Download TMC 224 - Rail defects and testing

RailCorp Engineering Manual — Track
Rail Defects and Testing
TMC 224
Defect Indication or size
Action
Visible crack with disjoint across crack faces
Visible crack which has turned up into the head or turned
down into the web (including down into a weld) or any
crack running into a bolthole
Stop Trains
Visible crack on both sides of the rail
Visible crack greater than 1m in length
Dip greater than 3.5mm
Any visible crack
Dip greater than 1.2mm and up to 3.5mm
Where a VSH crack has changed into another type of
defect at a weld (such as a horizontal crack or transverse
defect)
Discoloration band
Internal defect passes within 100mm of a weld or bolthole
Internal defect is continuous greater than 1m (continuous
including where less than 200mm between continuous
internal cracks)
Priority 1
20/10kph
Monitor
Remove urgently
Priority 2
40/20kph
Remove defect within 48hrs
Visually reassess every 12hrs
Test ultrasonically every
24hrs
Dip is greater than 0.5mm up to 1.1mm
Defects not meeting any of the above criteria
Classify defect as Large,
Medium or Small in
accordance with sizing
criteria in Section C4-6.
Table 10 - Vertical Split Head Assessment Guidelines
C11-3
Recording and reporting VSH defects
1. Complete a Rail Fail Form RF1 (see Appendix 1) using the guidelines in Chapter 13 and the
additional information in Step (1) below for each VSH defect.
2. Record the following additional information on the form:
∼
If the gap between two or more defects is less than 100mm classify the defects as one
continuous defect.
Detection
∼
If found by Manual Ultrasonic testing from non-routine testing, circle “Special Manual
Ultrasonic Test”.
∼
If found as a result of Rail Cleanliness Testing, circle “Rail Cleanliness Testing”.
Rail Cleanliness Testing is special testing to look for rail inclusions and very small defects
in the rail.
∼
Use the space in the item to record the name and position of the person who has
classified the defect.
Defect type
∼
If more than one defect has been found in the one rail length (between flashbutt welds)
write in the number of additional defects after “Other” in the form “xx additional defects.”
Rail section
∼
Measure the head height (as for tangent wear) and write the measurement after “Other”.
3. Send completed Rail Fail forms for VSH defects by fax to Rail Inspection Services within 2
working days of the detection of a VSH defect.
If there is any delay in completing the form fax in an interim form as soon as possible with the
word “INTERIM” written at the top of the form.
© Rail Corporation
Issued December 2009
UNCONTROLLED WHEN PRINTED
Chapter 11 – Page 2 of 1
Version 1.1