Technical Specifications for BUFFER-STOPS,

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1 ISRAEL RAILWAYS LTD INFRASTRUCTURE DIVISION TRACK AND RIGHT OF WAY DEPARTMENT Technical Specifications for BUFFER-STOPS, FIXED BUFFER STOPS and BRAKING WHEEL STOP SETS No. E October 2011

2 Contents 1 SCOPE 2 2 GENERAL REQUIREMENTS 2 3 BUFFER STOPS, FIXED BUFFER STOPS AND BRAKING WHEEL STOP SETS - TECHNICAL REQUIREMENTS 3 4 MANUFACTURE'S TECHNICAL DRAWINGS 5 5 MANUFACTURING 6 6 BUFFER STOPS, FIXED BUFFER STOPS AND BRAKING WHEEL STOP SETS - MARKING 6 7 MANUFACTURING TESTS 6 8 ISR INSPECTION 7 9 LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL 7 10 LIST OF DOCUMENTS TO BE DELIVERED WITH EVERY ISR ORDER 8 11 PACKING 9 12 WARRANTY 9 13 INSTALLATION AND TRAINING 9 APPENDIX A STOPING DISTANCE DEFINITION 10 APPENDIX B - ISRAEL CLIMATE AND ENVIRONEMENTAL CONDITIONS 11 APPENDIX C EXAMPLE FOR RED AND WHITE REFLECTOR SIGN 12 1

3 1. SCOPE 1.1 This technical specification pertains to the manufacture and supply of buffer stops with different working mechanism methods and different amount of energy absorption for use with 60E1, 60E2 and 54E1 rails. For rolling stock vehicles, railbound construction and maintenance machines (EN14033) in emergency cases stopping without serious injury to the driver and passengers. 1.2 This technical specification pertains to the manufacture and supply of fixed buffer stops to be installed on track ends. The manufacture shall offer fixed buffer stops installed on track and/or on concrete construction. 1.3 This technical specification pertains to the manufacture and supply of braking wheel stops sets (*) design to install on rail heads to use on depot tracks and marshalling yard tracks to stop track motor vehicles, locomotives or light train (IC3 passenger train - single formation). ISR using wheels of several diameters the wheels profile types are in accordance with UIC and with DSB82-1 wheel type (IC3 trains). (*) braking wheel stops set means two braking wheel stops one for each rail of the track. 2. GENERAL REQUIREMENTS 2.1 The buffer stops, fixed buffer stops and braking wheel stop sets shall be designed for use with 60E1, 60E2 and 54E1 rails. 2.2 The buffer stops and fixed buffer stops shall be designed for use on standard gauge 1435 mm (-2,+5) railway track. The rail seats on each sleeper have nominal inclination of 1:30. Braking wheel stop sets shall be design to use on rails in depot and marshalling yards which have nominal inclination of 1:30 and of zero. 2.3 The buffer stops and fixed buffer stops shall be designed to enable railway vehicles stop safety at speed up to 10 km/h or at speed up to 15 km/h. 2.4 The braking wheel stop sets shall be designed with height above the rail head of 85 mm or 125 mm to enable railway vehicles stop safety at speed up to 5 km/h or at speed up to 10 km/h. 2

4 2.5 The buffer stops, fixed buffer stops and braking wheel stop sets shall be design for rolling stock vehicles, railbound construction and maintenance machines (EN14033) with axle loads of up to 22.5 ton. 2.6 The buffer stops and fixed buffer stops (if designed for track installation) shall be installed on track with electrical circuit and/or on track with electronic signaling or on depot track. 2.7 The buffer stops and fixed buffer stops (if designed for track installation) shall be installed on ballast track or on depot track (non ballast track). 2.8 The buffer stops and fixed buffer stops shall be install on track ends with concrete sleepers or wooden sleepers, 1667 sleepers per km or on depot track fasten to concrete spots. 2.9 The inspection and acceptance of the buffer stops, fixed buffer stops and braking wheel stop sets shall be performed by ISR's representative or an authorized company. 3. BUFFER STOPS, FIXED BUFFER STOPS AND BRAKING WHEEL STOP SETS - TECHNICAL REQUIREMENTS 3.1 The buffer stops, fixed buffer stops and braking wheel stop sets shall be installed on rail heads. 3.2 The buffer stop and fixed buffer stops shall be designed to arrest the full range of trains between the heaviest and lightest using a track without risk of serious injury to people on the train. Trains shall be brought to a controlled halt from the determined impact speed with an average deceleration rate not exceeding 0.15g (1.47 m/s 2 ). Where site constrains make it unavoidable, lightweight trains may be subjected to higher deceleration rates, but the average acceleration rate for any train shall not exceed 0.25g (2.45 m/s 2 ). (see section 3.11 for the required declaration for each type). 3.3 The buffer stops and fixed buffer stops shall be designed with side strikes with height of 1060±20mm above top of the rails. And on special cases (see table in section 3.11) the buffer stop shall be design with additional to the side strikes also center strike with height of 865±10mm above top of the rails. 3

5 3.4 The nature and main characteristics of the steel material and chemical composite shall be stated by the manufacturer and could not be modified without approved by ISR. 3.5 The dimensions of buffer stops, fixed buffer stops and braking wheel stop sets shall be in accordance with the technical drawings submitted by the manufacturer and approved by ISR. 3.6 The buffer stops, fixed buffer stops design shall be taken in consideration absorbing extra energy based on the following energy coefficient factors 1.2, 1.5, 1.8, The buffer stops and fixed buffer stops shall be design with maximum stopping distance (Lw) (see appendix A) of 12 meters. Minimum stopping distance for rolling stocks 8 meters. All other railway vehicles shall be design with minimum of 4 meters. The braking wheel stop sets stopping distance shall be meters. 3.8 The manufacturer shall submit buffer stops and braking wheel stop sets prototype testing reports including calculations and limit cases. 3.9 The buffer stops, fixed buffer stops and braking wheel stop sets life cycle shall not be less than 40 years All parts which are metallic and non-metallic shall be made of hot weather resistant materials, suitable for use at temperature of up to 70 C and under high corrosion conditions. Plastic parts shall be UV protected. Israel climate condition should be considered (see appendix B) The buffer stops, fixed buffer stops and braking wheel stop sets shall be designed in accordance with the following parameters: Parameter Buffer stop ISR101 Buffer stop ISR102 Buffer stop ISR103 Buffer Stop ISR104 Buffer Stop ISR105 Buffer Stop ISR106 Fixed Buffer stop ISR201 Braking wheel stop set ISR301 Braking wheel stop set ISR302 Impact speed 10 km/h 15 km/h 15 km/h 10 km/h 15km/h 10 km/h 5km/h 5 km/h 5 km/h Maximum mass 2200 ton 746 ton 746 ton 1590 ton 760 ton 3500 ton 116 ton 101 ton 180 ton Minimum mass 120 ton 410 ton 410 ton 90 ton 670 ton 670 ton 44.7 ton - Rail profile 54E1 60E1 60E1 54E1 60E1 60E1 60E1 60E1 60E1 Track gradient Track length for install buffer stop and ensure efficient stopping distance - Lv (see appendix A) 12 meter 12 meter 4 meter 15 meter 12 meter 12 meter 3 meter 3 meter Plain Track Distance in meter 200 meter 200 meter front of stop device meter meter meter meter Energy safety factor

6 Average deceleration Wheel diameter Center strike in addition to side strike braking wheel stop set - height above the rail head Sleepers type 0.15g (1.47 m/s2) 0.15g (1.47 m/s2) 0.15g (1.47 m/s2) 0.25g (2.45 m/s2) 0.15g (1.47 m/s2) 0.25g (2.45 m/s2) concrete concrete concrete concrete concrete concrete 0.25g (2.45 m/s2) 850 mm of IC3 trains with wheel type DSB mm and 1010 mm (UIC510-2) 125 mm 85 mm 3.12 The buffer stop and fixed buffer stops, on top of it, 1 meter length red and white reflector sign shall be installed (see appendix C example for red and white reflector sign). The reflector sign material shall be of a material used for traffic reflector sign of diamond grade, 3 rd generation, with the highest reflectibility all in accordance with SI 2247 (Israeli Standard). In addition red light illuminator electric device shall be installed on the buffer stops, all to increase safety The buffer stops, fixed buffer stops and braking wheel stop sets shall be galvanized and painted.the painting shall be done with two layers premier layer and second layer with pearl dark grey paint (RAL 9023). The second paint layer shall have high resistance to the environment condition including UV sun radiation, and corrosion environment, and high resistance to wear. 4. MANUFACTURE'S TECHNICAL DRAWINGS 4.1 The manufacturer shall submit together with its proposal technical drawings with dimensions and material main characteristics for 60E1, 60E2 and 54E1 rails of: Assembled buffer stops, including clamping components to the track, Assembled fixed buffer stops, including clamping components to the track or installation components to the concrete construction. Assembled braking wheel stop sets with installation components, including blow up draw. 4.2 The manufacturer shall submit together with technical drawings, technical description of buffer stops, fixed buffer stops and braking wheel stop sets and its components. 4.3 ISR uses SKL W12 and SKL W14 fastening systems, and the fastening system overall dimension are inside the envelope described in EN

7 4:2002+A1:2006 paragraph 5.6. It shall be taken into consideration when the buffer stops, fixed buffer stops and braking wheel stop sets will be designed. 5. MANUFACTURING 5.1 The buffer stops, fixed buffer stops and braking wheel stop sets components must be manufactured in accordance with the technical drawings and technical specification and must present a clean surface, smooth and free from blow-holes, flaws, cracks, folds or other faults. 6. BUFFER STOPS, FIXED BUFFER STOPS AND BRAKING WHEEL STOP SETS - MARKING 6.1 Each buffer stops, fixed buffer stops and braking wheel stop sets components shall be inscribed with at least the following marks: The supplier mark, The last two figures of the year of manufacturer, The product identification type. 7. MANUFACTURING TESTS 7.1 The manufacturer shall submit impact test reports certificates and calculations for the buffer stops, fixed buffer stops and braking wheel stop sets types. 7.2 The manufacturer shall submit testing certificates showing the source and method of steelmaking/casting used. And the results of the mechanical and chemical tests dimensions and finish inspection. 7.3 The laboratory performing the tests shall be certified with at least the following certifications: A laboratory certified in accordance with ISO/IEC17025:2005 in the field of steel quality testing. or A laboratory accredited by national laboratory accreditation authority in the field of steel quality testing. 7.4 The supplier shall submit together with his proposal quality management system process for sopping devices manufacturing in accordance with all the requirements in this technical specification based on EN ISO 9001:2008 or equivalent standard, which will be approved by ISR. 6

8 8. ISR INSPECTION 8.1 ISR shall appoint a representative, an authorized company which shall inspect manufacturing processes and checking reports of the buffer stops, fixed buffer stops and the braking wheel stop sets and the components. 8.2 Among other criteria the inspector shall check compliance of the technical drawings and the material properties according to this technical specification, the manufacturer technical drawings and management system procedures 8.3 The manufacturer shall extend to the said representative all necessary assistance and cooperation. 8.4 The manufacturer shall be responsible for the preparation and supply of all samples and shall supply all labor and apparatus which may be necessary for the performance of the tests. 8.5 The manufacturer shall be responsible to coordinate inspection process time table with the ISR representative. 9. LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL 9.1 The manufacturer shall submit names and documents of his sub-contractors for the buffer stops, fixed buffer stops and braking wheel stop sets components he does not manufacture, the manufacturer shall not replace his sub-contractors without ISR approval. 9.2 The manufacturer shall submit manufacturing process and testing procedure in accordance with all the requirements in this technical specification based on EN ISO 9001: The manufacturer shall submit certificates of test reports for impact test and all other calculation data. 9.4 The manufacturer shall submit technical drawing of clamping components dimension design in which envelope interface with fastening system components is avoided in accordance with EN :2002+A1:2006 paragraph

9 9.5 The manufacturer shall declare in a signed document the estimate for the buffer stops life cycle (in years), based on the requirements in this technical specification (as required in section 3.9). 9.6 The manufacturer shall submit process procedure for painting and corrosion protection. 9.7 The manufacturer shall submit environmental certificates for the painting used. 9.8 The manufacturer shall submit the nature and main characteristics of the metallic and non-metallic material and chemical composite for every component. 9.9 The manufacturer shall submit technical description for the galvanization process The manufacturer shall submit 2 hard copies and also 2 magnetic copies of all the manufacturing technical drawings. The manufacturer shall add to the technical drawings 2 hard copies and 2 magnetic copies the technical descriptions of the buffer stops and braking wheel stop sets including steel type and all clamping components The manufacturer shall submit to ISR technical drawings of the buffer stops, fixed buffer stops and braking wheel stop sets components marking The manufacturer shall submit signed and approved installing, maintenance and safety manuals. The manufacturer in maintenance manual shall specify what the needed instructions to guaranty safe operation during the product life cycle. 10. LIST OF DOCUMENTS TO BE DELIVERED WITH EVERY TYPE EQUIPMENT UNIT ISR WILL ORDER 10.1 Each type equipment unit shall be delivered with certificate that each components has manufactured according to technical drawings submitted and the requirements of this technical specification. Each type equipment unit shall be delivered with testing certificates of dimensions, material and structure. 8

10 10.2 Each type equipment unit shall be delivered with 2 signed technical drawing. Another technical drawing copy shall be sent by in PDF file form For each type equipment unit, packing list shall be sent by in PDF file form. 11. PACKING 11.1 The buffer stop, fixed buffer stops and braking wheel stop sets components shall be packed in wooden boxes and will put in container. The wooden box arrangement shall enable easy and safe unpackaged and storage the goods Each package shall include packing list with the following details: o Components name and type; o Production batch number; o Date of manufacture; o Component barcode; o Component quantity in box; o Gross and net weight; o Manufacturer recognition number or name; o ISR recognition number; o ISR order number; o Ordinal number on the packing list. The labeling shall be with black letters and shall be on 3 spots on the package (one on top of the package and the two others on the sides). 12. WARRANTY 12.1 The warranty period for the buffer stops, fixed buffer stops and braking wheel stop sets shall be 10 years The manufacturer, every two years during the warranty period, shall send technician to check every buffer stops, fixed buffer stops and braking wheel stop sets it manufacture in Israel railways facilities on its own expense, and submit technical report with recommendations. 13. INSTALLATION AND TRAINING 13.1 The manufacturer shall send technician to Israel railways facilities on its own expense training and management control the first of each type of buffer stops and fixed buffer stops installation. 9

11 APPENDIX A STOPING DISTANCE DEFINITION Lv Track length for install buffer stop and ensure efficient stopping distance Lb Buffer stop length Lw - Maximum stopping distance 10

12 APPENDIX B - ISRAEL CLIMATE AND ENVIRONNEMENTAL CONDITIONS A.1 Climate and Environmental Conditions Max. ambient temperature 50 C (shade) Min. ambient temperature -5 C Relative humidity 10 to 90 % Altitude -400 to +800 meter Sunny 3300 hours per year UV Radiation 360 to 600 MJ/m² per year Rainfall 400 to 800 mm/year A.2 Dust Conditions in the atmosphere Maximum Half Hour Maximum Daily Average Value* Value* NOx SO O Suspended Dust *(Microgram per m³ atmosphere) A.3 Suspended Particulate Matter (SPM) Particle size to micron A.4 Sea Salt Concentrations in the Atmosphere Salt Element Na* Cl* SO 4 * Position Dry Wet Dry Wet Dry Wet Sea Air at Coast Line m from Shore m from Shore * (Micrograms per m³ atmosphere) 11

13 APPENDIX C EXAMPLE FOR RED AND WHITE REFLECTOR SIGN (Dimensions in millimeters) >

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