Rail Fastening System

The function of rail fastening system is to fix rails to railway sleeper or railroad ties. Generally, a rail fastening system is consisted of rail anchors, rail tie plates, chairs, fasteners, spikes, screws, bolts, etc.

Design criteria of rail fastening system

There are strict criteria on producing rail fastening system; this is because the safety of rail road can’t be compromised. We should consider the features of rail fastening system and then produce the most reliable finished products.

Rail clamping force. Clamping forces may be difference according to different kinds of fastening system and customer requirements. Generally, most fastening systems offer a clamping force between 7.5 to 12.5 KN with deflections of the clips toe between 10 and 15mm. According to European standards, for most main line railroad track the minimum force to push the rail through the fastening system is 7kN and 9 KN for high speed rail and heavy freight lines.
Anchor/shoulder. The shoulder/anchor is quite important in fastening system. It has to withstand the impact of loads and vibration transmitted to the sleeper under the circumstances of protecting the sleeper from breaking or getting loose. Based on the European standard, all the parts of fastening should be able to withstand a 60KN pullout force without breaking the sleeper.
Insulator. In order to stop the wearing of other fastening components, insulator is necessary, it works as a cushion. So the materials must be resistant to wear, can attack form chemical and can degrade from ultra violet light. As the change of nature of the signaling and electrical systems, the requirements of insulator are different.
Rail pads. Sometimes, there is heavy burden in the rail and the bad joints, track irregularities and faults in rolling stock can strength the load. In order to solve the problem, rail pads can come into play. Usually, the rail pad is made of rubber with 10 mm thick, and is a plastic such as EVA between 5 mm and 10 mm thick. The typical stiffness of the pad is in the rang 40-450 kN/mm and the 5 mm plastic pad can offer stiffness as high up to 6000 kN/mm.

AGICO rail fastening systems

AGICO is designer, producer and exporter of cost-saving resilient rail fastening systems for various types of track lines and traffic conditions. It supplies safe and reliable fastening systems with high tensioning force and creep resistance to effectively protect the rail against tilting. The fastening system range includes both those for ballasted and slab tracks under various conditions, from heavy haul to subway to high speed rails as well as urban rail lines.
Building on over 50 years’ experience and solutions for global end users, our fasteners are well used to ensure the rail track maintaining same properties all the time, especially the tension clamps with super dynamic fatigue strength and holding force to guarantee the safe operation of the rails even under special conditions, which lower the maintenance cost and frequency for the end users.

Types of rail fastening systems from AGICO:

SKL3/SKL12/SKL14 rail fastening system

Specifications for ONE unit of SKL type rail fastening system

Item	Quantity	Material
SKL tension clip	2	60Si2CrA, 60Si2CrA, 38Si7
Ss35 screw spike	2	Grade 4.6: Q235
		Grade 5.6: 35#
		Grade 8.8: 45#
Flat washer	2	Q235
Plastic dowel	2	HDPE, Reinforced Nylon 66 (PA66)
Guide plate	2	Reinforced Nylon 66 (PA66)
Rail pad	1	EVA, or rubber

E-clip fastening system

Specifications for E type rail fastening systems

Item	Quantity	Material
E clip	2	60Si2MnA, 60Si2CrA
Shoulder	2	QT500-7, QT450-10
Rail pad	1	HDPE, rubber or EVA
Insulator	2	Reinforced Nylon 66 (PA66)

KPO rail Fastening System

Specifications for ONE unit of KPO type rail fastening system

Item	Quantity	Material
KPO clip	2	Q235
Screw spike	2	Grade 4.6: Q235
		Grade 5.6: 35#
		Grade 8.8: 45#
HS bolt 4	4	Grade4.6: Q235
		Grade5.6: 35#
		Grade8.8: 45#
Hex nut 2	2	Grade 5: 35#
Hex nut 2	2	Grade 8: 45#
Double coil spring washer	2	65Mn

Spring Blade Fastening

Specifications for ONE unit of Spring Blade Fastening:

Item	Quantity	Material
Nabla clip	2	60Si2MnA, 60Si2CrA
Insulator	2	Reinforced Nylon 66 (PA66)
Screw spike	2	Grade5.6:35#
Spring washer	2	ML08AI

Rail Spike Fastening system

Rail spike fastening system is popular used in North American market, especially America.

Specifications for ONE unit of Rail Spike Fastening system:

Item	Quantity	Material
Track/Cut	Spike	Q235A
Tie plate	1	QT450-10 for casting Q235 for rolling

High speed WJ-8 rail fastening system

WJ-8 rail fastening system is often used for 60kg/m rails with ballast less slab or tie sleepers with shoulders. It meets the operation conditions for:

A passenger train at a speed of 350km/h with axle load no more than 170kN,
A mixed passenger and freight train at a speed of 250km/h with axle load no more than 230kN.

Specifications for ONE unit of WJ-8 Rail Fastening system:

Item	Quantity	Material
Rail clip	2	60Si2MnA
Screw spike	2	20MnTiB
Flat washer	2	Q235A
Rail Insulator	2	PA66
Guide plate	2	Reinforced Nylon 66 (PA66)
Rail pad	1	EVA, or rubber
Tie plate	1	QT450-10
Plastic dowel	2	HDPE, Reinforced Nylon 66 (PA66)
Rail Adjustable Pad	2	PE
Tie Plate adjustable pad	2	PE

High speed WJ-7 rail fastening system

WJ-7 rail fastening system is often used for 60kg/m rails with ballastless slab or tie sleepers without shoulders. It meets the operation conditions for:

A passenger train at a speed of 350km/h with axle load no more than 170kN;
A mixed passenger and freight train at a speed of 250km/h with axle load no more than 230kN.

Specifications for ONE unit of WJ-7 rail fastening system:

Item	Quantity	Material
Rail clip	2	60Si2MnA
T-bolt nut washer	2	Q235A
Rail Insulator	2	PA66
Tie plate	1	QT450-10
Insulated buffer plate	1	Rubber
Rail pad	1	EVA, or rubber
Anchor bolt	1	Q235A
Spring Washer	2	60Si2Mn
Plain washer	2	QT450-10
Plastic dowel	2	HDPE, Reinforced Nylon 66 (PA66)

High speed Type V fastening system

Type V rail fastening system is often used for 60kg/m rails with ballast or concrete ties with shoulders. It meets the operation conditions for:

A passenger train at a speed of 350km/h with axle load no more than 170kN;
A mixed passenger and freight train at a speed of 250km/h with axle load no more than 230kN.

Specifications for ONE unit of Type V rail fastening system:

Item	Quantity	Material
Rail clip	2	60Si2MnA
Screw spike	2	20MnTiB
Flat washer	2	Q235A
Space pieces	2	Q235A
Gauge apron	2	Rubber
Rail pad	1	EVA, or rubber
Adjustable pad	1	PE
Plastic dowel	2	HDPE, Reinforced Nylon 66 (PA66)

Type IV fastening system

Type IV rail fastening system is often used for 60kg/m rails with ballast or concrete ties without shoulders. It meets the operation conditions for:

A passenger train at a speed of 350km/h with axle load no more than 170kN;
A mixed passenger and freight train at a speed of 250km/h with axle load no more than 230kN.

Specifications for ONE unit of Type IV rail fastening system:

Item	Quantity	Material
Rail clip	2	60Si2MnA
Rail insulator	2	PA66
Rail shoulder	2	QT450-10
Rail pad	1	EVA, or rubber

Clip II /Clip I Fastening System

Clip II/Clip I Fastening System applies to 50/60 kg/m standard rail line or line of semidiameter≥300m of concrete sleeper with shoulder. Except for the clip, Clip II fastening system is same as Clip I fastening system.

Specifications for ONE unit of Clip II/Clip I rail fastening system:

Item	Quantity	Material
Rail clip	2	60Si2CrA
Sleeper screw+ nut +washer	2	Q235A
Rail insulator	2	Q235
Baffle board	2	PA66
Rail pad	1	EVA, or rubber

Clip III fastening system

Clip III fastening system applies to 60 kg/m rail of sleepers without shoulders, and it’s a boltless system. It includes rail clips, rail shoulders and insulators.

Specifications for ONE unit of Clip III rail fastening system:

Item	Quantity	Material
Rail clip	2	60Si2MnA
Rail insulator	2	PA66
Rail shoulder	2	QT450-10
Rail pad	1	EVA, or rubber

Quality Control of AGICO Rail Fastening System

Every item fastener we produce will be strictly tested and inspected in the whole manufacturing process, from raw material purchase to the completed product, to ensure their qualification and safety in usage.

Quality Control Process:

Raw material testing
First product manufactured inspection
Inspection during production
Inspection to finished products

Quality testing items:

Chemical composition
Physical properties: 1. Tensile strength, yield strength and elongation 2. Bending 3. Hardness 4. Metallographic analysis
Impact inspection
Anti-corrosion property testing
Dimensional and appearance quality

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