has
not yet occurred.
Table 20 - Summer Updating Analysis - Influence of Major Track Disturbance is the
Summer Updating Analysis and is used to update the analysis during the summer
period as the effect of track disturbance is reduced as time passes.
Notes 1. Manual Resleepering. Track Disturbance occurs due to partial resleepering
involving manual processes eg. boodling, beater packing.
2. Mechanised timber resleepering and concrete resleepering are included in the Tie
and Surfacing category. Steel sleepers are not included. This work generally

© Rail Corporation Page 137 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

involves a greater amount of disturbance to sleepers being replaced and also the
adjacent sleepers.
3. Reconditioning and Underline Crossings by excavation are to be treated similarly to
ballast cleaning.
Loss of Track Stability (% of total stability) for the following Summer
April August Manual Surfacing Tie & Ballast
Analysis Analysis PRS Ballast Stab Surfacing Cleaning
Ballast Stab

W/out With W/out With W/out With

Last Jan Last Jan 0 0 0 0 0 0 0
Last Feb Last Feb 0 0 0 0 0 0 0
Last March Last March 0 0 0 0 0 0 0
April Last April 0 0 0 0 0 0 0
Next May Last May 0 9 0 10 0 14 11
Next June Last June 0 15 3 17 3 22 15
Next July Last July 0 20 14 22 14 27 20
Next Aug August 11 22 14 26 14 28 20
Next Sept Next Sept 17 24 14 26 14 28 20
Next Oct Next Oct 20 24 14 26 14 28 20
Next Nov Next Nov 20 24 14 26 14 28 20
Next Dec Next Dec 20 24 14 26 14 28 20
Next Jan Next Jan 20 24 14 26 14 28 20
Next Feb Next Feb 20 24 14 26 14 28 20
Next March Next March 20 24 14 26 14 28 20

Table 19 - Influence of Major Track Disturbance.

Loss of Track Stability (% of total stability)
Months since work Manual Surfacing Tie & Ballast
performed PRS Ballast Stab Surfacing Cleaning
Ballast Stab
W/out With W/out With W/out With
Over 6 0 0 0 0 0 0 0
5 to 6 0 9 0 10 0 14 11
4 to 5 0 15 0 17 0 22 15
3 to 4 0 20 0 22 0 27 20
2 to 3 11 22 0 26 0 28 20
1 to 2 17 24 3 26 3 28 20
0 to 1 20 24 14 26 14 28 20
Any future work 20 24 14 26 14 28 20
planned
Table 20 - Summer Updating Analysis - Influence of Major Track Disturbance

© Rail Corporation Page 138 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

4. Effect of tonnage on track disturbance.

Table 21 provides a comparison of reduction in track stability loss due to traffic
tonnage.

Surfacing Tie & Surfacing Ballast

Tonneage Manual Ballast Stab Ballast Stab Cleaning
(,000 GT) PRS W/out With W/out With W/out Wit
h
0 20 24 14 26 14 28 20
125 11 14 5 15 5 20 14
500 6 8 3 8 3 11 8
1000 2 3 3 3 3 3 3
2000 0 1 1 1 1 1 1
3000 0 0 0 0 0 0 0
Table 21 - Affect of Tonneage on Track Disturbance

Note: Completion date is required NOT starting date.

5. Determine an appropriate Track Stability Loss using Table 19. Where tonneage
information is available Table 21 can be used to determine Track Stability [Link]
part of the Primary Analysis.
6. Record all disturbances for the 500m section. Different activities are not cumulative.
Example:
If ballast cleaning is set for next March (28% result) and surfacing in September
(24% result) the loss of Stability would be the worst ie. 28% loss of stability (not
52%).
The use of a Ballast Stabilising Machine in conjunction with resurfacing works
provides an immediate improvement in track stability. Table 19, Table 20 and Table
21 indicate the percentage of stability loss to be added when a Ballast Stabilising
Machine is used.
Note:- Because of the restrictions placed on the use of the BSM in some locations,
some track which has been resurfaced may not have been stabilised. If non
stabilised track occurs in a 500m section then it must be separately noted and the
maximum disturbance value used.
Additional precautions should be taken regarding protecting the worksite at the time
of major work in accordance with district or division instructions.
7. Deal with areas subject to ongoing disturbance e.g. pumping joints as shown in
Table 13.

C13-8 Stability Loss - Track Condition

The general condition of track can be measured by the Track Condition Index (TCI)
provided by the Track Recording Car. Poor sleeper condition, formation problems,
geometry variations as well as causing a deterioration to the TCI also cause the track to
lose lateral stability. The deteriorated track conditions often provide the "trigger"
mechanism for misalignment.
1. Table 22 - Influence of General Track Condition indicates the loss of Track Stability
for track condition. Use the worst TCI for each 500m section, excluding turnout
assessments, as the basis for determining the Stability Loss.

© Rail Corporation Page 139 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Loss of Track Stability (% of total stability)

Loss of Loss of Loss of
TCI TCI TCI
Stability Stability Stability
Up to 45 0 56 4 67 9
46 1 57 5 68 9
47 1 58 5 69 9
48 1 59 6 70 9
49 2 60 7 71 9
50 2 61 7 72 9
51 2 62 7 73 9
52 3 63 8 74 10
53 3 64 8 75 10
54 3 65 8 Over 75 10
55 4 66 8
Table 22 - Influence of General Track Condition

2. Record the result on Form WTSA 3, (for manual analysis) or enter directly into the
WTSA software.

C13-9 Stability Loss - Preliminary Result

The addition of individual results will give a preliminary assessment of track stability loss
due to:

Down rail adjustment %

Up rail adjustment %
Anchors %
Ballast deficiencies %
Track disturbance %
Track condition %
Preliminary Stability Assessment %
NOTE: When the analysis is applied to 500m of concrete sleepered track the Preliminary
Stability Assessment may be reduced by the amount indicated in Table 13 due to the
increased lateral stability of concrete sleepered track.

C13-10 Location Factor in WTSA Analysis

1. Determine a Location Factor for each 500m section adding factors selected from
Table 23 - Location factor.
Each 500 metres of track has its own unique characteristics. The features of the
500m section will affect the track stability beyond those described in Section C13-9
above.
There will be different location factors for each 500m and they will be in the range
1.00 to 1.42.
Location factors will generally remain constant year after year and can be calculated
once by the Civil Maintenance Engineer.
2. Record the Location factors on Form WTSA 3 or enter into the WTSA software as a
fixed entry.

© Rail Corporation Page 140 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. Review the location factors annually The factors need only be altered if there is a
significant change.
Curvature 0 - 400m 0.20 Increased stability loss
400 - 800m 0.12 " " "
800 - 1600m 0.07 " " "
1600 + 0.00 " " "
Grade > 1:60 0.05 " " "
between 1:60 and 1:120 0.02 " " "
< 1:120 0.00 " " "
Single line (traffic in both Yes 0.00 " " "
directions) No 0.02 " " "
Heavy braking zone 0.05 " " "
Steady braking zone 0.02 " " "
Non braking zone 0.00 " " "
Rail bunching points in section Yes 0.10 " " "
eg. crossovers, level crossings, No 0.00 " " "
fastening type changeover, bridges,
etc.

Location Factor = 1.0 + Sum of relevant items

Table 23 - Location factor

C13-11 Primary Analysis Final Result

1. Adjust the preliminary Stability Assessment.
Final Stability Assessment Preliminary = Stability Assessment x Location Factor.
2. Record the results.

C13-12 Stability Limits

1. Compare the Primary Analysis Final Result with the following tolerances:­

Priority 1 55% loss or greater Location requires immediate

attention or evasive action
Priority 2 40% to 55% loss Location requires programmed
attention or evasive action.

C13-13 Secondary Analysis

1. Inspect/review the priority locations to confirm the accuracy of the input data.
The primary analysis accumulates the loss of stability due to all aspects that may
occur over 500m of track.
2. Assess the cumulative effects within the 500m section.
Experience has shown that some defects occur at different points within the 500m
such that their effects are not, in fact, cumulative as assumed in the analysis.

© Rail Corporation Page 141 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Example:
Ballast Anchor
Deficiency Deficiency PRS site

0.5km km
defects not cumulative
Ballast
Deficiency PRS site

0.5km Poor Adjustment km

defects are cumulative

3. Amend the primary stability loss result to reflect the review.

4. Re-evaluate the effect of track disturbances.
Table 21 provides a comparison of reduction in track stability loss due to traffic
tonnage.
5. Re-calculate the location factor as set out in Section C13-10, reassessing all
contributing factors.
6. Where there is an indication that the track adjustment varies significantly over the
500m section an analysis should be carried out over a shorter length (the worst
section) using the methods in Section C13-1.2 or C13-2.4.
7. Determine the most appropriate corrective action.

C13-14 Additional Tools

Additional tools may be used in Secondary Analysis. These tools include:

C13-14.1 Stress Measurement Device (Verse System)

Use the procedure in TMC 223:
1. When the track adjustment has been determined for a uniform 500m section then
the total creep shown for the section can be reduced to 2/3 of the difference between
that predicted by the creep points and the Verse System.
2. When the track adjustment has been determined for a section up to a fixed point
then the total creep shown for the section (up to the fixed point) can be reduced to
2/3 of the difference between that predicted by the creep points and the Verse
System.
3. When the track adjustment has been determined for an isolated location of potential
adjustment error within a section such as at a curve pullin (where otherwise the
creep would be OK) then the total creep shown for the section would remain
unchanged. If the test result showed less creep than predicted by the alignment and
tangent creep information then the methodology above (ie a reduction of 2/3 the
difference) can be applied.
In all three situations above the creep marks for the section should be updated to reflect
the calculated changes to adjustment.

C13-14.2 Credit for Interspersed Concrete Sleepers

A pro-rata allowance based on 100% concrete providing a 25% saving in stability loss,
can be used for review in secondary analysis. This will only apply where sleeper spacing
is consistent to a tolerance of one sleeper where there has been an adjustment to

© Rail Corporation Page 142 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

spacing. For example concrete installed at 1 in 3 (allowing for some odd locations of 1 in
4 and 1 in 2) could attract a saving of (25%/3 = 8.3% stability benefit). The minimum
spacing that can be considered is 1 in 4 (allowing odd locations of 1 in 5 when the
tolerance is considered).

C13-14.3 Credit for Painted Rail

0
A saving of 10 C is permitted when full compliance to the painting requirements is
achieved in accordance with the procedure in Engineering Manual TMC 211 - Track
Geometry and Stability.

C13-15 Action to be Taken

1. Assess the Final % Stability Loss
2. Take appropriate assessment or evasive action according to the "Limits and
Responses" table in Section C2-4.

C13-16 Control of the Correction Process

When WTSA priorities are corrected the stability loss must be recalculated to ensure the
priority has been reduced below P1 level preferably below P2 level to avoid having a
priority again the following year).

C13-17 Non Standard Welded Track - Priorities for Corrective Action

When non-standard welded track is encountered it must be dealt with as a Priority 1
location. Since there is no general indication of the amount of stability loss due to rail
adjustment it is necessary to examine and take action on a priority basis.

For general guidance the following order of priority (highest first) is suggested as a
general rule. Local circumstances will dictate whether or not the order is appropriate.
1. Dogspiked track CWR - no alignment or creep
2. Dogspiked track CWR - no alignment
3. Dogspiked track LWR > 220m
4. Dogspiked track CWR - alignment no creep
5. Resilient fastened track - CWR no alignment or creep
6. Resilient fastened track - CWR no alignment
7. Resilient fastened track - LWR
8. Resilient fastened track - CWR alignment no creep
9. Concrete sleepered track - CWR no alignment or creep
10. Concrete sleepered track - CWR no alignment
11. Concrete sleepered track - LWR
12. Concrete sleepered track - CWR alignment no creep
Within these priorities individual locations can be ranked in order of concern eg:

1. curves < 400m radius

2. fixed points (approach side)
3. curves 400 - 800m radius
4. track disturbance

© Rail Corporation Page 143 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 14 Rail Wear and Condition Examination

The following examination (preventive maintenance) tasks are undertaken to meet the
requirements of ESC 100 - Civil Technical Maintenance Plan.

C14-1 Rail Wear Examination

When performing this type of inspection, examiners need to have the following
equipment:
− A rail wear gauge for the rail size (or sizes) being examined.
− Combination gauge (fitted with wear angle indicator).
− Rail Measuring callipers.
1. Examine track visually to find locations that are showing signs of wear. Carefully
look for rail wear by visually scanning the gauge face and running surfaces of rails.
NOTE: Rail wear is not usually confined to a single point on a rail. If wear is
detected, checks at intervals along the rail for the duration of wear. This will often
mean checking wear for the full length of curves.
Where isolated rail wear is identified, look for the factors that are causing it. These
will often include irregularities in track alignment and superelevation.
2. Where rail wear is evident, mark the rail with a permanent mark at intervals of 10m
throughout the affected area.
3. Use the rail wear gauge to check the extent of reduction in head width of 53 and
47kg rails at each marked interval. Follow-up measurements are taken at the same
points on subsequent examinations.
To check reduction in head width, place the wide portion of the template over the
running surface of the rail. The additional recess in the template is designed to allow
for use of the gauge when head flow is present. The recessed section of the gauge
is placed over the outer edge of the rail. (See Figure 19 and Figure 20).
If the gauge cannot be placed so that the upper portion of the template touches the
running surface, the extent of reduction in head width is satisfactory.
If the upper portion of the template touches the running surface of the rail, wear has
reached reportable limits and is to be noted as unsatisfactory. Further measurement
of head width with calipers is necessary.
Where a rail wear gauge is not available (45, 41 and 31 kg rails) use rail calipers
(See Figure 21 – measurement "B") and compare measurements to the P3 Limits in
Section C5-5.

Figure 19 - Checking head width(B) with rail wear gauge

© Rail Corporation Page 144 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

60 Top of Rail

Space
60 Head
touches
Gauge
Gauge
Face

IMPORTANT Gauge
Make sure you have the Face
correct gauge for the rail size
you are checking
Don't Report Report

Figure 20 - Checking Head Width (B)

B

Running
Running Face
16mm
Face
C
A 16mm
Measurement of
Curve Wear “B”
D Curve Wear “C”
16mm prior to rails being Measurement of
transposed Tangent Wear “A”

Measurement of Tangent
Wear “D” after Curve
Wear “C”

Figure 21 – Measurement of rail wear with vernier callipers

4. Use the appropriate rail wear gauge to check the extent of reduction in head depth of
60, 53, 50 and 47kg rails at each marked interval.
To check reduction in head depth, place the narrow portion of the template against
the gauge face of the rail. The recess in the template will allow rails with head flow
to be checked. The recess is placed over the upper edge of the rail. (See Figure 22
and Figure 23).
If the gauge cannot be placed so that the template contacts the gauge face, the
extent of reduction in head depth is satisfactory.
If the template touches the gauge face, wear is approaching condemning limits and
is to be noted as unsatisfactory. Further measurement of head width with calipers is
necessary.
Where a rail wear gauge is not available (45, 41 and 31 kg rails), use rail calipers
(See Figure 21 – measurement "A") and compare measurements to the P3 Limits in
Section C5-5.

© Rail Corporation Page 145 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 22 - Checking Head Depth (A)

Gauge
60

Face

60
Gauge
Face

Space Side of Gauge

touches Rail Head
Don't Report Report

Figure 23 - Checking head depth (A)with rail wear gauge

5. Use the rail wear angle reporting gauge to check the rail wear angle at each marked
interval.
Place the gauge on a 25mm square non-metallic rod (timber or equivalent) spanning
the track.
Put the “Reporting – 24” end of the gauge against the gauge face of the rail. If there
is a space between the rail and the gauge BELOW the touching point, (see
Figure 24) then the rail wear angle is satisfactory. If there is no space or a there is
space between the rail and the gauge ABOVE the touching point (see Figure 25),
the rail wear is above the reporting limits and must be reported.
If the rail wear angle is above the reporting limits, reverse the gauge and check the
rail wear angle against the “condemning – 26” end of the gauge. (Note the gauge will
now sit on the opposite side of the bar and you will need to move the bar 25mm
along the track to measure the same point). If
A Track Examiner's Combination Gauge has a sliding jaw with an attachment for
measuring the wear angle of rails. If there is a space between the rail and the gauge
ABOVE the touching point (see Figure 26), the rail wear is above the condemning
limits and must be reported.

© Rail Corporation Page 146 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Space HERE
OK
Don't Report

Figure 24 - Rail Wear Angle Reporting Gauge - OK

Space HERE
NOT OK
REPORT
Reverse Gauge and
CHECK Condemning

Figure 25 - Rail Wear Angle Reporting Gauge - Reporting

Space HERE
NOT OK
REPORT

Figure 26 - Rail Wear Angle Reporting Gauge - Condemning

C14-1.1 Measurement of Tangent Wear When Curve Wear is Present

If any curve wear is present, measurement of tangent wear cannot be undertaken from
the gauge side of the rail (the measuring point 16mm in from the gauge face will be in the
head web transition region and give a false reading).

Measure the tangent wear by taking measurements of the rail head height with the
callipers located on the field side of the rail.

If a flow lip exists particularly on the high rails take the measurements of the rail head
width with the callipers, but the width of the flow lip is to be estimated and noted.

© Rail Corporation Page 147 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

If rail is found to be at or below the reportable wear limits, and the wear measurements
are found to be impeded by curve wear or flow on the gauge side, or flow on the field
side, use the ‘Railmate’ (or equivalent) system to take the head profile of the rail. The rail
wear measurements will be based on the ‘Railmate’ outputs.

C14-1.2 Actions
1. Record the location and extent of the worn area by noting the commencement and
the end of the "Reportable Wear" where the rail dimensions are below P3 limits
detailed in Section C5-5.
2. Record the worst example of head width and depth reductions on the inspection
Form Rail 1 "Inspection of Rail Wear" together with the rail type and date of rolling of
the rail.
3. Assess any defects found according to the "Limits and Responses" tables in Section
C5-5.
4. Arrange appropriate protection and/or correction.
5. List the defects on Form 2 "Weekly Summary of Defects Report" or transfer to
Teams3 directly from Form Rail 1.

C14-2 Rail Condition Examination

Examine the rail for visual evidence of defects.

The reportable conditions include:

− Gauge corner fatigue damage (visible as fishscaling and or spalling.)
− Surface damage due to wheelburns.
− Squats.
− Cracking or spalling of the rail head.
− Rail contact fatigue.
− Rail corrugations.
− Vertical split head defects.
− Rail damaged by plant and equipment.
Further information on rail defects is available in TMC 226 "Rail Defects Handbook".

C14-2.1 Actions
1. Record any defects found on Form Rail 1 "Inspection of Rail Wear."
2. Assess any defects found according to the "Limits and Responses" tables in Section
C5-6.
3. Arrange appropriate protection and/or correction.
4. List the defects on Form 2 "Weekly Summary of Defects Report" or transfer to
Teams3 directly from Form Rail 1.

C14-3 Rail Corrosion Examination

This examination is normally undertaken in tunnels and other locations where corrosion is
an actual or potential problem (including electrolytic corrosion).

The examination should, preferably, be carried out on a wet day to confirm the locations
of water ingress into the tunnel.
1. Remove ballast and debris from the rail foot.
2. Examine head, web and foot of rails for evidence of corrosion.

© Rail Corporation Page 148 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. Where there is evidence of corrosion mark the rail with a permanent mark at
intervals of no more than 5m throughout the affected area. This will allow
progressive measurements to be taken to indicate the rate of deterioration. Pick the
worst spots, even if they are close together.
4. Scrape the rails free of sand, dirt and grease, and chip off any rust. Use a wire
brush where necessary.
5. Inspect the rail both before and after cleaning with the wire brush, carefully
searching for cracks or flaws.
6. Pay particular attention to the fillets under the head and above the flange.
7. Check rail ends, both at fishplates and welded joints, for cracks starting from bolt
holes, as well as fillet cracks.
8. Examine dogspikes for excessive throat-cutting or corrosion. It is necessary to draw
a number of dogsikes for this examination - especially just near the portals.
9. Examine resilient fastenings for excessive corrosion.
10. Examine sleeper plates for corrosion, wear on the surface in contact with the rail
flange, and for enlargement of the dogspike holes.
11. Where there is evidence of corrosion of the head, measure the head width
(measurement "B" Figure 27) and depth (measurement "A") with the rail wear
gauges or with standard vernier callipers (jaws cut back to 16mm long).
12. Where there is evidence of corrosion of the web, measure thickness (measurement
"E") with ‘transfer callipers’. Select the worst position to take this measurement.
13. Where there is evidence of corrosion of the foot, measure thickness (measurement
"F") and width (measurement "G") with an ultrasonic depth gauge or callipers.
14. Measure foot thickness and width where the rail rests on a sleeper plate, or sleeper.
If callipers are being used to take the measurement you will need to move the
sleeper or lift the rail off the sleeper plate to do this. Where there is considerable
corrosion, a number of sleepers should be moved to obtain the worst condition. If an
ultrasonic depth gauge is being used there is no need to lift the rail off the sleeper
plate or move the sleeper. Measure the thickness of the foot on each side, and
record the smaller measurement.
Using an ultrasonic depth gauge, measurement of foot thickness can be made on
rail with continuous rubber support or in other situations where moving the rail may
cause damage to components.
An inspection of the rail foot thickness (measurement "F") shall be carried out on the
rail foot whenever rail is removed in the tunnel areas, such as for rail defect removal.
If a high level of corrosion is found in any such case the details are to be reported to
the Chief Engineer Track.
Track inspection staff are asked to keep a special eye on the area involved during
their routine patrol and detailed walking inspections.

© Rail Corporation Page 149 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

16

A Gauge
Face

16

16 16
F F
G
Figure 27 – Measurement points for rail wear and corrosion
C14-3.1 Actions
1. Record the results on Form Rail 2 "Examination of Rail Corrosion". Make sure the
worst dimensions in the area are recorded.
2. Where no corrosion is found during the examination, complete a “NIL” return
3. Assess any defects found according to the "Limits and Responses" tables in Section
C5-6.
4. List the defects on Form 2 "Weekly Summary of Defects Report" or transfer to
Teams3 directly from Form Rail 2.
5. Arrange appropriate protection and/or correction.

© Rail Corporation Page 150 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 15 Examination of Mechanical Joints

Mechanical joints in welded track are to be maintained to a high standard of top and line
to avoid rail end damage.

Removal of fishplates for crack detection is not necessary where ultrasonic rail flaw
detection services operate.

C15-1 Examination Procedure

1. Examine rail joints for satisfactory operation as a sliding joint to accommodate
designed rail movement of the welded rail.
Look for signs of frozen joints or excessive joint gap. Remove fishplates, grease joint
and arrange any further action required if joint is frozen.
2. Note any tight joints due to rail creep caused by traction forces and make
arrangements for any necessary adjustment.
3. Where there is evidence of undue stress of the fishbolts such as marked bending,
replace all fishbolts.
4. If it is noted that the rail end is damaged, bent down, or otherwise deformed, arrange
any necessary work to restore the joint to the required standard.
6. Check sleeper support at the joint.
7. Check fishplates for cracks.
8. Examine rail joints for broken, missing or loose bolts or swage fasteners.
9. Remove any end flow on rails.
10. If fishplates are removed and rail defects are found, protect, report and remove them
in accordance with the requirements of TMC 224 “Rail Defects & Testing”. If
possible the whole joint is to be removed and the rail continuously welded.
11. Check rail joints for alignment and profile. Where there is a mismatch at the gauge
faces (commonly known as a “foul joint”) as shown in Figure 28, measure the
amount of mismatch and respond according to the "Limits and Responses" table in
Section C5-8. The priority will depend on the joint situation (high rail in facing
direction is of most concern), the degree the 3mm limit is exceeded and any
evidence of hitting wheels on the gauge corner.

Path of tip of flange

Area of potential
concern

Mismatched Joint

Figure 28 – Foul joint

© Rail Corporation Page 151 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C15-2 Action to be Taken

1. Record all examination details on Form 2 "Examination of Length."
2. Assess any defects found according to the "Limits and Responses" tables in Section
C5-8.
3. Arrange appropriate protection and/or correction.
4. List the defects on Form 2 "Weekly Summary of Defects Report" or transfer to
Teams3 directly from Form 2.
5. When a mechanical joint fault has been identified, if possible, carry out the
necessary repairs using the procedures in Engineering Manual TMC 221 - Rail
Installation & Repair.
6. If repairs are beyond the capacity of the examination team:
∼ Take appropriate protective action if defects require immediate action, OR
∼ List the defects on the Form 2 "Weekly Defect Summary Report".

© Rail Corporation Page 152 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 16 Examination of Insulated Joints

The examination of Insulated Joints includes non-operational joints, particularly
redundant glued insulated joints.

During examination it is necessary to look at the overall performance of the joint. This
includes checking rail adjustment, insulation performance of the joint and the mechanical
integrity of the joint, as well as rail wear, the holding ability of fastenings and the
soundness of the sleepers and ballast bed.

Areas with the potential to deteriorate rapidly causing signal failures are the main target,
especially the high rail of sharp curves and mechanical insulated joints with the potential
to close up in hot weather.

If a defect is suspected in the portion of a component that is screened from view, the
component must be removed for detailed examination.

If any defect is detected then it is essential that components are examined.

The inspection is performed by visually examining each insulated joint and looking for the
following conditions.

C16-1 Examination Procedure

C16-1.1 At the Insulation Post
1. Check the rail for wear as detailed in Chapter 14.
2. Visually check the rail for damage caused by wheel burns, shelling or other surface
defects which may cause cracking. End batter of rails causes rail steel to flow
across the joint which ultimately will bridge the joint.
3. Visually check the area around the joint key for defects which may cause cracking or
steel pieces that may short the insulation key.
4. Check for loss of the insulation key, squeezing out due to rail movement, or visible
cracking and disintegration of the key.
5. At Glued Insulated Joints check for signs of failure of the glue with a visible crack
line at the endpost or under the fishplates. If cracking is detected, the joint is to be
treated as a mechanical insulated joint and anchored accordingly.
6. When there is loss of bond evident in redundant glued insulated joints because of
failure of the epoxy glue, the GIJ should be given priority for replacement (not
because of signal failure but because of fatigue loading of joint plates).

Figure 29 – No Surface Defects – No action required

© Rail Corporation Page 153 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 30 – Visible Surface Defects

Figure 31 – Excessive Visible Surface Defects

C16-1.2 At the Plates

1. Visually inspect for any build up of grease or foreign matter, in particular metal
pieces, wires and slivers that can cause electrical bridging. Slivers originating from
wheel burns or skids tend to settle around the joint because of magnetic attraction.
2. Visually check for cracks or fractures in the fishplates. Cracks can be difficult to
detect. Rusty traces are often a good indication of their presence. Cracks may
occur around boltholes or near the rail joint.
3. Fishplate Bolts may be loose, bent, cracked or broken. Tapping bolts gives an
indication of loose or broken bolts if a rattling sound is present or bolts drop out.
4. Visually inspect bolts for damage or cracks. Cracks can be detected by rusty traces
that originate from cracks.

C16-1.3 Associated Trackwork

1. Track fastenings may be loose, cracked or broken. Loose plates are caused by
missing, damaged or loose clips and spikes. Pulling and tapping will reveal any
loose components. Damaged components can be visually detected. Cracks can be
detected by rusty traces which originate from cracks.
2. Check that fastenings have been correctly installed at insulated joints. Track
fastenings can short-circuit the insulation by coming into contact with the fishbolts.
This is particularly the case with resilient fastenings. Installation requirements are
detailed in Engineering Manual TMC 221.
3. Visually inspect sleepers for condition. They may be ineffective, and not support the
joint adequately or hold the rail firm. Look for broken portions, splitting, decayed or
loose spike holes caused by spike hole decay or severe end splitting.

© Rail Corporation Page 154 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

4. Visually inspect ballast for profile and condition. Ballast can be at the incorrect level
(i.e. above or below the upper sleeper level) or it can be degraded. Degraded or foul
ballast will not support the joint and leads to "pumping" or "hanging" sleepers.
Pumping sleepers give little support to the joint as the pumping action will displace
the generally foul ballast under each load. Hanging sleepers are not in contact with
the ballast and give no support to the joint.
5. Excessive ballast heaped around the joint provides potential for short circuiting of the
insulation and should be removed.
6. Visually inspect for poor drainage that is indicated by water logged ballast or mud
reaching the surface of the ballast bed. Moisture could cause electrical bridging of
joint.

C16-1.4 At Mechanical Insulated Joints

In addition to the aspects detailed above for Glued Insulated Joints, the following
examination is required:
1. If defects are suspected, dismantle the mechanical insulated joint. A Signalling
representative MUST to be present during this examination.
2. Examine the condition of end posts, liners and ferrules.
3. On dogspiked track, check the anchoring pattern in accordance with the installation
requirements in Section C12-6. Mechanical Insulated joints are not an expansion
joint and therefore may need extra anchors to reduce the tension loads on the joint.

C16-1.5 At Glued (or bonded) Insulated Joints

At locations outside of turnouts & special trackwork, examine the track condition within
the area of each Glued Insulated Joint (GIJ). If there is excessive pumping indicated by
one or more of the following, record as GIJ requiring Supplementary Track Patrol.
1. Visible evidence of top or twist conditions (that may be assessed as P2 or worse)
affecting the joint.
5. Visible signs of formation failure affecting the joint ie heaving beyond the ends of the
sleepers or between the sleepers.
6. Bog holes affecting the joint ie track and ballast fouled and/or with mud pumping
through the ballast.
7. Chipped rail ends at GIJs and/or evidence of heavy impact (extensive whitened
ballast).
8. GIJ plates working loose.
9. Timber sleepers that do not meet "good sleeper" condition within 2 metres of the GIJ.
10. Timber transoms that do not meet "effective transom" condition within 2 metres of the
GIJ.

Figure 32 - Poor support conditions- supplementary patrol of GIJ required

© Rail Corporation Page 155 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 33 - GIJ OK - no whitening of ballast - Rail end damage limited – does not require
a supplementary patrol of GIJ

C16-2 Action to be Taken

1. Record all examination results on Form Rail 3 "Inspection of insulated joints
2. If the GIJ condition meets the requirements for Supplementary Patrol, mark the entry
on Form Rail 3.
3. Assess any defects found according to the "Limits and Responses" tables in Section
C5-9.
4. When an insulated joint fault has been identified, if possible, carry out the necessary
repairs.
5. If repairs are beyond the capacity of the examination team:
∼ Take appropriate protective action if defects require immediate action, OR
∼ List the defects on "Weekly Summary of Defects Report" or transfer to Teams3
directly from Form Rail 3.

Note If not OK is ticked on the inspection form then the column “Is supplementary patrol
required” must be answered with Y or N. Guidance on conditions that require
supplementary patrol is found in section C16-1.5

Note If insulated joints are affected by severe spark erosion the location should be
referred to signals staff so bonding can be checked.

© Rail Corporation Page 156 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 17 Examination of rail lubricators

The following examination (preventive maintenance) tasks are undertaken to meet the
requirements of ESC 100 - Civil Technical Maintenance Plan.

C17-1 Examination procedure - (mechanical plunger type lubricators)

Check the operation of each lubricator and record the results on Form Rail 4
“Examination of Rail Lubricators / TORFMA”. The key aspects to check when inspecting
a lubricator unit include:

C17-1.1 At the Lubricator

Main Container
1. Check the grease status of the main container. Does it need filling?
2. Check the main container for signs of damage especially for cracks around bolt
holes in the back cover.
3. Check that the filler valve is clean and has a cover fitted.
Pump Assembly
1. Check plunger condition.
2. Check plunger height above rail.
3. Activate plungers to ensure grease is being delivered to blade.

Greasing Plate Assembly

1. Check blade for signs of wear.
2. Check blade height below rail head.
3. Observe rail around lubricator grease plate for excessive grease delivery to the rail
head and adjacent track structure.
4. Observe rail around lubricator greasing plate for insufficient grease delivery.
General
1. Check hoses for obvious damage.
2. Check all hoses, blade ends and pumps for grease leakages.

C17-1.2 Rail adjacent to lubricator in the curve

1. Check that grease is being carried around curve providing adequate lubrication to
protect the curve.
2. Observe for indications of severe wear, in the form of steel shavings along the rail
foot and around rail anchors, or rough surface on the gauge face.
3. If a lubricator is not functioning satisfactorily or rails are showing signs of excessive
wear, record appropriate information. If lubricators are found to be functioning
correctly the lubrication strategy should be reviewed and may need to be modified.

C17-2 Examination procedure - TORFMA/GFL units (electronic control

electric pump type)
Check the operation of each GFL and TORFMA unit and record the results on Form
Rail 4 “Examination of Rail Lubricators / TORFMA”. The key aspects to check when
inspecting a GFL or TORFMA unit include:

© Rail Corporation Page 157 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C17-2.1 Off site checks

Basic functionality can be established offsite from the Website. Refer to Website
Instructions for detailed instructions
1. Check Website for faults indicated
Every alert is not necessarily a fault or the fault may be so short term that it’s not
even worth noting. Parameters are set to try and make sure all actual faults result in
alerts. The example in Figure 34 below indicates 11 locations with alerts.

Figure 34 – Summary showing alerts and product remaining (EXAMPLE ONLY)

Figure 35 –Example of operation

In the example in Figure 35 above the unit is operating correctly except for a
moment around 1400.

Figure 36 – Example operation showing a fault

In the example in Figure 36 above there is an actual fault. Hardly any product is
being delivered.
Check the Website regularly for faults not necessarily able to be determined by Alert
Parameters. Such faults include wheel sensor partial failure as shown in Figure 37
below.

© Rail Corporation Page 158 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 37 – Example showing a wheel sensor failure

2. Check Website for percentage (%) of product remaining

The summary page of the website (see Figure 34) shows product remaining as a
percentage which will be a good guide if, when filled, the “Pot Filled button” is
pressed. Make sure the button is only pressed if the reservoir or tank is actually
filled. Due to the high viscosity of the product the flowmeter is not 100% accurate.
Curve grease does not flow and so when filling the tank of a GFL as much grease as
possible should be heaped toward the tank end above the pump.
NOTE: Fill tanks or reservoirs before they get down to 10%. The units will be much
more reliable if they are not let run empty.
3. Check the Voltage graph
In the example in Figure 38 below, if there is a solar panel installed it is not charging
the battery. The battery is nearly flat and needs replacement before the unit fails.

Figure 38 – Example of voltage graph

C17-2.2 Checks on site at the GFL/TORFMA unit

Tank
1. Check reservoir as per main container in C17-1.1 above
2. Check the fill level of the tank. Does it need filling?
3. Check the grease. Does it need mixing and trowelling toward the pump end?
This may be needed so the grease can be pumped. When filling the tank heap as
much product as possible toward the tank end above the pump. If this is done the
pump will generally draw grease properly till the tank is about 50% full.
Refill tanks on GFL’s before the tank falls to around 50% full, or using gloves and
plastic scraper push the remaining grease and heap it against the tank end above
the pump.
Battery
1. Check the battery voltage. Is it 23V or above when the button is pressed?
2. Check the wires. Are wires to the battery in good condition?

© Rail Corporation Page 159 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Wheel Sensor and pump

1. Check the wheel sensor. Open the control box lid and watch while a train passes.
Does the wheel sensor light flash when each wheel passes over?
If there is no train passing, use the “Train On” button to simulate a train by pressing it
multiple times, each press is one wheel, or wave a magnetic object (e.g. a spanner)
directly (<40mm) over the sensor a number of times(~20) to simulate passing
wheels.
2. Check that the wheel sensor operates the machine.
∼ Does the pump turn on and the pressure gauge rise after a few wheels have
passed?
∼ Does the pump deliver product to the rail?
∼ Does the pump turns off again after a few seconds and cycle as per the settings
through the train.
If there is no train passing, use the “Pump On” button to simulate a train by pressing
it multiple times, each press is one wheel, or wave a magnetic object (e.g. a
spanner) directly (<40mm) over the sensor a number of times(~20) to simulate
passing wheels.
3. Check the belt driving the pump. Does it drive smoothly or jump?
Solar Panel
1. Check the solar panel is facing the correct direction. Does it get full sun without
being shaded significantly for 3 hours per day?
2. Check the polycarbonate cover sheet. Is it very dirty or graffiti covered?
3. Check the LED charge lights. Are they brightly lit when panel is in full sun?
GFL blades (curve lubricators with dual 16 port blades)
1. Check the blades for port blockage. Are at least 75% of the ports open and
delivering? i.e. 24 of 32
All of the total 32 ports (2 blades each with 16 ports) are open and delivering an
even very small bead of grease. Note that virtually no grease is being left on the
blades.
Correct operation of a GFL unit is achieved when at least twelve (12) ports on a 16
port blade are dispensing curve grease in small droplets as shown in Figure 39. If
less than twelve ports are operating, as shown in Figure 40, then the blade should
be swapped out and cleaned.

© Rail Corporation Page 160 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Fourteen (14) Ports Dispensing Lubricant

and two (2) blocked

Figure 39 - This GFL blade has fourteen of the sixteen ports operational (small globules
of lubricant are clearly seen) and so can remain in service.

Seven (7) Ports Blocked

Nine (9) Ports Dispensing Lubricant

Figure 40 - This GFL blade has only nine operating ports with the remaining seven ports
blocked. It should be changed out and cleaned.

NOTE: Grease delivery is only monitored at the exit from the machine. If blades are
partially blocked lubrication may still be poor even though the ideal quantity of
grease is being delivered. The grease will be delivered as larger beads through the
open ports and will be more likely to cause running surface contamination or be
wasted into the ballast.
2. Check the blade height. Is the top edge of the blade just below the shiny surface of
the gauge face and not being hit?
3. Check the blade setup. Is the blade edge fitted up snugly to the gauge face?
4. Check the grease delivery. Is almost all grease being picked up by wheels?

© Rail Corporation Page 161 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Distribution units (TOR)

1. Check TORFMA distribution units for leakage or worn rubber pad.
Check that the rubber pads are fitted flush to the field side of the rail and that the top
surface of the rubber has not been damaged to an extent that the product runs over
top and down the back of the distribution unit. Adjust the fit to the rail and/or replace
the rubber pads if this is the case.
2. Check the rubber pad retaining plates. Are they fitted well to the field side of the
rail?
Correct operation of a TORFMA unit is achieved when the blades apply a small
puddle of product to the top of the rail head, as shown in Figure 41.
General
1. Check for leaks around fittings and hoses on the control box and to the track. Leaks
which do not result in “no delivery” from the flow meter will not be detected by
sensors or meters.
2. Check for signs of visible damage, e.g. wheel strike causing bent blades or damaged
wheel sensors, loose hoses leading to leakage, graffiti or vandalism (especially on
the solar panel),

Obvious puddle of TORFM on Top of Rail

Figure 41 - This TORFMA unit is operating correctly as seen by the small puddle of
TramSilence applied to the top of the rail when simulating a train passby.

C17-2.3 Rail adjacent to lubricator in the curve

1. Check that grease is being carried around curve providing adequate lubrication to
protect the curve.
2. Observe for indications of severe wear, in the form of steel shavings along the rail
foot and around rail anchors, or rough surface on the gauge face.
3. If a lubricator is not functioning satisfactorily or rails are showing signs of excessive
wear, record appropriate information.
4. If severe wear is present and the lubricators are found to be functioning correctly, the
lubrication strategy should be reviewed and may need to be modified.

© Rail Corporation Page 162 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C17-3 Lubrication Distribution Test (Finger Wipe Test)

In order to assess the distribution of GFL and TORFMA product across the rail head and
along the rail length, use the finger print test at the locations listed on Form Rail 5
“Lubrication Inspection Sheet”. An example of how to fill in the inspection sheet is
provided in Figure 42.

Use the following procedure:

1. With a clean protected* finger, wipe along the portion of the rail head under test (i.e.
running surface, gauge corner or gauge face) for a distance of 50mm,
* Operators should wear disposable gloves when performing this test to prevent
contact between the grease and skin.
2. Dab the accumulated product (Rocol / TramSilence) onto the appropriate section of
the inspection sheet,
3. Tick the appropriate box to indicate the level of product that this represents (on a
scale from “wet” to “dry”)
DOWN Rail UP Rail

Reasonable

Reasonable
Location on

Good

Good
Track Km

None

None
Poor

Poor
Wet

Wet
Rail Finger Print Finger Print

Running Surface

UP 6.060 Gauge Corner

Gauge Face

Figure 42 - Sample Lubrication Inspection Sheet showing how to complete the required fields

C17-4 Action to be taken

1. Record all examination details on Form Rail 4 “Examination of Rail Lubricators /
TORFMA”.
2. Assess any defects found according to the "Limits and Responses" tables in Chapter
5 and this chapter.
3. Repair lubricator defects if possible or otherwise arrange for repairs.
4. If repairs are beyond the capacity of the examination team
∼ Take appropriate protective action if defects require immediate action, OR
∼ List the defects on the Form 2 "Weekly Defect Summary Report".

C17-5 Fault detection

Fault detection is undertaken:
1. From the website - The Server generates Alerts shown on Website giving us the
ability to detect almost all faults remotely and to do some basic troubleshooting to
establish possible repair tasks required to be carried out.
2. Visually when on site - take note of operation of unit as a train passes or simulate a
train using the “Train On” button and check operation against what is expected.

C17-5.1 From the website

Note: Not every Red Alert in the summary is a failure.

The set operation parameters may have only been exceeded for one data row and the
settings may be such that alternate trains are likely to produce an alert.

© Rail Corporation Page 163 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C17-5.1.1 Pressure alerts

Pressure alerts are generated according to the “Product Flow Rate” graph which
compares calculated product delivery per train in wheels/ml (green symbols) to actual
delivery (blue symbols)

Figure 43 – Example of flow rate error producing an alert

In the graph in Figure 43 above delivery is excellent except for between 1400 and 1530.
No or virtually no delivery occurred in this period but then either track staff visited and
fixed the unit or it self-rectified.

Figure 44 – Example of more detailed analysis using Pressure and Flow graph

The Pressure Flow graph (Figure 44) allows us to troubleshoot. It shows that the unit lost
pressure around 1400 but recovered around 1530. This suggests that product level near
the pump may be getting low or there was a small pocket of air trapped in the grease
when it was last refilled.

PRESSURE ALERT – High pressure Low delivery

Figure 45 below shows a typical fault till 1400 that it was corrected from about 1400 and
back to working normally.

Figure 45 – Example of High pressure Low delivery display

© Rail Corporation Page 164 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Note that till around 1400 the blue and red symbols are both high. The red is the
pressure and the blue is the wheels per ml at pump off/valve close. This means that the
pump is operating to build up pressure but no or virtually no product is being registered
as delivered to track. This indicates a flow meter jam or less likely, flow meter failure or a
blockage in the delivery line to track.

PRESSURE ALERT – Low pressure Low delivery

Figure 46 – Example of Low pressure Low delivery display

In Figure 46 above the blue symbols are high and the red symbols are low indicating Low
Pressure No delivery. Possible faults are motor fail, pump relay fail, jammed pump, belt
fail, belt loose, loose grub screw in belt drive pulley, blocked filter, air in system,
tank/reservoir empty or hose from pump disconnected.

The most likely are tank/reservoir empty or air in system.

C17-5.1.2 Voltage alerts

These occur when unit voltage falls below a set parameter.

Figure 47 – Example of voltage graph

In Figure 47 above the graph of voltage history shows a battery failure on 13th March.
The alert was sent when the voltage dropped below the threshold setting of 20V and
product delivery ceased when the unit shut down at 18V. This particular unit has no
Solar panel which can be seen from no charging cycles being present.. In this case the
battery was replaced with a good charged battery, which is shown by the resumption of
good operating voltage.

If the unit is fitted with a solar panel, possible faults include dirty polycarbonate cover
sheet, voltage regulator failure, extended bad weather or shading of the panel, damage to
leads or plugs between the panel and body, flat battery or bad battery.

© Rail Corporation Page 165 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C17-5.1.3 No Response Alert

This occurs when the unit fails to dial-in within the set parameter time period.

This may not be a fault with the unit but may result from a Server or Website fault, unit
turned off or simply congestion from too many units dialling in.

If there is a fault with the Unit then it may be “stuck in download”, electronic package
“dead”, failed electronic package, failed SIM card or it may result from a flat battery which
has died too quickly for a voltage alert to be generated.

C17-5.1.4 No train alert

This occurs if the unit has not detected any trains within the set parameter time period

This may not be a fault with the unit but may be a result of no trains due to possession or
track affected by a possession in another area.

Possible unit faults are wheel sensor dislodged, wheel sensor incorrectly mounted, wheel
sensor damaged including cable or wheel sensor not working correctly.

C17-5.2 On site
Follow the procedure in C17-2.2 to check on the operation of the unit on site.

If the unit does not seem to operate correctly note what seems wrong….No pressure, No
delivery to track, wheel sensor light not flashing, is LCD screen showing Download for an
extended period, Is the LCD screen blank, etc.

C17-6 Fault investigation

This is invariably done by a site visit but backed up by knowing the symptoms from the
website unless the fault has been visually identified in the first place. Keep in mind there
may be more than one fault or one fault may have caused another. Use the following
table to investigate faults.

Note: Repair Tasks detailed in the table are found in TMC 221 “Rail Installation and
Repair”.

Action Observation Response Observation Response

Pressure Alert
High Pressure - Low/No Delivery
Press Pump On Confirm pressure Yes- Continue
Button Gauge rises No - Go to Low
pressure/No delivery
Does product freely Yes ­ confirm the Does the Website Yes – Go to Repair
appear on the rail? Website still indicates still indicate fault? Task Flowmeter
the fault Repair Replace
No – Then it has Self-
rectified
No - Continue
Remove Hose to track from Flowmeter
Press Pump On Does product flow Yes – Go to Repair
button freely from Task Hose Blocked
Flowmeter No- Perform Repair Does Flowmeter Yes – Continue
hosetail? Task Flowmeter Backflush result in No – Go to Repair
Backflush product flowing Task Flowmeter
freely from Clean.
Strainer?

© Rail Corporation Page 166 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Action Observation Response Observation Response

Press Pump On Does product flow Yes – Fault is rectified
button for a few freely from No – Perform Repair Does Backflush Yes – Continue
seconds. Flowmeter Task Flowmeter Flowmeter result in
hosetail? No – Go to Repair
Backflush again. product flowing Task Flowmeter
freely from Clean.
Strainer?
Low Pressure Low/No Delivery
Press pump on Confirm Pressure Yes – Continue
button for a few Gauge does not No – Confirm Website Does the Website Yes – Check wire
seconds rise still indicates the fault still indicate fault? Electronic Package to
Relay
No – Then it has self-
rectified
Inspect Unit Is there sufficient Yes – Continue
Battery power No – Perform Task
23V+? Battery Replace
(Check this without
Solar panel
connected.)
Is there sufficient Yes – Continue
product in No – Perform Repair
Reservoir or Tank? Task Fill Reservoir or
Tank then continue.
Are all Hoses in Yes – Continue
place and not No – Reinstate Hoses Was Hose from Yes – Continue
leaking Pump to Strainer in No – Perform Task
significantly? place? Strainer Clean then
continue
Is the pump drive Yes – Continue
belt in place and No – Perform Task
tensioned? Pump Drive Belt
Replace or Tension
Press Pump On Does the Pump Yes – Continue
Button for a few Motor shaft turn? No – Inspect wiring Does Motor shaft Yes – Continue
seconds then Perform Task turn now? No – Perform Task
Relay Replace or Motor Test or
Repair Replace.
Does the Motor Yes – Continue
Drive Pulley turn? No – Perform Task
Grub screw Tighten
Pulley to shaft
Does the Pump Yes – Continue
Drive Belt turn the No – Check belt? Does the belt jump Yes – Perform Task
pump? over teeth? Pump Unjam
No – Perform task
Grub Screw Tighten of
pump pulley
Does the Pump Yes – Perform Task
drive Belt jump Pump Drive Belt
teeth as it turns Replace or Tension
pump? No - Continue
Does the Pressure Yes – Continue
gauge show rising No – Perform Task
Pressure Pump Bleed
Is product now Yes – Continue
delivered to track? No – Go to High
Pressure No
Delivery

© Rail Corporation Page 167 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Action Observation Response Observation Response

Watch train Confirm correct Yes – repair complete
pass or press operation as per No – Contact Expert
Train on button settings
to simulate a
train.
Voltage alert
Voltage fallen below set parameter, generally 20V
Press Voltmeter Is Voltage 23V+ Yes – Unplug Solar Is voltage now low Yes – Continue
button with solar panel in panel after pump is run No – Advise Possible
sun? for a shot time? Error
No - Continue
Is Solar Panel Yes – perform Task
cover sheet Solar Panel clean or
Graffiti’d or dirty? replace polycarbonate
cover sheet.
No – Continue
Does Solar Panel Yes – Continue
get clear sun for 3 No – perform Task
hours per day in Solar Panel Setup
current orientation?
Is solar Panel Yes – Continue Note: Check
Cable to Control No – Perform Task connections by
Box connecting Solar Cable Repair or Multimeter on pins
properly? Replace at each end of
cable
Are both Charging Yes – Continue
LEDs in Voltage No – Perform Task
regulator case lit Solar Panel Test and
while in sun? Repair
Has there been an Yes – Perform Task * If the battery
extended period of Battery Replace. taken out already is
poor weather? No – * Mark the marked suspect
battery taken out as then do not
suspect and perform recharge but
task Battery Replace discard.
NO RESPONSE ALERT
Unit has failed to Dial in within the time Parameter set
Press Battery Is the Battery Yes – Continue
Test Button Voltage 23V+? No – Go to Voltage
fallen below Set
Parameters
Inspect Site Does the unit Yes – Note as
appear to be working correctly then
working normally Continue
No – Note unit as
Failed then continue
Inspect the LCD Is the screen Yes – Perform Task Is the screen still Yes – Perform Task
Screen on the Blank? Reboot Electronic blank after the Fuse test and replace
Control Panel Package reboot? then continue
No - Continue
No - Continue
Is the screen still Yes – Perform Task
blank? Electronic package
test and replace
No - Continue
Does the screen Yes - Perform Task k
show Downloading Reboot Electronic
for an extended Package
period of time? No - Continue

© Rail Corporation Page 168 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Action Observation Response Observation Response

Press the Link Does the unit show Yes – Continue
button until the Downloading on No - Perform Task After Reboot does Yes – Continue
screen flashes the LCD screen Reboot Electronic the Link button No - Perform Task
Package produce Electronic package
Downloading? test and replace
Does the unit Yes – Repair Note: Congestion
Download data to completed on the server may
the Server No – Perform Task prevent download
Modem and Sim Card first time so try
Check or replace twice.
Does the unit now Yes – Repair
Download data to Complete
the Server No – Perform Task
Electronic package
test and replace
NO TRAIN ALERT
Unit has not detected any trains within the set parameter time period or a lesser period
expected to be a fault
Consider Track Does this track Yes – Ignore Alert
operating have periods of this No – Continue
conditions length where it is
normal for no trains
to be running?
Is there a Track Yes – Ignore alert
possession? No – Continue
Are trains definitely Yes – Inspect
running in this No – Check running
period of no
detection?
Check Battery Is the Battery Yes – Continue
maintaining good No – perform Task
voltage while train Battery Replace
passes?
Inspect train Does each wheel Yes – Continue
passing passing result in No – Perform Task
light on panel Wheel Sensor Mount
flashing? Inspection
Does each wheel Yes – Continue
passing result in No – Perform Task
light on panel Wheel Sensor Wiring
flashing? Inspection
Does each wheel Yes – Continue
passing result in No – Perform Task
light on panel Wheel Sensor Body
flashing? Inspection or
Replacement
Is the power LED in Yes – Continue
the top of the No – Perform Task
Sensor Body Lit? Wheel Sensor Reset
Does Data now Yes – Repair
show wheel complete
detection is No – Perform Task
correct? Electronic package
test and replace
Does Data now Yes – Repair
show wheel complete
detection is No – Call expert
correct?

© Rail Corporation Page 169 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 18 Sleeper Inspection

C18-1 Timber Sleeper Inspection
1. Inspect the sleepers for condition.
If sleepers and fastenings are not visible, they HAVE NOT BEEN INSPECTED.
(Visible means sufficient to establish that each sleeper is bearing and that sleepers
provide adequate resistance to spread road.)
2. If ballast or other material is covering the sleepers and fastenings you MUST remove
it.
3. If you cannot remove it you MUST record that the inspection is incomplete and tell
your supervisor (Move it up the line to someone who can arrange to get it removed).
4. When the material has been removed you MUST complete your inspection.

Important
You MUST be able to show:
- A sign off that ALL sleepers have been inspected within the required cycle,
OR
- Evidence (entries in Teams3, emails etc) that any section that can’t be
inspected has been reported up the line for action, and that action is planned
to remove the obstruction.
5. Test all sleepers for drumminess.
6. Check for loose spikes or fastenings.
7. Determine whether sleepers are good, effective, ineffective or failed in accordance
with the definitions detailed in Section C18-4.1.
Local opinion and knowledge will assist in this aspect.
8. Assess the groupings of failed, missing and ineffective sleepers and determine
repair actions according to the "Limits and Responses" table in Section C5-10.
9. Identify locations where timber sleepered track (including transoms) is not well tied
for at least 5 years or where sleepers and transoms at that location do not provide
adequate vertical support. Record these locations as requiring Supplementary Track
Patrol.
10. Mark sleepers that are to be renewed with paint.
Mark the sleeper with a daub of paint in the four-foot and also a daub of the same
coloured paint on the flange of the rail on the four-foot side of the Down rail.
Use one of the following colours:
LIGHT GREEN, LIGHT GREY, LIGHT BLUE , or LIGHT PINK
The colour to be used for each year is to be decided by the Team Manager but
should be different from recent years.
11. Mark sleepers that require immediate renewal by routine maintenance with yellow
chalk in addition to the paint mark.
12. Pay special attention to the general pattern of deterioration. It may be necessary to
arrange early renewal of sleepers in certain locations ahead of the renewal team
program to avoid clusters of ineffective sleepers.
13. Take a realistic approach to marking to ensure that sections of the track do not reach
the state where all sleepers will eventually require renewal at the one time. This will
occur if marking is too heavy or too light.

© Rail Corporation Page 170 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

14. The marking should require no more than 25% renewal in each half kilometre by a
Production team and preferably only 20%.
15. The recommended renewal rates for a 5yr cycle are 25% total or 5% p.a. i.e. every
fourth sleeper.
16. Check sleeper spacing. Where sleepers have become bunched up due to rail creep,
etc., It may be more practical to place an additional sleeper than to re-space over
some distance. Provide an additional paint mark on the rails in such cases.

C18-2 Concrete Sleeper Inspection

Concrete sleepers are less prone to failure but require inspection to insure there is no
damage to the sleeper or the associated fastenings, insulators and pads.

Inspect concrete sleepers for the following.

1. Check for sleepers that have been dislodged/knocked down by trackwork.
2. Check for sleepers that have been severely damaged.
3. Check that the shoulders of the sleeper are not corroded or damaged
4. Check for any missing fastenings.
5. Check for corroded fastenings.
6. Check for over sprung/ineffective fastenings. This may also indicate that the pad or
rail seat are worn.
7. Check for worn, incorrectly inserted or squeezed out insulators.
NOTE: If insulators are worn on a face there is a high likelihood that the pads under
the rail will also be worn.
8. Check that the pads under the rail are not severely worn. Gauge readings on track
recording graphs can be reviewed to assist in determining if there are areas of
potential pad damage. If pads are severely worn then check to determine if the rail
seat on the sleeper itself is worn/backcanted.

C18-3 Resilient Baseplate Inspection

Resilient baseplates are basically maintenance free if they have been correctly installed.
During examination:
1. Examine baseplate installations for missing, worn, damaged or incorrectly placed
clips, rail pads and insulators
Check for loose fastenings, washer uncompressed, screwspikes lifted
Check the double helical spring washers to ensure the correct gap between the coils
is achieved.

Figure 48: Pad cracked. Washer compression

© Rail Corporation Page 171 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

2. Examine baseplate installations for derailment or impact damage

3. Examine baseplate casting for cracks or visual faults
4. Examine rubber insert in baseplates for delamination, cracks, holes or other signs of
deterioration that may indicate a potential full-depth failure of the rubber moulding.
The rubber in the baseplates may be overstressed and may crack. This may lead to
the potential failure of the fastenings.

Figure 49: Cracked rubber insert

Figure 50: Rubber de-bonded

5. Check for excessive water around the fasteners due to blocked drains, seepage,
leakage etc.
There is potential for water to affect rail and fastenings

© Rail Corporation Page 172 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 51: Water coming up through slab

6. Check for metal objects or rubbish jammed between the rail and track support (slab.
or sleeper)
7. Check for excessive build-up of grease on the fasteners
8. Check the torque of the screwspikes/bolts on a random basis. Approximately 20 to
50 fixations should be checked

Track Form Recommended Screwspike

Torque
Concrete Slab with cast in HDPE dowel using Ss8 250 - 270Nm
screwspike & Fe6 washer
Timber sleeper Based on 19mm pre drilled hole in 250 - 270Nm
Tallow wood using Ss8 screwspike & Fe6 washer
Polymer Sleeper with cast in Nylon Dowel Ss8 160- 180Nm
screwspike & Fe6 washer
Table 24 – Recommended torque

9. In corrosive areas examine the conditions of all components of the baseplate and its
fixation.
10. In wet areas remove one or more baseplate installations to monitor corrosion
11. Identify and record all defects and compare to Current Defect List noting new and
deteriorating defects and defects that have been removed

© Rail Corporation Page 173 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C18-4 Definition of Condition

C18-4.1 Timber Sleepers
Failed / missing Sleepers that are broken, missing or do not give vertical
sleepers support to the rails.
Effective sleeper Sleeper/fastening system provides vertical support and
lateral restraint. Restraint must allow no lateral movement of
the fastenings relative to the timber. The sleeper must provide
gauge restraint and must be one piece that will not separate
along its length or transversely.
Sleepers should not be excessively backcanted more than 1
in 30. For double shouldered sleeper plates this is equivalent
to backcanting into the timber on the outer edge of the plate of
5mm. For Pandrol Plates this is equivalent to backcanting into
the timber on the outer edge of the plate of 6mm. For both
plates this is approximately equal to ½ the plate thickness.
Good sleeper Is an effective sleeper that will remain effective for at least 5
years under normal operating conditions prevailing at the time
of the inspection. ie If the track normally carries 10MGT of 21t
axle load traffic at 115km/h then a good sleeper will continue
to carry the same amount of traffic and remain effective for at
least 5 years.
Ineffective sleeper Sleeper that is not effective. Timber sleepers with rot, or holes
(Poor sleeper) through which ballast can be seen are not satisfactory. At
least 300mm is required between rail foot and sleeper ends
for effective tamping.
(For the purposes of assessment effective sleepers includes good sleepers).

(For the purposes of assessment ineffective sleepers include those that are missing or
failed).

C18-4.2 Concrete Sleepers

Concrete sleepers are considered “failed” when the following conditions are identified:

Condition Curve radius

< 350m > 350m
Ballast abrasion >20mm >25mm
Cracks Continuous through sleeper Continuous through sleeper
Spalling >15% along sleeper length >20% along sleeper length
Chemical damage >20% cross section affected >25% cross section affected
Tamper damage >20% cross section lost >25% cross section lost
Wear at rail toe (side
TBD TBD
insulators)
Insulating
effectiveness of rail
TBD TBD
pads, side insulators,
toe clip insulators

© Rail Corporation Page 174 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C18-4.3 Sleeper Fastenings

Fastenings, when they deteriorate or are damaged, have the same impact as ineffective
sleepers. Check the condition of the fastenings in the following table. If they are classed
as ineffective, determine how many and how they are spaced, then check the Operating
limits for ineffective sleepers.

Condition Curve radius

<600m 600 – 800m 800 – 1200m >1200m
Resilient Fastenings
Loss of Toe load Clips keep falling out
Section loss 5% 10% 15% 20%
Dogspikes
Section loss 10% 15% 20% 30%
Screwspikes (24mm)
Section loss TBD TBD TBD TBD
Screwspikes (27mm)
Section loss TBD TBD TBD TBD
Lockspikes
Section loss 5% 10% 15% 20%
Lockscrews
Section loss TBD TBD TBD TBD
Dogscrews
Section loss TBD TBD TBD TBD
Sleeper Plate
Wear or damage Allows rail movement beyond horizontal or vertical limits for an
effective sleeper

C18-5 Action to be Taken

1. Record all examination locations on Form 2 "Examination of Length”, or keep other
detailed records of locations examined.
2. If timber sleeper condition meets the requirements for Supplementary Patrol, mark
the entry on Form 2.
3. Action any defects found or investigated during a sleeper examination according to
the "Limits and Responses" table in Section C5-10.
∼ Take appropriate protective action if defects require immediate action, OR
∼ Include repair action in a work program.
∼ Report the fault to the Team Leader or Team Manager as appropriate.
∼ Monitor the fault during future examinations until further deterioration requires
action.
4. List the defects on Form 2 "Weekly Summary of Defects Report" or transfer to
Teams3 directly from inspection records.
5. When sleeper marking, record the number of sleepers marked each half kilometre
for renewal.
6. Use the recorded information to develop Asset Management Plans.

© Rail Corporation Page 175 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 19 Clearance Examination

This chapter details the procedure for inspection of:
− Lateral and vertical clearances at platforms.
− Lateral clearance to structures in all areas.
− Vertical clearance to overhead structures.
− Track centres between adjacent tracks.
− Track centres at clearance points associated with catchpoints
− Mid cycle visual inspection of platforms
The lateral clearance examination is required for all tracks where there are structures that
could infringe on the structure gauge. "Structures" include retaining walls, rock faced
cuttings, bridge members, tunnel walls, overhead wiring masts and signals.

C19-1 Inspection Procedure

When performing this type of inspection, the examiner is to have the following equipment
available.
− a non metallic tape measure, laser or other suitable measuring equipment,
− a plumb bob, spirit level or other suitable equipment,
− a board for measuring superelevation,
− a list of structures to be examined and applicable design clearances, track centres
and superelevation for the length provided by the Civil Maintenance Engineer,
− a list of approved infringements to the structure gauge detailing the required
clearances, special actions, etc. provided by the Civil Maintenance Engineer.

C19-2 Detailed Inspection of Clearance to Platforms

Examination staff
1. Measure and record the clearances between track and survey plaques at all
platforms.
At platforms survey plaques are normally provided, detailing the correct position of
the adjacent track. The design information from each survey plaque is listed on the
measurement form.
Measure and record horizontal and vertical distance from survey plaques to rail at
each survey plaque. (See Figure 52).
∼ Measure horizontal clearance to the gauge face of the nearest rail.
∼ Measure vertical clearance to the low rail.
∼ If survey plaques are not provided take the horizontal and vertical
measurements from the coping at maximum intervals of 10 metres. (See
Figure 54)
Measure and record superelevation at each measurement location. Use the
methods of measurement in Section C4-3 and Section C4-8.
Record dimensions on Form Clear 1 if available or the old form if not.

© Rail Corporation Page 176 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Platform
X mm
Survey
plaque
Y mm

Figure 52 – Measurement of clearances to Survey plaques at platforms

+ve Platform −ve Platform
FURTHER AWAY CLOSER
from track to track
+ve Platform ABOVE Design Height
−ve Platform BELOW Design Height

Design Rail Level −ve Track ABOVE Design Rail Level

+ve Track BELOW Design Rail Level

Figure 53 - Measurement Conventions

2. Measure and record the clearances between the track and the platform coping at all
platforms.
At the survey plaques, measure the horizontal clearance from the track to the face of
the coping and the vertical distance from the track to the top of the coping. (See
Figure 54) Use the method of measurement in Section C4-8.
Record the dimensions on Form Clear 1.

Platform

X mm Y mm

Figure 54 - Measurement of clearances to platform copings

3. Measure the vertical and horizontal clearance to any protrusions (signal troughing,
pipes etc) on the platform wall that stick out further than the edge of the coping.
(See Figure 55). Pick the worst example/s to measure. Use the method of
measurement in Section C4-8.
Record the dimensions on Form Clear 1.

© Rail Corporation Page 177 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Platform X mm

Y mm

Figure 55 - Measurement of clearances to platform wall protrusions

4. It may also be necessary to measure clearances to structures located on platforms.

5. Calculate variations and conduct an initial assessment.
Alignment (platform gap)
Calculate variations between actual and design measurements.
Record the variations on the examination form.
Record the variations as + or -. (+ is where there is an increased clearance between
track and structure – is where there is a decreased clearance. (See Figure 53)
Determine at the time of the examination any locations where the horizontal
clearance is reduced by more than -30mm and assess if there are any signs where
rapid deterioration is possible and/or where immediate action is required. (e.g. Signs
of track pulling in on curves especially in winter, platforms leaning etc.)
Superelevation
Calculate variations between actual and design measurements at each survey mark.
Record the variations on the examination form.
Record the variations as + or – (+ is where the superelevation variation increases
the clearance between the track and the structure – is where the variation decreases
the clearance. (See Figure 53)
Determine at the time of the examination any locations where the superelevation
variation is greater than -15mm and assess if there are any signs where rapid
deterioration is possible and/or where immediate action is required. (e.g. Severe bog
holes, severe top defects in rail closest to the structure, areas where recent
excavation work has been performed)
Combined effects of Alignment and superelevation
When the alignment error is more than 25mm check also if the combined clearance
is reduced by more than 30mm by including 50% of any contributing superelevation.
Where the above tolerances have been exceeded the combined effects of the
superelevation error and alignment error should also be considered in setting
priorities and in determining the need for any operating restrictions pending
correction (about 50% of the super error contributes to the alignment).
Team Manager
Review all inspection sheets for obvious errors.
Ensure all variations outside of tolerance listed above have been assessed and
appropriately actioned.
Forward completed examination sheets to CME
Civil Maintenance Engineer
Review all examination sheets to ensure that any areas which fall outside the
following limits are identified and actioned. The track design alignment and the
relationship to the coping should be considered. The track may infringe the design

© Rail Corporation Page 178 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

alignment but still be clear of the actual platform coping

Alignment
The default minimum clearance is that the track must not be more than 20mm closer
to the platform edge than the design alignment.
Superelevation
The default minimum clearance is that the track must not have superelevation more
than 10mm from design in the direction tilting the train towards the platform.
Combined alignment and superelevation
Where tolerances have been exceeded the combined effects of the superelevation
error and alignment error can be considered in setting priorities and in determining
the need for any operating restrictions pending correction. For standard access
allow 70% of the super error and for level access allow 80% of the super error which
contributes to the alignment).
The combined impact of the alignment and factored superelevation error should be
considered in relation to the surveyed alignment and coping position. Strategies for
future maintenance should consider this relationship. The priority is to ensure that
safe clearance to the coping is not compromised. Some issues to be considered are:
∼ The track may be too close to the surveyed alignment but clear of the platform
coping. This would be satisfactory in the short term but strategies would need to
be put in place to correct the track alignment in the event of any coping
adjustment.
∼ The track may be satisfactory with regard to the surveyed alignment but is too
close to the actual coping. An assessment of the current situation would need to
be conducted which may require short term measures such as a speed
restriction or closer monitoring. In the longer term correction may require an
adjustment to the coping or a realignment of the track.
The default is that the combined alignment and factored super errors should not
exceed 25mm tilting towards the coping.
Where the platform gap compared to the design alignment is more than 30mm tilting
the train away from the platform then this should be considered in setting corrective
maintenance priorities for track resurfacing. Stakeholders should be advised where
the actual gap to the coping is beyond the standard for its position by more than
30mm and the contributing factors for this (track relative to design alignment or
platform coping).
Height (platform step)
Over time track level may creep up. For track at Level Access platforms the
maximum permitted level shall be -100mm (ie a level of 1100mm rail to coping for
straight track). For Standard Access platforms the track is to be maintained between
-20mm and +100mm of design:
Where Standard Access platform locations are low to design, consideration should
be given to whether the platform is to be converted to Level Access. If this is the
case then, where practical, an integrated design should be developed between
platform works and trackwork to achieve the revised grading. This may involve
staging over a number of years with interim heights somewhere between Standard
Access and Level Access. Agreement with relevant stakeholders must be obtained
for such arrangements.
In any case track should not be lifted just to bring it back to standard access from a
position intermediate between standard access and level access. However track
lifting should be undertaken if the track is so low as to be outside the tolerances for
level access.
Where track is otherwise out of tolerance a review should be undertaken as to
whether the track or platform is at fault. A design review should be initiated to

© Rail Corporation Page 179 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

determine the best solution.

Note that maintenance actions for track must consider the variation along the
platform. Track vertical alignment must be smooth. Localised track lifts cannot be
used to accommodate local variations in coping position.
Note: Measurement convention (+ means track is lower than design rail level) – see
Figure 53 below.

C19-3 Civil Maintenance Engineer and Team Manager review

1. Review all areas where the Civil Maintenance Engineer has determined that
tolerances have been exceeded. Visual Inspection of locations and review of
previous measurements may assist in determining action and priority.
2. Plan for rectification or other control of exceedents.
3. Ensure that all defects and applicable action and/or controls are recorded in a defect
management system.

C19-4 Mid Cycle Visual Inspection of Clearance to Platforms

Team manager
1. Conduct a visual inspection of each platform to check that there have been no major
changes to clearances caused by.
∼ Platforms being resurfaced.
∼ Additions to platform coping.
∼ Severe bog holes or obvious changes in track surface which could reduce
clearance.

2. If changes have occurred arrange for platform clearance measurements to be taken

and actioned at the affected location as detailed in C19-2.

C19-5 Inspection of Clearance to Structures

Examination staff
1. Check the clearances at listed structures. .
2. Measure the clearance at each indicated point using the method of measurement in
Section C4-8.
If no survey points exist for the listed structure measure clearance to the structure at
either end and at maximum intervals of 10 metres.
DO NOT assume that all structures are vertical. If there is an overhang, use a plumb
bob or other method to establish the position relative to the track.
3. Measure the cross-level or superelevation at each measurement point using the
method of measurement in Section C4-3.
4. Record track clearance and superelevation variations on Form Clear 1 "Clearance
Examination" as +/- mm from design.
Civil Maintenance Engineer
1. Review clearance measurements against minimum clearance requirements.
2. Plan for rectification or other control of identified defects.
3. Ensure that all defects and applicable action and/or controls are recorded in a defect
management system.

C19-6 Inspection of Track Centres

Examination staff
1. Check the clearances at listed locations and complete Form Clear 2.

© Rail Corporation Page 180 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Track centres are to be measured at the nearest survey mark to the tangent points
on straights. If the straight is more than 250m long, take intermediate measurements
at not more than 250m intervals.
Track centres are to be measured at maximum intervals of 50m on curves.
2. Measure track centres using the method of measurement in Section C4-9.
3. Measure the superelevation/cross-level for both tracks at each inspection point using
the method of measurement in Section C4-3.
4. If there is any visible variation in line or superelevation between inspection points
that would bring vehicles closer together, measure track centres and superelevation
at these points as well.
5. Record track centre and superelevation variations on Form Clear 2 "Inspection of
Track Centres and Rail Level" as +/- mm from design. Note + is when the variation
increases track centre clearance – is when the variation reduces track centre
clearance.
6. Where separate tolerances have been provided by the Civil Maintenance Engineer
for specific locations use those tolerances. Otherwise determine if there are
variations of greater than -30mm in track centre measurements and/or a combined
error of – 20mm in super variations. Calculate the total change as detailed in
Figure 56 for tangent track and Figure 57 for curved track. Record the total change
on Form Clear 2.
If the total loss of track centre clearance exceeds - 90mm then report the location to
the CME
7. At those locations also assess if there is potential for rapid deteriation where
immediate action is required. (e.g. Where there is evidence of curves pulling in, loss
of superelevation in the two inner “six foot” rails due to bog holes or excavation work
etc)
Team Manager.
1. Review all inspection sheets for obvious errors.
2. Ensure all variations outside of tolerance listed above have been assessed and
actioned as required.
3. Forward completed examination sheets to the Civil Maintenance Engineer
Civil Maintenance Engineer
1. Review all field sheets from track centre examination and determine appropriate
action and/or control for areas that infringe on the design clearance envelope.
2. Ensure all defects and appropriate action and/or controls are entered into a defect
management system.

© Rail Corporation Page 181 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Up Rail
Down Rail
Up Rail Down Rail

Down Track Up Track

TC

Convention: Down rail is datum rail

Where the Down Rail is lower than the Up Rail, Superelevation
is positive (+)
TC (Design) = 4000mm
TC (Actual) = 3955mm
TC (Variation) = - 45mm ( 45mm loss of clearance)

S(design) (Down Track) =0

S(Actual) (Down Track) = - 10mm
S(Variationl) (Down Track) = -10mm ( 10mm loss of clearance)

S(design) (Up Track) = 0

S(actual) (Up Track) = + 15mm
S(variation) (Up Track) = - 15mm (15mm loss of clearance)

Total loss.
TC (Variation) = - 45mm
Total Super variation = - 10 + - 15 = - 25
Total loss due to superelevation = – 25 x 3 = - 75
Total Variation in Track Centres = - 45 + - 75 = - 120 mm

Figure 56 - Calculation of Variation in Track Centres - Tangent track

SB
Track
Track
B
A
SA
TC

TC (Design) = 3900mm
TC (Actual) = 3870mm
TC (Variation) = - 30mm ( 30mm loss of clearance)

S(design) (Down Track) = 50

S(Actual) (Down Track) = 35mm
S(Variationl) (Down Track) = -15mm ( 15mm loss of clearance)

S(design) (Up Track) = 60

S(actual) (Up Track) = 80 mm
S(variation) (Up Track) = - 20 mm (20mm loss of clearance)
Total loss.
TC (Variation) = - 30 mm
Total Super variation = - 15 + - 20 = - 35
Total loss due to superelevation = – 35 x 3 = - 105
Total Variation in Track Centres = - 30 + - 105 = - 135 mm

Figure 57 - Calculation of Variation in Track Centres - Curved track

© Rail Corporation Page 182 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C19-7 Inspection of Track Centres at Clearance Points

The safety clearance point between two (2) adjacent converging tracks is the point where
a moving vehicle passes a stationary vehicle, on the adjacent track, with a minimum
distance between vehicles of 450mm.

The clearance points may be protected by use of catchpoints, fixed signals, track circuits
and insulated joints, etc.
The clearance at catchpoints should be checked at the time of the detailed examination
of catchpoints and is listed on Form STW 2 “Catchpoint examination”
At all other locations:
1. Check the clearances at listed. The list shows:
∼ Location
∼ Designed track centres
∼ Superelevations.
The inspection is carried out at locations where either track has an allowable speed
greater than 20kph.
If there are catchpoints, locate the clearance point by measuring 3.8m along the
track from the catch point throwoff rail (see Figure 58).
If there are NO catchpoints but a clearance peg (white peg) is provided, measure
clearance at this point (see Figure 59).
If there are NO catchpoints and NO clearance peg, locate the clearance point by
measuring 3m along the track from the insulated joint (see Figure 60).

Catchpoint Centre Line

3.8m of other track

Throw Off Rail

3.650 minimum
Track Centres

MAIN LINE

Figure 58 – Clearance Point location – with catchpoints

© Rail Corporation Page 183 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Centre Line
of other track

White Clearance Peg

3.650 minimum
Track Centres

MAIN LINE

Figure 59 - Clearance Point location – with clearance post

Centre Line
of other track

3m

Insulated joint

3.650 minimum
Track Centres

MAIN LINE

Figure 60 - Clearance Point location – with insulated joint

2. Check track centres by measuring the distance from the gauge faces of the up or
down rails of adjacent tracks.
Note: DO NOT measure track centres from adjacent rails of adjacent tracks.
Use a non-conductive tape measure for measuring track centres.
3. Record track centre variations on the inspection form as +/- mm from design. (See
Form Clear 2).
The track centres clearance required at the clearance point is 3.65m.
If the measured clearance is less than 3.65m notify the Civil Maintenance Engineer.
4. Measure and record the superelevation/cross-level for both tracks at each inspection
point. (See Form Clear 2).
5. Calculate changes in clearances due to changes in track centres and
superelevation.
6. Check the direction of the throw-off rail.
If the throwoff rail of the catchpoint is NOT parallel to, or leading away from the
adjacent track (see Figure 61), notify the Civil Maintenance Engineer.

© Rail Corporation Page 184 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Throw Off Rail direction

Catchpoint
OK

OK

NOT OK

MAIN LINE

Figure 61 – Direction of Throw-off rail

C19-8 Inspection of Rail Level

Designed rail levels beneath all structures and under overhead wiring are listed for each
Length.
1. Check rail levels by measuring the vertical distance from the survey mark,
monument, plaque or survey peg to the running surface of the datum rail using the
method of measurement in Section C4-6.
1. Where special survey plaques are provided at structures with restricted clearances,
measure the distances of the rails from the plaques instead of the actual clearances.

C19-9 Action to be Taken

Examination staff:
1. Record all examination results on Form Clear 1 "Clearance Examination", Form
Clear 2 "Inspection of Track Centres and Rail Level" or Form STW 2 – "Catchpoint
Examination."
2. Assess any defects found or investigated during the inspection that are outside the
limits stated in this chapter.
1. Take appropriate protective action or corrective action as stated in this chapter.
2. List defects and appropriate action or controls in Teams3 or other defect
management system.
Team Manager:
1. Check field sheets for errors
2. Ensure defects outside the limits stated in this chapter are assessed.
3. Ensure that all defects and actions and/or controls are entered in Teams3 or other
complying defect management system.
Civil Maintenance Engineer:
1. Check that all exceedents outside the limits stated in this chapter are assessed
2. Determine appropriate actions or controls in consultation with team managers.
3. Ensure that clearance infringements are to be managed in accordance with the
requirements of TMC 215 Transit Space Manual.

© Rail Corporation Page 185 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 20 Level Crossing Examination

C20-1 Examination Requirements
Level crossings are to be examined to identify defects in:
− conditions of ties and fastenings;
− rail condition;
− crossing surface;
− guard rail flangeways and guard rail effectiveness;
− top and alignment;
− drainage;
− condition of signs, gates, grids and fences.

C20-2 Crossing Types

There are two distinct types of level crossing construction:

Modular (or Special) - These are manufactured in concrete or rubber modular sections
and assembled on site.

Non-Modular -These are constructed from materials such as sleepers, ballast, bitumen
and in-fill concrete.

Most pedestrian crossings are non-modular types.

C20-3 Equipment
When performing this type of inspection, the Track Examiner should carry the following
equipment:
− a combination cross-level/gauge board;
− a 5m tape measure;
− a bar to clean out flanges.

C20-4 Examination Procedure

Examine all level crossings, whether sealed or not.
1. Measure and record gauge through the level crossing at 2m intervals.
2. Identify, measure and record any rail play.
In Modular Crossings, look for modules coming into contact with rails, rubbing marks
or rusty spots on galvanised components.
At bitumen paved crossings; look for cracks in the bitumen around the running rails
or guard rails, compressed 'humps' of bitumen behind the running rails.
Where rail play is suspected, insert a bar through the flangeway and lever it in an
attempt to widen the gauge. Record approximate values for rail play on the
inspection form.
3. Measure and record flangeway clearance and depth for both guard rails through the
crossing at 2m intervals.
4. Measure and record guardrail effectiveness for both guard rails through the crossing
at 2m intervals (see Figure 62). Take the measurement from the face of the guard
rail nearest the running rail to the gauge face of the opposite running rail. Take the
measurement for both guard rails.

© Rail Corporation Page 186 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

The Down guardrail effectiveness measurement is measured from the downside

guard rail to up rail and vice versa.
Down
Rail Up
Rail

Up Guardrail Effectiveness
Up
Down Guardrail Effectiveness Flangeway
Down
Flangeway

Gauge

Figure 62 – Measurement at level crossings

5. Visually inspect each end of the guard rails for "hit" marks. Measure and record the
width of the flare opening at each end of each guard rail.
6. Visually examine, assess and record the general condition of ties and fastenings.

Figure 63 – Corroded plates and fastenings

7. Check the height of the roadway surface relative to rail level.

8. Visually examine, assess and record the fit of components and condition of modular
crossings. Look for:
∼ Visible signs of differential levels in crossing surface between adjacent panels,
or between panels and rail head level or adjacent road surface level
∼ Visible signs of localized road surface wear, indicating possible differential
loading
∼ Gaps between panels
∼ Loose end restraint fastenings
∼ Movement of panels under road traffic loading.
Note that, except for ‘sitting obviously high’ and ‘movement under load’, the above

© Rail Corporation Page 187 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

are indicators only of possible loss of vertical restraint. If the indicators exist, further
examination is required to determine if there are any vertical restraint issues.
9. Visually examine, assess and record the condition of the roadway surface of Non-
Modular Crossings.
Look for pot holes, lifting timbers or other ineffective components.
10. Visually examine rail top and line. If there are visible irregularities, measure and
record the extent of defects.
11. Examine condition and visibility of level crossing signs and condition of fences and
gates.
12. Examine rail webs and flanges for evidence of rail corrosion. Use a bar to inspect
rust flakes through the flangeways.
13. Examine drainage condition.
14. Examine sighting distances on passive level crossings (crossings without lights and
bells) for vegetation or other sight obstructions.
This is best achieved by paint marking the sighting points on the rail. Stand at the
sighting point and look towards the level crossing. You must be able to see the point
where the vehicle driver will be sitting when he is looking for a train (Where the Level
Crossing is protected by a Stop Sign this will be 5m back from the level crossing. If
the Level Crossing is not protected by a Stop sign the vehicle driver’s sighting point
will be some distance back from the Level Crossing. This needs to be defined for
each level crossing and marked on the road approach). The method of determining
sighting distances is detailed in RailCorp Engineering Manual TMC 521 - Level
Crossing Manual.
Note: Sighting points are required for both road approaches and for all track
approaches to the level crossing.

C20-5 Action to be Taken

1. Record all examination results on Form LX 1 Level Crossing Examination.
2. Assess any track geometry defects found or investigated during the inspection
according to the "Limits and Responses" table in Section C5-4.1.
3. Assess other defects found or investigated during the inspection according to the
"Limits and Responses" table in Section C5-13 and the limits and responses in
TMC 521.
4. Take appropriate protective action or corrective action.
5. List the defects on Form 2 "Weekly Summary of Defects Report" or transfer to
Teams3 directly from Form LX 1.

© Rail Corporation Page 188 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 21 Special Track Inspection Issues

Staff involved in inspection and maintenance planning need to be aware of issues that
require special attention during inspections at various times of the year.

C21-1 Hot Weather Inspection Issues

C21-1.1 Pre-Season Inspection
Special inspections are required before the commencement of the summer period, and
during the summer period when rail temperatures approach the maximum levels.
1. Carry out a Walking inspection of the track to spot check that the Welded Track
Stability measurement has been correctly completed.
∼ Dogspikes and other fastenings are effective to resist side thrust.
∼ The expansion gaps at rail joints are correctly measured.
∼ Any indications of sleepers that are loose and need packing, or are centre
bound, are corrected.
∼ The anchors are holding firmly against sleepers and sufficient anchors provided
so that the resilient fastenings are not allowing the rail to move.
∼ The track is adequately ballasted especially on the shoulder.
∼ The ballast around all sleepers is properly boxed up.
∼ Any indications of hard foul ballast that could provide a glassy surface for easy
lateral movement of sleepers have been recorded and corrective action
programmed for completion prior to the hottest periods.
∼ The Track Stability Analysis is correct and corrective action is completed or is
programmed for completion.
∼ Recent track maintenance work has been properly completed.
∼ Locations of non-standard welded track have been appropriately identified and
dealt with.
2. During the inspection check that appropriate attention is to be paid to the potential of
misalignment triggers such as:
∼ Poor Rail/Weld alignment arising from incorrect crowing, rail end alignment,
poor rail profile matching, straight closures in curves, track alignment (including
gauge) glued insulated joints etc.
∼ Rail surface and track geometry defects including poor top, twists, dipped
welds, dipped joints, wheel burns and corrugations, pumping sleepers etc.
∼ Rail bunching at fixed points due to changes in grade, changes in fastener,
sleeper or rail type, bridges, turnouts, level crossings etc.
∼ Rail bunching due to stopping and starting of trains at signals, platforms etc.
∼ Local disturbances due to undertrack crossings, culverts etc.
∼ Curves less than 400m radius. Tight radius curves have a higher misalignment
risk, particularly if they are continuously welded on dogspiked sleepers. Pay
particular attention to these locations to correct any track instability or potential
misalignment triggers.
3. Check that full track stability has been restored at all previous misalignment sites
(say, 3-5 years).

© Rail Corporation Page 189 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C21-1.2 Track Inspection Issues in Summer

Track problems can affect the reliability of Signalling equipment in the summer period.
Problems arise from the movement of steel in the hot weather, from summer storms and
even from ballasting work carried out for WTSA.

Track staff involved in inspection and maintenance should be alert for such problems and
should work with Signal discipline staff to secure the reliability of the infrastructure.

The following issues require special attention during summer months:

Anchoring
Anchoring of turnouts and special trackwork is important to prevent the movement of
steel especially where there are non-elastic fastenings. Catchpoint areas are particularly
vulnerable. Anchoring is required within and adjacent to turnouts and special trackwork.
Additional anchors should be considered to prevent movement of steel.

Bolts in Turnouts
Chair bolts must be tight in the switch area of turnouts to resist longitudinal movement of
steelwork (as well as lateral movement and to prevent breakage).

Insulated Joint Gap and Clips

Make sure that small movements of the rail are not going to cause shorting, either from
clips too close to fishbolts or from the joint gap where there is rail end flow.

Switch Movement and Flow

Check that rail flow on the stockrail will not affect switch or stockrail movement in the
heat. Remove stockrail flow for at least 25mm beyond the switch tip.

Check that there is still travel available for the switch before the end of the stockrail
undercut or joggle. At least 25mm beyond the switch tip should be available for
longitudinal movement.

New Ballast
Thick layers of new ballast left in the four foot can cause signal failures from “sagging
track” especially if heavily contaminated with fine dust. New ballast should be ploughed
off. If this can't be done check with signal staff as to whether the track section involved is
sensitive to sagging.

Ballast Trains & possession work

Make sure ballast laid out does not foul signalling equipment especially at points and
trainstops). Also make sure hopper doors are fully shut, not just at the conclusion of the
work but if any turnouts are traversed between ballasting locations. Check point areas if
any spillage is suspected. After possession work, inspect point areas that could be
affected by ballasting work (including with off-track plant).

Drainage
Poor drainage can affect turnouts and special trackwork (from pumping track) and open
track where “track sagging” can result. Signal staff can identify vulnerable locations.
Track staff should be on the lookout for evidence of boggy track or locations where water
pools. Note that flogging heels on heeled switches is an area of particular vulnerability.

© Rail Corporation Page 190 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 22 Track Recording

The prime function of the Track Recording Car is to provide detailed information to district
and district management on the condition of main lines.

The Track Condition information provided is a guide to the overall condition of track. By
comparison with earlier reports it indicates any changes in track condition and is a guide
to the quality of work done between reports.

The Track Recording Car is required to operate on a cycle of examinations as detailed in

ESC 100 - Civil Technical Maintenance Plan.

C22-1 Field Duties Prior to Track Recording

When you are notified that the car will be recording on your length:
1. Obtain Track Recording program for area from the Manager Track Recording
2. Check kilometre posts in area of recording run to establish they are correctly located
and visible to car crews.
3. Obtain clear instructions about the distribution of the defect list and graphs at the
end of the run.

C22-2 Action required During Recordings

1. Travel on the Track Recording car on your track length.
2. Monitor Track Recording graphs as they are being recorded.
3. Compare the current recording with the last recording to check the effectiveness of
work completed, to look for repeats and to compare the general track condition.
4. Note Locations where recording has failed (derailed trolley etc).
5. Note recording car errors, particularly those showing as defects. Arrange to have
these signed off on the recording run by the operator.
6. Identify and record defects and compare to Current Defect List noting new and
deteriorating defects and defects that have been removed.
7. Where Emergency level (E1 and E2) defects in short twist, long twist or top are
recorded check with the Track Recording Vehicle operators that the defect is
genuine.
8. Arrange immediate PROTECTIVE action for EMERGENCY level defects during the
run, pending further corrective actions in accordance with the "Limits and
Responses" tables in Chapter 5.

C22-3 Distribution of Recording Graphs

At the end of each Length or as otherwise agreed, the car will stop and all copies or
recording graphs and Priority Location Lists will be provided to the field representative on
the car.
1. Take copies of recording graph and computer disk from the recording car.
2. Distribute or arrange distribution of Emergency and Priority 1 defect listings lists in
accordance with instructions provided by the Civil Maintenance Engineer.
The distribution must be carried out quickly to allow prompt attention to all
Emergency and Priority 1 locations.
3. Distribute or arrange distribution of copies of graphs and computer disk to
appropriate staff in accordance with instructions provided by the Civil Maintenance
Engineer.

© Rail Corporation Page 191 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

The Recording Graphs are to be distributed as follows:

∼ Original to the Civil Maintenance Engineer.
∼ 1 copy to Team Manager
∼ other copies are to be distributed as required by the Civil Maintenance
Engineer.
4. Notify the Civil Maintenance Engineer of any location that has not been inspected
because of recording failure or possession shortfall etc, so that alternative
inspections can be arranged.

C22-4 Defect Examination & Repair

1. Locate defects in the field and assess according to the "Limits and Responses" table
in Chapter 5.
2. Take appropriate protective action or corrective action.
3. Update Defect Listing and program repairs required.

C22-5 Missing Inspections

Inspection of Main lines and Crossing Loops by the Track Recording Car is a
fundamental requirement. Whilst the Track Recording Car is generally able to maintain
the inspection cycle for main lines it may sometimes miss Crossing Loops.

If directed by the Civil Maintenance Engineer, undertake a manual inspection of track

geometry.
1. Measure twist and gauge using portable track recording equipment or the
"trackmaster" measuring board.
2. Assess top and line visually, supplemented with stringline measurements if required.
3. Assess rail play visually.
4. Mark and record all Emergency level (E1 and E2) and Priority 1 (P1) for appropriate
maintenance action.

C22-6 Track Recording Analysis

The Track Recording Car provides an assessment of general track condition. This is
reported by the car as Track surface and Track Condition Index (TCI) and is often an
indicator of significant track problems.
1. Analyse Track Recording graphs for Track Condition Index (TCI).
2. Examine locations with high Track surface or TCI for planning of rectification work.
Inspect any significant track sections (over 50m) excluding turnouts reported with
condition exceeding:
∼ Track surface > 32
∼ TCI > 70
3. Compile a record of track with high Track surface or TCI, including assessment of
the locations and planned remedial actions.
4. Forward details of the work required and a proposed plan of rectification to the Civil
Maintenance Engineer.

© Rail Corporation Page 192 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 23 Turnout & Special Trackwork Examination

Turnout & Special Trackwork Examination is a detailed examination of turnouts and
diamond crossings, catchpoints and expansion switches.

C23-1 Examination Requirements

Turnouts and other special trackwork are to be examined at the frequencies documented
in ESC 100 - Civil Technical Maintenance Plan.

These are the minimum frequencies. At locations where obvious deterioration occurs at
higher rates due to such factors as curvature, usage, axle load or speed more frequent
inspections should be scheduled. These additional inspections may be reduced in scope
to address only those parts of the inspection affected by the additional factors.

Particular attention is drawn to any similar flexure turnouts (ie where the outside rail
nominally the 'high rail' is the stockrail) which are subject to curve wear. For such cases,
the fit of the switch against the stockrail, the condition of the switch, the stockrail and the
switch tip height, width and angle should be assessed more frequently. These additional
examinations may be conducted and recorded as part of the Detailed Walking
Examination in Chapter 9.

For tangential turnouts additional examination requirements are detailed in Section C23­
18.

C23-2 Equipment
When performing this type of inspection the examiner is to carry the following equipment:
− a light hammer,
− a 5m tape measure,
− a combination cross level/gauge board,
− a switch nose profile gauge,
− a 400mm bar for checking switch lever tension (if applicable),
− a housed points clearance gauge (if applicable),
− appropriate forms.

C23-3 Switch Examination

Switches should swing freely at the heel without being too loose and heels should not be
so tight that they would cause springing or bending. Slide chairs should be clean and
well oiled with even support to the switch throughout its length. All switch studs should
make light and even contact with the back of the switch. The “A”, “B” and “C” chairs
particularly should be firm and solid without any lateral movement. The switch should fit
snugly against the stock rail along the machined portion of the back edge and should be
crowed where necessary to ensure a neat fit. The point of the switch should be smooth
and sharp, not blunt or chipped.

1. Check Switch profiles of BOTH switches with a switch nose profile gauge using the
following procedure:
∼ Set the box section Track Supervisor's combination gauge on the adjacent
stockrails directly above the top of the arc on the switch nose.
∼ Set the switch tip profile gauge on the box section so that nib of the gauge
contacts the gauge face of the stockrail. (See Figure 64).

© Rail Corporation Page 193 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Top of Switch Arc

Figure 64 - Using Switch Nose Profile Gauge in conjunction with Track Supervisor’s
Combination Gauge

To check switch height:

∼ Place the gauge directly above the head of the stockrail with the nib contacting
both the gauge face of the stockrail and the top of the switch.
∼ If the gauge is observed to be touching the running surface of the stockrail, the
switch height is O.K. (See Figure 65).

Space here
Touching NO GO
OK

CORRECT INCORRECT

Figure 65 - Checking Switch Tip Height

∼ If there is a space between the gauge and the stockrail, the switch is too high.
∼ Measure and record the size of the space.
∼ This check is only valid if the heel of the switch is definitely not 'pumping'.
If the switch is too high, look for causes.
∼ Check the chairs. Taller chairs further back may be lifting the switch up.

© Rail Corporation Page 194 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ If the switch nose is rising under load – check the heel block.
To check switch width:
∼ Observe the gauge where the nib should contact the gauge face of the stockrail.
(See Figure 66).
∼ If the nib fails to make contact leaving a space, the switch is too wide ('blunt').
∼ Measure and record the size of the space.

No Space here Space here

OK NO GO

CORRECT INCORRECT

Figure 66 - Checking Switch Tip Width

To check the slope of the switch:
∼ Observe the spaces between the gauge and the face of the switch.(See Figure
67).

Space here as shown Space here decreasing

OK towards Bottom
NO GO

CORRECT INCORRECT

Figure 67 - Checking Switch Face Slope

∼ If there is a space gradually increasing toward the lower face of the switch, the
slope is O.K.
∼ If the space becomes wider towards the top of the switch face, the slope of the
switch is too flat.
∼ Record this condition.
2. Examine the switch tip for damage.
∼ Visually inspect the switch foot and web and check visually for any signs of

© Rail Corporation Page 195 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

cracking or severe notching from about 1.5m to 3m back from the tip.
Wipe off any surface dirt/ grease should be from the outside of the switch first.
A severe notch is where there is a sharp notch of 3mm or more or a rounded
notch of 4mm or more (see Figure 68).

Head of Switch

Sharp notch Rounded notch

Figure 68 - Notching in switch

∼ Visually examine the inside of the open switch.

Make arrangements to have the points reversed so that inside of the other
switch can also be visually examined.

CAUTION:
DO NOT put any part of your body or anything else between the switch and the
stockrail unless appropriate protective arrangements are made. Worksite
supervisors should review the protection required but it would at least require
having the points secured and clipped by the signaller

Check for cracking on the

inside of switch (may
initiate from notching
and/or ariss

Figure 69 - Cracked switch initiation

∼ If cracking is discovered take immediate to protect the affected route as follows.

Crack size & location Switch Support Response

Condition
Small crack limited to the foot well supported Maximum speed 20km/hr
area
not well supported Maximum speed 10km/hr
Crack is into the web but clear switch is well supported Maximum speed 10km/hr with
of the head of the rail continuous monitoring until
replaced
not well supported Close the road
For anything worse than the above Close the road
3. Examine the bearing of the switch along its full length on the plates. It should bear
evenly on all plates.
This is particularly important for undercut stock rails in 60 kg conventional and
tangential turnouts due to the angle of the undercut.

© Rail Corporation Page 196 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

More than 1-1.5mm vertical clearance between the switch and plate at the “A” or “B”
timber can lead to lock and/or detection failures since the switch will move sideways
as well as down under load and may not always drive to a consistent position
against the stockrail.
Uneven bearing on plates through the length of the switch, in particular on the longer
switches, leads to high frictional loads, scoring on those few plates on which the
switch is bearing and failure of the switch to lay correctly up to the stock rail. Again
since there will be lateral movement when the switch is under load, detection failures
can result.
4. Examine the fit of switch and stockrail.
If either switch does not fit correctly, look for the cause. Look for rail flow on the
gauge face of the stockrail or for some obstruction between the switch and stockrail.
A 6.1m switch with 155 heel centres should fit tightly fit tightly against the stockrail
from the nose to a point 2.615m along the switch.
If the switch is opening up, check
∼ If studs are correct length or are damaged, and replace if necessary.
∼ If heel block bolts are loose.
If the Switch is not closing properly, check
for:
∼ loose switch stud bolts or studs not
placed in the correct order. Studs should
be properly adjusted so that each is
bearing against the web of the switch in
the closed position
∼ foreign material (eg ballast, old bolts, old
studs, etc sometimes gets between the
stockrail and the switch). This stops the
switch from closing correctly..
∼ bad top. If the heel of a switch is at a
low point on the rail, the point may rise
up away from the stockrail when a train
passes.
∼ rail wear. If the gauge face of the
stockrail is worn, there will be a gap
between the top of the switch and the
stockrail.
5. Examine the line of the open switch.
∼ Check that the open switch does not
have a narrow "belly" opening in the
middle (see Figure 70).
Figure 70 – Open Switch with narrow "belly

6. Check for evidence of stockrail creep at switches. Look for:

∼ Shiny marks in front of switches.
∼ Shiny marks on rail brace plate or chairs.
∼ Bent twisted or broken heel blocks.
∼ Points out of square.
7. Check the switch studs and chairs along the length of the switches for soundness.
Tap the studs and chairs with a light hammer.
Record details of loose studs, loose or cracked chairs.

© Rail Corporation Page 197 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

These studs (also called stop blocks) are made to fit each particular type of switch
and most are made to left and to right hand patterns. It is essential you provide for
the correct pattern for each item.
8. Check bolt condition in the switch area including:
∼ Holding down bolts/ spikes.
∼ Rail brace bolts/ switch stops.
∼ Nib bolts (that hold the rail brace to the brace plate in some timbers).
Loose bolts can be seen when the washer is not fully compressed.
Tighten or report loose or missing bolts or conditions that are non-standard such as
multiple washers. Both chair bolts and stud bolts are important.
Note the locations of any broken bolts and check if the holes are misaligned. Record
if there is a restriction to longitudinal movement of the timber such as a point motor
attached.
9. Check the fit of the stockrails on the plates.
Record the condition as a defect if the stockrail is not supported by the plate. ie there
is a gap between the stockrail and the plate.
10. Check the heel joint. Look for:
∼ Evidence of the joint pumping. (This condition will cause the nose of the switch
to lift under load and possibly derail a vehicle).
∼ Cracked heel block.
∼ Loose or missing heel bolts.
∼ Fouled heel joint. Never allow overflow across a heel joint. Cut it out with rail
saw, hack saw or grind it out. If left unattended it could fail the points.
∼ Loose spikes under the heel joint.
∼ Overtightened bolts. (This condition may make it excessively difficult to operate
the point reversing lever).
In tangential turnouts:
∼ If the heel blocks (stress transfer blocks) and their bolts are not kept tight there
is a danger that there will be excessive longitudinal movement of the switch
blades. In extreme cases this will result in loss of detection at the switch toes.
11. Check points operating gear for excess ballast and obstructions

At non-interlocked points
In addition to the examination of the switch condition detailed in steps 1 to 11 above:

1. Check the switch travel clearance of both switches at the nose of the switch (See
Figure 71 and Figure 72).
Measure and record the distance from the back of an open switch nose to the gauge
face of the stockrail.

© Rail Corporation Page 198 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 71 - Measuring Switch Travel Clearance

Figure 72 - Measuring Switch Travel Clearance

C23-4 Crossing and Checkrail Examination

Inspect crossings and checkrails using the following procedures.
1. Check the 'checkrail effectiveness' dimension for both the main line and turnout legs
of the crossings.

Checkrail
effectiveness

Figure 73 - Measuring checkrail effectiveness

Measure the distance from the 'checking face' of the checkrail to the 'gauge face' of
the crossing nose at the Practical Point of the crossing. Checkrail effectiveness and
gauge measurements at “V” &”K” crossings should be taken at a point just behind
(nominally 150mm) the actual point of the crossing to insure that varying crossing
nose shapes do not effect consistency of measurement. For “K” crossings this point
may have to be further away to allow the measuring board to be square to the
measurement point.
Checkrail effectiveness dimensions are critical. If the dimension is allowed to
significantly narrow, it becomes likely that a wheel flange will strike the practical point
of the crossing.

© Rail Corporation Page 199 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Gauge Checkrail
Crossing
Flangeway Checkrail Effectiveness Flangeway
Xing R R
Point Running
rail
Gauge Line
Checkrail

Figure 74 - Critical measurements in ‘V’ Crossings

Record the actual measurement on the inspection form and compare it to the
reporting tolerance.
12. Check the gauge of both the mainline and turnout sides of crossings.
Measure and record the distance between the gauge faces of the crossing and its
checkrail carrier at points 16mm below the running surfaces of the rails. (See
Figure 74).
13. Visually inspect the nose of the crossing and adjacent wing rails for excessive wear.
Wear is excessive when a visible 'saddle' has been worn into the crossing nose or
rail flow is evident on the inside faces of wing rails or crossing nose. Record wear of
crossings.

Figure 75 - Example of a Worn Crossing

14. Measure the dip at the crossing by placing a stringline from one wing to the other
over the front of the nose. Measure the dip with callipers. Record the dip
measurement.
15. Measure and record flangeway clearances (R) (See Figure 74 and Figure 76) for
both the main line and turnout at a point opposite the practical point of the crossing
on both sides.

© Rail Corporation Page 200 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 76 - Measuring Flangeway Clearance

C23-5 Gauge & Superelevation

1. Set up a series of permanent inspection points on each turnout at 2m intervals,
starting at a point 6m clear of the points and finishing 6m clear of the crossing.
Mark each inspection point with white paint and give it a number. Start the
o.
numbering with station N 1 in front of the points.
Mark the main line and crossover track at diamonds commencing with stations No.1
Main and No.1 Crossover on the Sydney end of the track work.
This will simplify inspections and help maintenance teams locate defects.
16. Measure gauge and superelevation at each inspection point through turnouts.
Alternatively use a turnout measuring trolley equipped with continuous recording
capability to measure and record gauge and superelevation electronically.
At crossovers, continue measurements through the connecting track for the full
length of the crossover.
Assess changes in superelevation over 14 metres.
17. Check for indications of rail play.
Rail play is any potential movement of the rail across the tie and, in particular,
movement which will make the track gauge widen under load.
Rail play can be:
∼ Where there is no plate and the tie is 'planed' by the rail or has a shoulder of
timber raised at the outer rail flange.
∼ Where the timber has been 'planed' by movement of a track plate.
∼ Where there is movement of the rail across a plate or between fastenings.
If rail play is observed measure and record TOTAL AMOUNT OF GAUGE
WIDENING POSSIBLE.
18. Examine line through the turnout. If there are visible defects, check the line by
stringlining.

© Rail Corporation Page 201 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C23-6 Bearer Condition

Examine condition of ties (bearers), fastenings and plates.

C23-6.1 Definition of Condition

C23-6.1.1 Timber Bearers
Failed / missing bearers Are those that are broken, missing or do not give vertical
support to the rails.
Effective bearers Bearer/fastening system where the required fastenings
are in place and which provides vertical support and
lateral restraint. Restraint must allow no lateral
movement of the fastenings relative to the bearer. The
bearer must provide gauge restraint and must be one
piece that will not separate along its length or
transversely.
Timber bearers must have a flat rail plate seat.
Timber Bearers may not have more than 20% loss from
any part.
A timber bearer that can be re-drilled will become
effective again. It must have sufficient material between
the rail fastenings (in the “four foot”) to withstand centre
bound conditions.
Ineffective bearer Bearer that is not effective. Timber bearers with rot or
holes through which ballast can be seen are not
satisfactory. At least 300 mm is required between the rail
foot and bearer ends for effective tamping.
(For the purposes of assessment ineffective bearers include those that are missing or
failed).

C23-6.1.2 Concrete Bearers

Examine concrete bearer fastening systems for evidence of corroded or broken
screwspikes

Corrosion may be found on plain (non-galvanised) screwspikes installed in older concrete

turnouts. Where galvanised screwspikes have been used, no problems have been found.
(See Figure 77 below)

Pay close attention to ungalvanised screwspikes, especially in areas of higher corrosion

potential. eg near the sea, where coal dust is common and in wet areas.

Where any broken screwspikes are found or if corrosion is suspected, sample check
other spikes by unscrewing.

Care is needed in removing the screwspikes in case they are rusted in or severely
corroded, in which case they may fail.

If corrosion is found replace all the screwspikes with the galvanised type.

© Rail Corporation Page 202 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Broken spike from severe

corrosion and fatigue

Area of corrosion

Screwpike with rusted area in upper shank

Corrosion resistant galvanised screwspike

Figure 77 – Corroded screwspikes

C23-6.1.3 Steel in-bearers

VAE steel in-bearers are designed to be installed in pairs.

The bearers are attached to the switch and stockrail with chair plates that are assembled
to the bearers with insulating pads and insulating bushes on both the top and bottom of
the assembly.

There are 8 plates attached to the switch assembly; two have forged horns and the other
6 have K clips that are bolted with D bolts that clamp the plates securely to the stock rails.
(See Figure 78)

Horn chair plate

K clips

Figure 78 – In-bearer assembly

© Rail Corporation Page 203 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

During turnout examination:

1. Check all bolts attaching the chair plates to the steel bearers for the correct tightness
and that the insulating bushes are intact and not damaged. Torque settings for bolts
are shown in Table 25.
Bolt type connection Bolt size Torque
Bolts without insulation M20 400Nm
Bolts with insulation bushes M20 180Nm
Bolts with K Clips M24 450Nm
Chair plate horn bolts M27 450Nm
Table 25 - Torque settings for bolts

2. Check for damage to the bearers from dragging equipment or vehicle damage
3. Check that the horn chair plate is securely attached to the stock rail on both
stockrails
4. Check on the ballast condition and the support for the steel in-bearers
5. Report any obvious debris inside the in-bearer and if the drain hole is blocked.

C23-7 General Condition

Check for general condition of trackwork including:
− Ballast deficiencies.
− Drainage.
− Rail wear.

C23-8 For Supplementary Patrol

Identify locations where any of the following conditions occur and record these locations
as requiring Supplementary Patrol:
1. Joints with poor vertical support (flogging joint) within turnout, indicated by one or
more of the following:
∼ Visible evidence of poor top or twist conditions (that may be assessed as P2 or
worse) affecting the joint.
∼ Visible signs of formation failure affecting the joint. ie. “heaving” beyond the
ends of sleepers or between sleepers.
∼ “Bog Holes” affecting the joint. ie. track and ballast fouled and/or with mud
actively pumping through the ballast.
∼ Chipped or battered rail ends at the rail joint and/or evidence of heavy impact
(extensive whitened ballast).
∼ Loose bolts in joint, indicating Fish plates working loose.
2. Joints with poor lateral support within turnout ie sleepers/bearers/fastenings failed, or
poor fastenings & bearers at crossing/checkrail. Indicated by bearers and sleepers
not satisfying all of the following criteria:
∼ Effective bearers as assessed in this examination.
∼ Sleepers are well tied for at least 5 years or provide adequate vertical support.
3. Locations with heeled switches (jointed) with the following conditions:
∼ Flogging heels or poor track condition in the area of the heel, as defined in 1.
Above.
∼ Heels damaged in other ways e.g. deformation or excessive wear in heel block.

© Rail Corporation Page 204 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

4. Locations with K crossings on curves.

C23-9 Action to be Taken

1. Record all examination results on Form STW 1 for turnouts, Form STW 2 for
catchpoints, or Form STW 3 and for diamonds. Where Turnout measuring trolleys
are used, the print out of the trolley recording of gauge and superelevation may be
used instead of the form. Attach the record to the form.
For Single and Double Slips use Form STW 3 and Form STW 4.
2. Assess any defects found or investigated during the examination according to the
"Limits and Responses" table in Section C5-12.
3. If the turnout condition meets the requirements for Supplementary Patrol, mark the
entry on Form STW 1.
4. Take appropriate protective action or corrective action.
5. List the defects on Form 2 "Weekly Defect Summary Report" or transfer to Teams3
directly from Form STW 1, Form STW 2, Form STW 3 or Form STW 4.

C23-10 Catchpoints Examination

1. Examine the switch area as for turnouts in Section C23-3.
2. Check the condition and security of the throw-off rail and derail block.
3. The examination of clearances at catchpoints detailed in Section C19-7 may be
conducted in conjunction with the examination of catchpoint condition.
4. Check the landing area for derailed trains. It should have a square even descent
using ballast (See Figure 79 and Figure 80).

This area of ballast should be sloped so that

the grade is no steeper than 1 in 4 from level
with top of sleeper to landing area

Figure 79 – Well shaped landing area

© Rail Corporation Page 205 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 80 – Example of catchpoint with good landing zone

Figure 81 – Example of catchpoint with poor landing zone

5. Record the results of the examination and take appropriate action in accordance with
Section C23-8.

C23-11 Housed Points Examination

1. Carry out the switch examination in C23-3 above.
2. Check housing clearances using the housed points clearance gauge.
∼ Check flangeway clearances on the housing checkrail, at a point 400mm in front
of the nose of the switch, and at points 400mm and 2m behind the nose of the
switch. (See Figure 82 and Figure 83).

© Rail Corporation Page 206 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

E A

A: 44mm flangeway clearance

419mm back from point of
switch
E: 152mm width of new housing
140mm minimum

Figure 82 - Check with gauge for new housing width and flange clearance

If any slack is detected when the gauge is inserted, measure and record the
actual clearance.

Figure 83 - Checking flangeway clearance

∼ Check the height of the housing above the stockrail by placing the gauge across
the running surface of the stockrail and observing the height of the upper
surface of the housing in relation to the gauge. (See Figure 84 and Figure 85).
If the housing is found to be above the level of the gauge, measure and record
the amount of additional height.
B

B: Top of new housing

25mm above Stockrail

Figure 84 - Check with gauge for height of housing above rail level

Figure 85 - Checking housing height

© Rail Corporation Page 207 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

∼ Check the clearance between the underside of the housing and the top of the
switch at various points along the length of the switch by inserting the gauge
turned on its flat side between the housing and the switch. The switch must be
in the open position when this check is being made. . (See Figure 86 and
Figure 87).
If the gauge cannot be inserted, the clearance is insufficient. Record this as a
defect condition.

C: 3mm minimum clearance

between underside of housing
and switch 419mm back from
point of switch

Figure 86 - Check with gauge for switch clearance

Figure 87 - Checking clearance between housing and top of switch

∼ Check the flare at the leading and trailing ends of the checkrail and housing.
Measure the clearance between the checking faces of the checkrail, housing
and the stockrail. (See Figure 88 and Figure 89).
∼ Record the clearance.

F: 102mm flare at end of housing and

end of checkrail
G: 44mm - 46mm checkrail flangeway
Checkrail
G Housing
44 44
A F
F

394 419 1664

Figure 88 - Standard housing

© Rail Corporation Page 208 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Figure 89 - Checking checkrail end flair

3. Check for obvious problems on and around the housing, including:

∼ Loose or broken bolts
∼ Loose studs.
∼ Loose fastenings on the stockrail chairs.
∼ Damaged switch noses, etc.
4. Record the results of the examination and take appropriate action in accordance with
Section C23-8.

C23-12 Switch Examination Olympic Park

For the tangential turnouts at Olympic Park (and at other nominated locations) where the
main line route has been bent to a sharp curve special inspection arrangements are to be
implemented as indicted below.

C23-12.1 Switch Surface Damage

1. Inspect the high rail switch.
2. Check for spalling or chipping of the switch in the area from the tip to a point 2m
from the tip.
3. Assess any spalling or chipping found against the following limits
Damage in the first 2m from the tip of the switch blade, deeper than 17mm from the
running surface and which extends more than 100mm along the blade, or
consecutive areas of damage less than 100mm apart forming a length more than
100mm.
Damage in the first 2m from the tip of the switch blade, deeper than 19mm from the
running surface”
4. Report defects immediately to the Civil Maintenance Engineer.

C23-12.2 Wear Angle Limit

1. Take electronic profiles of the switch fitted against the stockrail at the following
distances from the switch tip:
∼ 30mm, 300mm, 600mm, 900mm, 1200mm, 1500mm, 1800mm and 2100mm
2. Assess the profiles taken to determine the level of wear and compliance with the
following limits:

© Rail Corporation Page 209 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

No part of the running surface of the switch blade, between 17mm and 30mm from
0
the head of the rail, is to form a plane at an angle < 40 to the horizontal (see Figure
90).

17mm below Running Surface

19mm below Running Surface

0
40 30mm below Running Surface

Figure 90 - Rail Wear angle

3. Report defects immediately to the Civil Maintenance Engineer.

C23-13 Expansion Switch Examination

1. Check and record the gauge at the expansion switch.
Measure the gauge at 2 metre intervals commencing 6m in front of the expansion
switch tips and ending 8m past the switch tips. The gauge should not be more than
6mm tight or wide.
2. Check the running face condition of the switch rail, including tip profile and wear
angle of the switch rail relative to the stockrail using the method detailed in Section
C23-3.
Repair or replace switch rail and stock rail if required.
3. Look for rail flow on the gauge face of the stockrail or obstruction between the switch
and stockrail.
4. Examine switch area for condition of stockrails
5. Examine for evidence of switch rail movement relative to the stock rail.
The switch should move with changes in temperature. If there is no evidence of
movement, determine cause of binding and repair.
6. Check that the Neutral position is midway between the two transoms and that both
the switch tip and stock rail punch mark adopt the Neutral position when allowance is
made for ambient temperature using the design information supplied for that
location. (See Figure 92).
If the stock rail punch mark varies from the correct Neutral position by more than
50mm or the switch tip position relative to the stock rail punch mark varies by more
than 50mm after allowance for temperature, adjust the rail/s to relocate the switch
rail point and stock rail punch mark into the correct Neutral position.
Where VAE Expansion switches are installed, undertake the following additional
examination tasks. Refer to Figure 91 for general description.

7. Check each base plate for loose, broken or missing screw spikes.
Report loose, broken or missing screw spikes to the Team Manager for investigation
and repair or replace as required. .

© Rail Corporation Page 210 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

8. Examine for loose or broken D bolts along length of switch rail. (See Figure 93)
Report loose or broken D bolt assemblies to the Team Manager for investigation and
repair or replace as required.
9. Check the wear between the switch rail foot and the D bolt assembly.
If the gap between switch rail foot and D bolt assembly is more than 3mm, then
replace D bolt assemblies and / or switch rail.
10. Check each base plate for IBAV spring pins that are working loose. (See Figure 93)
Report loose or missing IBAV spring pins to the Team Manager for investigation and
repair or replace as required.
11. Examine for evidence of loose or broken safety roller assembly bolts. (See Figure
94)
Report loose or broken safety roller assembly bolts to the Team Manager for
investigation and repair or replace as required.
12. Check the safety roller spring tension / adjustment and adjust if required. .
The distance from the switch rail foot to the safety roller spring is to be between 5
and 7mm.
13. Examine for evidence of wear between safety rollers and switch rail foot.
If worn or seized, replace safety roller assembly.
14. Examine safety rollers for evidence of corroded or broken rollers springs.
If corroded or broken, replace all safety roller assemblies in expansion switch.
15. Lubricate the interface between the D bolt assembly and switch rail foot with railway
switch point lubricant (ROCOL BIO-SPL) or equivalent dry film lubricant.
16. Check the change in level between top of consecutive transoms, measured next to
the base plates along the Up rail. Repeat for the Down rail.
If the change in level is greater than 3mm replace and shim transoms where
required, ensuring the level between transoms is within ±2mm.
17. Visually examine the base plates and IBAV spring plates for fractures in the plates
and welds.
Report cracked or broken plates and welds to Team Manager.
18. Record the following information on Form STW 5:
∼ Tip Condition
∼ Switch Angle
∼ Opening
∼ Bolt tightness
∼ Condition of ties
∼ Condition of plates, bolts, screwspikes and fastening assemblies
∼ Condition of safety roller assemblies (if fitted)
19. Take appropriate action in accordance with Section C23-9.

© Rail Corporation Page 211 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

location of Safety rollers

switch tip

switch rail
Stock rail
D bolt

base plate

Failed D bolt assembly

IBAV spring plate

base plate

screw spike

Figure 91 – VAE Expansion switches

Neutral position

switch rail point

switch tip

Figure 92 – Neutral position

© Rail Corporation Page 212 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

D bolt
Dassembly
bolt
assembly
DD Bolt
Bolt
Assembly
Assembly

IBAV Spring
IBAV
Pin
Spring Pin
IBAVspring
IBAV spring plate
plate

Figure 93 – D Bolt assembly and IBAV spring assemply

safety roller
safety roller assembly

switch rail foot

Figure 94 - safety roller assembly

C23-14 Switch Lever Examination

1. Check the tension of the switch operating lever on both switches of manually
controlled points (Thornley levers, ball levers, throw-over levers). (See Figure 95
and Figure 96).
Insert a 400mm bar between the stockrail and switch at a point just beyond
separation of the switch and stockrail. Lever the bar against the switch in an attempt
to prize it open. Make a judgment on how easy or difficult it is to open.

© Rail Corporation Page 213 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

If the switch opens easily there will be insufficient tension available to keep the
switch closed under traffic
2. Compare the result with the limits in Section C5-15.
3. Take appropriate action in accordance with Section C23-9.

Figure 95 - - Checking Spring Lever Tension

Figure 96 - Checking Spring Lever Tension

C23-15 Diamond Examination

1. Examine V and K crossings using procedure in C23-4.
2. Measure all side and diagonal dimensions when the examination of crossings
reveals potential problems with the geometry of the diamond. Compare the
measurements with design tolerances.
3. Check the alignment of the 'V' assembly checking face and checking wingrail face
with a stringline or straightedge.
'K' Crossings have running AND checking surfaces.
4. Examine any insulated joints in the fully checked area of the diamond.
Check that the chock between the rails has not worn through the end post. If there
is external evidence of wear, such as squeezed end post, worn or bent bolts, loose
plates or loose bolts the joint should be pull the joint apart to check the condition of
the end post.

© Rail Corporation Page 214 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

5. Record the results of the examination on Form STW 3 and take appropriate action in
accordance with Section C23-9.

Secondary
Secondary

Main
Main

General Arrangement
S

a b
‘K1’

a b

Location of Checklines Identification of ‘K’

for each nose for crossing noses being
dimensions P, Q and R inspected

c d

‘K2’
c d
‘K’ Crossing Inspection
Gauge
Qa
Xing Pa
Point (a)
Xing Point (c)
Gauge Line

Checkrail Dimensions for ‘K’ Crossings

(Drawn for measurement of Crossing Point ‘a’)
Figure 97 - Explanatory diagrams for diamond inspections

© Rail Corporation Page 215 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Running Rail Check Rail Failed End Post not visible from above

Chock Curved end of Chock wears

Fishplate End Post Insulator

Chock
Running Rail

Check Rail

End Post worn by chocks on

either side
Figure 98 - Example of a Failed Insulated Joint in a fully checked Diamond

C23-16 Single and Double Slip Examination

Slips are a combination of switches and stockrails, and diamond crossings.
1. Conduct a diamond examination using the procedures in Section C23-15.
2. Examine the switch components and turnout rails not included in the diamond
examination using the procedures in Sections C23-3 and C23-5. The components
are numbered in accordance with the convention in Figure 99.
3. Take gauge and superelevation measurements from 6m in front of S1 and S2 points
to 6m past the front of S3 and S4 points. (Mark S3 and S4 Point location on the
form). For Double slips also take gauge and superelevation measurements from 6m
in front of S5 and S6 points to 6m past the front of S7 and S8 points. (Mark S7 and
S8 Point location on the form). Main line measurements are not required because
they have been measured and recorded in the diamond examination.
4. Record the results of the diamond examination on Form STW 3 and the remainder
of the slip examination on Form STW 4 and take appropriate action in accordance

© Rail Corporation Page 216 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

with Section C23-9.

‘K1’
Secondary Line
‘S1’ ‘S3’
‘V1’ ‘V2’

Main Line

‘S2’ ‘K2’ ‘S4’

Sydney
Single Slip

‘S5’ ‘K1’ ‘S7’

Secondary Line
‘S1’ ‘S3’
‘V1’ ‘V2’

‘S6’ ‘S8’
Main Line

‘S2’ ‘K2’ ‘S4’

Sydney
Double Slip

Figure 99 - Conventions for numbering components in slips

C23-17 Swingnose Crossing Inspections

Follow the procedures detailed in C23-4 and C23-5.

Additional inspection procedures for the swingnose crossing are detailed as follows.
Photos of the PRE and VAE swingnose crossings with explanatory notes is provided in
Figure 100 and Figure 101.

Note: When Level 1 and 2 inspections are undertaken, signalling staff are required to be
on hand to operate the swing nose in reverse and normal positions and to check
adjustments.

C23-17.1 During Level 1 Examinations:

C23-17.1.1 For PRE Installations
1. Check bearing of crossing nose rails on plates.
The two crossing nose rails (the point rail and tongue rail) bear on the crossing
plates. If there is clearance between the crossing plate and the rails, the geometry
needs to be adjusted.
2. Check fastening condition.
The majority of fastenings are huck bolts. If they are loose or broken they should be
replaced.

© Rail Corporation Page 217 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

3. Check fit of rail stops.

Rail stops are attached to the wing rails for the length of the point rail and tongue
rails. There should be no clearance between the web of the point rail and tongue rail
and the rail stops when the swing nose is operated in the normal and the reverse
positions. If clearance exists between the rail web and rail stops the cause should
be investigated and corrected.
4. Check crossing for wear.
Although there is no crossing throat as in standard turnouts, there is still a
discontinuity at the transition point between the wing rail and the point rail where
wheel transfer occurs. Wear will occur on the point rail and wing rail at this point.
Place a 1 metre straight edge along the rail with the centre at the tip of the point rail.
Move the straight edge around the gauge corner to the gauge point, checking 3 or 4
times. If the surface is smooth and nothing sticks up or out, then the wear is
satisfactory. If wear is unsatisfactory, build up the worn running faces or replace the
wing rail and point rail.
If it doesn't trip the gauge face angle gauge on the track supervisors’ board you don't
have any more of a problem than with open track.
5. Check rail head wear and gauge face angle on the point rail, tongue rail, splice rail,
wing rail, closure rail and stock rail in accordance with the requirements for plain
track in Chapter 14. Look for abnormal rail wear patterns.

C23-17.1.2 For VAE Installations

1. Check bearing of crossing nose rails on plates
The two crossing nose rails (the point rail and splice rail) bear on the switch plates.
If there is clearance between the switch plates and the rails, the geometry needs to
be adjusted.
2. Check fastening condition.
The majority of fastenings are bolts and nuts. If they are loose or broken they should
be tightened or replaced.
Wing rail, point rail and splice rail K clips and wing rail braces are fastened to the
crossing frame with T-bolts, nuts and double helix spring washers that may break or
become loose.
Wing rail braces are fastened to the wing rail with countersunk bolts that may shear
off or become loose.
3. Check fit of rail stops.
Rail stops are attached to the crossing frame for the length of the point rail and
splice rails. There should be no excessive clearance between the web of the point
rail and splice rail and the rail stops when the swing nose is operated in the normal
and the reverse positions. If clearance exists between the rail web and rail stops the
cause should be investigated and corrected. This may include adjustment of the
crossing frame rail stops and point rail / splice rail stops.
4. Check crossing for wear.
Although there is no crossing throat as in standard turnouts, there is still a
discontinuity at the transition point between the wing rail and the point rail where
wheel transfer occurs. Wear will occur on the point rail and wing rail at this point.
Place a 1 metre straight edge along the rail with the centre at the tip of the point rail.
Move the straight edge around the gauge corner to the gauge point, checking 3 or 4
times. If the surface is smooth and nothing sticks up or out, then the wear is
satisfactory. If wear is unsatisfactory, build up the worn running faces or replace the
wing rail and point rail.

© Rail Corporation Page 218 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

If it doesn't trip the gauge face angle gauge on the track supervisors board you don't
have any more of a problem than with open track.
5. Check rail head wear and gauge face angle on the point rail, splice rail, wing rail,
closure rail and stock rail in accordance with the requirements for plain track in
Chapter 14. Look for abnormal rail wear patterns.

C23-17.1.3 Common
1. Examine for ballast accumulation around swing nose. Remove excessive ballast.
2. Examine for obstructions or build up of material between the point and the wing rails.
3. Examine for Rolling contact fatigue defects (surface checking / cracks, spalls, scale
or squats).
4. Check for any cracking which may indicate a section of the nose or wing could break
out.
5. Record the results of the examination on Form STW 6 and take appropriate action in
accordance with Section C23-8.

C23-17.2 During Level 2 Detailed Examinations:

C23-17.2.1 For PRE Installations
1. Check fastening condition.
The crossing frame is attached to be concrete bearers with screw spikes. As with
standard turnouts these may become loose or break. The double helix spring
washers are not effective if they are not fully compressed. Replace loose or broken
screw spikes and double helix spring washer assemblies.
2. Check in the following locations for evidence of loose or broken huck bolts:
∼ Crossing plate rail brace to rail stop, wing rail A, B and F chocks, point rail
fabricated heel block, wing rail/splice rail C and D heel blocks.
If they are loose or broken they should be replaced.
3. Examine crossing plates and rail brace brackets for evidence of cracking.
The crossing plates are subject to stresses at the rail seats under the swing nose as
are the rail brace bracket welds. Report cracking for repair or replacement of the
crossing assembly.

C23-17.2.2 For VAE Installations

1. Check the point rail/splice rail connection.
The point rail/splice rail connection is a sliding joint. Check the joint for security as
follows:
∼ Check that the opening at the tip of the splice rail is ≤ 2mm
∼ Bolts, castellated nut, dished washer and disc spring are fitted and tight.
∼ Split pins are inserted in the castellated nuts. Replace the split pin if it has worn
25% through.
∼ Clearance of sliding joint has altered, indicating loss of pre-load of the joint
fasteners. Replace sliding joint disc springs (dished washers) if required and
tighten.
Additional security is provided at the point rail/splice rail connection by a safety
clamp. Examine the safety clamp for loose or broken fastenings. Replace loose or
broken bolts, nuts and washers and tighten.

© Rail Corporation Page 219 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

2. Check the heel block / anti creep block for evidence of loose or broken huck bolts:
Examine for evidence of loose rail stop brackets (point rail / splice rail to crossing
frame). Check the rail stop brackets for damage and replace if required. Replace
rail stop bracket bolt, nut and spring washer and tighten.
3. Examine for evidence of loose switch stops (splice rail to point rail). Check the switch
stops for damage and replace if required. Tighten loose switch stop fasteners and fit
new split pins if required.
4. Check the crossing frame and anti-creep brackets for evidence of cracking.
The crossing frame is subject to stresses in the webs, rail seats (switch plates) and
other loaded sections. These locations should be visually examined for evidence of
cracking. Report fractures for repair or replacement of the crossing assembly.
Visually examine anti-creep brackets for evidence of fractures.

C23-17.2.3 Common
1. Check bearer condition.
Examine crossing bearers and ties for evidence of degradation. Replace damaged
bearers and ties.
2. Check geometry.
Swing Nose crossings are particularly sensitive to variations in surface geometry and
line. Special care needs to be taken in the measurement and assessment of top and
line.
3. Check wing rail / point rail gauge face for wear.
Check for rail head overflow greater than 1mm adjacent to the point rail. This could
stop the nose closing properly. Remove if overflow is greater than 1mm. Ensure
that swing nose detection and locking is adjusted prior to return of the crossing to
traffic.
4. Check rail head wear and gauge face angle on the point rail, tongue rail, splice rail,
wing rail, closure rail and stock rail in accordance with the requirements for plain
track in Chapter 14. Look for look for excessive rail wear.
5. Check the profile of the front of the swingnose with a switch nose profile gauge using
the procedure in Section C23-3.
6. Check that the swing nose locates against the switch stops in the forward and
reverse positions. Replace worn switch stops.
7. Record the results of the examination Form STW 6 on and take appropriate action in
accordance with Section C23-8.

© Rail Corporation Page 220 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

F chocks

Heel block D
Splice rail
E chock
Heel block A
D chock
Heel block C

C chock Wing rails

Tongue rail
Rail stops/switch
stops

Crossing plates Point rail

Rail Brace with Huck

bolt fastenings

Wing rail / Point rail

transition point

B chock

Screw Spikes and

double helix spring
washer assemblies
A chock

Figure 100 - PRE Swing Nose Crossing

© Rail Corporation Page 221 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

anti creep block

Switch Stops with castellated

nut and split pin

Rail Stops

Splice rail Switch plates

anti-creep brackets
point rail / splice rail sliding
point rail / splice joint fastened with castellated
rail sliding joint nut and split pin

point rail / splice rail Rail stop brackets

safety clamp

wing rail brace

Point rail

wing rail /point rail

transition point
crossing frame

K clip

Screw spikes and double

helix spring washer
assemblies

Figure 101 - VAE Swing Nose Crossing

© Rail Corporation Page 222 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C23-18 Special Tangential Turnout Examination Requirements

C23-18.1 PRE Turnouts
C23-18.1.1 Switches
1. Check for Broken slide baseplates.
Broken baseplate jaws indicate that voids are present under the bearers.
Broken slide tables indicate either that the bearers are becoming indented or that the
baseplate was incorrectly seated at the time it was secured to the bearer.
2. Examine Switch soleplates on timber sleepers.
Slide baseplate end stops that become detached from the soleplate must be
replaced.
Slide baseplate end stops which become worn because the baseplate(s) are not
securely held down cannot easily be repaired. Arrange to replace the complete
soleplate and the supporting bearer.
Soleplate insulation fittings which are damaged must be replaced.

C23-18.2 TKL Turnouts

C23-18.2.1 Switches
TKL Rail uses the “Schwihag System” of inner stockrail bracing clips and special elevated
side tables.

Make sure all clip legs are fitted to their corresponding thrust abutments.

Slide plates should be lubricated regularly or when the slide surfaces of the tables show
signs of bright metallic streaks or rust.

C23-18.2.2 Crossings
Built up frogs Should be visually inspected for signs of excess wear or flow of the nose or
wing-rails.

C23-18.3 VAE Turnouts

C23-18.3.1 Switches
1. Check lubrication of chairs and operation of switch.
2. Check pins and keys of the inside fastening system for damage or breakage.
3. Check for any broken Pandrol clips especially around the heel area of the switch.
4. Check connecting rods and fittings to switch.
5. Inspect switch blade for wear. Grind off metal overflow if necessary.
6. Check switch stop bolts.

C23-18.3.2 Crossings
1. Check crossing for running condition, any signs of loose Huck bolts.
2. Check nose and wingrails for metal flow, grind if required.
3. Check plating for any broken Pandrol dips.

© Rail Corporation Page 223 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

C23-18.3.3 Guardrails
1. Check the gauge between guardrail to crossing in two (2) places:
∼ One just behind nose of crossing.
∼ Two just past knee of wingrail.
Adjust if required by inserting shims provided.
2. Check bolts and Pandrol dips on the guardrails and plating.

C23-18.3.4 General Requirements

1. Check turnout for loose bolts and any Pandrol clips that have broken.
2. Check line and top of turnout.
3. Check cross level throughout turnout but especially at the crossing.
4. Check insulating bush assemblies for damage.

© Rail Corporation Page 224 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 24 Drainage Examination

This chapter details the procedures for drainage examination as part of the Track
Examination System.

In this context, drainage is defined as:

− The surface flow of water away from the track structure and cess.
− Top and side drains along the railway reserve to direct water away from the rail track
formation to recognised water courses.
− Pipes installed expressly to collect water from between or beside tracks and direct it
away to a recognised side drain or water course.
− Waterways constructed under the track, whether pipes, culverts, or similar.
Without regular inspections and routine maintenance of drains, they may eventually
become blocked with either sediment, debris or weed growth. If drains are allowed to
become blocked or damaged they will fail in their function of draining the formation. They
may even make matters worse, as water standing or ponding in parts of the drainage
system may seep into the formation, via pipe slots or through the base of drainage
trenches. This may lead to softening and loss of firm support for the track.

C24-1 Examination Requirements

Detailed inspections of all the components of drainage systems are best carried out prior
to the wettest period of the year.

Study available plans and records to establish what drainage was actually installed. If no
records exist the following assumptions should be made (i.e. the types of drainage that
should be encountered in various locations):
− Cuttings; cess drains, catch drains on the high side of the cutting and mitre drains at
regular intervals. In newer or recently upgraded cuttings subsoil drains may be
found.
− Embankments; graded shoulders and catch drains.
− Platforms; subsurface type drains in the six foot and/or along the edge of the
platform base.
− Turnouts; graded shoulders, cess and/or subsurface drains.
− Tunnels; open drains along the sides or centre drains. In newer or recently
upgraded tunnels there may be either centre or side subsurface drains.
− Bridges; weep holes in abutments, and in ballast top bridges there may be weep
holes in the parapet wall and/or subsurface drains.
− Other track location; graded shoulders.

C24-2 Examination Procedure

1. Examine general track area. Look for:
∼ Bog holes, heaves and slips.
∼ Foul ballast, mud pumping and its severity i.e. mud around the sleeper ends or
mud volcanos.
∼ Poor track alignment (line) and level (top) at locations where foul ballast or mud
pumping exists.
∼ Erosion or slipping of cutting or embankment faces or evidence of track
formation failure.

© Rail Corporation Page 225 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

2. Examine all surface drains. Look for:

∼ Water ponding in drains or near the track or at the base of cuttings and
embankments.
∼ Erosion of drainage channels, inlets or outlets.
∼ Blocked drains due to weed growth, debris from track maintenance (old
sleepers and rails) and or sediment build-up.
3. Examine each sump or pit of a drainage system. Look for:
∼ Blocked sumps, grates and/or covers. Is it working or is it filled with silt or
rubbish?
∼ The amount of sediment in silt traps.
∼ Broken pipes or sumps.
∼ Missing sump covers or grates as well as covers and grates not correctly
replaced after track maintenance work.
4. Examine all waterways. Look for:
∼ condition of each waterway. Is the inlet clean? Is the invert clear of sediment,
debris and weed growth?
∼ the physical condition of each structure, pipe etc. This can only be checked by
looking through the pipe etc. Has it changed since the last inspection?
5. Record the condition of each drain or asset whether satisfactory or unsatisfactory
and the occurrence and extent of any of the above defects.
6. Note the location and type of drain being inspected.
7. Note any work required to restore the drainage to a satisfactory condition.
8. Record any other works required as a result of drainage.
e.g. slipping of cutting or embankment faces, track formation failure, failure of
structures adjacent to the track.

C24-3 Action to be Taken

1. Record all examination results on Form Drain 1 “Examination of Drainage.”
19. Assess any defects found or investigated during the examination in accordance with
Section C24-4.
20. Take appropriate protective action or corrective action.
21. List the defects on Form 2 "Weekly Defect Summary Report" or transfer to Teams3
directly from Form Drain 1.

C24-4 Assessment of Condition

1. Assess whether the drain being inspected is satisfactory or unsatisfactory.
If a drain does not appear to be blocked and seems to be transporting water
adequately (i.e. there is no water ponding or evidence of water ponding) the drain is
satisfactory.
If the drain is blocked with sediment, debris, or weed growth to such an extent that
water is unable to flow through the drain, it is unsatisfactory.
∼ Clear any drain considered to be blocked > 50%.
∼ Clear any waterway opening greater than 300mm such as pipes, culverts etc
including underbridges where siltage or blockage > 25%.
22. If the drain is unsatisfactory note why this is so.

© Rail Corporation Page 226 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

23. In order to establish to what extent the condition of the existing drainage system is
affecting the track formation and/or its supporting earth structures (e.g. cuttings and
embankments), it may be necessary to examine track recording data to establish
whether there has been any repeated problems for top and line in areas
corresponding with poor drainage. If so this may suggest the likelihood of more
severe problems in the future if the drainage system is not repaired.
24. Areas may be ranked according to the effect they have on the surrounding track
formation or surrounding earth structures.
25. For example the following situations are listed in order of decreasing importance:
∼ Bog holes, heaves (i.e. severe formation failures).
∼ Slips and slumping of slopes (saturation of slopes).
∼ Mud pumping up through ballast, top and line problems.
∼ Foul ballast plus top and line problems.
∼ Water ponding alongside track or at the base of earth structures.
∼ Erosion of cutting face (i.e. ineffective catch drains).
∼ Minor blockages and sediment build-up.
∼ Rubbish lying in drains.

© Rail Corporation Page 227 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 25 Track Inspections by CME and Team Manager

Civil Maintenance Engineers and Team Managers carry out track inspections for the
following purposes:
1. To ensure that track defects and irregularities are observed and rectified quickly,
efficiently and economically, to maintain the tracks in a safe condition for the
passage of trains. This includes the inspection of temporary supports for bridges.
26. To collect information for the preparation of the following programs in the area:
∼ Resurfacing program.
∼ Rerailing and resleepering program.
∼ Turnout renewal program.
∼ Ballast program.
∼ Ballast re-conditioning program.
∼ Cutting and embankment improvement program.
∼ Vegetation management program.
27. To collect information and plan the work routine for each of the teams on the area,
and for the issuing of the necessary instructions to carry out the work.
28. To observe and check whether the planned routine given to team leaders is being
carried out - checking the productivity of the staff.
29. To gather information and plan the supply of stores and equipment.
30. To inspect tools and plan their adequate use and supply.
31. To observe work methods of team leaders and to instruct them in the correct
methods of working to meet the demands of efficiency, economy and safety.
32. To discuss work problems and problems involving human relations with the staff.
33. To plan and check the work of mechanical equipment, to see that machines are
being used correctly and efficiently, and that they are adequately maintained. To
see that fuel, oil and spare parts are being maintained.
34. To ensure that the quality of the trackwork carried out by renewals teams is up to the
required standard.
35. To check that the various administrative functions for which team leaders are
responsible are being correctly carried out.
36. To see that good housekeeping habits are being practiced.

© Rail Corporation Page 228 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Chapter 26 Records
In all cases, inspection personnel are to report the results of preventive maintenance
examinations to their Civil Maintenance Engineer or other nominated officer (where
applicable).

Details required are:

− Date service or examination was carried out.
− Name of the person performing the service or examination.
− Asset identification which will include Equipment Description, Line Section, Track
and kilometrage.
− Details of any new defects or previously recorded defects that have deteriorated
further including:
∼ nature of defect
∼ size
∼ location
∼ assessment of condition
∼ any action taken
Detailed reports are to be compiled in approved formats and retained.

All records of the Track Examination System (including all completed examination forms
and reports of defects on Weekly Report forms) must be retained on site for a minimum of
three (3) years for audit purposes. Note that there are separate requirements for longer
term retention and archiving of inspection records specified by the State Records Act of
1998.

© Rail Corporation Page 229 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
RailCorp Engineering Manual — Track
Track Inspection TMC 203

Appendix 1 Examination forms

Form Index
Form No. Form Name Page No.
Form 2 Examination of Length 232
Form 2 Weekly Defect Summary Report 232
Form WTSA 1 WTSA Manual Analysis Input 233
Form WTSA 2 WTSA CWR Field Sheet 235
Form WTSA 3 WTSA Manual Analysis 236
Form WTSA 4 WTSA Weekly Report 237
Form Rail 1 Inspection of Rail Wear 238
Form Rail 2 Examination of Rail Corrosion 239
Form Rail 3 Inspection of insulated joints 240
Form Rail 4 Inspection of Rail Lubricators 241
Form Clear 1 Clearance Examination 243
Form Clear 2 Inspection of Track Centres 244
Form LX 1 Level Crossing Examination 245
Form Drain 1 Examination of Drainage 246
Form STW 1 Turnout Examination 247
Form STW 2 Catchpoint Examination 249
Form STW 3 Diamond Examination 250
Form STW 4 Slip Examination 251
Form STW 5 Expansion Switch Examination 252
Form STW 6 Turnout Inspection - Swingnose Crossing 253

© Rail Corporation Page 230 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Examination of Length Form 1

WEEK ENDING: ................................ LENGTH: ........………………..…...............................

Date Track examined Track Up/ Examination type

Down
From To Walk HiRail Engine MTP Supp Front of Detail
Signature
Patrol Patrol Patrol Detail Patrol (see Train Walk
Review attached
list)

Other examinations completed during week (e.g. Turnouts etc.)

For Detail Walking and Sleeper Inspections – Do any track sections require Supplementary Patrol? YES NO
If YES, which
Sections?

My signature in the right hand column confirms that the above length has been examined as stated, to the best of our ability in
accordance with RailCorp requirements. At any location where defects were found, appropriate corrective action has been taken or
necessary protection applied. The defects have been entered in Teams3 (or recorded on the Weekly Defect Summary Report)

© Rail Corporation Page 231 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Weekly Defect Summary Report Form 2

WEEK ENDING:………………NAME…………………SIGNATURE:…………………POSITION………………………….
How found. FP Foot Patrol. EP Engine Patrol. HP High Rail Patrol. MTP Mechanised Track Patrol. DW Detailed Walk

How Found
Date Defect Type KM Details of Work required or completed Who

Priority
Track

Size
Found
& Other Comments
initial
From To

© Rail Corporation Page 232 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

WTSA Manual Analysis Input Form WTSA 1

Rail Adjustment Inspection: Name/Signature _______________________ Date _______________________

Up Rail Down Rail Alignment Combined Stability
Loss
Creep (CWR) Gaps (LWR) LINE: Gaps (LWR) Creep (CWR)
%
Km
Av.
Error in direction of
Creep Analysis Temp Analysis Gap TRACK: Gap Analysis Creep Analysis Alig Index
arrow
n

Tangent Creep Av Rail Length Av Rail Length Tangent Creep

Tangent Temp Av. Rail Gap Av. Rail Gap Tangent Temp
Error Error
Curve Temp Theor. Meas Theor. Meas Curve Temp
Error Temperature Temperature Error
Total Rail Rail Temp Rail Temp Total Rail
Temp Error Error Error Temp Error
Loss of Loss of Loss of Loss of
Stability Stability Stability Stability
Tangent Creep Av Rail Av Rail Tangent Creep
Length Length
Tangent Temp Av. Rail Gap Av. Rail Gap Tangent Temp
Error Error
Curve Temp Theor. Meas Theor. Meas Curve Temp
Error Temperature Temperature Error
Total Rail Rail Temp Rail Temp Total Rail
Temp Error Error Error Temp Error
Loss of Loss of Loss of Loss of
Stability Stability Stability Stability
Tangent Creep Av Rail Av Rail Tangent Creep
Length Length
Tangent Temp Av. Rail Gap Av. Rail Gap Tangent Temp
Error Error
Curve Temp Theor. Meas Theor. Meas Curve Temp
Error Temperature Temperature Error
Total Rail Rail Temp Rail Temp Total Rail
Temp Error Error Error Temp Error
Loss of Loss of Loss of Loss of
Stability Stability Stability Stability
Tangent Creep Av Rail Av Rail Tangent Creep
Length Length
Tangent Temp Av. Rail Gap Av. Rail Gap Tangent Temp
Error Error
Curve Temp Theor. Meas Theor. Meas Curve Temp
Error Temperature Temperature Error
Total Rail Rail Temp Rail Temp Total Rail
Temp Error Error Error Temp Error
Loss of Loss of Loss of Loss of
Stability Stability Stability Stability

© Rail Corporation Page 233 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

WTSA Manual Analysis Input Form WTSA 1 (Page 2)

Ballast Inspection Anchors Inspection

Length: ………………………………..

Examiners Name/Signature: …………………….. Date: ……………. Examiners Name/Signature: ………………………. Date: ………………………….
Ballast profile Order details Line: Anchor analysis

KM Signs of
Shoulders Cribs Date Date Not to Elastic
t/20m t/20m
Total
Ordered Ordered
Track:
Pattern
Missing Ineffective OK creep
fastening
Action
Y/N

© Rail Corporation Page 234 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

WTSA CWR Field Sheet

Form
WTSA 2
Form 1 CWR WTSA – TMC203 RailCorp Engineering Form
Description Basecode Measured by Signature Date
2012 Up 2012 Dn Ballast Ballast
KM Identification Track Align Align 2012 Align IA FB PJ RB SA RC BR Comments
Rail Rail T/20m
Layout Design Revised Align Error T/20m
Creep Creep Shoulder Crib

Note: IA: Ineffective Anchors FB: Foul Ballast PJ: Pumping Joints RB: Rail Bunching SA: Sharp Alignment RC: Rail Corrugation BR: Round Ballast

Team Manager Date Signature Data Entry By Date Entered Signature

© Rail Corporation Page 235 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

WTSA Manual Analysis Form WTSA 3

Line ________________ Track ________________ Team Manager Name/Signature_________________ Team Leader Name/Signature ______________
Date ________________ Date ______________
Track Rail Adjustment Loss of Stability
Ballast Anchor Track Condition Action Plan
Disturbance Up Rail Down Rail Assessment
Km
Creep Gap Creep Gap Last Prelim Location Final
Activity Result Result Result Result
Result Result Result Result Worst TCI Result Factor Result

© Rail Corporation Page 236 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

W.T.S.A Weekly Report Form WTSA 4

Area Week Ending

TOTAL MEASUREMENT ANALYSIS CORRECTION OF No.1 PRIORITY

TRACK SECTION TRACK Planned Planned Total Cumulative. Planned
(km) Outstanding Complete Complete No.
Completion. Completion. Priority 1 Actual Completion.
(km) (%) (Yes/No/%) Remaining
Date Date Locations Done Date

TOTALS

© Rail Corporation Page 237 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Inspection of Rail Wear Form Rail 1

Track: ...................................................... Length ................................................................... Examiners Name/signature ......................................................

Kilometrage Down Rail Up Rail If unsatisfactory give details
Date of
From To OK Not OK Not Kilometrage Wear Head Head Rail Date Rail Condition inspection
OK OK from to angle width depth section rolled

© Rail Corporation Page 238 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Examination of Rail Corrosion Form Rail 2

Track ..................................... Rail UP/DOWN Length ............................................ Examiners Name/signature .....................................................

Tunnel ..................................... Portals - from ......................... Km to .......................... Km Date examined ................................................................

Rail Head Head Web Foot Foot Fastening condition Comments
KM section Height Width Thickness Thickness Width
"A" "B" "E" "F" "G"

© Rail Corporation Page 239 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Inspection of Insulated Joints Form Rail 3

Length……………………………………… Examiners Name/Signature…………………………………………………………………………………….…

Location of Insulated Joints Joint Type √ Condition

Supplementary
Rail √

Defect Priority
Kilometrage Track OK NOT OK Details of Faults

Patrol Required
√ √ Date Inspected

Mechanical

Benkler
Glued
Up T/O

Down T/O
Down
Up

© Rail Corporation Page 240 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Examination of Rail Lubricators / TORFMA Form Rail 4

Length ........................................................................................................ Examiners Name/signature .......................................................................................................

Location of Lubricator GFL Only Reservoir was
Lubricator Visible Function
Ports Operational
Type Damage check – Date

Almost full
Track Rail Date of

Half full
Correct

Empty
If Yes – damage description inspection repairs
Kilometrage operation &/or filling carried out
Blade 1 Blade 2
UP DN UP DN GFL TORFMA YES NO (Y/N)

© Rail Corporation Page 241 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Lubrication Inspection Sheet Form Rail 5

Length ............................................. Examiners Name/signature ____________________________________

DOWN Rail UP Rail

Reasonable

Reasonable
Location on
Kilometrage Track

Good

Good
None

None
Poor

Poor
Rail

Wet

Wet
Finger Print Finger Print

Running surface

Gauge Corner

Gauge Face

Running surface

Gauge Corner

Gauge Face

Running surface

Gauge Corner

Gauge Face

Running surface

Gauge Corner

Gauge Face

Running surface

Gauge Corner

Gauge Face

© Rail Corporation Page 242 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Clearance Examination Form Clear 1

Length ........................................................................... Examiners Name/signature Date

......................................................... .........................................

Structure ............................................................................................. Track ...............................................................................................

Clearance to edge of Clearance to
Horizontal clearance to structure Vertical clearance to structure Superelevation
platform coping protrusions
Direction of
Kilometrage Track needs
aligning
super
Design Actual Variation Design Actual Variation Design Actual Variation (Actual) Horizontal Vertical Horizontal Vertical
Away
To
from
plaque
plaque

© Rail Corporation Page 243 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Inspection of Track Centres Form Clear 2

Examiner’s
Length .......................................... Name/signature ............................................................................
Date ...............................................................

Tracks Measured: Track “A” ...........................................................................

Track “B” ...................................................................................
Total of Difference in Total Track
Track centres TRACK “A” Track layout TRACK “B” Track Centre
Super Centre
Superelevation A B A B A B Superelevation Variation (A
due to Super
Kilometrage
(D x 3) Variation
Design Actual Variation Design Actual Variation Design Actual Variation & C)
(E + B)
B A C D E

© Rail Corporation Page 244 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Level Crossing Examination Form LX 1

LEVEL CROSSING .......................................... Start Km: ................... End Km: ................... Examiners Name/Signature ......................................Date
..... .....................
DOWN TRACK or SINGLE TRACK UP TRACK
Guard rail Track Guard rail Track
Gauge Flangeways Rail top Gauge Flangeways Rail top
Effectiveness Alignment Effectiveness Alignment

STATION
Rail Play Rail Play
Is there Are variations Are variations Is there Are variations Are variations
evidence of visible visible evidence of visible visible
Down Rail Up Rail Down Rail Up Rail
Actual Rail Play Total Gauge Down Rail Up Rail Actual Rail Play Total Gauge Down Rail Up Rail
Y N Y N Y N Y N Y N Y N
Play Width Depth Width Depth Variation Variation Play Width Depth Width Depth Variation Variation
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
Guard Rail Flare Sydney End Guard Rail Flare Sydney End
(mm) Country End (mm) Country End
General Condition General Condition
Level crossing Fences Level crossing Fences Roadway
Sleepers Fastenings Rail corrosion Roadway surface Sleepers Fastenings Rail corrosion
signs and gates signs and gates surface
OK Not OK OK Not OK OK Not OK OK Not OK OK Not OK OK Not OK OK Not OK OK Not OK OK Not OK OK Not OK OK Not OK OK Not OK

Sighting Obstruction assessment Does the LXing have Active Protection? YES NO If NO complete the Sighting Obstruction Assessment
Is Sighting unobstructed from ALL sighting points? YES NO Is Sighting unobstructed from ALL sighting points? YES NO
Comments

© Rail Corporation Page 245 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Examination of Drainage Form Drain 1

Length ........................................................ Examiners Name/signature .......................................................................

* Surface Drainage
Culvert, Pipe & Sump Drains
& Water Courses
Kilometrage
Description of Date of
Condition Inlet Outlet Structure Comments / Works Required
DRAINS / ASSETS Inspection
From To Not Not Not Not
T/S OK T/S OK T/S OK OK
OK OK OK OK

LEGEND: T/S Column refers to which side of the track the item is on. D = Downside; U = Upside; C = Centre or Six Foot; DC = Between Down tracks; UC = Between Up tracks.

* This column is to be used for all Cess, Top, and Mitre drains and Water Courses

© Rail Corporation Page 246 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Turnout Examination Form STW 1 – Page 1 of 2

Line: Location: Track From/To:
Team: Km: [Link]: Name/Signature:
MIMS Equipment No: Date:
"V" Crossing
Should be Measurement (mm) OK (Y/N) If "Not O.K.", give details, action required, priority (When must repairs be completed?)
Main Line
Gauge
Turnout

Checkrail Main Line

Effectiveness Turnout

Flangeway Main Line

Clearance Turnout
Does Crossing Nose Need Building Up? Yes/No Dip at Crossing: _____mm Details action and priority of crossing defects.
Are Bolts/Fastenings Effective? Yes/No Manganese crossing Y / N
Points
OK (Y/N) If "Not O.K.", give details, work required, and priority (When must repairs be completed?)
Left
Switch Fitting Correct?
Right
Left
Condition of Heel (Transfer block)?
Right
Evidence of stockrail creep? YES NO
Left
Switches bearing on plates?
Right
For Manual Points ONLY
OK.(Y/N) If "Not O.K.", give details, work required, and priority (When must repairs be completed?)
Left
Switch clearance
Right
Lever effectiveness
Switch Tip
OK.(Y/N) If "Not O.K.", give details, work required, and priority (When must repairs be completed?)
Left Is switch a 47/53kg
Height standard switch?
Right
Y / N
Left If Y use switch tip
Width
Right gauge
Was Switch tip Profile
Left Gauge used?
Angle
Right Y / N
Do Switches need grinding? YES NO
Housed Points
Dimension Size OK (Y/N) If "Not O.K.", give details, action required, priority (When must repairs be completed?)
"A" mm
"B" mm
"C" mm
"D" mm
"E" mm
"F" mm
"G" mm
General
If "Not OK.", give OK If "Not OK.", give
OK (Y/N) Work Required Target Date
details (Y/N) details
Drainage Stockrails LH Tighten bolts & studs Yes/No
Ties/Bearers RH Mechanised Resurfacing Yes/No
Ballast Studs/Chairs Weld out mechanical joints Yes/No
Alignment Rails M Weld out insulated Joints Yes/No
Anchors Sec Pandrol Plate turnout Yes/No
Fastenings Plates Type Adjust & square points Yes/No
Checkrails & bolts Cond Recondition track Yes/No
Renew /replace turnout Yes/No

© Rail Corporation Page 247 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Turnout Examination [Link]:…………… Form STW 1 – Page 2 of 2

STATIONS 1 2 3 PT 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Tight
GAUGE

Wide

Play

Total
widening
STATIONS 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

Tight
GAUGE

Wide
MAIN

Play

Total
widening

1 8 15 22 29 36 43 50 Comments
SUPERELEVATION

2 9 16 23 30 37 44 51
3 10 17 24 31 38 45 52
Pts 11 18 25 32 39 46 53
5 12 19 26 33 40 47 54
6 13 20 27 34 41 48 55
7 14 21 28 35 42 49 56

Calculate worst short twist &

list all short twist defects Work/Action required
on defects:
Calculate worst long twist &
Target date (repairs):
list all long twist defects

STATIONS 1 2 3 PT 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Tight
GAUGE

Wide

Play

Total
widening
STATIONS 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

Tight
SECONDARY
GAUGE

Wide

Play

Total
widening

8 15 22 29 36 43 50 Comments
SUPERELEVATION

9 16 23 30 37 44 51
10 17 24 31 38 45 52
Pts 11 18 25 32 39 46 53
5 12 19 26 33 40 47 54
6 13 20 27 34 41 48 55
7 14 21 28 35 42 49 56

Calculate worst short twist &

Work/Action required on
list all short twist defects
defects:
Calculate worst long twist & Target date (repairs):
list all long twist defects
Bearers RM Priority MPM Year _____
Does Turnout require
Turnout Timbers 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 6.0
Supplementary Patrol
YES NO
Number RM
Req'd: MPM

Comments

© Rail Corporation Page 248 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Catchpoint Examination Form STW 2

Line: Location: Track From/To:

Team: Km: [Link]: Name/Signature:
MIMS Equipment No: Date:
STATIONS 21
1 2 3 PT 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Tight

0
GAUGE

Wide

Play

Total
gauge
widening

Design
SUPER

Actual

OK. OK. If "Not OK.", give details, action

Switch Tip (Y/N)
If "Not OK.", give details, action required. Points (Y/N) required.
Height Switch fitting correctly
Was Switch tip
Profile Gauge Condition of Heel (Transfer
Width
used? block)?
Yes/No Evidence of stockrail
Angle Yes/No
creep?
For Manual Points ONLY Doe switch need grinding? Yes/No
Switch clearance Switches bearing on plates?
Lever
effectiveness

OK. If "Not OK.", give OK. If "Not OK.", give

General (Y/N) details General (Y/N) details Work Required Target Date

Drainage Stockrail Tighten bolts & studs Yes/No

Ballast Heel block Mechanised Resurfacing Yes/No
Alignment Studs/Chairs Remove excess ballast Yes/No
Anchors Rails Weld out mechanical joints Yes/No
Fastenings Throw off rail Weld out insulated Joints Yes/No
Bolts Plates Type Renew /replace catchpoint Yes/No
Derail block Cond Recondition track Yes/No

Bearers Pick up scrap Yes/No

Turnout Timbers 2.8 3.0 3.2 3.4 3.6 3.8 4.0
Number Req'd:
OK.
Throw off Rail (Y/N)
If "Not OK.", give details NOTE Throw Off Rail must be parallel or
leading away from adjacent Track
Throw off Rail Direction
Measurement OK. Throw Off Rail SECONDARY
Clearance Point (mm) (Y/N)
If "Not OK.", give details 3.8m Catch Point LINE
OK
Track Centre Clearance OK
Comments NOT OK
_________________________________________________________________________________ CLEARANCE POINT
CL
_________________________________________________________________________________
L
C MAIN LINE
_________________________________________________________________________________
_________________________________________________________________________________
3650 Track Centres Clearance
_________________________________________________________________________________
_________________________________________________________________________________

© Rail Corporation Page 249 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Diamond Examination Form STW 3

Line: Location: Track From/To:

Team: Km: [Link]: Name/Signature:
MIMS Equipment No: Date:
STATIONS 1 2 3 V 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Tight

0
GAUGE

Wide
MAIN

Play

Total
gauge
widening

Design
SUPER

Actual

STATIONS 1 2 3 V 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Tight
SECONDARY

0
GAUGE

Wide

Play
Total
gauge
widening

Design
SUPER

Actual

"V1" Crossing Measurement OK. If "Not OK.", give "V2" Crossing Measuremen OK. If "Not OK.", give details,
(Sydney End) (mm) (Y/N) details, action required. (Country End) t (mm) (Y/N) action required.
Main Main
Gauge Line Gauge Line
Sec Line Sec Line
Main
Checkrail Checkrail Sec Line
Line
Effectiveness Effectiveness
Sec Line Turnout
Main Main
Flangeway Line Flangeway Line
Clearance Clearance
Sec Line Turnout
Does Crossing Nose Need Building Up? Yes/No Dip at Crossing: ___mm Does Crossing Nose Need Building Up? Yes/No Dip at Crossing: ___mm
Are Bolts/Fastenings Effective? Yes/No Are Bolts/Fastenings Effective? Yes/No
Measurement OK. If "Not OK.", give Measuremen OK. If "Not OK.", give details,
"K1" Crossing (mm) (Y/N) details, action required. "K2" Crossing t (mm) (Y/N) action required.
(Q + R)a (Q + R)c
Gauge Gauge
(Q + R)b (Q + R)d
Checkrail Qa Checkrail Qc
Effectiveness Qb Effectiveness Qd
Flangeway Ra Flangeway Rc
Clearance Rb Clearance Rd
Does Crossing Nose Need Building Up? Yes/No Dip at Crossing: ___mm Does Crossing Nose Need Building Up? Yes/No Dip at Crossing: ___mm
Alignment of “Checking” Alignment of “Checking”
Are Bolts/Fastenings Effective? Yes/No Yes/No Are Bolts/Fastenings Effective? Yes/No Yes/No
face and wingrail face OK? face and wingrail face OK?
OK. OK.
If "Not OK.", give
General (Y/N If "Not OK.", give details General (Y/N
details Work Required Target Date
) )
Drainage Rails Tighten bolts & studs Yes/No
Ties/Bearers Plates Type Mechanised Resurfacing Yes/No
Ballast Cond Remove excess ballast Yes/No
Alignment Checkrails & bolts Weld out mechanical joints Yes/No
Anchors Fastenings Weld out insulated Joints Yes/No

Bearers Renew /replace diamond Yes/No

Turnout Timbers 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 6.0 Pandrol Plate Diamond Yes/No
Number Req'd: Recondition track Yes/No

© Rail Corporation Page 250 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Slip Examination Form STW 4

Line: Location: Track From/To:

Km
Team: [Link]: Name/Signature:
:
MIMS Equipment No: Date:
STATIONS 1 2 3 PT 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
SINGLE SLIP – POINTS S1 & S2

Tight
GAUGE

Wide

Play

Total gauge
widening

Design
SUPER

Actual

Switch Tip S1 & OK. OK. If "Not OK.", give details, action
(Y/N)
If "Not OK.", give details, action required. Points S1 & S2 (Y/N) required.
S2
Left Was Switch fitting Left
Height
Right Switch tip correctly Right
Profile
Left Condition of Heel Left
Width Gauge
Right (Transfer block)? Right
used?
Left Switches bearing on Left
Angle
Right Yes/No plates? Right
Evidence of stockrail creep? Yes/No Do switches need grinding? Yes/No

Switch Tip S3 & OK. OK. If "Not OK.", give details, action
(Y/N)
If "Not OK.", give details, action required. Points S3 & S4 (Y/N) required.
S4
Left Was Switch fitting Left
Height
Right Switch tip correctly Right
Profile
Left Condition of Heel Left
Width Gauge
Right (Transfer block)? Right
used?
Left Switches bearing on Left
Angle
Right Yes/No plates? Right
Evidence of stockrail creep? Yes/No Do switches need grinding? Yes/No
STATIONS PT 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
DOUBLE SLIP –POINTS S5 & S6

Tight
GAUGE

Wide

Play

Total gauge
widening

Design
SUPER

Actual

Switch Tip S5 & OK. OK. If "Not OK.", give details, action
(Y/N)
If "Not OK.", give details, action required. Points S5 & S6 (Y/N) required.
S6
Left Was Switch fitting Left
Height
Right Switch tip correctly Right
Profile
Left Condition of Heel Left
Width Gauge
Right (Transfer block)? Right
used?
Left Switches bearing on Left
Angle
Right Yes/No plates? Right
Evidence of stockrail creep? Yes/No Do switches need grinding? Yes/No

Switch Tip S7 & OK. OK. If "Not OK.", give details, action
(Y/N)
If "Not OK.", give details, action required. Points S7 & S8 (Y/N) required.
S8
Left Was Switch fitting Left
Height
Right Switch tip correctly Right
Profile
Left Condition of Heel Left
Width Gauge
Right (Transfer block)? Right
used?
Left Switches bearing on Left
Angle
Right Yes/No plates? Right
Evidence of stockrail creep? Yes/No Do switches need grinding? Yes/No

© Rail Corporation Page 251 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Expansion Switch Examination Form STW 5

Line: Location: Track From/To:

Team: Km: [Link]: Name/Signature:
MIMS Equipment No: Date:
STATIONS 1 2 3 PT 5 6 7 8 STOCKRAILS
Tight OK Not Ok If "Not Ok" or "No", give details
GAUGE

0 Left
Condition
Wide Right
Play Do Stockrails Require Left YES NO
Total Widening Grinding Right YES NO
CREEP
Relative to Neutral Punch Marks OK Not Ok If "Not Ok" or "No", give details, action required, priority (when must repairs be completed?
Neutral Punch Mark Left
(Central Between Transoms) Right
Left mm
Switches (max. 50mm)
Right mm
Left mm
Stockrails (max. 50mm)
Right mm
OK Not Ok If "Not Ok" or "No", give details, action required, priority (when must repairs be completed?
Left
Switch Fitting Correctly
Right
Switch Opening Left
(max. 2mm) Right
Left YES NO
Switches Sliding effectively
Right YES NO
Left YES NO
Do Switches Require Grinding
Right YES NO
SWITCH TIPS
OK Not Ok If "Not Ok", give details, action required, priority (when must repairs be completed?
Left
Condition
Right
Left
Height
Right Was Switch Tip
Left Profile Gauge
Width Used
Right
Left Yes No
Angle
Right
D BOLT ASSEMBLY (for VAE Expansion switches)
OK Not Ok If "Not Ok" or "No", give details, action required, priority (when must repairs be completed?
Wear Left mm
(Between switch foot & D Bolt assembly)
Max. 3mm Right mm

Left
D Bolts
Right
SAFETY ROLLERS (for VAE Expansion switches)
OK Not Ok If "Not Ok" or "No", give details, action required, priority (when must repairs be completed?

Left
Safety Rollers
Right
IBAV ASSEMBLY (for VAE Expansion switches)
OK Not Ok If "Not Ok" or "No", give details, action required, priority (when must repairs be completed?

Left
Springs
Right
Left
Base Plates
Right
GENERAL
OK Not Ok If "Not Ok", give details Work Required Yes No Target Date
Alignment Tighten bolts & studs
Fastenings Lubricate
Studs/Chairs
Rails
Plates
Transoms
Lubrication

© Rail Corporation Page 252 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3
 RailCorp Engineering Manual — Track
Track Inspection TMC 203

Turnout Inspection - Swingnose Crossing Form STW 6

Location:_____________ Track:______________ I.D. No.:______________

Length: ______________ Date: _____________ Name/Signature:____________________
Swingnose Measurement Should Be OK Not OK Remarks
Mainline 1435 ±3
Gauge
Turnout 1435 ±3
Tip
OK.(Y/N) If "Not O.K.", give details, work required, and priority (When must repairs be completed?)
Height Was Switch
tip Profile
Width Yes/No
Gauge
Angle used?

Do Switches need grinding?

General L* OK Not OK If not OK give details

Is swing nose free of built up ballast and other material? 1
Is point rail or splice rail (tongue rail in PRE) bearing on the switch 1
plates?
Are all bolts, clips, nuts, split pins tight and effective (not loose / broken) 1
in wing rail, crossing frame, point rail, tongue rail, splice rail?
Wear of wing rail and point rail at the transition point 1
Are there signs of abnormal wear on the rail head running surface and 1
gauge face on point rail, splice rail and wing rail
Are there signs of excessive wear on the rail head running surface and 2
gauge face on point rail, splice rail and wing rail
Rolling contact fatigue defects (surface checking / cracks, spalls, scale 1
or squats)on point rail, splice rail, wing rail
Fit of point rail and splice rail against the crossing frame rail stops in the 1
normal and reverse position
Bearer condition 2
Condition of screw spikes and washers 2
Rail head overflow on wing rail / point rail gauge face adjacent to the 2
point rail
PRE only
Condition of huck bolts at the following locations - F chock, crossing 2
plate, rail brace to rail stop, wing rail A, B and F chocks, point rail
fabricated heel block, wing rail / splice rail C and D heel blocks
Condition of crossing plates 2
Fit of swing nose against the switch stops in the forward and reverse 2
positions.
VAE only
Fit of splice rail to point rail switch stops. 1
Crossing frame condition 2
Point Rail / Splice Rail Sliding Joint 2
Are fasteners, castle nut and split pins fitted and tight? 2
Are safety clamp fasteners satisfactory? 2
Condition of anti-creep brackets 2
Condition of heel block / anti creep block huck bolts 2
Condition of rail stop brackets (point rail / splice rail to crossing frame) 2
Condition of switch stops (splice rail to point rail). 2

L is Level of Examination

© Rail Corporation Page 253 of 253

Issued April 2013 UNCONTROLLED WHEN PRINTED Version 5.3