Rail Products

www.corusgroup.com Technical Guide

Innovation in rail
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Rail Products
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Railway Infrastructure Services

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Technical Guide

World-class rail products that

enhance the performance of
railways across the globe

Corus Rail Products offers one of the

widest and most comprehensive rail
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
of excellence in manufacturing and metallurgy. Corus Rail Products is also
able to exploit the huge bank of railway industry expertise available within
the larger Corus Group, which employs 14,000 engineers and technologists
worldwide.

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

Corus employs a team of technical and commercial representatives on every

continent to work closely with customers. In addition, rail experts at Corus
can offer a multitude of solutions for the packaging, transporting, handling
and storage of rails together with technical assistance for the optimization
of in-service performance of rail and track systems.

01 Introduction
02 The Corus manufacturing and supply processes
08 Finishing, test and inspection
10 Despatch
11 The Corus product range

1
Technical Guide
The Corus manufacturing and
supply processes
Rail Manufacturing
Corus has 130 years of rail
manufacturing experience, both in
France and the UK; from the introduction
of continuous cast steel and the
invention of universal rail rolling to
the development of innovative heat
treatment processes and low noise
rails, they have developed a reputation
as a world leader in technological
development. The recent £100m
investment has transformed rail
manufacturing in the UK, building on the
Hayange mill’s long-established leading
market position.
In 2000, Corus invested £20m in
steelmaking and casting at Scunthorpe
to produce world-class rail steel. This
provided the quality and quantity
of bloom required to supply both of
Corus’ rail mills, Hayange in France and
Workington in the UK. During 2005,
Corus worked in close cooperation
with key customers in the UK to
2 3
understand their future requirements;
the strong requirement for longer rail
and optimised supply chain logistics
from steelmaking to installation in track
provided the rationale to develop 120m
rail manufacture at Scunthorpe. A major
enhancement to the existing Medium
Section Mill comprised a new furnace,
close coupled seven stand finishing
mill train, rotary stamper, hot saw and
a cambering & cooling bank. A new
service centre was built to carry out all
rail finishing operations using the best
available technology.
The addition of a welding plant to the
Rail Service Centre at Scunthorpe
has allowed Corus to provide the UK
market with the most complete solution
to the customer’s requirements, with
108m rail welded into 216m strings
that are delivered to track with a single
movement.
Corus Rail’s Hayange manufacturing
plant in north east France provides
world class rail solutions to western
£100m investment in rail manufacturing during 2006-7,
to create world class rail facilities in France and the UK.
Europe and across the globe, and
the location provides an ideal hub
for delivery worldwide, with excellent
rail, road and river links. Heat-treated
products are available with hardness
values over 400BnH, and the unique
patented process ensures exceptionally
low residual stress levels. Hayange
pioneered universal rolling to ensure the
dimensional consistency that is essential
for high-speed track; when SNCF broke
the world train speed record on the new
TGV Est line in April 2007, it was on
Hayange rail.
Corus Manufacturing customers to fully understand future
Philosophy requirements; the partnership approach
adopted with key customers helps to
ensure that investment in product and
The Corus manufacturing philosophy is
plant development is aligned to their
built on the principle that all activities
needs. A leadership role in the European
must be undertaken in a safe and
project Innotrack is an example of how
healthy way and with due regard for the
Corus is working closely with the major
environment. The company is committed
railways of Europe including SNCF,
to developing a culture of Continuous
Network Rail and Deutsche Bahn to
Improvement based on lean principles.
establish the performance of new rail
Strategy deployment cascades through
grades and support structures, and to
all levels of every business to ensure
optimise logistics options.
that business strategies are aligned
to corporate objectives and that every
employee understands not only what
the business is trying to achieve, but
also how they can contribute to the
achievement of these objectives. The
promotion of a common set of goals
helps the business to harness the full
potential of its manpower resource.
Customer Requirements
The railway industry needs to make rapid
progress to ensure that it can meet the
challenges for higher traffic volumes,
heavier axle loads and higher speeds;
track trials of new rail grades in a range
of track conditions, from heavy haul to
high-speed, are demonstrating the value
of a harder rail and the opportunity to
improve contact fatigue performance.
At Corus we work closely with our
Technical Guide
Corus manufacturing and
supply processes
The Corus commitment to product quality is evident in our world-
class steel manufacturing process; this philosophy extends to the
rolling and finishing of rail products and to the well-proven process
for delivering products to the exacting requirements of customers
worldwide.
This commitment has been emphasized by the recent investment
at the rail manufacturing sites at Scunthorpe (UK) and Hayange
(France) totalling over £100 millions. This has further strengthened
our steelmaking capability by increasing production flexibility to
meet changing volume demands, and has also improved logistics by
providing rails and steel sleepers closer to the market.
4 5
Steel making
The Technology
Scunthorpe, in north-east England,
boasts one of Corus’ major steel plants.
The manufacture of rails at this site adds
to an already wide range of products
including plates, structural sections,
special profiles, semis and wire rod; this
diverse product range at a single site
provides a huge flexibility in steelmaking
operations and associated competitive
advantages, which is reflected in a
record production of 4.5 million tonnes
against a rated capacity of 3.8 million
tonnes. Although the generic plant
and process route for the manufacture
of rail steels is very similar among all
the major manufacturers, consistent
quality can only be achieved through
robust practices and process control
techniques that depend on experience
and a commitment to continuous
improvement.
The Process
Hot liquid iron with low levels of residual
elements provides ideal feedstock
for the manufacture of today’s rail
steel, essential for the increasing duty
conditions on modern railways. At
Corus, the manufacture of quality rail
steel starts by reducing this high
quality iron ore in blast furnaces,
followed by the associated post
treatment of the liquid iron through
desulphurisation units.
The liquid iron is further refined in one
of three 300 tonne oxygen steelmaking
converters through controlled oxidation
of carbon and other elements in charged
hot metal and scrap. The precise control
of the entire steelmaking operation relies
on sophisticated computer models and
a wide variety of intelligent process
control equipment. These systems allow
the process to be closely monitored by
highly skilled operators; the refined steel
is then ready for tapping into ladles for
the next stage of manufacture.
The desired steel chemistry is achieved
through careful addition of alloying
elements, and close control of the
deoxidation process ensures a very
high level of steel cleanness and
absence of oxide inclusions that, in the
past, have been the cause of “Tache
Ovale” type defects.
The secondary steelmaking operations
at Scunthorpe are focused on three
ladle metallurgical furnaces (LMF) and
two RH degassers. The LMF, equipped
with electromagnetic stirring as well
as facilities for the precise addition of
alloying materials, ensures the control
of steel chemistry to consistent and
narrow bands. Temperature control is
also an important function of this stage
of steelmaking as it ensures low levels of
central segregation in the cast bloom.
The maximum vacuum achieved and the
time spent at this vacuum are two of the
essential process control requirements
for the RH recirculating degassers, which
reduce the hydrogen content of the steel
to well beyond the maximum stated in
international specifications. However, if
lower levels of hydrogen are required by
the customer, further dehydrogenisation
is achieved through controlled slow
cooling of the cast blooms in specially
constructed units, the results of which
have been verified through modelling
and measurements.
The introduction of continuously cast
feedstock for the manufacture of rails
in the mid 1970s has been one of
most influential single developments in
enhancing the integrity of rails in track.
Rails manufactured from continuously
cast feedstock on a rolling mill equipped
with modern NDT inspection facilities
have eliminated the classic “Tache
Ovale” defects that were a major cause
of rail failures from ingot feedstock;
however, further developments in
continuous casting technology have
been necessary to consistently achieve
a bloom with minimum levels of
segregation and free of hinge, side and
corner cracks. The recent investment
to enhance the Scunthorpe casters
was aimed at these objectives, and
incorporates mould electromagnetic
stirring and dynamic spray control.
Various bloom cross sections are
produced by the continuous casters
but the two most common for rail
manufacture are 355mm x 305mm and
330mm x 254mm.
The manufacture of rail steel blooms is
closely controlled at each stage through
appropriate sampling and analysis of
steel chemistry and other product quality
attributes; this regular testing, coupled
with stringent product identification
and tracking, ensures that quality is
guaranteed.
The Benefits
The manufacture of a rail steel bloom
requires a robust tracking and process
control system to promote continuous
improvement through intelligent analysis
of the interdependence of process
parameters and product quality. The
sophisticated and tightly-controlled
steelmaking process, when combined
with the precise rolling techniques
employed at the two Corus Rail mills,
results in homogeneous mechanical
properties over the full length of the
rail, ensuring consistent and reliable in-
service performance.
Corus’ bloom suppliers
operate quality
management systems
certified to ISO 9001 and
ISO 14001. They also work
to detailed specifications
to ensure adherence to rail
standards.
Technical Guide
Rolling
The Technology
Corus’ rolling mills at Scunthorpe in
the UK and Hayange in France utilise
modern process technology to achieve
outstanding results. Computer modelling
and computer-controlled heating and
cooling processes utilise novel roll pass
design and modern process technology.
The Process
Blooms are reheated in a natural gas-
fired furnace. Computer modelling and
control of the reheating process result in
tight control of rolling temperatures and
ensure consistent product dimensions
and surface quality. On leaving the
furnace, blooms are descaled using
high-pressure water jets.
The rolling process is undertaken using
reversing stands to achieve the initial
bloom reduction. There are up to nine
passes in a bloom-sizing mill to adjust
the section for entry into the intermediate
mill, where another three passes are
made. At Scunthorpe, the 7 stand
universal finishing train ensures tight
dimensional control to the final section.
Surface quality is controlled using high
pressure water descaling to remove
secondary scale prior to entry, as well as
within within the finishing train to ensure
a high standard of surface finish for all
rolled products.
6 7
The universal rail rolling process
was perfected by Corus at Hayange.
Traditional rolling-in passes on two-
high reversing roughing mills obtain a
symmetrical 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 the head and
the foot. The last rolling pass is designed
to give the section its precise and final
dimensions and is undertaken in a semi-
universal finishing stand.
During the final rolling pass, relief
branding is applied on the rail web.
This carries information 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 stamped
automatically at regular intervals along
the length of each rail. The hot stamping
mark provides full product traceability
back through the manufacturing
process, linking product attribute 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 chemical properties.
After hot sawing, rails are transferred
to cooling banks where they cool to an
ambient temperature. Rails are pre-
cambered before cooling to compensate
for the natural curvature, that occurs
during cooling.
Steel sleepers are also manufactured
in Scunthorpe. The rolling process is
similar; however, these products are
hot sheared into multiple lengths before
being cooled and stacked ready for
further processing.
Rails are heat treated to improve wear
and rolling contact fatigue resistance to
enhance life. The heat treatment process
employed at Corus, Hayange, involves
controlled heating and cooling of the full
cross section of the rail.
At the Hayange plant, the rails after
natural cooling are straightened in
both planes. They are then heated
in excess of 900ºC using inductors;
the novelty of this process is that the
entire rail section is heated above the
pearlite to austenite transformation
temperature. The rails are then cooled
using a computer controlled system to
refine the microstructure and increase
the hardness of the rail head up to
420HB. Compressed air from a set
of nozzles positioned around the rail
makes it possible to control the cooling
of both the head and base in such a
way that the rails do not require further
straightening. This process allows the
delivery of rails with optimised residual
stresses, and guarantees no opening of
the rail web during the saw cut test.
The microstructure obtained on all the risk of failure initiation and growth at the The Benefits
treated rails consists of 100% ultra point within the rail where the loading is
fine pearlite with no transition zone. at its highest. This is a major benefit on • The substantial capacity, flexibility
Because of this process, the hardness the foot of the rail, where low residual and process consistency offered
values decrease very slowly with depth, stresses reduce the risk of fatigue failure by Corus rolling mills enables the
resulting in minimal plastic deformation associated with a corrosion pit and there production of a wide variety of rail
and reduced wear under significant is no reliable method of inspecting the and sleeper sections to high quality
axle loads. The high values achieved for foot in service. The compressive stresses standards.
elongation and reduction of area assure in the rail head may also offer benefits • The hardening processes are so
optimum resistance to deformation and in delaying the growth of rolling contact efficient that, even at a depth of
brittle failure. fatigue (RCF) cracks. Transversely, 20mm below the running surface, a
the residual stresses are negative hardness of 365HB is achieved – a
The above Corus heat treatment process everywhere, with a mean value of -55 feature that results in exceptional
produces rails that do not require roller MPa, -50 MPa and -5 MPa in the head, in-service life of Corus heat-treated
straightening after heat treatment, and the web and the base respectively. rail sections.
the residual stresses measured on the
rails in their delivery condition are of an
extremely low level. The resulting state
of compression significantly reduces the
Rolling
Conditions Longitudinal stresses (MPa) measured Saw cut test
by strain gauges - 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 Heat treatment Off line heat treatment without straightening -86 +41 -30 -1.5
Residual stresses vs. straightening conditions
Technical Guide
Finishing, test and inspection
The Technology
Ongoing investment in modern test and
inspection equipment plays a major role
in ensuring that Corus’ rail products
are of a consistently high quality. Laser,
eddy-current and ultrasonic technologies
are utilised alongside conventional
testing methods to provide evidence
that products meet the specified
requirements.
The Process – Finishing
Rail straightening is undertaken using
computer-synchronised straightening
machines to produce ultra-straight and
ultra-flat rails. The primary straightener
acts in the vertical plane and the
secondary straightener acts in the
horizontal plane with the rollers mounted
onto conical spindles to eliminate
eccentricity. Rails are cut to the
customer’s ordered length by sawing 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
hole diameter/hole location tolerances
can be achieved.
Roller straightening has only a limited
effect on rail ends. Rail ends are
checked in both lateral and vertical
planes by a combination of laser beams
and straight edges. This check is
combined with hydraulic presses, and
guides the operator during the process.
8 9
Corus is the UK’s market leader in the
field of rail welding and is responsible
for the development of the patented
‘Invisible Weld’ Narrow Heat Affected
Zone welds. The company's welding
facilities are co-located with the Rail
Service Centre at Scunthorpe, where
highly-qualified welding technicians
produce rails in lengths up to 216
metres. The flash butt welding process
uses the resistance welding method
to create a weld made purely of parent
material. State-of-the-art scanning
equipment is used to ensure all welded
rail lengths meet specification.
For sleeper finishing, hot rolled
sleeper blanks are despatched in
short blank lengths (sheared at Corus)
or long multiple lengths, which are
subsequently cut prior to finishing.
Sleepers are finished using several
processes including cold forming to
produce the tilt angle and spade end
shape. Fasteners are then attached
and sleepers are then stacked and
strapped in bundles ready for storage
and despatch – each identified to show
exactly when and where they were
produced.
The Process – Test and
Inspection
The development of high-speed trains
means that rail straightness is a crucial
factor governing performance of the
rail in track. Corus uses state-of-the
In keeping with its
reputation for innovation,
Corus is at the forefront of
rail inspection technology.
art laser technology to measure the
flatness and straightness of rails.
A wave meter is used, and is composed
of a series of laser rangefinders
measuring flatness of the rail running
surface and a second series of laser
rangefinders measuring flatness on
the side of the rail head. The position
of the sensors has been calculated
so as to measure all the specified
variations in straightness. Signals are
processed automatically to obtain
the equivalent results obtained
using a sliding straight edge, the
lengths of which are stipulated in the
standards (3 metres; 1.5 metres and
2 metres in Europe). Different signal
processing programs are used to check
straightness in accordance with the
order specification.
Eddy current testing is used to
identify any surface defects that
exceed specification limits. The test
equipment comprises electromagnetic
coils, which induce eddy currents archived for each rail. Calibration is The cold profile gauge installed in the The Benefits
in the rail. The amplitude and form carried out regularly on artificial defects NDT lines is a continuous dimensional
of the eddy-currents depend on the machined into ‘calibration rails’. measurement device, which is an • The quality finishing process
surface condition of the test surface excellent rail dimensional control ensures that all Corus products
thus allowing surface defects to be A range of acceptance tests is improvement tool. The process principle are manufactured to the highest
detected. undertaken to customer specification – is based on optical sectioning. Five standard, suitable for a range of
and in the presence of a customer lasers project their beams on the rail, environments including high speed,
Based on the 60kg profile the in-line representative if required. itself monitored by seventeen cameras heavy haul, mixed traffic systems,
ultrasonic testing equipment inspects directed at 45° with respect to the urban environments and industrial
more than 90 per cent of the rail head These tests include tensile and axis of the product under inspection. applications.
and more than 60 per cent of the rail hardness, decarburisation The computer program processes the • In addition to post-production tests,
web and the central part of the foot. measurements, segregation checks and pictures provided by the cameras, thorough inspection is undertaken
Ultrasonic testing detects internal steel cleanness assessments. Testing is standardises them and then puts them throughout the manufacturing
defects such as inclusions, which can carried out at the Corus manufacturing together to recreate the full straight process, including profile dimension
have an adverse effect on in-service rail sites – ensuring quick availability of section of the rail. and hot surface quality checks. The
life. Coverage of the profile is achieved results after the product has been rolled. inspection results are used to make
by means of seven probes for the head, The large number of laser sources and any appropriate adjustments to
up to six probes in the web and two or At the final stage of manufacture, full cameras is necessary for the wide range production processes and ensure
three on the foot. profile and full rail surface quality of profiles to be inspected, the same that Corus rail products are of the
inspection is undertaken. This final technique is used irrespective of whether highest quality and meet customer
Defects detected by the in-line test inspection includes dimensional they are symmetrical or asymmetrical, requirements.
are inspected manually using portable checks using calibrated profile gauges for switches and crossings or
ultrasonic testing equipment in order including the cold profile gauge. A check tramways (grooved rails), and nearly
to confirm the presence of a genuine for rail end twist can also be made forty dimensions are measured and
defect. A test report is established and using gauges. computed.
Technical Guide
Despatch
The Technology
When the manufacturing process is
complete, Corus’ team of logistics
experts comes into its own – ensuring
the safe and cost-effective delivery of
products to customers across Europe
and around the world. Once again,
Corus utilises the best in modern
technology – from special handling
equipment to purpose-designed rail
wagons – to ensure the integrity of its
products in transit.
The Process
Following final inspection, rails are
loaded for despatch directly onto
wagons using special handling
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 unique section specific Camlok
system, electro-magnets or clamps.
The Corus mills at Hayange and
Scunthorpe have substantial experience
of delivery by rail to UK, French and
other European customers. Hayange
lies at the heart of the efficient railway
and waterway networks that guarantee
rapid access to the majority of European
destinations – and beyond – via the
port of Antwerp. A private branch line at
Hayange links directly to the public rail
marshalling yard at Ebange and the river
port of Illange. Each location is within
10km of the Corus mill. In the UK, Corus
10
utilises efficient rail and road links to the
major northern English ports of Teesside,
Immingham and Liverpool. Road and rail
links to the Channel Tunnel allow rapid
delivery to mainland Europe.
Corus has extensive experience of
river transport for the delivery of rail
products. The waterway route via the
canalised Moselle and Rhine remains
the most competitive transport 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 the
river craft.
For marine transport, Corus at
Scunthorpe has various shipping options
to choose from. The nearby port of
Flixborough Wharf is capable of handling
vessels up to 4,000 tonnes, and
for heavier shipments the port of
Immingham can accommodate vessels
up to 25,000 tonnes. Both ports are rail
connected. Overseas export orders from
Hayange usually transit via the port of
Antwerp, which offers regular departures
to numerous destinations including the
United States and the Far East. Corus
has extensive experience in direct
handling and marine transport of long
rails (73m) to European destinations.
The UK can also utilise road transport
for rail lengths under 28m; this is
undertaken by a fleet of road lorries.
HIAB facilities are available for offloading
rails at work sites and where access is
difficult.
In addition to producing rail for its high-speed network,
Corus worked with SNCF in France to develop dedicated
transport methods for delivery of the rail. The result was a
fleet of special rail wagons, allowing rails of up to 80m to be
carried over a large proportion of the continental network.
Corus was the first company to successfully transport 120m
rail across Europe.
Long welded rail delivery from
Scunthorpe is undertaken by rail,
utilising special trains equipped to
handle and offload rail up to 216m long.
The rail can be offloaded directly at
the work site, with shorter rail lengths
transported on a fleet of purpose-
designed rail wagons. Corus’ specially
designed fleet of trains allows for
complete control of the supply chain and
gives JIT ability on key high profile work
sites.
Thanks to its expertise in rail coating
and corrosion protection, Corus can
deliver rail that is protected against
corrosive marine environment 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 quality and reliability, Corus has
a fully developed acceptance and
monitoring system at the port of
Antwerp.
The Corus
product range
Corus was the first company in
Europe to manufacture rail for high-
speed lines – its rail manufactured
for SNCF in France included the East
line of the high-speed network where
a TGV train broke the world speed
record in April 2007, reaching a speed
of 574.8km/h (356mph).
Rail
for high-speed networks The development of Corus rail steel manufacturing processes
has improved the in-service fatigue life of rails through its
Requirement: facilities. Further reduction in the incidence of rolling contact
Commercial operating speeds on these networks range from fatigue has been achieved through the judicious use of newly
150km/h to more than 300km/h. Lines are mainly composed developed rail steels and an appropriate rail grinding strategy.
of straight stretches and large radius curves that are generally
considerably greater than 4,000 m. Track is based on rail In order to guarantee perfect electrical contact between train
sections of 50 to 60kg/m, usually of non heat-treated steel wheels and rails in zones with low traffic, Corus has developed
grade with a hardness ranging from 200 to 300HB. In order to Sogenox™ where the upper part of the head is covered by
reduce the dynamic loads, the axle load is limited to 17 tonnes a layer of stainless steel which prevents any rusting. The
for high-speed trains. Detection of high-speed trains by track stainless steel is deposited by welding a steel strip on the face
circuit is a major element in rail safety and has implications for of the bloom, with the result that the head of the rail at the end
the quality of the rails used. of the rolling has a stainless steel thickness greater than 1mm
on the running surface and the active sides of the rail head. Re-
Corus Products: heating, rolling, finishing and inspections are realised according
With its world-class rail straightening and testing facilities at to the usual process and following the current specifications.
both Scunthorpe and Hayange, Corus has been able to give
full support to the development of high-speed networks. Corus This process can be applied to all profiles of symmetrical
rails have been used by SNCF for its high-speed lines in France railway rails and switch rails rolled by Corus.
since 1980 and Corus has equipped more than 1,500km of new
line where trains run at commercial speeds of 270 to 320km/h.
11
Technical Guide
Rail continued
for heavy haul networks
Requirement:
These rails are used by trains with very high axle loads (25
to 35 tonnes) or where the cumulative amount of loads
transported is substantial (around 100 to 150 MGT/yr). The
routes may be diverse and the terrain crossed frequently,
requiring the construction of tight radius curves of less than
200m. In order to increase wear resistance and improve fatigue
life, high strength rail grades are recommended.
Corus Products:
Corus offers heat-treated rail with optimised residual stresses.
Roller straightening is undertaken following heat treatment in
most major heat treated rail manufacturing processes in use
today. This operation induces tensile stresses 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 roller straightening. The rails produced by this
process are characterised by longitudinal compressive stresses
at the railhead and foot and vertical compressive stresses
in the web. During the web saw-cut test, closure is always
observed and is a guarantee against catastrophic 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 other
applications and not exclusively in the heavy haul environment.
In addition to heat-treated rails, Corus supplies naturally hard
grades with a hardness of 300 – 340HB which offer a good
combination of fatigue and wear resistance for tangent and
shallow curved track.
Corus rail is used in heavy haul networks across five
continents.
12
for mixed traffic networks
Requirement:
Mixed traffic networks cover tracks where the commercial
operating speed is usually lower than 150km/h and where
freight trains (up to 25t axle load) and passenger trains share
the same line. The types of lines are extremely varied – from
long straight stretches across 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 include Coreprotec.
Silent Track™ has been developed by Corus as an ecomonic
solution to meet European noise legislation. Silent Track™ is a
noise reduction system using sound absorbers applied on the
web and upper part of the foot of rails. Its use avoids the need
for costly construction of noise abatement walls.
Corus also has significant experience in producing rails and
special sections for switches and crossings. The product
range includes sections adapted to the requirements 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 R 260 Cr.
for urban networks and mass transit for industrial settings
schemes
Requirement:
Requirement: Rail for industrial applications includes track laid on a
Increasing urbanisation and traffic congestion, coupled with temporary or semi-permanent basis in plantations, forests or
growing environmental awareness, has encouraged the use of quarries. These systems are generally intended to be portable
tramways and metro systems worldwide. Tramways in the and comprise light rail sections. Other industrial uses range
heart of towns require special rails with U-shaped profiles, from permanent tracks serving large industrial sites to small,
which can be set flush into the roadway. These rails are specialised tracks. Traffic often includes high axle loads or
often cambered to very tight curves (15m – 25m) and must high traffic intensity. Site layout constraints may result in very
demonstrate a high degree of wear resistance. Track noise tight curves or steep gradients.
reduction is a major imperative and, because of access
difficulties, rails must also be easily weldable. Corus Products:
Reliable product quality is essential to cater for the varied and
Corus Products: often less than optimal service conditions. For industrial track,
There is no single rail solution to the multiplicity of conditions Corus uses prime steel, rolled using proven techniques to
on urban networks and mass transit schemes. Corus offers ensure the highest product quality is achieved.
a wide range of products that have been utilised on a large
number of urban schemes across the globe. These include a Corus also supplies track for cranes - including mobile, semi-
choice of 13 different grooved rail profiles developed for the mobile and overhead travelling cranes – and for specialised
urban market. Corus is also able to work with customers to applications such as ship-launching equipment.
meet non-standard requirements for grooved rail.
As a result of close involvement in the redevelopment of
tramways in France, Corus is able to demonstrate the highest
levels of accuracy for tramway profile dimensions – particularly
rail asymmetry and web-head offset.
Another development from Corus is the novel (patented)
process for in-situ weld restoration of worn grooved rails
involving deposition of relatively thick layers of an austenitic
stainless composition to increase wear resistance and extend
life further.
13
Technical Guide

Steel Grades Rail Profiles This list is indicative of the profiles

produced at Corus, however other
profiles can be requested.

High speed and mixed traffic systems CEN Design Rail Sections

Specification Grade Chemical composition % by mass Mechanical properties Specification 36E2 39E1 45E1 46E1 46E2 49E1
(prev S40) (prev 80 A) (prev 90 A) (prev SBB1) (prev U33) (prev DIN S49)
C Si Mn P S Cr Al V H2 Rm Elong BHN Rm
Head crown Single radius mm • •
(ppm) (MPa) -ation Hardness (KSI)
Double radius mm 200/60 300/80 200/60 300/80
(%) Centre line
Gauge corner Radius J=mm 13 13 13 13
UIC 860-O 700 0.40/0.60 0.05/0.35 0.80/1.25 ≤0.050 ≤0.050 680/830 ≥14
J=7/16in. •
900A 0.60/0.80 0.10/0.50 0.80/1.30 ≤0.040 ≤0.040 880/1030 ≥10
J=1/2in •
900B 0.55/0.75 0.10/0.50 1.30/1.70 ≤0.040 ≤0.040 880/1030 ≥10
Head width Taper 1:20 • • Parallel 1:20 1:17.2
EN 13674-1 R 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 ≥14 200/240
Fishing tapers Upper & lower 1:2.75 • •
R 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
Upper Fishing taper 1:3 1:4 1:3 1:3
R 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
Upper fillet Radius mm 7 6/30 7 7
R 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
Double 5/16 & 7/8in. • •
EN 13674-2 R 260Cr 0.40/0.60 020/0.45 1.20/1.60 ≤0.025 0.008/0.025 0.40/0.60 ≤0.004 ≤0.060 ≤2.5 ≥880 ≥10 260/300
Web Parallel Yes Yes Yes Centre portion only
Radius mm 80/120
Heavy haul tracks
Face radius M=20” • •
Double tapered foot • •
Specification Grade Chemical composition % by mass Mechanical properties
Lower fillet Radius mm 7 6/30 7 7
C Si Mn P S Cr Al V H2 Rm Elong BHN Rm Radius L= 1/ in
2
1/ in.
2
(ppm) (MPa) -ation Hardness (KSI) Lower Fishing taper 1:3 1:4 1:3 1:3
(%) Centre line Outer Flange taper 1:10 1:4 1:10 1:7.81
Arema Standard 0.74/0.84 0.10/0.60 0.75/1.25 ≤0.020 ≤0.020 ≤0.25 ≤0.10 ≤0.10 ≥98 ≥10 ≥300 143 Rail height A in. 5 1/ 5 5/
4 8
Low alloy mm 128 133.35 142.88 145 145 149
Standard 0.72/0.82 0.10/0.50 0.80/1.10 ≤0.020 ≤0.020 0.25/0.40 ≤0.005 ≤0.10 Foot width B in. 4 5/8 5
Intermediate 0.72/0.82 0.10/1.00 0.70/1.25 ≤0.020 ≤0.020 0.40/0.70 ≤0.005 ≤0.10 ≥1015 ≥8 ≥325 147 mm 115 117.47 127.00 125 134 125
High Strength 0.74/0.84 0.10/0.60 0.75/1.25 ≤0.020 ≤0.020 ≤0.25 ≤0.10 ≤0.10 ≥1180 ≥10 370/410 171 Head width C in. 2 1/2 2 5/8
Low alloy mm 60 63.50 66.67 65 62 67
High Strength 0.72/0.82 0.10/1.00 0.70/1.25 ≤0.020 ≤0.020 0.40/0.70 ≤0.005 ≤0.10 ≥1180 ≥10 370/410 Web thickness D in. 33/ 35/
64 64
UIC 860-O 1100 0.60/0.82 0.30/0.90 0.80/1.30 ≤0.030 0.008/0.035 0.80/1.30 ≥1080 ≥9 157 mm 13 13.10 13.89 14 15 14
EN 13674-1 R 320Cr 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 ≥9 320/360 157 Head area in.2 3.52 4.01
R 350HT 0.72/0.80 0.15/0.58 0.70/1.20 ≤0.020 0.008/0.025 ≤0.15 ≤0.004 ≤0.03 ≤ 2.5 ≥1175 ≥9 350/390 170 mm2 1989 2270 2590 2543 2510 2982
R 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 ≥9 370/410 170 Web area in.2 1.56 1.78
Corus Rail MHH 0.72/0.82 0.40/0.80 0.80/1.10 ≤0.020 ≤0.20 0.40/0.60 ≤0.004 ≤2.0 ≥1280 ≥12 381/408 186 mm2 866 1007 1147 1192 1121 1106
Foot area in.2 2.77 3.11
Urban transport
mm2 1806 1789 2008 2147 2263 2204
Total area in.2 7.85 8.90
Specification Grade Chemical composition % by mass Mechanical properties
mm2 4661 5065 5745 5882 5894 6292
Elong BHN Section weight lb/yd 80.15 90.91
H2 Rm -ation Hardness Rm kg/m 36.59 39.76 45.10 46.17 46.27 49.39
C Si Mn P S Cr Al V (ppm) (MPa) (%) Centre line (KSI) Moment of inertia lxx in.4 28.9 37.6
EN 14811:2006 R200G 0.40/0.60 0.15/0.58 0.70/1.20 ≤0.035 ≤0.035 ≤0.15 ≤0.004 ≤3.0 ≥680 ≥14 200/240 cm4 1020 1205 1564 1641.1 1642.7 1816
R220G 0.50/0.65 0.15/0.58 1.00/1.25 ≤0.025 ≤0.025 ≤0.15 ≤0.004 ≤3.0 ≥780 ≥12 220/260 Section modulus zxx in.3 10.8 13.1
R260G 0.63/0.82 0.15/0.58 0.70/1.20 ≤0.025 ≤0.025 ≤0.15 ≤0.004 ≤2.5 ≥880 ≥10 260/300 cm3 151 177 215 217 213 240.3
Corus Rail 700V 0.20/0.30 0.20/0.30 1.20/1.50 ≤0.025 ≤0.025 0.10/0.16 ≤3.0 685/853 ≥14 Distance of neutral axis in. 2.67 2.87
900V 0.41/0.51 0.20/0.30 1.10/1.40 ≤0.025 ≤0.025 0.10/0.15 ≤2.5 ≥885 ≥10 from top of rail mm 67.68 67.89 72.79 75.65 77.14 75.59
Customer E 24-2NE* ≤0.17 ≤0.045 ≤0.045 ≥ 0.02 340/460 (1) ≥28 Moment of inertia Iyy in.4 5.3 6.8
300** 0.040/0.06 0.25/0.45 ≤0.025 ≤0.020 ≥300 Resistance < 14 µΩ. cm cm4 203 220 285 298.2 329.3 319.1
* piste, ** conductor rail (1) Re ³ 235 Mpa and KCV at +20°C > 35 J/cm² Section modulus Zyy in.3 2.3 2.7
cm3 35 37 45 47.7 49.1 51
Steel sleepers

EN 10025 S275 0.16/0.22 0.20/0.49 0.60/0.90 ≤0.040 0.010/0.025 ≤0.004 400/510 ≥20

14 15
Technical Guide

CEN Design Rail Sections CEN Design Rail Sections

Specification 52E1 54E1 54E2 54E3

Specification 50E1 50E2 50E3 50E5 50E6
(prev 52RATP) (prev UIC54) (prev UIC54E) (prev DIN S54)
(prev U50E) (prev 50 EB-T) (prev BV50) (prev UNI50) (prev U50)
Head crown Single radius mm 350
Head crown Single radius mm 400
Double radius mm 300/80 300/80 300/80
Double radius mm 200/60 300/80 300/80 200/60
Gauge corner Radius J=mm 12 13 13 13
Gauge corner Radius J=mm 13 13 13 14 13
Head width Taper Parallel 1:20 1:20 1:17.2
Head width Taper 1:20 1:20 1:20 1:16 1:20
Upper Fishing taper 1:2 1:2.75 1:2.75 1:3
Upper Fishing taper 1:3 1:3 1:3 1:3 1:3
Upper fillet Radius mm 12 8/22 8/22 16
Upper fillet Radius mm 12 8/30.81 7 7 12
Web Parallel
Web Parallel Yes Yes Centre portion only Yes
Radius mm 400/600 508 508 500
Radius mm 450 80/120
Lower fillet Radius mm 12 16 16 16
Lower fillet Radius mm 12 8/30.81 7 7 12
Lower Fishing taper 1:2 1:2.75 1:2.75 1:3
Lower Fishing taper 1:3 1:3 1:3 1:3 1:3
Outer Flange taper 1:10 1:10 1:10 1:7.81
Outer Flange taper 1:10 1:8 1:8.31 1:8 1:10
Rail height A mm 150 159 161 154
Rail height A mm 153 151 155 148 153
Foot width B mm 150 140 125 125
Foot width B mm 134 140 133 135 140
Head width C mm 65 70 67.01 67
Head width C mm 65 72 70 67 65
Web thickness D mm 15 16 16 16
Web thickness D mm 15.5 15 14 14 15.5
Head area mm2 2959 2901 2942 3223
Head area mm2 2745 2608 2836 2946 2745
Web area mm2 1102 1486 1486 1338
Web area mm2 1273 1279 1295 1106 1273
Foot area mm2 2583 2590 2428 2391
Foot area mm2 2397 2478 2240 2310 2465
Total area mm2 6643 6977 6856 6952
Total area mm2 6416 6365 6371 6362 6484
Section weight kg/m 52.15 54.77 53.82 54.57
Section weight kg/m 50.37 49.97 50.02 49.9 50.9
Moment of inertia lxx cm4 1970.9 2337.9 2307 2074
Moment of inertia lxx cm4 1987.8 1988.8 2057.8 1844 2017.8
Section modulus zxx cm3 247.1 278.7 276.4 262.8
Section modulus zxx cm3 246.7 248.5 259.5 242.1 248.3
Distance of neutral axis
Distance of neutral axis
from top of rail mm 79.76 83.87 83.47 78.93
from top of rail mm 80.56 80.04 79.3 76.15 81.26
Moment of inertia Iyy cm4 434.2 419.2 341.5 354.8
Moment of inertia Iyy cm4 365 408.4 351.3 362.4 396.8
Section modulus Zyy cm3 57.9 59.9 54.6 56.8
Section modulus Zyy cm3 54.5 58.3 52.8 53.7 56.7

16 17
Technical Guide

CEN Design Rail Sections A.S.C.E. Design Rail Sections

Specification A.S.C.E. 75 A.S.C.E. 80 A.S.C.E. 85 A.S.C.E. 90

Specification 55E1 56E1 60E1 60E2
Head crown Single radius 12 in • •
(prev U55) (prev BR113A) (prev UIC60) (prev UIC60)
Double radius 300 & 80mm
Head crown Single radius mm
Gauge corner Radius J= 5/16 in. • •
Double radius mm 200/60 305/80 300/80 200/70
Radius J= 13mm
Gauge corner Radius J=mm 13 12.7 13 8/16
Head width Parallel • •
Head width Taper 1:20 1:20 1:20 1:20
1:20 taper
Upper Fishing taper 1:3 1:2.75 1:2.75 1:2.75
Fishing tapers Upper & lower 13°=1:4.3 • •
Upper fillet Radius mm 12 8 7/35 7/35
Upper & lower 1:2.75
Web Parallel Yes Yes Centre portion only Centre portion only
Fillet radii Upper & lower 1/4 in. • •
Radius mm 120 120/120
Upper mm
Lower fillet Radius mm 12 15 7/35 7/35
Lower mm
Lower Fishing taper 1:3 1:2.75 1:2.75 1:2.75
Foot Double tapered
Outer Flange taper 1:10 1:10 1:14 1:14
Outer taper
Rail height A mm 155 158.75 172 172
Web Fully radiused M=12” Rad. • •
Foot width B mm 134 140 150 150
Fully radiused M= 508mm Rad.
Head width C mm 62 69.85 72 72
Upper & lower radii 120mm
Web thickness D mm 19 20 16.5 16.5
Centre parallel
Head area mm2 2897 2860 3084
Rail height A in. 4 13/16 5
Web area mm2 1465 1712 1730
mm 122.24 127.00 131.76 142.88
Foot area mm2 2775 2597 2856
Foot width B in. 4 13/16 5
Total area mm2 7137 7169 7670 7648
mm 122.24 127.00 131.76 130.18
Section weight kg/m 56.03 56.3 60.21 60.03
Head width C in. 2 15/32 2 1/2
Moment of inertia lxx cm4 2150.4 2321 3038.3 3021.5
mm 62.71 63.50 65.09 65.09
Section modulus zxx cm3 255.2 275.5 333.6 330.8
Web thickness D in. 17/ 35/
Distance of neutral axis 32 64
mm 13.49 13.89 14.29 14.29
from top of rail mm 84.26 84.24 91.08 91.33
Head area in.2 3.07 3.30
Moment of inertia Iyy cm4 418.4 421.6 512.3 500.5
mm2 1981 2129
Section modulus Zyy cm3 62.4 60.2 68.3 68.1
Web area in.2 1.54 1.64
mm2 996 1059
Foot area in.2 2.72 2.93
mm2 1756 1890
Total area in.2 7.34 7.87
mm2 4733 5078
Section weight lb/yd 74.90 80.36
kg/m 37.18 39.86 42.2 44.65
Moment of inertia lxx in.4 22.92 26.45
cm4 954 1101 1255.8 1610.8
Section modulus Zxx in.3 9.11 10.09
cm3 149 165
Distance of neutral axis in. 2.51 2.62
from top of rail mm 63.9 66.59
Moment of inertia Iyy in.4 5.42 6.21
cm4 226 259 288.7
Section modulus Zyy in.3 2.25 2.49
cm3 37 41

18 19
Technical Guide

A.R.E.M.A. Designs Various Rail Sections

Specification 100RE 115RE 119RE 132RE 136RE 141RE

Specification 100CP 122CB 124JK 136RE10 136RE14 136CN 136JK 136OP
(prev 141AB)
Head crown Single radius mm 355.6 4in.
Head crown Single radius 14 in.
Double radii 254/31.75 203.2/44.45 254/31.75 355.6/31.75
Double radii 10in. & 1 1/4in. 10 in. & 10 in. & • • 8 in. &
Triple radii
1 1/2 in. 1 1/2 in. 1 3/4 in.
Gauge corner Radius J= in. 9/
16in.
Gauge corner Radius J= 3/8 in. • • •
Radius J= 13mm 14.29 9.63 9.53/14.29 14.29 14.29 14.29
Radius J= 9/16mm • • •
Head width Taper 1:20 1:16 1:20 1:40 1:40 1:40 1:40
Head width Taper 1:40 • • • •
Upper Fishing taper 1:3 1:4 1:2.75 1:4 1:4 1:4 1:4
1:16 1:11.4
Upper fillet Radius in. 5/ in. & 3/ in
16 4
Fishing tapers Upper & lower 1:4 • • • • •
mm 9.53 19.05 19.05 19.05 19.05 7.74
Upper 1:3, lower 1:4 •
Web Parallel
Upper fillet radii Single 3/8 in. •
Parallel in. 8/
20in.
Double 3/4 in. & 3 in. rad. • •
Radius mm 355.6 76.2/355.6 203.2/506 203.2/508
Double 5/16 in. & 3/4 in. rad. • • •
Radius M mm 355.6 203.2
Double 7/16 in. & 3/4 in. rad.
Lower fillet Radius in. 3/ in.
4
Web Face radius M in. 14 14 14 8 & 16 8 & 20 8 & 20
mm 15.88 19.05 19.05 19.05 19.05 19.05
Lower fillet L radius 3/4 in. 5/ in.
8 • • 7/ in.
8 • •
Lower Fishing taper 1:3 1:4 1:13.703 1:4 1:4 1:4 1:4
Rail height A in. 6 6 5/8 6 13/16 7 1/8 7 5/16 7 7/16
Outer Flange taper 1:10
mm 152.40 168.27 173.04 180.97 185.74 188.91
Rail height A in. 7 11/32
Foot width B in. 5 3/8 5 1/2 5 1/2 6 6 6
mm 153.99 172.24 174.63 185.74 185.74 186.53 185.74 185.74
mm 136.52 139.70 139.70 152.40 152.40 152.40
Foot width B in. 6
Head width C in. 2 11/16 2 23/32 2 21/32 3 2 15/16 3 1/16
mm 136.53 152.4 139.7 152.4 152.4 152.40 152.4 152.4
mm 68.26 69.06 67.47 76.20 74.61 77.79
9/ 5/ 5/ 21/ 11/ 11/ Head width C in. 2 15/16
Web thickness D in. 16 8 8 32 16 16
mm 65.6 72.53 73.48 74.61 74.61 74.61 73.48 74.01
mm 14.29 15.87 15.87 16.67 17.46 17.46
Web thickness D in. 11/
16
Head area in.2 3.80 3.92 4.31 4.43 4.82 5.37
mm 14.29 16.67 15.88 17.46 17.46 17.46 17.46 17.46
mm2 2450 2524 2770 2855 3099 3465
Head area in.2 4.86
Web area in.2 2.21 3.04 3.04 3.61 3.64 3.55
mm2 3136
mm2 1428 1961 1961 2332 2347 2290
Web area in.2 3.64
Foot area in.2 3.90 4.29 4.29 4.87 4.87 4.87
mm2 2347
mm2 2518 2770 2770 3142 3142 3142
Foot area in.2 4.87
Total area in.2 9.91 11.25 11.64 12.91 13.33 13.80
mm2 3142
mm2 6396 7256 7510 8329 8600 8903
Total area mm2 6478 7748 7831 8593 8632 8625
Section weight lb/yd 101.21 114.68 118.67 131.66 135.88 140.70
Section weight lb/yd 136.49
kg/m 50.21 56.89 58.87 65.31 67.40 69.79
kg/m 50.85 60.74 61.39 67.36 67.66 67.62 67.33 67.17
Moment of inertia lxx in.4 48.40 65.90 71.40 87.90 94.20 100.44
Moment of inertia in.4 94.88
cm4 2015 2743 2972 3659 3921 4181 lxx cm4 2064.4 3065.1 3164.1 3920.9 3954.2 3949.6 3916 3910.3
Section modulus Zxx in.3 14.87 18.10 19.40 22.40 23.70 25.24 Section modulus in.3 23.79
cm3 244 297 318 367 388 414 Zxx cm3 247 331.5 343.5 388.4 393.3 389.8
Distance of neutral axis in. 3.26 3.63 3.69 3.92 3.97 3.97 Distance of neutral in. 3.99
from top of rail mm 82.78 92.20 93.73 99.57 100.83 100.85 axis from top of rail mm 83.57 92.46 92.11 100.84 100.45 101.31
Moment of inertia Iyy in.4 9.29 10.73 10.84 14.40 14.44 14.91 Moment of inertia in.4 14.47
cm4 387 447 451 599 601 621 Iyy cm4 386.3 528.9 483.8 601 603.5 604.8 602.7 600.4
Section modulus Zyy in.3 3.44 3.90 3.94 4.79 4.82 4.97 Section modulus in.3 4.82

cm3 56 64 65 78 79 81 Zyy cm3 56.6 69.4 69.3 79 79.3 79.4

20 21
Technical Guide

Various Rail Sections

Specification 30kg/m Ethiopia UNI 36 (MOD) 36kg India 52 R43 R65 CHN 50 CHN 60 Australia 60kg/m
(prev R50-50 CH China) (prev China 60)
Head crown Single radius mm Flat 300 300
Double radii mm 200 & 29 305 & 80 500/80 300/80 300/100
Gauge corner Radius J= in.
Radius J= 13mm 9 12 • 13 15 13 13 15
Head Parallel • • • 1:20 Parallel 1:20 1:20
Upper Fishing taper 1:4 1:2 1:2.75 1:3 1:4 1:4 1:3 1:4
Upper fillet Radius in.
mm 7.8 9 8 & 22.5 5 & 10 7/15 5/12 8 & 25 20
Web Parallel • 381 & 381
Face radii in.
mm 706 350 370/400 350 400 300
Lower fillet Radius in.
mm 7.8 9 13 15 25 20 20 20
Lower Fishing taper 1:4 1:2 1:2.75 1:3 1:4 1:4 1:3 1:4
Outer Flange taper 1:15 1:5.56 1:6 1:6 1:9
Rail height A in.
mm 125.5 130 128 156 140 180 152 176 170
Foot width B in.
mm 106 106 115 136 114 150 132 150 146
Head width C in.
mm 56 60 58.27 67 70 73 70 73 70
Web thickness D in.
mm 11 14 13 15.5 14.5 18 15.5 16.5 16.5
Head area in.2
mm2 1723 2084 2882 2422 2902 3009
Web area in.2
mm2 898 882 1334 1214 1979 1974
Foot area in.2
mm2 1231 1705 2367 2042 2864 2752
Total area in.2
mm2 3852 4671 6583 5678 8264 6560 7745 7735
Section weight lb/yd
kg/m 30.24 36.67 36.54 51.68 44.57 64.87 51.50 60.80 60.72
Moment of inertia lxx in.4
cm4 839.1 1031 1019.7 2105 1479 3543.1 2026.6 3217 2935
Section modulus Zxx in.3
cm3 132 155 260 206 359 249.4 339 370
Distance of neutral axis in.
from top of rail mm 62.1 66.48 80.89 71.65 98.7 81.27 94.77 90.65
Moment of inertia Iyy in.4
cm4 133.4 164 354 257 570.1 374.9 524 490
Section modulus Zyy in.3
cm3 25.17 31 52 45 76 56.8 70 67.1

22 23
Technical Guide

British Standard ‘A’ Designs Special Rail Sections for Switches and Crossings

Specification 60A 90AM 90R Specification 50E6A1 50E2T1 54E1A3 60E1A4 60E1A5 60E1T2 60E2A2
Head crown Single radius 12 in • 9 (prev Incli- (prev (prev (prev (prev (prev (prev
Double radii 12” & P=3 1/8in. ned U60) 63T) 54D) 60D) 60 D 40) A74) Zu60 E2-40)
Gauge corner radius J=3/8in. • Head crown Double radii 300 & 80mm 200 & 60 • • • • •

J=7/16in. Single radius mm

J=1/2in. 1/ Gauge corner Radius J= 13mm • 13 13 13 13 13

2
Head side taper 1:20 • Head width Taper 1:20 • • • •

Fishing tapers Upper & lower 1:2.75 • 1:3/1:6 Parallel

Upper fillet radii Double 5/16 & 7/8in. • Upper Fishing taper 1:2.75 1:3 1:3 1:2.75 1:2.75 1:2.75 1:2.75 1:2.75

Single 8mm 3/ Web Parallel web • • • • • Centre only •

8
Web Face radius M=20” • Radius mm 120/120

Parallel • Fillet radii Upper and lower mm 12 16 16 12 12 16 19

Lower web radius 15 Lower Fishing taper 1:2.75 1:3 1:3 1:2.75 1:2.75 1:2.75 1:2.75

Lower fillet radius L= 3/ in. 3/ Short flange taper 1:10 1:8 1:12 1:13 1:13 1:14 1:4
8 8
Double tapered foot • Single Long flange taper 1:10 1:8 1:17 1:17 1:17 1:14 1:17

Rail height A in. 4 1/2 5 5/8 Inclination to vertical 1:20

mm 114.30 142.88 142.88 Rail height A mm 155 151 129 142 142 172 134

Foot width B in. 4 5/16 5 3/8 Foot width Short/long mm 78/70 70/70 60/85 65/85 65/85 75/75 55/85

mm 109.54 127 136.53 (B) total mm 148 140 145 150 150 150 140

Head width C in. 2 1/4 2 5/8 Head width C mm 65 72 70 72 72 72 72

mm 57.15 67.17 66.67 Web thickness D 8/8 15/15 16.25/16.25 16.25/16.25 16.25/16.25 15/15 28/16

Web thickness D in. 7/ 35/ mm 16 30 32.5 32.5 32.5 30 44

16 64
mm 11.11 13.89 13.89 Head area mm2 2742 2608 3403 3100 3116 3307 3362

Head area in.2 2.63 3.77 Web area mm2 1314 2532 1802 2015 2015 2919 2654

mm2 1698 2433 Foot area mm2 2847 2882 3545 3780 3780 3231 3258

Web area in.2 1.12 1.88 Total area mm2 6906 80.19 87.41 8895 8911 9460 9274

mm2 725 1213 Section weight kg/m 54.21 62.95 68.62 69.83 69.95 74.24 72.8

Foot area in.2 2.29 3.14 Moment of inertia lxx cm4 2213 2171 1552.5 2025.8 2035.7 3304 1716.3

mm2 1477 2024 Section modulus zxx cm3 259 263 210 250.4 252.1 355.1 227.7

Total area in.2 6.05 8.79 Distance of neutral axis

mm2 3900 5670 from top of rail mm 85.3 82.5 73.92 80.9 80.75 93.1 75.35

Section weight lb/yd 61.72 89.71 Moment of inertia Iyy cm4 497 482 772.5 764.4 764.3 615.7 739

kg/m 30.62 44.91 44.51 Section modulus Zyy cm3 65 69 96 93.6 93.7 82.1 89.9

Moment of inertia lxx in.4 16.7 38.1

cm4 696 1549.7 1584
Section modulus Zxx in.3 7.2 12.9
cm3 117 212
Distance of neutral axis in. 2.34 2.94
from top of rail mm 59.32 74.78
Moment of inertia Iyy in.4 3.6 8.0
cm4 150 279 333
Section modulus Zyy in.3 1.7 3.0
cm3 27 49

24 25
Technical Guide

Other Rail and Track Sections Conductor/Electric Contact Rails

Specification 33C1 Bull Head Rail
(prev Check Rail U69) BS95RBH Specification Section No. 75 Section No. 74TW Section T52
Head crown Single radius mm 12in. Head crown Single radius 380mm 610 •
Double radii mm Gauge corner Radius J= mm 6.5 7 3
Gauge corner Radius J= in. 1/ in. Head width Parallel • • •
2
Radius J= mm 13mm Upper Fishing taper 1:4.3 1:4.9
Head width Parallel head • Upper fillet Radius 6.5 7
Upper Fishing taper 1:2.75 • Web Parallel web • •
Upper fillet Radii 1/ in. Lower fillet Radius 6.5 7
4
Parallel web • Lower Fishing taper 1:4.3 1:4.9
Lower Fillet radius 1/ in. Rail height A mm 103.5 138 100.5
4
Lower Fishing taper 1:2.75 • Foot width B mm 124 140 44
Outer Flange taper 1:10 Head width C mm 105 89 101
Foot base single radius 12in. Web thickness D mm 70 22.5 46
Rail height A in. 5 23/32 Head area mm2 3960 3867 3874
mm 93 145.26 Web area mm2 2477 1185 2790
Foot width B in. 2 3/4 Foot area mm2 3053 4525
mm 40 69.85 Total area mm2 9489 9576 6664
Head width C in. 2 3/4 Section weight kg/m 74.49 75.18 52.31
mm 80 69.85 Moment of inertia lxx cm4 972.3 2164 540.8
Web thickness D in. 3/ Section modulus zxx cm3 184 286 89.6
4
mm 20 19.05 Distance of neutral axis
Head area in.2 4.48 from top of rail mm 52.72 75.78 40.18
mm2 2846 2891 Moment of inertia Iyy cm4 773.9 892 374.3
Web area in.2 1.98 Section modulus Zyy cm3 124.8 127 68.1
mm2 765 1275
Foot area in.2 2.84
mm2 589 1830
Total area in.2 9.29
mm2 4202 5996
Section weight lb/yd 94.88
kg/m 32.99 47.07
Moment of inertia lxx in.4 35.03
cm4 297 1458
Section modulus Zxx in.3 11.5
cm3 51.8 188
Distance of neutral axis in. 2.67
from top of rail mm 35.67 67.89
Moment of inertia Iyy in.4 4.1
cm4 219 171
Section modulus Zyy in.3 2.98
cm3 44.4 49

26 27
 Steel sleepers
Technical Guide

Grooved Rails

Specification 46G1 55G1 55G2 59R1 59R2 60R1 60R2 62R1 62R2 68G1
(prev (prev (prev (prev (prev (prev (prev (prev (prev (prev
SEi60G) 35GP) 41GP) Ri59) Ri59N) Ri60) Ri60N) Np4aM) NP4aS) SEi70G)
Rail height A mm 150 152.5 152.5 180 180 180 180 180 180 200
Foot width B mm 140 141.5 141.5 180 180 180 180 180 180 180
Head width C mm 125 111.8 116.8 113 113 113 113 116 116 146
Web thickness D mm 11 13 13 12 12 12 12 12 12 13
Guage corner radius mm 13 10 10 10 13 10 13 10 13 13
Total area mm2 5814 6978 7049 7515 7414 7721 7611 7945 7886 8699
Section weight kg/m 45.64 54.78 55.33 59.00 58.20 60.60 59.75 62.37 61.91 68.29
Groove width mm 60 36 41 42 42 35.98 36.35 34.44 33.98 70
Groove depth mm 45 45.9 45.9 47 47 47 47 63 63 47
Steel sleepers have been used throughout the world Improved performance and through-life economics
for decades and Corus has been producing them for more than • Long spade ends for good lateral stability during passage of
80 years. traffic.
Special Grooved Sections • Spade designs with dynamic stability features.
The traditional sleeper range embraces the needs of railways • Well distributed load which reduces ballast pressure.
Specification G51 35GP13 35GPu 41GP13 41GPi 41GPu operating in arduous environments and with difficult conditions • Less tamping required during sleeper life.
for track building. For European higher speed applications,
Rail height A mm 152 152.5 152.5 152.5 152.5 152.5
Corus has developed new products which respond to the Environmental benefits
Foot width B mm 149 141.5 141.5 141.5 141.5 141.5
conditions of modern track for both high-speed trains and • Corus steel sleepers are recyclable and reusable.
Head width C mm 126 111.8 110.6 116.8 115.6 115.6
under heavy loads. Corus’ experience in the manufacture of • Reduced ballast requirement.
Web thickness D mm 12 13 13 13 13 13
fatigue-resistant products has been applied with care to its • No problems of chemical leaching (as can happen with
Guage corner radius mm 9 13 13 13 13 13
range of advanced steel sleepers. The principles of design timber sleepers).
Total area mm2 6470 6969 6837 7041 6890 6911
for the modern range of steel sleepers were established
Section weight kg/m 50.79 54.71 53.67 55.27 54.09 54.25 through joint research and in-track testing with customers. All Corus steel sleepers are manufactured from the 3 basic
Groove width mm 61.5 34.34 36 39.33 41 41 This combines the virtues of fatigue resistant rail seat design, trough rolled sections.
Groove depth mm 45 45.89 45.9 45.9 45.9 45.9 low section height, optimised section properties and spade
options for different stability requirements depending on track
design and duty. Lightweight, dimensionally more accurate and
more resistant to overload than wooden or concrete sleepers,
Sleeper data
the design and manufacture of Corus sleepers is subject to a
rigorous programme of testing and evaluation.
Section ID 202 436 600
Corus sleepers can be used with a range of fasteners Principle dimensions
including Vossloh and Nabla type systems and the recently Rail seat thickness mm 7.5/1.2 11.8 14.25
Track Running Rails adopted Pandrol Fastclip. Rail seat width mm 160 168 168
Leg thickness mm 6.75 7.125 7.6
Specification Piste Matra Piste RATP The success of steel sleepers is due to the large number of Section width B mm 240 260 280.5
Rail height A mm 250 230 benefits they offer compared with other sleeper types. These Section height A mm 82.5 100.75 115.25
Head width C mm 120 140 include:
Section weight kg/m 62.85 68.33 Section properties
Installation savings Moment of Inertia Ixx cm4 200 452.79 655
• Time and cost savings due to a reduced ballast requirement.
Section modulus cm3 34.4 65.85 81.3
• Simplified logistics resulting from sleeper stackability and
Height of neutral
low weight.
axis from base mm 58.1 68.76 80.5
• Unique design ensuring compatibility with mechanised track
Plate weight kg/m 22.1 31.69 39.53
laying methods.

Section 202 Section 436 Section 600

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