Replacement Guidelines for Worn Fastening Systems

Timely replacement is critical when damage exceeds repair thresholds.

Replacement Triggers:

Cracked Clips: Fractures >5mm length.

Corroded Components: Metal loss >10% of thickness.

Permanent Deformation: Bent clips failing tension tests.

Replacement Steps:

Isolate Track Section: Use POS (Possession of Site) protocols.

Remove Old Fasteners:

Cut seized bolts with rail saws.

Extract clips using extraction tools.

Install New System: Follow manufacturer's torque/alignment specs.

Special Cases:

Tunnels: Use low-profile fasteners for clearance.

Data Insight:
Replacing every 15-20 years is cost-optimal for ballasted tracks .

Routine Tasks:

Lubrication: Apply graphite grease to bolt threads to prevent seizing.

Clip Re-tensioning: Adjust every 5 years for spring clips.

Pad Replacement: Swap hardened pads (>70 Shore A hardness) every 8-10 years.