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Specifications And Components of SKL21 Fastening System

AGICO Rail is engaged in manufacturing and supplying SKL21 type fasteners which are exclusively used in railways. Fabricated with optimum quality raw materials, these SKL21 fasteners are designed with high precision which impart high tensile strength and corrosion resistance. Our products can also be customized according to clients' requirement at a client desired price.
sample of SKL21 fastening system from AGICO Rail
 
Strict dimensional control and the high quality spring steel ensure that the elastic rail clip and other elastic railway fastenings supplied by AGICO are within specified ranges aimed at meeting customer requirements.

General characteristics of the SKL21 fastening system

It will be suitable for the pre-assembly at the factory.
The manufacturer will warrant that the fastener system and fasteners are comply with the last version of EN 13481 standard.
Will be C class mentioned it EN 13481-1 standard and will warrant to use safely up to 300 km/h speed.
The manufacturer will have 3.1 and/or 3.2 certificate acc. To EN 10204 standard.
W21 fastening system and fasteners’ tests (EN 13146 [1-9]) will be applied to the whole fastening system and fasteners and related standards (except EN 13146-8. This test will be done if the Administration requests).
fasteners of SKL21 fastening system
The static and dynamic stiffness tests of the under sleeper elastic pad will be done acc. To EN 13146-9 standard.
The fasteners’ tests will be done acc. To the last version EN standards. After factory acceptance, if there is a standard change then the test will ve repeated.
The tests to be done for the parts of the fasteners will be done acc. To the updated version of the EN, DIN, ISO standards.
All of the parts of the fastener system can easily ve replaceable.
No hprizantal force to the screws.
The system will be protected against overturn of the rail and overloading the spring parts.
The non metalic parts of the fasteners’ will be made of a material to endure air temperature (-35, +75 oC) and high corrosion conditions.
It will be possible +-10 mm horizontal adjusting at the track. Therefore, the system will be designed so that it can be done in 2,5 mm steps.

Fasteners’ Specifications Belong to W21 B07 System

SKL 21 Clips

We are extremely capable of producing elastic rail clip for any type of toe load and axle load requirements to fix the rails on wooden, steel or concrete sleepers. We offer various elastic rail clips with size steel bar diameter from 12mm to 20mm. We manufacture different types of elastic rail clips with flat toe for broad gauge line, having the toe load from 850kgf to 1100kgf, and are capable of providing any type of toe load and axle load to fix the rails on wooden, steel or concrete sleeper.
The surface hardness of the clips which is tested acc. To EN ISO 6507-1 will be heat treated in order to provide 400-600 Vickers30.
The spring steel manufacturer will have EN 10204 3.1 certificate.
The purity of the spring steel will be at least K3=<30 acc. To DIN 50602. Or the manufacturer will report to identify the amount of inclusion by another suitable method appropriate by the Administration. The material will be treated by melting procedure.
The clips will be free from any manufacturing defect. There will be no cracks, cracks, misalignments, burrs and other defects in the materials.
Rail mounted clips must provide a spring force of about 2 * 10: 20 kN pushing force per rail sitting area in order to provide not less than 14 mm spring streching.
Dimension and workmanship, the dimension given in the drawing of the attachment will be produced according to the tolerance and will be checked with the gauge.

Plastic Angle Guide

Agnle Guides acc. To DBS 918 208 will be reinforced with 30% glass fiber, and made of Polyamide (Nylon) 6 or 6.6 material resistant to deformation resistant ultraviolet radiation or equivalent synthetic material with the same physical properties as the Administration appropriates.
The material will have the following specifications. (the final product will be tested acc. To EN ISO 2818)
•    Density: 1,30 – 1,42 gr/cm3, It shall be determined according to the immersion test method in accordance with EN ISO 1183-1
•    İmpact Resistance: >40 Kj/m2 (the test will be on the 10x10x80 mm part acc. To EN ISO 179-1)
•    Humidity (after heat treatment): 1-2,5%
•    Viscosity: Min.130 ml / g on the raw material, the value measured in the raw material after the test to be made on the sample coming out from the mold will not change by more than 10%. (by sulphuric acid solvent)
•    Elasticity Module: >= 6000 Mpa, will be determined  by tensile test acc. To EN ISO 527-2 (the test will be on the 5x5x75 mm part)
•    Melting Temperature (thermogram acc. To DSC method): acc. To ISO 11357-3; for PA6 215-225 oC and for PA66 255-265 oC
The angle guide plate shall be at least 108 Ohm x cm provided that the Volume Resistive Self is made on the raw material (Acc. To IEC 60093/IEC 60167).
The specimens to be prepared for determination of impact strength and modulus of elasticity shall be tested dry.
It will be proven that there will be no crack affects the performance and no burr and damage to affect the strength and the body has proper density and homogeneous appearance by Visual Control. A suitable reference sample shall be provided by the manufacturer for evaluation during the visual inspection. Samples to be subject to visual examination shall be cut off when necessary.
There will be no air bubbles in the material to affect its performance excessively. Stabilizer, coloring, fusing, filler, reinforcing additive and so on. The additional materials will be homogeneously dispersed within the product. This will be determined by visual inspection and the appropriate reference sample shall be provided by the manufacturer for the evaluation during the visual inspection and samples to be subjected to the visual inspection shall be cut off when necessary. Guide sections taken from different regions will be photographed and added to the report for air bubble detection.
The product produced with the mixture of PA 6 and PA 66 will not be accepted
The weight of the angle guide will be checked during production.
The test specimens to be prepared by processing shall be prepared in accordance with EN ISO 2818 and shall meet the requirements specified in the relevant standard. In addition, the prepared test specimens will be stored in the desiccator until the test.
Dimension and workmanship will be produced according to the dimensions and tolerances given in the technical drawing of the attachment and will be inspected with gauge.

Elastic Under Rail Baseplate

The elastic under rail baseplates is made from ZW1000 type baseplate and will comply to B07 Pre Stretched Monolithic Track Sleeper. The baseplates will be made from elastomer (püre rubber, polyurethan, EPDM etc) materials.
The elasric under rail baseplates will have the following specifications:
•     Static elasticity: 40 kN mm FSP1: 18 kN, FSPmax: 85 kN, FSP2: 68 kN acc. To EN 13481-2)
•     Volume Resistive Self: Min. 108 ohm x cm (acc. To IEC 60093/IEC 60167)
By adding suitable protective material to the material, it will be ensured that it is resistant to oxidization and to decay. These additional materials will be homogeneously dispersed within the product.
Elastic under rail baseplates will be resistant to water, oil, grease, light and ultraviolet damage.
The recycling material will not be used in the manufacture of elastic under-rail baseplates.
Elastic under rail baseplates will be flat with clean cut sides and smooth surface. Elastic under rail baseplates will be free from casting defects. There will not be any deposits or foreign matter on the surface of the baseplates.
The tests shown in DBS 918 235 for the required tests during the qualification period of the pads are based on Table 4. Only Elastic Baseplate Static and Low Frequency Dynamic hardness tests shall be carried out according to EN 13146-9 in accordance with the values specified in EN 13481-2.
Dimension and workmanship will be produced according to the dimensions and tolerances given in the technical drawing of the attachment and will be inspected with gauge.
Marking will be made to cover the following information:
•     Product's Abbreviated Name (eg Zw 1000)
•     Nominal Static Elasticity of Product (kN / mm)
•     Name of Raw Material used
•     Manufacturer Identification Mark
•     Last Two Digits of Production Year

Screw And Feeding Washer

The screws will be manufactured from materials acc. To DIN ISO 898-1 and EN 10025.
The galvanizing completed trilons will provide the following mechanical properties:
•    Tensile Strength: Minimum 500 N / mm2
•    Elasticity Limit: Minimum 300 N / mm2
•    Elongation after fracture: minimum 20%
The screws will be manufactured from a single piece, without welding, in accordance with the dimensions and tolerances in the attached drawing.
Screw heads will be manufactured with hot forging.
Screw heads will be manufactured by hot rubbing, and the pitches will be smooth and complete. The pitch measurements shall be in accordance with the dimensions and tolerances given in the technical drawing.
The heads and body of the screws will be the same axis and will not be misaligned at the end of the pitch extraction.
The surfaces of the finished screws should be properly trimmed. This correction will not cause any metal tearing or roughness on the contact surfaces.
Screw and washers are galvanized against corrosion. Before galvanizing, the parts must be free of grease and paste and, if necessary, cleaned with acid or abrasive to remove oil. 10-20% cold hydrochloric acid can be used for acid cleaning. Then the parts are dried before galvanizing. In galvanizing, hot dip galvanized coating values shall be provided according to TS EN 1461 Table 4, the spot coating thickness shall be minimum 40μ and the average coating thickness shall be minimum 50μ. Galvanizing should be done by immersion in zinc bath at 440-470ºC for 2-20 minutes and then cooling in water.
There will be a suitable feeding washer given at the picture under the Screw Head.
The main axle of the screw should not be more than 1 mm in all radial directions from the center.
The material of the feeding washer will be produced from the material suitable for the material shown in the technical drawing.
•     Tensile Strength: 590-1000 N / mm².
•     The Chemical Analysis will be in accordance with the norm of the material given in the drawing.
•     Feeding washers shall be produced from sheet metal produced by cold rolling method and pore tension lines, etc will be protected against corrosion by hot dip galvanization according to ISO EN 1461.
Dimension and workmanship will be produced according to the dimensions and tolerances given in the technical drawing and will be inspected with gauge.

Plastic Dowel

Plastic dowels shall be made of Polyamide / Nylon 6 (PA 6) or Polyamide Nylon 6.6 (PA 66) according to DBS 918 280. Materials other than these materials will not be accepted. The product produced with the mixture of PA 6 and PA 66 will not be accepted
During the manufacture of the dowels, the materials left from the molds (gating etc.) will not be used again for manufacturing the dowels. In addition, the additional materials like stabilizer, coloring, fusing, filler, reinforcing additive and so on. will be homogeneously dispersed within the product. There will be no air bubbles in the material to affect its performance excessively. These situations will be determined by visual inspection; A suitable reference sample shall be provided by the manufacturer for evaluation during the visual inspection; The samples to be subjected to visual examination shall be cut off when necessary for comparison.
The dowels shall have the following physical values (The test specimens to be prepared on the final product shall comply with the EN ISO 2818 standard):
•     Density: 1,10 - 1,15 gr / cm3 will be determined according to the immersion test method in accordance with EN ISO 1183-1.
•     Volume resistivity self (on raw material): Minimum 108 Ohm x cm.
•     Elasticity Module: ≥ 2000 MPa shall be determined by tensile test in accordance with EN ISO 527-2. (This test shall be carried out on L = 75mm lenght, b1 = 5mm lenght and h = 2-5 mm on the part of the thickness that the Administration deems suitable).
•     Viscosity: Min.130 ml / g on the raw material, the value measured in the raw material after the test to be made on the sample coming out from the mold will not change by more than 10%. (In accordance with EN ISO 307, with sulfuric acid solvent).
Melting Temperature (thermogram acc. To DSC method): acc. To ISO 11357-3; for PA6 215-225 oC and for PA66 255-265 oC.
Dimension and workmanship will be produced according to the dimensions and tolerances given in the technical drawing and will be inspected with gauge.
The dowels will be free from cracks, burrs and damage that will affect its strength. This shall be determined by visual inspection and shall be provided by the manufacturer of the appropriate reference sample for evaluation during the visual inspection; The samples to be subjected to visual examination shall be cut off when necessary for comparison.
The lower parts of the dowels are designed as holes to allow drainage.
The dowels will be stored in closed and dry areas for protection from rain, moisture, dirt and other damages that will affect its characteristics and specifications in the negative.
Dowel weight will be checked during production.
The specimens to be prepared for the determination of the elasticity modulus shall be subjected to the test under dry conditions. In this case the test shall be carried out either on specimens prepared as described in 7.2.4 or on newly emerged specimens.
The test specimens to be prepared by processing shall be prepared in accordance with EN ISO 2818; In addition, the prepared test specimens will be stored in the desiccator until the test.
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