corus rails

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Technical Handbook

Rail Products

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

Corus offers one of the widest and most comprehensiverail product ranges in the world.

Corus rail, steel sleepers and associated track products are produced in the UK and France where skilled staff are able to draw on more than a century ofexcellence in manufacturing and metallurgy. Corus Rail Products is also able to exploit the huge bank of railway industry expertise available within the largerCorus Group, which employs 14,000 engineers and technologists worldwide.

Corus has supplied rail and track products to customers in more than 85 countriesthroughout the world. The company’s global reach is matched by its proven abilityto set international standards in manufacturing processes, product performanceand customer service.

Corus employs a team of technical and commercial representatives on everycontinent to work closely with customers. In addition, rail experts at Corus canoffer a multitude of solutions for the packaging, transporting, handling and storageof rails.

Introduction02 Manufacturing philosophy05 Manufacturing & supply processes12 Finishing, test and inspection16 Despatch18 The Corus product range

Corus Rail Products

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The Corus manufacturingphilosophy

A skilled workforce, ongoing investment ineffective production methods and many decadesof experience in the development and supply ofrail products lie at the heart of Corus’ ability tosatisfy the demands of the railway industry.

However, Corus knows that these vitalingredients are not enough to guaranteeproducts that will satisfy the exactingrequirements of today’s customers. Throughoutits operations in France and the UK, Corus iscommitted to four guiding principles that shapeits manufacturing operations and contribute tothe performance, reliability and high standards of its products.

1. A commitment to safety and the environmentCorus is fully committed to addressing safety and environmental concerns in its design,production and business management processes.

Corus implements the DuPont™ system of safety, which drives a health and safetyculture by focusing on behavioural and cross-business audits. These are undertaken in order to share information and achieve a consistent approach throughout theorganisation. ‘Best Safety Practices’ are entered in a database and used as commonstandards. The Corus safety policy, comprising eight key principles, is scrupulouslyapplied across the company so that every employee takes full responsibility for workingsafely. All contractors are encouraged to participate in a ‘Safety Passport Scheme’.

Corus plays its part in the protection of the environment by minimising the impact of itsoperations and ensuring continuous improvement in environmental performance andcontrol. The company’s mills and welding centres operate an ISO 14001 environmentalmanagement system, which is accredited by independent auditors.

2. A quest for qualityAt the Corus mills and welding centres in the UK and France, more than 125 years of manufacturing experience is combined with continuing investment in modernequipment and processes. This ensures that all Corus products bear the hallmarks of quality and are produced to consistent high standards.

Corus manufacturing facilities comply with the most up-to-date quality managementstandards – ISO 9001. In pursuit of excellence, process-based quality systems focuson customer satisfaction and exploit technology to the full.

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Corus manufacturing andsupply processes

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The Corus manufacturing philosophy continued

3. A desire for continuous improvementSophisticated process monitoring equipment at the Corus mills plays a crucial role in continuous improvement. As rolled steel is produced, any necessary processadjustments detected by the monitoring and analysis systems are recorded for future reference. The data is used to facilitate continuous improvement of both process and product.

High importance is placed on staff training and job competencies in the pursuit ofproduct quality. Staff in all disciplines across the business also participate in regular,productive initiatives to identify product and process improvements. Corus has anenviable record in the implementation of improvements suggested by its employees.

4. A commitment to innovationAlongside its dedication to quality and continuous improvement, Corus has earned a reputation for innovative products and services that meet the challenges of modernday railways.

Heavier traffic, an increasingly discriminating public, complex operating scenarios andnew legislation are all issues that affect our railways. Issues like these place demandson rail product performance and call for an innovative response from the railwayinfrastructure industry.

Corus’ achievements as a result of investment in product research and developmentare well recognised within the rail industry. Successful development programmes haveraised the quality of our products.

In recent decades, Corus has supplemented its traditional and successful manufacturingtechniques with modernised and improvedprocesses in order to produce a comprehensiverange of high-performance products to suit awide variety of applications.

The Corus commitment to product quality isevident in the process for the initial manufactureof steel and extends through the rolling andfinishing of rail products to the well-provenprocess for delivering products in peakcondition to customers around the world.

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Vacuum treatment in a RH steel recirculating degasser allows efficient reduction of hydrogencontent and eliminates subsequent risks of internal defects forming in the rails. If necessary,the degassing process is completed by controlled slow bloom cooling after casting.

During continuous casting, re-oxidation of the steel is prevented using refractory shroudsto protect the stream of liquid steel from the atmosphere. The process enables the settingand control of the liquid steel level in the casting strand in order to control the bloomsurface quality. Water spray cooling is automatically adjusted to the casting speed andbatch analysis in order to control segregation. The continuous casters also utilise automaticoxygen cutting and marking identification systems to ensure complete traceability of railback to steel manufacture.

Various bloom cross-sections are produced by the continuous casting plants. The mostcommon section used for rail rolling is 254mm x 330mm. At each stage of manufacture(converter, secondary steel making, vacuum degassing and continuous casting), chemicalcomposition samples are taken for laboratory analysis. This regular testing – linked with a stringent product identification procedure – ensures tight control of the manufacturingprocess and of product quality.

The Benefits• The sophisticated and tightly controlled steel making process results in homogeneous

mechanical properties over the full length of the rail. This ensures consistent andreliable behaviour of the rail in the track.

• Each bloom is given a unique identity to provide traceability of product through theentire steel making process. Cast, strand and position in the strand are marked and the identification is entered into a computerised monitoring system that links each railidentity to its bloom at the start of the rolling process.

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Steel making

The TechnologyRail steel is produced from liquid iron using modern computer-controlled processes andsophisticated monitoring techniques to guarantee quality.

The ProcessIron is produced by reducing iron ore with coke in the blast furnace process. This providesa source of consistently low residual iron that is ideal for the manufacture of rail. Ifnecessary, desulphurisation of the iron is achieved by injecting a magnesium containingblend into the transfer ladle. The resulting slag is removed before charging the liquid ironinto an oxygen converter where it is then further refined in casts of 260 - 300 tonnes.Oxygen is blown into the vessel using a water-cooled lance to react with the carbon, silicon and manganese, to remove these from the steel. At this stage, phosphorous is alsoremoved from the steel. The steelmaking process is controlled by sophisticated computermodels and on-line process control systems such as gas analysis, audiometry andsublance sampling. These allow highly skilled operators to monitor manufacturing bymeasuring the progress of the blow. After 30 minutes, the steel, which is around 1700°C,is tapped from the vessel into a refractory lined ladle. Alloys are added to bring the steelwithin customer specification.

Control of the deoxidation of the steel prevents the formation of aluminates, which areparticularly harmful to the fatigue performance of rail.

The secondary steel making process uses a ladle metallurgical furnace (LMF) equipped for electro-magnetic stirring and weighing hoppers for the controlled addition of alloyingmaterials. The precision and homogeneity of the chemical composition for every cast of rail steel is tightly controlled. The process ensures very low levels of non-metallic inclusionsas a result of proper flotation and separation of inclusion particles. Electromagnetic stirringand electrical power input at the LMF ensures the homogeneity and management of thesuperheat temperature to produce a bloom that has minimal internal segregation.

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


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Rolling

The TechnologyCorus’ rolling mills at Workington in the UK and Hayange in France utilise modern processtechnology to achieve outstanding results. Computer modelling and computer-controlledheating and cooling processes all play a part in ensuring product dimensions and surfacequality.

The ProcessBlooms are reheated in a natural gas-fired walking beam furnace. Computer modelling and control of the reheating process results in tight control of rolling temperatures andensures consistent product dimensions and surface quality. On leaving the furnace, bloomsare descaled using high-pressure water jets (100 bar).

At Corus in Workington, the rolling process is undertaken using cross-country reversingmills. Typically, for heavy rail, each bloom is rolled through 14 passes to achieve thefinished profile. There are five passes in a bloom-sizing mill to adjust the section for entryinto the roughing mill where another five passes are made. A final four passes are made inthe finishing mill. Temperature is carefully controlled to ensure consistency of finished profiledimensions. Surface quality is controlled using high pressure water descaling (200 bar) toremove secondary scale between rolling passes and oil lubrication is also used on the rollpasses. Both technologies ensure a high standard of surface finish for all rolled products.

The universal rail rolling process was perfected by Corus at Hayange and is used there today. Traditional rolling-in passes on two-high reversing roughing mills obtain asymmetrical blank. The blank is then subject to a succession of passes in universal stands.Each of the universal passes is followed by an edging pass to control the expansion of thehead and the foot. The last rolling pass is designed to give the section its precise and finaldimensions and is undertaken in a semi-universal finishing stand.

During the final rolling pass, relief branding is applied on the rail web. This carriesinformation such as the rail profile, grade of steel and year of manufacture. After leaving the finishing stand, identification marks unique to each hot sawn rail are stampedautomatically at regular intervals along the length of each rail. The hot stamping markprovides full product traceability back through the manufacturing process, linking productattribute data to manufacturing parameters.

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

Steel sleepers and baseplate sections are also manufactured in Workington. The rollingprocess is similar, however these products are hot sheared into multiple lengths beforebeing cooled and stacked ready for further processing.

Rails may be heat treated to improve wear resistance in particular track locations orapplications. Heat treatment is carried out on the full length of the rails.

At the Hayange plant, the rails after natural cooling are straightened in both planes. Theyare then heated in excess of 900ºC using inductors, the novelty of this process is that theentire rail section is heated above the pearlite to austenite transformation temperature. Therails are then cooled using a computer controlled system to refine the microstructure andincrease the hardness of the rail head up to 420HB. Compressed air from a set of nozzlespositioned around the rail make it possible to control both the cooling of the head andbase in such a way that the rails do not require further straightening. This process allowsthe delivery of rails with optimised residual stresses, and guarantees no opening of the railweb during the saw cut test.


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Conditions Longitudinal stresses (MPa) Saw cut measured by strain gauges test

Typical values (mm)

Head Web Foot

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

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

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

Residual stresses vs. straightening conditions

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The microstructure obtained on all the treated rails consists of 100% ultra fine pearlite withno transition zone. Due to this process, the hardness values decrease very slowly withdepth, resulting in minimal plastic deformation and reduced wear under significant axleloads. The high values achieved for elongation and reduction of area assure optimumresistance to deformation and brittle failure.

The above Corus heat treatment process produces rails that do not require rollerstraightening after heat treatment. The residual stresses measured on the rails in theirdelivery condition are of an extremely low level. The resulting state of compressionsignificantly reduces the risk of failure initiation and growth at the point within the rail wherethe loading is at its highest. This is a major benefit on the foot of the rail, where low residualstresses reduce the risk of fatigue failure associated with a corrosion pit and there is noreliable method of inspecting the foot in service. Also the compressive stresses in the railhead may offer benefit in delaying the growth of rolling contact fatigue (RCF) cracks.Transversely, the residual stresses are negative everywhere, with a mean value of -55 MPa,-50 MPa and -5 MPa in the head, the web and the base respectively.

The Benefits• The substantial capacity, flexibility and process consistency offered by Corus rolling

mills enables the production of a wide variety of rail, sleeper and baseplatesections to high quality standards.

• The hardening processes are so efficient that, even at a depth of 20mm below the running surface, a hardness of 365HB is achieved – a feature that results in exceptional in-service life of Corus heat-treated rail sections.


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Finishing, test andinspection

The TechnologyOngoing investment in modern test and inspection equipment plays a major role in ensuringthat Corus’ rail products are of a consistent high quality. Laser, eddy-current and ultrasonictechnologies are utilised alongside conventional testing methods to provide evidence thatproducts meet the specified requirements.

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

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

Corus is the UK’s market leader in the field of rail welding and is responsible for thedevelopment of the patented ‘Invisible Weld’. The companies welding facilities are located inCastleton in the north of England where highly-qualified welding technicians produce rails inlengths up to 216 metres. The flash butt welding process uses the resistance welding methodto create a weld made purely of parent material. State-of-the-art scanning equipment is usedto ensure all welded rail lengths meet specification.

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

The Process – test and inspectionThe development of high-speed trains means that rail straightness is a crucial factorgoverning performance of the rail in track. Corus uses state-of-the-art laser technology to measure the flatness/straightness of rails.

A wave meter is used, and is composed of a series of laser rangefinders measuringflatness of the rail running surface and a second series of laser rangefinders measuringflatness on the side of the rail head. The position of the sensors has been calculated so asto measure all the specified variations in straightness. Signals are processed automaticallyto obtain the equivalent results obtained using a sliding straight edge, the lengths of whichare stipulated in the standards (3 metres; 1.5 metres and 2 metres in Europe). Differentsignal processing programs are used to check straightness in accordance with the orderspecification. Results are stored on a computer for a period of 10 years

Eddy current testing is used to identify any surface defects that exceeds specificationlimits. The test equipment comprises electromagnetic coils, which induce eddy currents inthe rail. The amplitude and form of the eddy-currents depends on the surface condition ofthe test surface thus allowing surface defects to be detected. These are automaticallymarked by a paint jet.

Based on the 60E1 profile the in-line ultrasonic testing equipment inspects more than90 per cent of rail head and more than 60 per cent of the rail web and the central part ofthe foot. Ultrasonic testing detects internal defects such as inclusions, which can have anadverse effect on in-service rail life. Coverage of the profile is achieved by means of sevenprobes for the head, up to six probes in the web and two or three on the foot.

Defects detected by the in-line test are automatically paint marked and are inspectedmanually using portable ultrasonic testing equipment in order to confirm the presence of agenuine defect. A test report is established and archived for each rail. Calibration is carriedout regularly on artificial defects machined into ‘calibration rails’.

A range of acceptance tests is undertaken to customer specification – and in thepresence of a customer representative if required. These tests include tensile andhardness, decarburisation measurements, segregation checks and steel cleannessassessments. Testing is carried out at the Corus manufacturing sites – ensuring quickavailability of results after the product has been rolled.

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

In keeping with its reputation forinnovation, Corus is at the forefrontof rail straightening technology


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Test and inspection

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

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

The Benefits• The quality finishing process ensure that all Corus products are manufactured to the

highest standard suitable for a range of environments including high speed, heavy haul,mixed traffic systems, urban environments and industrial applications.

• Modern machining methods mean that even the tightest engineering tolerances can be achieved – ensuring products meet exacting specifications.

• In addition to post-production tests, thorough inspection is undertaken throughout themanufacturing process – including profile dimension and hot surface quality checks.The inspection results are used to make any appropriate adjustments to productionprocesses and ensure that Corus rail products are of the highest quality and meetcustomer requirements.


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For marine transport, Corus at Workington has a private rail link direct to port facilitiessituated less than 3 km from the mill. The port has a long association with the shipping andhandling of rails and can lift loads up to 28 tonnes, servicing ocean-going vessels up to8,000 tonnes. Overseas export orders from Hayange usually transit via the port of Antwerp,which offers regular departures to numerous destinations including the United States andthe Far East. Corus has extensive experience in direct handling and marine transport oflong rails (73m) to European destinations.

Road transport for rail lengths under 28m is undertaken by a fleet of road lorries. HIABfacilities are available for offloading rails at work sites and where access is difficult.

Long welded rail delivery from Castleton is undertaken by rail, utilising special trainsequipped to handle and off-load rail up to 216m long. The rail can be offloaded directly atthe work site. Shorter rail lengths can be transported on a fleet of purpose-designed railwagons. Corus’ specially designed fleet of trains allows for complete control of the supplychain and gives JIT ability on key high profile work sites.

Thanks to its expertise in rail coating and corrosion protection, Corus can deliver railprotected against marine conditions during transportation and storage.

The Benefits• Corus’ proven and efficient product despatch process means that delivery costs are

reduced and the risk of rail damage during handling and transit is minimised.

• In order to provide an improved response to customers’ requirements for qualityand reliability, Corus has a fully developed acceptance and monitoring system at theport of Antwerp.

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Despatch

The TechnologyWhen the manufacturing process is complete, Corus’ team of logistics experts comes intoits own – ensuring the safe and cost-effective delivery of products to customers acrossEurope and around the world. Once again, Corus utilises the best in modern technology –from special handling equipment to purpose-designed rail wagons and river craft – toensure the integrity of its products is protected.

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

The Corus mills at Hayange and Workington have substantial experience of delivery by railto UK, French and other European customers. Hayange lies at the heart of the efficientrailway and waterway networks that guarantee rapid access to the majority of Europeandestinations – and beyond – via the port of Antwerp. A private branch line at Hayange linksdirectly to the public rail marshalling yard at Ebange and the river port of Thionville. Eachlocation is within 10km of the Corus mill. In the UK, Corus utilises efficient rail and roadlinks to the major northern English ports of Teesside, Immingham and Liverpool. Road andrail links to the Channel Tunnel allow rapid delivery to mainland Europe.

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

In addition to producing rail for its high-speed network, Corus worked withSNCF in France to develop dedicated transport methods for delivery of therail. The result was a fleet of special rail wagons, allowing rails of up to 80mto be carried over a large proportion of the continental network.


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for heavy haul networksRequirement:These rails are used by trains with very high axle loads – 25 to 35 tonnes – or where thecumulative amount of loads transported is substantial – around 100 to 150MGT/yr. The routes may be diverse and the terrain crossed frequently, require the construction oftight radius curves of less than 200m. In order to increase wear resistance and improvefatigue life, high strength rail grades are recommended.

Corus Products:Corus offers heat-treated rail with optimised residual stresses. Current rail manufactureprocesses all include roller straightening after heat treatment. This operation induces tensilestresses in the railhead and foot seen as an opening of the web during the saw-cut test.This produces a risk of sudden longitudinal fracture of the core during service.

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

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

In addition to heat-treated rails, Corus supplies naturally hard grades with a hardness of300 – 340HB which offer a good compromise between fatigue and wear for tangent track.

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

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Railfor high-speed networksRequirement:Commercial operating speeds on these networks range from 150km/h to more than300km/h. Lines are mainly composed of straight stretches and large radius curves that aregenerally considerably greater than 4,000 m. Track is based on rail sections of 50 to 60kg/m,usually of non heat-treated steel grade with a hardness ranging from 200 to 300HB. In orderto reduce the dynamic stresses, the axle load is limited to 17 tonnes for high-speed trains.Detection of high-speed trains by track circuitry is a major element in rail safety and hasimplications for the quality of the rails used.

Corus Products:With its world-class rail straightening and testing facilities, Corus has been able to give fullsupport to the development of high-speed networks. From 1980 onwards, Corus rails havebeen used by SNCF for its high-speed lines in France and Corus has equipped more than1,500km of new line where trains run at commercial speeds of 270 to 350km/h.

The development of Corus rail steel manufacturing processes has improved the in-servicefatigue rail life through improved steel cleanness and homogeneous mechanical properties.Grinding work and the development of new rail steels are reducing the incidence of rollingcontact fatigue.

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

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

The Corus product range

Corus was the first company in Europe to manufacture rail for high-speedlines – its rail manufactured for SNCF in France included the Atlantic branch of the high-speed network where the TGV no 325 reached a speed of 515.3km/h (320.2mph) as early as 1990.


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

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

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

Corus has also developed the ready-to-use, dual-material rail Sogeplex™ which can playa key role in combating the problem of noise in urban areas. Sogeplex™ has anti-wear and anti-squeal properties and is well suited to tight radius curves.

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

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

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

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Rail continued

for mixed traffic networksRequirement:Mixed traffic networks cover tracks where the commercial operating speed is usually lowerthan 150km/h and where freight trains (with up to 22.5 tonne axle loads) and passenger trainsshare the same line. The types of lines are extremely varied – from long straight stretchesacross plains to very tight alpine curves. The track gauge may be standard (1435mm), wide(1524mm) or narrow (1067mm). A wide range of rail sections and steel grades are required in order to meet the constraints of existing structures and specific operating conditions.

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

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

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

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


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CEN Design Rail Sections

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

46E 1 46 E 2 46 E 3 46 E 4 49 E 1(previously (previously (previously (previously (previously

SBB1) U33) NP46) UNI46) DIN S49)

Head crownSingle radius mm 400Double radius mm 300/80 200/60 300/80 300/80

Gauge corner Radius J= mm 13 13 13 14 13

Head widthTaper Parallel 1:20 1:16.5 1:20 1:17.2

UpperFishing taper 1:4 1:3 1:4 1:4 1:3

Upper filletRadius mm 6/30 7 6 5 7

WebParallel Yes Yes Centre portion Centre portion Centre portion

only only onlyRadius mm 80/120 80/120

Lower filletRadius mm 6/30 7 6 5 7

LowerFishing taper 1:4 1:3 1:4 1:4 1:3

OuterFlange taper 1:4 1:10 1:4 1:4 1:7.81

Rail height A mm 145 145 142 145 149

Foot width B mm 125 134 120 135 125

Head width C mm 65 62 73.72 65 67

Web thickness D mm 14 15 14 14 14

Head area mm2 2543 2510 2671 2586 2982

Web area mm2 1192 1121 1175 1157 1106

Foot area mm2 2147 2263 2097 2235 2204

Total area mm2 5882 5894 5944 5978 6292

Section weight kg/m 46.17 46.27 46.66 46.9 49.39

Moment of inertia lxx cm4 1641.1 1642.7 1605.9 1688 1816

Section modulus zxx cm3 217 213 224.2 221.6 240.3

Distance of neutral axis 75.65 77.14 71.64 76.16 75.59from top of rail mm

Moment of inertia lyy cm4 298.2 329.3 307.5 338.6 319.1

Section modulus Zyy cm3 47.7 49.1 51.3 50.2 51

MA D

J

C

B

High speed and mixed traffic systems

Steel Grades

Specification Grade Chemical Analysis Physical Properties

% in mass Hardness HBC Si Mn P S Cr Al V H2 Rm A Running table

(ppm) (MPa) (%) centre

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

(1986) 900A 0.60/0.80 0.10/0.50 0.80/1.30 ≤ 0.040 ≤ 0.040 880/1030 ≥ 10

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

EN 200 0.40/0.60 0.15/0.58 0.70/1.20 ≤ 0.035 0.008/0.035 ≤ 0.15 ≤ 0.004 ≤ 0.030 ≤ 3.0 ≥ 680 ≥ 14 200/400

13674-1 220 0.50/0.60 0.20/0.60 1.00/1.25 ≤ 0.025 0.008/0.025 ≤ 0.15 ≤ 0.004 ≤ 0.030 ≤ 3.0 ≥ 770 ≥ 12 220/260

(2003) 260 0.62/0.80 0.15/0.58 0.70/1.20 ≤ 0.025 0.008/0.025 ≤ 0.15 ≤ 0.004 ≤ 0.030 ≤ 2.5 ≥ 880 ≥ 10 260/300

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

prEN 260X 0.40/0.60 0.20/0.45 1.20/1.60 ≤ 0.025 0.008/0.025 0.40/0.60 ≤ 0.004 ≤ 0.060 ≤ 2.5 ≥ 880 ≥ 10 260/300

13674-2

BS 11 Normal 0.45/0.60 0.05/0.35 0.95/1.25 ≤ 0.040 ≤ 0.040 ≥ 710 ≥ 9

(1965) A 0.65/0.80 0.10/0.50 0.80/1.30 ≤ 0.040 ≤ 0.040 ≥ 880 ≥ 8

B 0.55/0.75 0.10/0.50 1.30/1.70 ≤ 0.040 ≤ 0.040 ≥ 880 ≥ 8

Heavy haul tracksSpecification Grade Chemical Analysis Physical Properties



Arema 300BHN 0.74/0.84 0.10/0.60 0.80/1.25 ≤ 0.035 ≤ 0.037 ≤ 0.25 ≥ 940 ≥ 9 ≥ 300

(2004) High Strength 0.74/0.84 0.10/0.60 0.80/1.25 ≤ 0.035 ≤ 0.037 ≤ 0.25 ≥ 1175 ≥ 10 341/388

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

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

13674-1 350HT 0.72/0.80 0.15/0.58 0.70/1.20 ≤ 0.020 0.008/0.025 ≤ 0.10 ≤ 0.004 ≤ 0.03 ≤ 2.5 ≥ 1175 ≥ 9 350/390

(2003) 350LHT 0.72/0.80 0.15/0.58 0.70/1.20 ≤ 0.020 0.008/0.025 ≤ 0.30 ≤ 0.004 ≤ 0.03 ≤ 2.5 ≥ 1175 ≥ 9 350/390

Corus SHH 0.72/0.82 0.10/0.50 1.00/1.25 ≤ 0.025 ≤ 0.25 0.14/0.30 ≤ 0.004 ≤ 2.5 ≥ 1200 ≥ 11 360/388

MHH 0.72/0.82 0.40/0.80 0.80/1.00 ≤ 0.025 ≤ 0.25 0.40/0.60 ≤ 0.004 ≤ 2.0 ≥ 1300 ≥ 12 370/410

Urban transport tracksSpecification Grade Chemical Analysis Physical Properties



VDV OR 700 0.45/0.65 ≤ 0.35 0.60/1.00 ≤ 0.045 ≤ 0.045 680/830 ≥ 14

13.1 800 0.45/0.65 ≤ 0.50 0.80/1.20 ≤ 0.045 ≤ 0.045 780/930 ≥ 12

(1995) 900 0.60/0.80 ≤ 0.50 0.80/1.30 ≤ 0.045 ≤ 0.045 880/1030 ≥ 10

Corus 700V 0.20/0.30 0.20/0.30 1.20/1.50 ≤ 0.045 ≤ 0.045 0.10/0.16 685/853 ≥ 14

900V 0.41/0.51 0.20/0.30 1.10/1.40 ≤ 0.045 ≤ 0.045 0.10/0.15 ≥ 885 ≥ 10

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

Customer 300** 0.40/0.06 ≤ 0.025 ≤ 0.020 ≥ 300 Résistivité < 14 __cm*

* Tyre tracks ** Conductor rails (1) Re ≥ 235 MPa and KCV at + 20ºC > 35J/cm_

Steel sleepersSpecification Grade Chemical Analysis Physical Properties



BS 500 EN 10025 0.16/0.22 0.20/0.49 0.60/0.90 ≤ 0.040 0.010/0.025 ≤ 0.040 410/560 ≥ 20(2000) S275

23



MA D

J

C

B

50E 3 50E 4 50 E 5 50 E 6 52 E 1(previously (previously (previously (previously (previously

BV50) UIC50) UNI50) U50) 52 RATP)

Head crownSingle radius mm 400 350Double radius mm 300/80 300/80 200/60

Gauge cornerRadius J= mm 13 13 14 13 12

Head widthTaper 1:20 1:20 1:16 1:20 Parallel

UpperFishing taper 1:3 1:2.75 1:3 1:3 1:2

Upper filletRadius mm 7 8/22 7 12 12

WebParallel Centre portion Yes

onlyRadius mm 450 508 80/120 400/600

Lower filletRadius mm 7 15 7 12 12

LowerFishing taper 1:3 1:2.75 1:3 1:3 1:2

OuterFlange taper 1:8.31 1:8.01 1:8 1:10 1:10

Rail height A mm 155 152 148 153 150

Foot width B mm 133 125 135 140 150

Head width C mm 70 70 67 65 65

Web thickness D mm 14 15 14 15.5 15

Head area cm2 2836 2901 2946 2745 2959

Web area cm2 1295 1358 1106 1273 1102

Foot area cm2 2240 2169 2310 2465 2583

Total area mm2 6371 6428 6362 6484 6643


Moment of inertia lxx cm4 2057.8 1934 1844 2017.8 1970.9

Section modulus zxx cm3 259.5 252.3 242.1 248.3 247.1


Moment of inertia lyy cm4 351.3 315.2 362.4 396.8 434.2

Section modulus Zyy cm3 52.8 50.4 53.7 56.7 57.9

24 25


MA D

J

C

B

49 E 2 49 E 3 49 E 4 50 E 1 50 E 2(previously (previously (previously (previously (previously

S49T) DIN S49b) Hush 113lb/54kg) U50E) 50 EB-T)

Head crownSingle radius mm 400Double radius mm 300/80 300/80 200/60 300/80

Gauge cornerRadius J= mm 14 13 13 13 13

Head widthTaper 1:16 1:15.2 1:20 1:20 1:20

UpperFishing taper 1:3 1:3 1:2.75 1:3 1:3

Upper filletRadius mm 7 7 8/22 12 8/30.81

WebParallel Centre portion Centre portion Centre portion Yes Yes

only only onlyRadius mm 80/120 80/120

Lower filletRadius mm 7 7 16 12 8/30.81

LowerFishing taper 1:3 1:3 1:2.75 1:3 1:3

OuterFlange taper 1:7.81 1:7.81 1:10 1:10 1:8

Rail height A mm 148 146 110 153 151

Foot width B mm 125 125 140 134 140

Head width C mm 67 67 70 65 72

Web thickness D mm 14 14 22 15.5 15

Head area cm2 2946 2773 2876 2745 2608

Web area cm2 1106 1106 838 1273 1279

Foot area cm2 2204 2204 2590 2397 2478

Total area mm2 6255 6083 6304 6416 6365


Moment of inertia lxx cm4 1796.3 1705 875.1 1987.8 1988.8

Section modulus zxx cm3 239.4 227.2 145.9 246.7 248.5


Moment of inertia lyy cm4 318.4 310.8 417.4 365 408.4

Section modulus Zyy cm3 50.9 49.7 59.6 54.5 58.3


2726

U.I.C. and A.S.C.E. Design Rail Sections

MA D

J

C

B

U.I.C. A.S.C.E.50 54 60 40 60 75 80

Head crownSingle radius 12in • • • •Double radii 300 & 80mm • • •

Gauge cornerRadius J= 5/16 in. • • • •Radius J= 13mm • • •

Head widthParallel • • • •1:20 taper • • •

Fishing tapers Upper & lower 13° = 1:4.3 • • • •Upper & lower 1:2.75 • • •

Fillet radiiUpper & lower 1/4 in. • • • •Upper mm 8 & 22 8 & 22 7 & 35Lower mm 15 16 7 & 35

FootDouble tapered • • •Outer taper 1:8 1:10 1:14

WebFully radiused M=12" Rad. • • • •Fully radiused M= 508mm Rad. • •Upper & lower radii 120mm •Centre parallel

Rail height A in. 31/2 41/4 413/16 5mm 152 159 172 88.90 107.95 122.24 127.00

Foot width B in. 31/2 41/4 413/16 5mm 125 140 150 88.90 107.95 122.24 127.00

Head width C in. 17/8 23/8 215/32 21/2

mm 70 70 72 47.63 60.33 62.71 63.50

Web thickness D in. 25/6431/64

17/3235/64

mm 15 16 16.5 9.92 12.30 13.49 13.89

Head area in.2 1.64 2.49 3.07 3.30mm 2899 2899 3085 1059 1603 1981 2129

Web area in.2 0.85 1.24 1.54 1.64mm2 1318 1486 1730 547 803 996 1059

Foot area in.2 1.48 2.21 2.72 2.93mm2 2169 2590 2856 953 1426 1756 1890

Total area in.2 3.97 5.94 7.34 7.87mm2 6385 6934 7686 2559 3832 4733 5078

Section weight lb/yd 40.50 60.64 74.90 80.36kg/m 50.12 54.43 60.34 20.09 30.08 37.18 39.86

Moment of inertia Ixx in.4 6.58 14.58 22.92 26.45cm4 1930 2346 3055 274 607 954 1101

Section modulus Zxx in.3 3.58 6.61 9.11 10.09cm3 251 279 335 59 108 149 165

Distance of neutral in. 1.83 2.20 2.51 2.62axis from top of rail mm 76.82 83.87 91.05 46.45 55.96 63.9 66.59

Moment of inertia Iyy in.4 1.60 3.61 5.42 6.21cm4 314 417 513 67 150 226 259

Section modulus Zyy in.3 0.91 1.70 2.25 2.49mm3 50 60 68 15 28 37 41


MA D

J

C

B

54 E 1 54 E 2 54 E 3 55 E 1 56 E 1 60 E 1(previously (previously (previously (previously (previously (previously

UIC54) UIC54E) DIN S54) U55) RT113A) UIC60)

Head crownSingle radius mmDouble radius mm 300/80 300/80 300/80 200/60 305/80 300/80

Gauge cornerRadius J= mm 13 13 13 13 12.7 13

Head widthTaper 1:20 1:20 1:17.2 1:20 1:20 1:20

UpperFishing taper 1:2.75 1:2.75 1:3 1:3 1:2.75 1:2.75

Upper filletRadius mm 8/22 8/22 16 12 8 7/35

WebParallel Yes Yes Centre portion

onlyRadius mm 508 508 500 120

Lower filletRadius mm 16 16 16 12 15 7/35

LowerFishing taper 1:2.75 1:2.75 1:3 1:3 1:2.75 1:2.75

OuterFlange taper 1:10 1:10 1:7.81 1:10 1:10 1:14

Rail height A mm 159 161 154 155 158.75 172

Foot width B mm 140 125 125 134 140 150

Head width C mm 70 67.01 67 62 69.85 72

Web thickness D mm 16 16 16 19 20 16.5

Head area cm2 2901 2942 3223 2897 2860 3084

Web area cm2 1486 1486 1338 1465 1712 1730

Foot area cm2 2590 2428 2391 2775 2597 2856

Total area mm2 6977 6856 6952 7137 7169 7670

Section weight kg/m 54.77 53.82 54.57 56.03 56.3 60.21

Moment of inertia lxx cm4 2337.9 2307 2074 2150.4 2321 3038.3

Section modulus zxx cm3 278.7 276.4 262.8 255.2 275.5 333.6

Distance of neutral axis 83.87 83.47 78.93 84.26 84.24 91.08from top of rail mm

Moment of inertia lyy cm4 419.2 341.5 354.8 418.4 421.6 512.3

Section modulus Zyy cm3 59.9 54.6 56.8 62.4 60.2 68.3


2928

Ethiopia Indonesia N.Z.R C.I.E. N.Z.R 100 136 136 EgyptUNI 30 S40 R42 91lb 50 50 CP RE RE 51.75

RE CN OPT

Head crownSingle radius mm 200 356 355.6 250

(14in.) 4in.

Double radii 200 & 60mm • 320 & 60 300 & 80 300 & 80

Triple radii 8in, 11/4 in. & 7/8in. •

Gauge cornerRadius J= in. (3/8in.) 9/16in. 9/16in.Radius J= 13mm 14 • • 9.5 • • 14.29 14.29 14.29 14

Head width Taper 1:20 1:11.4 • 1:14.4 • • • 1:16 1:40 1:40 •

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

Upper fillet Radius in. (3/8in. & 3/4in.) 5/16in. & 3/4in. 5/16in. & 3/4in.

mm 7.8 7 10 9.5 &19 8 & 22 19 9.53 7.74 19.05 8

WebParallel • •Parallel in. (14in.) 8/20in. 8/20in.Radius M mm 706 320 356 508 500 355.6 203.2 508 80 & 120

Lower filletRadius in. (5/8in.) 3/4in. 3/4in.

mm 7.8 7 10 15.9 16 15 15.88 19.05 19.05 8

Lower Fishing taper 1:3 1:4 • 1:4 1:4 1:2.75 1:2.75 1:4 1:4 1:4 •

Outer Flange taper 1:10 1:15 • • 1:4 •

Rail height A in. 55/8 711/32 75/16

mm 128 128 138 142.88 150 153 153.99 186.53 187.74 155

Foot width B in. 53/16 6 6mm 106 115 110 131.76 140 132 136.53 152.40 152.40 141

Head width C in. 29/16 215/16 215/16

mm 61.2 60 68.5 65.09 70 66 65.6 74.61 74.61 66

Web in. 9/1611/16

11/16

Thickness D mm 11 13 13.5 14.29 15 15 14.29 17.46 17.46 15

Head area in2 3.20 4.86 4.79mm2 1853 1989 2386 2063 2735 2531 3136 3093 2834

Web area in2 2.17 3.64 3.64mm2 895 866 1215 1399 1321 1416 2347 2347 1284

Foot area in2 3.50 4.87 4.87mm2 1232 1806 1826 2260 2310 2453 3142 3142 2475

Total area in2 8.87 13.37 13.30mm2 3981 4661 5426 5722 6364 6400 64.78 8625 8581 6593

Section weight lb/yd 90.54 136.49 135.90kg/m 31.25 36.59 42.60 44.92 49.96 50.24 50.85 67.71 67.41 51.75

Moment of in4 37.96 94.88 93.94inertia lxx cm4 879 1020 1369 1580 1911 1970 2064.4 3949 3910 2128

Section in3 12.29 23.79 23.63modulus Zxx cm3 135 151 196 201 245 241 247 390 397 261

Dist of neutral in 3.09 3.99 3.97axis from top of rail mm 62.67 67.68 69.70 78.46 78.03 81.76 83.57 101.31 100.86 81.50

Moment of in4 7.57 14.47 14.41inertia lyy cm4 138 203 232 315 365 338 386.3 602 600 411

Section in3 2.92 4.82 4.80modulus Zyy cm3 26 35 42 48 52 51 57 79 79 58

Various Rail Sections

MA D

J

C

B

A.R.E.M.A. Designs

MA D

J

C

B

100 RE 115 RE 119 RE 132 RE 133 RE 136 RE 141 AB

Head crownSingle radius 14in.

Double radii 10in & 11/4in. 10in. & 10in. & • • • 8in. &11/2in. 11/2in. 13/4in.

Gauge corner Radius J= 3/8in. • • • •Radius J= 9/16in. • • •

Head widthTaper 1:40 • • • •

1:16 1:14.3 1:11.4

Fishing tapers Upper & lower 1:4 • • • • •Upper 1:3, lower 1:4 • •

Upper fillet radiiSingle 3/8 in. •Double 3/4 in. & 3in. rad • •Double 5/16 in. &3/4 in. rad • • •Double 7/16 in. & 3/4 in. rad •

WebFace radius M in. 14 14 14 8 & 16 8 & 16 8 & 20 8 & 20

Lower filletL radius 3/4 in.

5/8in. • • 7/8in. • • •

Rail height A in. 6 65/8 613/16 71/8 71/16 75/16 77/16

mm 152.40 168.27 173.04 180.97 179.39 185.74 188.91

Foot width B in. 53/8 51/2 51/2 6 6 6 6mm 136.52 139.70 139.70 152.40 152.40 152.40 152.40

Head width C in. 211/16 223/32 221/32 3 3 215/16 31/16

mm 68.26 69.06 67.47 76.20 76.20 74.61 77.79


5/821/32

11/1611/16

11/16

mm 14.29 15.87 15.87 16.67 17.46 17.46 17.46

Head area in2 3.80 3.92 4.31 4.43 4.74 4.82 5.37mm2 2450 2524 2770 2855 3057 3099 3465

Web area in2 2.21 3.04 3.04 3.61 3.46 3.64 3.55mm2 1428 1961 1961 2332 2236 2347 2290

Foot area in2 3.90 4.29 4.29 4.87 4.88 4.87 4.87mm2 2518 2770 2770 3142 3146 3142 3142

Total area in2 9.91 11.25 11.64 12.91 13.07 13.33 13.80mm2 6396 7256 7510 8329 8432 8600 8903

Section weight lb/yd 101.21 114.68 118.67 131.66 133.25 135.88 140.70kg/m 50.21 56.89 58.87 65.31 66.10 67.40 69.79

Moment of inertia lxx in4 48.40 65.90 71.40 87.90 86.20 94.20 100.44cm4 2015 2743 2972 3659 3588 3921 4181

Section modulus Zxx in3 14.87 18.10 19.40 22.40 22.30 23.70 25.24cm3 244 297 318 367 367 388 414

Distance of neutral in 3.26 3.63 3.69 3.92 3.86 3.97 3.97axis from top of rail mm 82.78 92.20 93.73 99.57 98.01 100.83 100.85

Moment of inertia lyy in4 9.29 10.73 10.84 14.40 14.40 14.44 14.91cm4 387 447 451 599 599 601 621

Section modulus Zyy in3 3.44 3.90 3.94 4.79 4.81 4.82 4.97cm3 56 64 65 78 79 79 81


3130


GKN Ethiopia Ceylon Zambia S.A.R. India29.3 UNI 36 (MOD) 88lb R43 91lb 48 52

Head crownSingle radius mm 305 381 300 305 305

(15in.) (12in.)Double radii mm 200 & 29 305 & 80

Gauge cornerRadius J= in. (1/2 in.) (1/2 in.)Radius J= 13mm 8 12 12.7 • 12.7 • •

HeadParallel • • • • • • •

UpperFishing taper 1:4.3 1:2 1:4 1:3 1:3 1:4 1:2.75

Upper filletRadius in. (5/16 in.) (5/16 in. & 7/8 in.)

mm 6.5 9 7.94 5 & 10 8 & 22 8 8 & 22.5

WebParallel • • • •Face radii M in. (7in. & 15in.)

mm 305 350 178 & 381 355 381 & 381

Lower filletRadii in. (5/16 in.) (1/2 in.)

mm 6.5 9 7.94 15 12.7 10 13

LowerFishing taper 1:4.3 1:2 1:4 1:3 1:6 1:4 1:2.75

OuterFlange taper 1:5.56 1:11 1:6 1:8 1:6

Rail height A in. 47/8 515/16

mm 109.5 130 123.82 140 150.81 150 156

Foot width B in. 51/2 5mm 101.6 106 139.70 114 127.00 127 136

Head width C in. 211/16 221/32

mm 60.3 60 68.26 70 67.47 68 67

Web D in. 9/1635/64

thickness mm 11.2 14 14.29 14.5 13.89 14 15.5

Head area in2 4.10 3.74mm2 1697 2084 2647 2422 2413 2510 2882

Web area in2 1.35 2.18mm2 743 882 872 1214 1406 1430 1334

Foot area in2 3.21 3.01mm2 1334 1705 2070 2042 1941 2140 2367

Total area in2 8.66 8.93mm2 3373 4671 5589 5678 5761 6080 6583

Section weight lb/yd 88.44 91.16kg/m 29.62 36.67 43.87 44.57 45.22 47.6 51.68

Moment of inertia in4 27.09 43.16lxx cm4 615 1031 1128 1479 1796 1822 2105

Section modulus in3 10.72 14.15Zxx cm3 112 155 176 206 232 234 260

Distance of neutral in 2.53 3.05axis from top of rail mm 55.08 66.48 64.18 71.65 77.45 77.80 80.89

Moment of inertia in4 8.75 7.13lyy cm4 136 164 364 257 297 325 354

Section modulus in3 3.18 2.85Zyy cm3 27 31 52 45 47 51 52

MA D

J

C

B


Australia Sitarail UNI50 China R50-50 R65 124JK UIC 6060kg/m 30kg/m 60 CH E2

(Flat (Flat ChinaBottomed Bottomed

Rail) Rail)

Head crownSingle radius mm Flat 400 300Double radius mm 300/100 300/80 500/80 203.2/44.45 200/70

Gauge cornerRadius J= mm 15 9 14 13 13 15 9.53/14.29 8/16

Head widthTaper 1:20 Parallel 1:16 1:20 Parallel 1:20 1:40 1:20

UpperFishing taper 1:4 1:4 1:3 1:3 1:4 1:4 1:4 1:2.75

Upper fillet Radius mm 20 7.8 7 8 & 25 5/12 7/15 19.05 7/35

WebParallel Centre Centre

portion only portion onlyRadius mm 300 706 80/120 400 350 370/400 76.2/355.6 120/120

Lower filletRadius mm 20 7.8 7 20 20 25 19.05 7/35

LowerFishing taper 1:4 1:4 1:3 1.3 1:4 1:4 1:4 1:2.75

OuterFlange taper 1:15 1:8 1:9 1:14

Rail height A mm 170 125.5 148 176 152 180 174.63 172

Foot width B mm 146 106 135 150 132 150 139.7 150

Head width C mm 70 56 67 73 70 73 73.48 72

Web thickness D mm 16.5 11 14 16.5 15.5 18 15.88 16.5

Head area mm2 3009 1723 2945 2902

Web area mm2 1974 898 1106 1979

Foot area mm2 2752 1231 2310 2864

Total area mm2 7735 3852 6362 7745 6560 8264 7831 76.48

Section weight kg/m 60.72 30.24 49.94 60.80 51.50 64.87 61.39 60.03

Moment of inertia lxx cm4 2935 839.1 1844 3217 2026.6 3543.1 3164.1 3021.5

Section modulus zxx cm3 370 132 242 339 249.4 359 343.5 330.8

Distance of neutral axis 90.65 62.10 76.15 94.77 81.27 98.7 92.11 91.33from top of rail mm

Moment of inertia lyy cm4 490 133.4 362.4 524 374.9 570.1 483.8 500.5

Section modulus Zyy cm3 67.1 25.17 53.7 70 56.8 76 69.3 68.1

MA D

J

C

B


3332

British Standard ‘A’ Designs

MA D

J

C

B

60 A 70 A 75 A 80 A 90 A 95 A 100 A 110 A 113 A*

Head crownSingle 12" radius • • • • •Double radii 12" & P=31/8in. • • • •

Gauge corner radius J=3/8 in. • •J=7/16 in. • •J=1/2 in. • • • • •

Head side taper 1:20 • • • • • • • • •

Fishing tapers Upper & lower 1:2.75 • • • • • • • • •

Upper fillet radiiDouble 5/16 & 7/8 in. • • • • • • • •Single 8mm •

WebFace radius M=20" • • • • • • • •Parallel •

Lower fillet radius L= 3/8 in. 7/16 in. 7/16 in. 1/2 in. 1/2 in. 1/2 in. 9/16 in. 5/8 in. 15mm

Double tapered foot • • • • • • • • •

Rail height A in. 41/2 47/8 51/16 51/4 55/8 513/16 6 61/4 61/4

mm 114.30 123.82 128.59 133.35 142.88 147.64 152.40 158.75 158.75

Foot width B in. 45/16 43/8 41/2 45/8 5 51/8 51/4 51/2 51/2

mm 109.54 111.12 114.30 117.47 127.00 130.17 133.35 139.70 139.70

Head width C in. 21/4 23/8 27/16 21/2 25/8 23/4 23/4 23/4 23/4

mm 57.15 60.32 61.91 63.50 66.67 69.85 69.85 69.85 69.85


1/233/64

35/6437/64

19/325/8 -

mm 11.11 12.30 12.70 13.10 13.89 14.68 15.08 15.87 20.00

Head area in2 2.63 3.13 3.41 3.52 4.01 4.21 4.43 4.47 4.43mm2 1698 2018 2198 2270 2590 2713 2856 2883 2860

Web area in2 1.12 1.35 1.43 1.56 1.78 1.99 2.09 2.28 2.65mm2 725 828 925 1007 1147 1281 1350 1473 1712

Foot area in2 2.29 2.39 2.55 2.77 3.11 3.15 3.39 4.01 4.01mm2 1477 1543 1648 1789 2008 2033 2187 2590 2590

Total area in2 6.05 6.87 7.40 7.85 8.90 9.34 9.91 10.77 11.10mm2 3900 4434 4771 5065 5745 6027 6393 6946 7161

Section weight lb/yd 61.72 70.16 75.50 80.15 90.91 95.37 101.16 109.91 113.32kg/m 30.62 34.81 37.45 39.76 45.10 47.31 50.18 54.52 56.21

Moment of inertia in4 16.7 21.9 25.2 28.9 37.6 41.8 47.1 55.8 55.7lxx cm4 696 911 1049 1205 1564 1742 1961 2323 2318

Section modulus in3 7.2 8.9 9.9 10.8 13.1 14.2 15.4 16.9 16.8Zxx cm3 117 146 162 177 215 233 252 277 275

Distance of neutral in 2.34 2.46 2.55 2.67 2.87 2.94 3.06 3.30 3.31axis from top of rail mm 59.32 62.49 64.81 67.89 72.79 74.65 77.69 83.86 84.17

Moment of inertia in4 3.6 4.1 4.7 5.3 6.8 7.4 8.2 10.0 10.1lyy cm4 150 171 195 220 285 308 340 418 418

Section modulus in3 1.7 1.9 2.1 2.3 2.7 2.9 3.1 3.7 3.7yy cm3 27 31 34 37 45 47 51 60 60

* High Crown Modified BS 113A Rail

50 ‘O’ 80 ‘O’ 60 R 75 R 80 R 90 R 95 R 100 R 95 N

Head crownSingle 9" radius • • • • • • •Single 12" radius • •

Gauge corner radius J= in. 11/323/8

3/87/16

7/161/2

1/21/2

1/2

Head widthParallel • • • • • • • • •

Fishing tapers Upper & lower 1:2.75 •Upper & lower 1:4 • •Upper = 1:3 • • • • • •Lower = 1:6 • • • • • •

WebFully parallel • •Upper web parallel • • • • • •Lower web radius in. 9 12 12 15 15 15Fully radiused web M=20" •

Fillet radii Upper in. 7/32

1/47/32

1/45/16

3/83/8

3/85/16 & 7/8

Lower in. 7/321/4

11/323/8

3/83/8

3/83/8

1/2

FootSingle taper • • • • • •Double taper • • •

Rail height A in. 315/16 5 41/2 51/16 51/4 55/8 513/16 6 513/16

mm 100.01 127.00 114.30 128.59 133.35 142.88 147.64 152.40 147.64

Foot width B in. 315/16 5 45/16 413/16 5 53/8 59/16 53/4 51/2

mm 100.01 127.00 109.54 122.24 127.00 136.53 141.29 146.05 139.70

Head width C in. 21/16 21/2 21/4 27/16 21/2 25/8 211/16 23/4 23/4

mm 52.39 63.50 57.15 61.91 63.50 66.67 68.26 69.85 69.85


7/1633/64

17/3235/64

9/169/16

35/64

mm 10.32 13.89 11.11 13.10 13.49 13.89 14.29 14.29 13.89

Head area in2 2.37 3.49 2.64 3.18 3.37 3.77 4.01 4.26 4.03mm2 1527 2251 1703 2053 2172 2433 2589 2750 2602

Web area in2 0.85 1.47 1.20 1.59 1.70 1.88 2.00 2.07 1.94mm2 548 947 774 1023 1099 1213 1292 1337 1254

Foot area in2 1.69 2.89 2.05 2.55 2.76 3.14 3.29 3.45 3.29mm2 1089 1863 1321 1643 1783 2024 2124 2223 2125

Total area in2 4.90 7.84 5.89 7.31 7.83 8.79 9.31 9.78 9.27mm2 3163 5061 3799 4719 5054 5670 6005 6318 5981

Section weight lb/yd 50.03 80.09 60.11 74.67 79.97 89.71 95.03 99.84 94.64kg/m 24.83 39.73 29.82 37.04 39.67 44.51 47.14 49.53 46.95

Moment of inertia in4 10.2 26.4 16.4 25.5 28.4 38.1 43.0 48.4 42.6lxx cm4 424 1100 681 1061 1224 1584 1791 2013 1775

Section modulus in3 5.2 10.2 7.1 9.7 10.7 12.9 14.2 15.5 14.2Zxx cm3 85 167 116 159 176 212 232 254 233

Distance of neutral in 1.97 2.60 2.31 2.63 2.74 2.94 3.04 3.12 3.00axis from top of rail mm 50.03 65.94 58.70 66.70 69.57 74.78 77.11 79.34 76.10

Moment of inertia in4 2.5 6.6 3.6 5.4 6.2 8.0 9.0 9.9 8.5lyy cm4 105 276 148 223 259 333 373 414 354

Section modulus in3 1.3 2.6 1.7 2.2 2.5 3.0 3.2 3.5 3.1Zyy cm3 21 43 27 37 41 49 53 57 51

British Standard ‘O’, ‘R’ and ‘N’ Designs

MA D

J

C

B


3534

Special Rail Sections for Switches and Crossings

Inclined 63 54 60 60 A74 Zu60U60 T D D D40 E2-40

Head crownDouble radii 300 & 80mm 200 & 60 • • • • •Single radius mm

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

Head widthTaper 1:20 • • • •Parallel

UpperFishing taper 1:2.75 1:3 1:3 1:2.75 1:2.75 1:2.75 1:2.75 1:2.75

WebParallel web • • • • • Centre only •Radius 120/120

Fillet radiiUpper and lower mm 12 16 16 12 12 16 19

LowerFishing taper 1:2.75 1:3 1:3 1:2.75 1:2.75 1:2.75 1:2.75

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

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

Inclination to vertical 1:20

Rail height A mm 155 151 129 142 142 172 134

Foot widthShort/long mm 78/70 70/70 60/85 65/85 65/85 75/75 55/85(B) total mm 148 140 145 150 150 150 140

Head width C mm 65 72 70 72 72 72 72

Web thickness D 8/8 15/15 16.25/16.25 16.25/16.25 16.25/16.25 15/15 28/16mm 16 30 32.5 32.5 32.5 30 44

Head area mm2 2742 2608 3403 3100 3116 3307 3362

Web area mm2 1314 2532 1802 2015 2015 2919 2654

Foot area mm2 2847 2882 3545 3780 3780 3231 3258

Total area mm2 6906 80.19 87.41 8895 8911 9460 9274

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

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

Section modulus Zxx cm3 259 263 210 250.4 252.1 355.1 227.7

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

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

Section modulus Zyy cm3 65 69 96 93.6 93.7 82.1 89.9

A D

J

C

B

AD

C

B

J

AD

C

B

J

Light Section Rails

BS 20M BS 30M BS 35M BS 35R BSC 40 S 10 S 14 S 18 S 20

Head crownSingle radius 5in. • • • 9in. •Single radius mm 228.6 140 160 180 200

Gauge cornerRadius J= 5/16in. 1/4in. • • • 23/64in.Radius J= mm 9.13 6 8 8 9

Head widthParallel • • • • • • • • •

UpperFishing taper 1:4 • • • 1:3 • • • • •

Upper filletRadius 3/16in. • • • • 9/32in.Radius mm 7.14 5 6 6 7

WebFully parallel web • • • • • • • •Upper web parallel •Lower web radius 71/2in. •

Lower filletRadius 1/4in. 3/16in. • • • 17/64in.Radius mm 6.75 5 6 6 7

LowerFishing taper 1:4 • • • 1:6 • • • • •

Rail height in. 29/16 231/32 33/16 33/8 315/32

mm 65.09 75.41 80.96 85.73 88.11 70 80 93 100

Foot width B in. 23/16 23/4 3 31/4 311/64

mm 55.56 69.85 76.20 82.55 80.57 58 70 82 82

Head width C in. 17/32 11/2 111/16 13/4 151/64

mm 30.96 38.10 42.86 44.45 45.64 32 38 43 44


23/6421/64

31/64

mm 6.76 9.13 9.13 8.33 12.30 6 9 10 10

Head area in2 0.82 1.20 1.60 1.60 1.78mm2 530 777 1030 1031 1149 593 707 934 1018

Web area in2 0.37 0.56 0.57 0.65 0.90mm2 239 359 369 422 579 241 428 553 604

Foot area in2 0.76 1.16 1.26 1.18 1.25mm2 490 748 816 764 806 437 637 824 904

Total area in2 1.95 2.92 3.43 3.44 3.93mm2 1259 1883 2215 2216 2534 1272 1771 2312 2526

Section weight lb/yd 19.91 29.80 35.05 35.07 40.09kg/m 9.88 14.79 17.39 17.40 19.89 9.98 13.90 18.15 19.83

Moment of inertia lxx in4 1.70 3.34 4.53 5.34 5.91cm4 71 139 188 222 246 85 152 271 343

Section modulus Zxx in3 1.26 2.10 2.76 3.12 3.39cm3 21 34 45 51 56 24 36 56 66

Distance of neutral in 1.35 1.59 1.64 1.71 1.74axis from top of rail mm 34.34 40.37 41.61 43.48 44.20 34.92 41.77 48.33 52.01

Moment of inertia lyy in4 0.34 0.79 1.08 1.21 1.22cm4 14 33 45 50 51 14 27 47 53

Section modulus Zyy in3 0.31 0.57 0.72 0.74 0.77cm3 5 9 12 12 13 5 8 12 13

MA D

J

C

B


3736

Other Rail and Track Sections

Bull Head Rails CheckBS Manx Rail

95R BH Centre U69Breaking Rail

Head crownSingle radius 12in. 9in.Double radii

Gauge cornerRadius J= in. 1/2in. 1/4in.Radius J= mm 12.7mm 6.35mm

Head widthParallel head • •

UpperFishing taper 1:2.75 • •

Upper filletRadii

1/4in. 5/16in.

Parallel web • •

LowerFillet radius

1/4in. 5/16in.

LowerFishing taper 1:2.75 • •

OuterFlange taper 1:10

Foot base single radius 12in 9in.

Rail height A in. 523/32 5mm 145.26 127.00 93

Foot width B in. 23/4 21/4

mm 69.85 57.15 40

Head width C in. 23/4 21/4

mm 69.85 57.15 80


mm 19.05 14.29 20

Head area in.2 4.48 2.69mm2 2891 1735 2846

Web area in.2 1.98 1.29mm2 1275 831 765

Foot area in.2 2.84 2.69mm2 1830 1735 589

Total area in.2 9.29 6.67mm2 5996 4301 4202

Section weight lb/yd 94.88 68.06kg/m 47.07 33.76 32.99

Moment of inertia lxx in.4 35.03 19.94cm4 1458 830 297

Section modulus Zxx in.3 11.50 7.97cm3 188 131 51.8

Distance of neutral in. 2.67 2.50axis from top of rail mm 67.89 63.50 35.67

Moment of inertia lyy in.4 4.10 2.03cm4 171 84 219

Section modulus Zyy in.3 2.98 1.80cm3 49 30 44.4

A

C

D

B

J

AD

C

B

J

No. 13 No. 16 No. 20 No. 28 No. 35 No. 50

Head crownHollow ‘top hat’ • • • • •Solid ‘top hat’ profile •Flat cavity top •Semi-circular cavity top • • • •

Head crownFlat • • • • • •

Gauge cornerRadius J= mm 11 10.5 9.5 9 10 10

CavityTop corner radius mm 7Top radius mm 10.5 14.5 13 15.5Side taper 1:8 • 1:21.7 • • •To foot base radius mm 6.5 8 9 9 10

Head widthTaper 1:24 1:12 1:44 • • • 1:25

Lower filletRadius 8mm • • 9 9 10 •

Flange topTaper 1:16.6 1:20.5 1:36.6 1:20 1:18 1:10.5

Rail height A mm 48 54 55.5 67 76 76

Cavity height mm 30 38 35 36 41.5

Head thickness D mm 18 16 20.5 31 34.5

Head width C mm 36 44.5 50 50 58 58.5

Cavity top width mm 21 22.5 29 26 31

Foot width B mm 92 108 127 152 160 165

Total area mm2 1695 2042 2530 3646 4506 6392

Section weight kg/m 13.31 16.03 19.86 28.62 35.38 50.18

Moment of inertia lxx cm4 39 65 82 167 266 326

Section modulus Jxx cm3 15 22 28 44 64 70

Distance of neutral axis from top of rail mm 26.54 29.60 29.68 38.01 41.65 46.67

Moment of inertia lyy cm4 74 117 193 371 505 720

Section modulus Jyy cm3 16 22 30 49 63 87

Crane Rails

A

B

C

J

A

C

B

DJ


3938

Crane Rails

No. 56 No. 89 No. 101 No. 164 175CR PRI 85R

Head crownFlat • • • • •Single radius 18in. •

Gauge cornerRadius 10 mm • • • • (11) 7/16in. 9.52 max

Head widthParallel • • • • •Taper 10° = 1:5.7 •

UpperFishing taper 1:1.75 1:2 1:2.5 1:2.5 1:4.7 (theo) 1:4.7

Upper filletRadius mm 8 10 12 20 (51) 2in. 31.75

WebParallel • • • • •Face radius mm 100

Lower filletRadius mm 10 10 12 20 (28.5) 11/8in. 19.05

LowerFishing taper 1:6.6 1:7 1:7 1:8 1:4.7 1:4.7

Step on flange top face • • •

Rail height A in. 6mm 101.5 114 155 150 152.40 152.4

Foot width B in. 6mm 171 178 165 230 152.40 152.4

Head width C in. 41/4

mm 76 102 100 140 107.95 101.6

Web thickness D in. 11/2

mm 35 51 45 75 38.10 34.9

Head area in.2 6.09mm 3190 6447 5456 9593 3926 4579

Web area in.2 6.15mm 1067 807 3395 2252 3971 29.21

Foot area in.2 4.90mm 2979 4187 3936 9407 3164 35.62

Total area in.2 17.14mm 7236 11441 12788 21252 11060 11062

Section weight lb/yd 175.02kg/m 56.81 89.81 100.38 166.83 86.82 86.84

Moment of inertia lxx in.4 70.52cm4 836 1502 3411 4784 2935 3035.9

Section modulus Zxx in.3 23.38cm3 147 246 420 581 383 395.8

Distance of neutral in. 3.02axis from top of rail mm 56.97 61.00 81.12 82.41 76.63 76.71

Moment of inertia lyy in.4 21.66cm4 702 1434 1266 5160 902 964.9

Section modulus Zyy in.3 7.22cm3 82 161 153 449 118 126.6

D

B

C

A

J

AD

C

B

J

A D

C

B

J

Conductor/Electric Contact Rails

Section Section Section SectionNo. 65 No. 75 No. 74TW T52

Head crownSingle radius 380mm • • 610

Gauge cornerRadius J= mm 6.5 7 6.5 3

Head widthParallel • • • •

UpperFishing taper 1:2.7 1:4.9 1:4.3

Upper filletRadius mm 7 6.5

WebParallel • • •

Lower filletRadius mm 7 6.5

LowerFishing taper 1:4.9 1:4.3

Rail height A mm 102 138 103.5 100.5

Foot width B mm 70 140 124 44

Head width C mm 89 89 105 101

Web thickness D mm 22.5 70 46

Head area mm2 3867 3960 3874

Web area mm2 1185 2477 2790

Foot area mm2 4525 3053

Total area mm2 8333 9576 9489 6664

Section weight kg/m 65.41 75.18 74.49 52.31

Moment of inertia cm4 677 2164 972.3 540.8

Section modulus cm3 127 286 184 89.6

Distance of neutral axis from top of rail mm 48.86 75.78 52.72 40.18

Moment of inertia lyy cm4 484 892 773.9 374.3

Section modulus Zyy cm3 109 127 124.8 68.1

A

B

C

J

A D

C

B

J

A D

B

C

J


4140

Grooved Rails

AD

C

B

A

C

35GP 35GP13 41GP 41GP13 Ri60 Ri60N Ri59 Ri59N Np4aM NP4aS

Rail height A mm 152.5 152.5 152.5 152.5 180 180 180 180 180 180

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

Head width C mm 111.4 111.8 116.8 116.8 113 113 113 113 116 116

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

Gauge corner mm 10 13 10 13 10 13 10 13 10 13radius

Total area mm 6978 6969 7049 7041 7721 7611 7515 7414 7945 7886

Section kg/m 54.78 54.71 55.33 55.27 60.60 59.75 59.00 58.20 62.37 61.91weight

Special Grooved Sections

G51 SEi60G SEi70G 41GPu 41GPi 35GPu

Rail height A mm 152 150 200 152.5 152.5 152.5

Foot width B mm 149 140 180 141.5 141.5 141.5

Head width C mm 126 125 146 115.6 115.6 110.6

Web mm 12 11 13 13 13 13thickness D

Gauge corner mm 9 13 13 13 13 13radius

Total area mm 6470 5814 8699 69.11cm2 68.90cm2 68.37cm2

Section kg/m 50.79 45.64 68.29 54.25 54.09 53.67weight

Track Running Rails

Piste PisteMatra RATP

Rail height A mm 250 230

Head width C mm 120 140

Section kg/m 62.85 68.33weight

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

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

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

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

Installation savings

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


4342

Section ID 202 436 600

Principal dimensions

Rail seat thickness 7.5/12 11.8 14.25mm

Rail seat width 160 168 168mm

Leg thickness 6.75 7.125 7.6mm

Section width B 240 260 280.5mm

Section height A 82.5 100.75 115.25mm

Section properties

Moment of 200 452.79 655Inertia Ixx cm4

Section modulus 34.4 65.85 81.3cm3

Height of neutral 58.1 68.76 80.5axis from base mm

Plate weight 22.1 31.69 39.53kg/m

B B

A A

B

A

Sleeper Data

Improved performance and through-life economics

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

Environmental benefits

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

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

Section 202 Section 436 Section 600

Track components

In addition to its full rail and steel sleeper range, Corus alsoproduces other rolled steel track components including a wide choice of baseplates and fishplates.

All track components benefit from Corus’ proven expertise in the development of steel products that deliver extended life and exceptional performance in a range of demanding in-service conditions.


4544

For use with rail N.Z.R. Zambia N.Z.R N.Z.R 13272lb 91lb 91lb 91lb RE

Rail cant 1:20 • • • • 1:40

Rail foot width in. 5 53/16 53/16 6mm 117.5 127.00 131.76 131.76 152.4

Plate rail seat width in. 411/16 53/32 51/4 63/32

mm 119.06 129.38 133.35 133 154.78

Double shoulders • • • • •

Ribbed underside • • •

Overall plate width in. 10 91/4 103/4 14mm 254 234.95 273.05 254 355.6

Plate thickness at rail seat in. 75/1289/16

81/12851/64

centre mm 14.88 14.29 16.07 15.65 20.24

As rolled plate weight lb/yd 66.55 58.26 73.89 75.3 104.31kg/m 33.1 28.9 36.65 37.35 51.74

No. of spike holes 4 4 4 4

Hole diameter in. 15/1615/16

15/16

mm 23.8 23.8 23.8 24

No. of spike holes 8Hole size - square in. 3/4

mm 19.05

Plate length in. 7 7 7 73/4

mm 177.8 177.8 177.8 178 196.85

Extended baseplate mm

Finished plate weight lb 12.349 10.78 13.76 13.88round holes kg 5.60 4.89 6.24 6.30

Square holes lb 21.47kg 9.74

Baseplates – Conventional Shoulders Rolled Steel Baseplates (‘Pandrol’ Baseplates)

Steelsleeperrecon- BS

ditioning BS UIC Taiwan J.N.R. B.S. 5in. U UIC 110/ BSFor use with rail plate 35.7kg 80A 50 50kg 50N 90A base 33 54 113A 95N S54

Rail cant 1:20 flat plate • • • 1:40 1:40 • • • • • • •

Rail foot width in. 43/8 45/8 5 5 51/2 51/2

mm 111.12 110 117.47 125 127 127 127 127 134 140 139.7 139.7 125

Plate rail seat width in. 41/2 423/32 53/32 59/16 519/32

mm 114.30 112 119.86 126.75 128 128.75 129 129.38 135.5 141 141.29 142.1 127

Overall plate width in. 11 141/2 14 151/4 141/2

mm 279.4 320 368.3 378 355 381 365 355.6 362 387 387.35 368.3 393

Plate thickness at in. 3/85/8

5/813/16

11/16

rail seat centre mm 9.52 16 15.87 19.25 14.1 20.5 18 15.87 16 20.5 20.64 17.5 21.45

As rolled plate weight lb/yd 47.7 92.16 88.29 122.82 97.17kg/m 23.66 38.57 45.72 57.56 39.81 58.8 48.7 43.8 46.68 60.93 60.93 48.20 60.28

No. of spike holes 4 4 4 4 4 4 3 4 3 3 4

Hole diameter in. 11/1615/16 11/16

7/8

mm 26.99 26 24 24 25.5 23.8 24 23.5 26.99 22.2 24

No. of spike holes 4 4 4 4 6 6hole size - square in. 11/16* 11/16*(*alternative design) mm 17.5 17.5 17.5 17.46 17.5 17.46

Plate length in. 4 6 6 8 6mm 101.6 150 152.4 150 135 180 150 152.4 154 152 203.2 152.4 160

Extended baseplate mm 215

Finished plate weightround holes lb 14.92 14.37 26.87 15.97

kg 6.77 8.42 5.22 10.39 7.11 6.52 7.07 9.09 12.19 7.24 9.45

Square holes lb 14.48 26.85kg 5.68 5.27 10.45 6.57 7.03 12.18

Blank lb 5.30kg 2.40

Extended plateRound holes kg 8.40Square holes kg 8.45


4746

Fishplates – British Standard ‘A’ Series Rails

60A 70A 75A 80A

Upper bolt stop rib • • • •

Lower bolt stop rib • • • •

Upper & lower fishing tapers 1:2.75 1:2.75 1:2.75 1:2.75

Overall plate length 4 hole 16in./406.4mm 16in./406.4mm 16in./406.4mm 16in./406.4mmOverall plate length 6 hole 24in./609.6mm 24in./609.6mm 24in./609.6mm 24in./609.6mm

Hole centres 4in./101.6mm 4in./101.6mm 4in./101.6mm 4in./101.6mm

Distance between fishing taper 27/32 in./56.36mm 213/32 in./61.12mm 215/32 in./62.71mm 219/32 in./65.88mmintercepts on rail centre line

Theoretical minimum 3/16 in./4.76mm 3/16 in./4.76mm 3/16 in./4.76mm 3/16 in./4.76mmstand-off of plate from rail web

Hole diameter 13/16 in./20.64mm 15/16 in./23.81mm 15/16 in./23.81mm 15/16 in./23.81mm

As-rolled section weight 25.28lb/yd 28.59lb/yd 30.58lb/yd 33.93lb/yd12.54kg/m 14.18kg/m 15.17kg/m 16.83kg/m

Distance of neutral axis above 0.126in/3.2mm 0.117in./2.96 0.124in./3.16mm 0.178in./4.51mmof plate from bolt hole centre below

Moment of inertia lxx in4 1.856 2.47 2.8 3.354cm4 77.25 102.8 116.3 139.59

Finished weight 4 hole 21.70lb/9.84kg 24.48lb/11.10kg 26.06lb/11.82kg 28.99lb/13.15kgper pair 6 hole 32.55lb/14.76kg 36.72lb/16.65kg 39.29lb/17.73kg 43.48lb/19.72kg

90A 113A heavy

Upper bolt stop rib • •

Lower bolt stop rib • •

Upper & lower fishing tapers 1:2.75 1:2.75

Overall plate length 4 hole 18in./457.2mm 507mmOverall plate length 6 hole 27in./685.8mm 914mm

Hole centres 41/2in./114.3mm 127mm

Distance between fishing taper 225/32 in./70.64mm 79.4mmintercepts on rail centre line

Theoretical minimum 3/16 in./4.76mm 6.0mmstand-off of plate from rail web

Hole diameter 11/16in./26.99mm 27mm

As-rolled section weight 40.0lb/yd19.84kg/m 30.94kg/m

Distance of neutral axis above 0.181in/4.59mm 0.85mmof plate from bolt hole centre below

Moment of inertia lxx in4 4.58cm4 190.41 339.67

Finished weight 4 hole 38.55lb/17.49kg 30.11kgper pair 6 hole 57.83lb/26.23kg 54.64kg

British Standard ‘O’ and ‘R’ Series Rails

Various Fishplates

50 ‘O’ 80 ‘O’ 60 ‘R’ 60 ‘R’ 75 ‘R’ 75 ‘R’ 80 ‘R’ 80 ‘R’Shallow Shallow Shallow Angled Shallow Angled Shallow Angled

Lower bolt stop rib • • • • • • •

Upper and lower fishing taper 1:4 • •

Upper fishing taper 1:3 • • • • • •

Lower fishing taper 1:6 • • • • • •

Overall plate length4 hole 16in. (406.4mm) • 20in. • • • • • •

(508mm)6 hole 24in. (609.6mm) • 30in. • • • • •

(767mm)

Hole centres 4in. (101.6mm) • 5in. • • • • • •(127mm)

Distance between fishing taper in. 163/64 29/16 27/16 27/16 249/64 249/64 27/8 27/8

intercepts on rail centre line mm 50.40 65.09 61.91 61.91 70.25 70.25 73.02 73.02

Theoretical minimum stand-off in. 1/85/32

7/327/32

1/41/4

1/41/4

of plate from rail web mm 3.17 3.97 5.56 5.56 6.35 6.35 6.35 6.35

Hole diameter in. 13/1615/16

13/1613/16

15/1615/16

15/1615/16

mm 20.64 23.81 20.64 20.64 23.81 23.81 23.81 23.81

As rolled section wt. lb.yd 17.68 31.35 22.59 28.81 28.41 35.18 30.90 38.25intercepts on rail centre line kg/m 8.77 15.55 11.20 14.29 14.09 17.45 15.33 18.97

Distance of plate neutral axis from bolt hole centres on C.L.

above in. 0.013mm 0.32

below in. 0.035 0.278 0.036 0.325 0.043 0.339mm 0.89 7.06 0.91 8.25 1.08 8.61

Moment of inertia lxx in.4 0.80 2.31 1.70 2.58 2.76 3.99 3.25 4.65cm4 33.4 96.2 70.9 107.4 115.1 166.0 135.2 193.6

Finished weight per pair4 hole lb 14.72 32.45 19.30 24.84 24.13 30.14 26.29 32.82

kg 6.68 14.72 8.75 11.27 10.95 13.67 11.92 14.896 hole lb 22.36 50.02 28.96 37.26 36.19 39.44 49.24

kg 10.14 22.69 13.14 16.90 16.42 17.89 22.33

CIE 85lb CIE 87lb skirted CIE 90/95lb skirted 60kg

Upper bolt stop rib •

Lower bolt stop rib •

No bolt stop • • •

Upper & lower fishing tapers 1:3.73 1:3.73 1:2.75 1:2.75

Overall plate length 4 hole 18in./457.2mm 18in./457.2mm 18in./457.2mm 610mmOverall plate length 6 hole

Hole centres 41/2in./114.3mm 41/2in./114.3mm Type 1 41/2 - 5 - 41/2in. 165mm-130mm-165mmType 2 41/2in

Hole diameter 27mm

Pear shaped holes in. 1 x 15/16 in. 1 x 15/16 in. 1 x 15/16 in.dia. x length mm 25.4mm x 33.34mm 25.4mm x 33.34mm 25.4mm x 33.34mm

As-rolled section weight 33.12lb/yd 50.07lb/yd 48.98lb/yd16.43kg/m 24.83kg/m 24.30kg/m 29.89kg/m

Distance of neutral axis above on centre lineof plate from bolt hole centre below 0.639in./16.23mm 0.7124in./18.095mm 2.381

Moment of inertia lxx in4 2.48 9.29 9.09cm4 103.17 386.63 378.35 439.6

Finished weight 4 hole 30.92lb/14.02kg 48.83lb/22.15kg 45.73lb/20.74kg 35.57kgper pair 6 hole


48

Fishplates British Standard 95lb Bull Head Rails

95lb deep tunnel 95lb deep tunnel 95lb deep tunnelround holes pear-shaped holes modified blank

No bolt stop • • •

Upper & lower fishing tapers 1:2.75 1:2.75 1:2.75

Overall plate length 4 hole 18in./457.2mm 18in./457.2mm 470mm

Hole centres 4 hole 41/2 - 5 - 41/2in. 41/2 - 5 - 41/2in.114.3mm-127mm-114.3mm 114.3mm-127mm-114.3mm

Distance between fishing taper 215/32 in./62.71mm 215/32 in./62.71mmintercepts on rail centre line

Theoretical minimum stand-off 1/4 in./6.35mm 1/4 in./6.35mmof plate from rail web

Hole diameter 1in./25.4mmor 11/16 in./26.99mm

Pear shaped holes in. 1 x 15/16 in.dia. x length mm 25.4mm x 33.3mm

As-rolled section weight lb 46.62lb/yd 46.62lb/yd 71.22kg/mkg 23.13kg/m 23.13kg/m 35.32kg/m

Distance of neutral axis aboveof plate from bolt hole centre below 0.747in./18.97mm 0.747in./18.97mm

Moment of inertia lxx in4 8.83 8.83cm4 367.45 367.45

Finished weight per pair 4 hole 43.16lb/19.58kg 42.92lb/19.47kg 73.2lb/33.2kgor 42.95lb/19.48kg (no holes)


www.muchmorethanrail.com

Ref: CRP/th/rev1/may05

UK – Manufacturing Facilities & Commercial

Rail ProductsMoss Bay Derwent Howe WorkingtonCumbria CA14 5AE

Tel +44 (0) 1900 64321Fax +44 (0) 1900 842400

Rail Products HQFrance – Commercial

Rail Products2 Avenue du President Kennedy78100 Saint Germain en LayeFrance

Tel +33 (0) 139 046 300Fax +33 (0) 139 046 344

France – Manufacturing Facilities

Rail Products164, rue de Maréchal Foch57705 Hayange CedexFrance

Tel +33 (0) 382 574 504Fax +33 (0) 382 574 544

Care has been taken to ensure that the contents of this publication are accurate, but Corus UK Limited and its subsidiary companies do not accept responsibility for errors orfor information which is found to be misleading. Suggestions for or descriptions of the end use or application of products or methods of working are for information only andCorus UK Limited and its subsidiaries accept no liability in respect thereof. Before using products supplied or manufactured by Corus UK limited customers should satisfythemselves of their suitability.


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