The Journal of Pandrol Rail Fastenings 2008 - Pandrol USA

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DIRECT FIXATION NEW ASSEMBLIESPRODUCTSThe Feasibility of the Vortok Pandrol e clipStressing Rollers on a Network Rail High OutputBallast Cleaning Siteby Ian Saul, Project Engineer, Network Rail, High Output Renewals, MP&IVortok stressing rollers have been developed for both Pandrol FASTCLIP and ‘e’ Clip fastenings, and are now in widespread use aroundthe world. The following report details Network Rails experience with the ‘e’ Clip version.Trial site at Corby GlenNetwork Rail has recently approved thenew Vortok Stressing Roller (eVSR)designed for use with the Pandrol e Clipfastening system. A feasibility studywas carried out for use on the HighOutput Ballast Cleaning project toassess the possible benefits the rollerscould offer in key areas of the HOBCprocess and in particular, based aroundfour points.• Technical improvement• Safety• Speed• Cost (when compared to manpower savedagainst initial outlay of funds)Two methods were used to conduct the study.• Desktop study (using the Vortokpaperwork and data provided byNetwork Rail)• On site trialDESKTOP STUDYAs a technical improvement the rollers aredesigned to reduce the friction betweensleeper and rail by a high factor (the VortokeVSR has a friction factor of 0.0012 reducedfrom a factor of 0.12 with the traditionalmethods).This reduced friction allows for a farbetter distribution of stress throughout the railthat has been pulled. This improved distributionof stress also allows for much greater length oftrack being possible to stress (up to 1200m) oreven greater, as against the current UK limitof 900m.As a safety issue, the eVSR holds the rail upwithout the use of jacks, with the rollerssupporting the rail under the head of the rail,and holds the track in a way that the rail willnot fall while it is raised (the rollers go past thecentre point of the lift with the downwardforce of the rail locking the rollers in place – theactual roller therefore would have tocompletely fail for the rail to drop). This meansthat the possibility of operators getting theirfingers trapped under the rail is virtuallyeliminated.Due to the reduction in processes such asno jacking of rail, no use of side rollers andreduced manpower requirements coupled withfaster operation compared to the traditionalmethods, there are potentially large costsavings to be envisaged.TRIAL DETAILSThe trial was carried out as part of an 800mstress on both legs of the Up main at CorbyGlen on the East Coast Main Line (ECML) nearGrantham in Lincolnshire. The forty four VortokeVSR rollers were used over 190m of the sixfoot rail/leg.28
NEW PRODUCTSThe site consisted of a curved area of trackwhich favours the speed of the Vortok eVSR asthe traditional method requires extra work thanon straight track (traditional side rollers wouldnormally have to be used on the inside radiusof curved track). The trial also focused on thespeed of use of the eVSR rollers and thestaffing savings with the method comparedwith the traditional rollers used elsewhere onthe same site.TRIAL METHODThe Vortok eVSR’s were supplied in plasticcrates holding eight rollers (each crate is laidout on track every 44 sleepers). The quantity ineach crate is to allow a maximum weight of25kg per box – this allows each crate to becarried safely by one man.The rollers were then laid out every 11sleepers which was the suggested distancebetween the sleepers on the radius curve at thetrial site. On this site, 11 sleepers equates toapproximately 7 metres. Vortok does not statein any documentation the correct spacing’s ofthe rollers, as this should be determined by thelocal technician working to the agreedspecification for the network.After the rail was cut, it was unclippedaway from the pull point. Installation of theeVSR’s was delayed until unclipping hadreached at least thirty metres from the pullpoint. This was important because raising therail with the eVSR closer than this to a securedclip makes it more difficult to operate thestressing rollers. The Vortok rollers were theninstalled and spaced at intervals of every elevensleepers and then raised. This operation processwas timed and compared to the timestaken on the other rail which was beingstressed using the traditional methods andequipment. As soon as all rollers of bothtypes had been installed, the rail was stressed.As soon as the stressing was completedthe rollers were lowered and removed andclipping up of the rail commenced. Again, timeswere taken of both methods of operation.TRIAL SPEED RESULTSVortok eVSR.i. Installation by two men using VortokeVSR’s took 10mins and 4 seconds to put up190m of rail on one leg. This time includedthe time waiting for the rail to be unclippedafter the roller team caught up with theunclipping team. This means that 800mof rail could be up on Vortok rollers in42mins and 23 seconds.ii. Removal using two men the Vortok eVSR’stook 6mins and 41 seconds to lowerand remove 190m of rail on one leg.This means that 800m of rail could be takendown using Vortok rollers in 28mins and9 seconds.Traditional Side/Under Rollersiii. Installation by four men using the traditionalrollers (with side rollers) took 24mins and15 seconds to put up 190m of rail on oneleg. This means that 800m of rail could beraised up on traditional rollers in 102minsand 6 seconds.iv. Removal by four men using the traditionalrollers (with side rollers) took 17minsand 21 seconds to lower and remove190m of rail on one leg. This meansthat 800m of rail could be taken downusing traditional rollers in 73mins and3 seconds.eVSR at Croby Glen in raised position29
Page 1 and 2: DIRECT FIXATION ASSEMBLIESThe Journ
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Page 25 and 26: PROJECTS444km (277 miles) of new do
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Page 32: 32PANDROL VANGUARD installed on Per

The Journal of Pandrol Rail Fastenings 2008 - Pandrol USA

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