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The Benefits of Correct Turnout

Installation

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The benefits of Correct Installation

• Reduced Maintenance Costs

– Component life and maintenance

• Improved Reliability

– Reduction in failures

• Reduced Operational delays

– Speed restrictions and switch failures

3

The Inputs into Correct Installation

• Design Issues

• Component Issues

• Construction Issues

4

Design Issues

• Surveying

– Control survey for correct alignments

– Ensure that design alignments for approaches are

used

• Design Considerations

– Size of turnouts and operational speeds

• Clearances

– Review clearances against standards to ensure

operational and safe working is maintained

– Waivers and concessions may be sought to vary

standards and design requirements

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Standard designs in use on Sydney Trains Network

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Pros and Cons for Tangential geometry

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Typical Upgrading Plans of Cross Over

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Design Issues

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Component Issues

• Switches

– Undercut conventional switches

– Undercut tangential switches

• Bearers

– Concrete

– Timber

– Fibre reinforced foamed Urethane (FFU)

– In bearer switch bearers

Component Issues

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Conventional Switch Tip

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Undercut tangential Assymetric switch

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Rollers for switch Blade

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FFU Bearers

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In Bearer Rodding ready to be installed

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In Bearer Rodding in track

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Traditional Rodding

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Construction Issues

• Earthworks and compaction

– Compaction and capping layers

– Geotextile between layers

– 250-350mm of ballast below bearers

• Placing of turnout units

– Crane

– Drag

– Desec

– Rollers

Construction Issues

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• Welding

– Alumino thermic

– Mobile flashbutt

• CWR adjustments

– Neutral temperature for surrounding rail

– Anti Creep Devices

Construction Issues Cont

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Excavation and Capping Layer

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Pre Assembly of switch

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Pre assembly of switch

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Delivery of preassembled switch

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Desec Installation system

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Placing Turnout panel with Desec

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Rolling preassembled switch

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Rolling Continued

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Rolled into Position

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Alumino Thermic Weld

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Alumnothermic Weld

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Creep Brackets

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Creeping Switch

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Construction Issues Cont.

• Tamping

– Correct alignment

– Design Crossfall on bearers

– Ensure lifting points can support full bearers

– Tamp around vee and switch blades to ensure

compaction

• Rail Brace Bolts

– Correct tension

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Tamping Issues on Concrete Bearers

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Construction Issues Cont.

• Adjustment of switching systems

– Ensuring rodding is parallel

– Ballast is clear of switches and rodding

– Motors are secure

– Wiring systems correctly located

– Lubrication

– Rollers

– Facing Points locks

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Construction Issues Cont.

• Grinding of components

– Establish profile on machined parts

– Remove flow of soft metal as parts harden under load

– Regular grinding of all areas

– Establish rail profiles on plain rail

– Use modified tangent profiles and high leg profiles

– Remove the decarbonised zone to stop flow

– Grind at the tangent tonnages

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Running on Gauge Corner uncantedd rail

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Unground rail and running band

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Turnout Grinder

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Continued

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Spark Gards up!!

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Reduced Operational Delays

• Speed Restrictions

• Book out of turnouts

• Switches failing to shut properly

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Tangential Switch well fitted

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Tangential Switch

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Speed Restrictions

• Component damage

– Worn switch blades

– Worn vees

– Averaging 15 crossings per annum requring major

repairs

– Averaging 15 Rail Brace Bolts causing major

incidents on the network

• Geometry Issues

– Rough ride

– Misalignments

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Geometry Issues

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Ballast fouling from Load Out

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Poor Geometry during set up

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Transfer of wheel load across crossing

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Grinding of components

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Rail not on plates

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Overdriven Clips

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Damage to plates

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Insulated Joints separating

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