GCRC5522 Iss 1 - Recommended Action To Be Taken N Discovery of A Broken or Defective Rail

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Railtrack Approved Code of Practice
GC/RC5522
Issue One
Date October 2000
Recommended
Action to be
Taken on
Discovery of a
Broken or
Defective Rail
Synopsis
This document gives
recommendations for the minimum
actions to be taken on discovery of a
broken or defective rail. It supports
Railway Group Standard GC/RT5022.
Submitted by
This document is the property of
Railtrack PLC. It shall not be
reproduced in whole or in part without
the written permission of the Controller,
Dean Benson Railway Group Standards,
Standards Project Manager Railtrack PLC.
Published by:
Authorised by Safety & Standards Directorate
Railtrack PLC
Railtrack House DP01
Euston Square
London NW1 2EE
Brian Alston
Controller, Railway Group Standards Copyright 2000 Railtrack PLC
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GC/RC5522
Issue One
Recommended Action to be Taken on Date October 2000
Discovery of a Broken or Defective Rail Page 1 of 32
Contents
Section Description Page
Part A
Issue Record 2
Responsibilities 2
Health and Safety Responsibilities 2
Supply 2
Part B
1 Purpose 3
2 Scope 3
3 Definitions 3
4 Inroduction 4
5 Recommended Action to be Taken upon the Discovery of Broken Rails 4
6 Recommended Action to be Taken upon the Discovery of Rail Defects 5
7 Recommended Action to be Taken upon the Discovery of Cracked or Broken
Fishplates 6
8 Flame Cut Holes in Rails and Fishplates 7
9 Equipment Used to Pass Trains over Broken or Defective Rails 7
Appendices
A Recommended Action to be Taken upon the Discovery of Broken Rails 9
B Recommended Actions to be Taken upon the Discovery of Defects in Rolled
non-AMS Rails 16
C Recommended Action to be Taken upon the Discovery of Defects in Rolled
AMS Rails 20
D Recommended Action to be Taken upon the Discovery of Defects in Cast Rails
and Crossings 25
E Recommended Action to be Taken upon the Discovery of Cracked or Broken
Fishplates 31
References 32
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GC/RC5522
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Date October 2000 Recommended Action to be Taken on
Page 2 of 32 Discovery of a Broken or Defective Rail
Part A
Issue Record
This document will be updated when necessary by distribution of a complete
replacement.
Revisions in the reissued document will be marked by a vertical black line in the
right hand margin adjacent to the revision.
Issue Date Comments

One October 2000 New issue. Supersedes Appendices D, E, F
and G to Railway Group Standard
GC/RT5019 and Appendix B to Railway
Group Standard GC/RT5020.
Responsibilities
Railway Group Standards are mandatory on all members of the Railway Group *
and apply to all relevant activities that fall into the scope of each individuals
Railway Safety Case. If any of those activities are performed by a contractor, the
contractors obligation in respect of Railway Group Standards is determined by
the terms of the contract between the respective parties. Where a contractor is
a duty holder of a Railway Safety Case then Railway Group Standards apply
directly to the activities described in the Safety Case.
Railtrack Approved Codes of Practice are non mandatory documents detailing

suitable and sufficient means of meeting the mandatory requirements of a
Railway Group Standard.
* The Railway Group comprises Railtrack and the duty holders of the Railway
Safety Cases accepted by Railtrack
Health and Safety

Responsibilities
In issuing this document, Railtrack PLC makes no warranties, express or
implied, that compliance with all or any document published by the Safety &
Standards Directorate is sufficient on its own to ensure safe systems of work or
operation. Each user is reminded of its own responsibilities to ensure health and
safety at work and its individual duties under health and safety legislation.
Supply
Controlled and uncontrolled copies of this document may be obtained from the
Industry Safety Liaison Dept, Safety and Standards Directorate, Railtrack PLC,
Railtrack House DP01, Euston Square, London, NW1 2EE.
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Part B
1 Purpose
This document gives recommendations for the minimum actions to be taken on
discovery of a broken or defective rail. It supports Railway Group Standard
GC/RT5022.
2 Scope
This document contains recommendations that are applicable to the duty holders
of the following category of Railway Safety Case:
Infrastructure Controller.
The recommendations of this document apply to all running lines on Railtrack

Controlled Infrastructure, as defined in Appendix A to Railway Group Standard
GA/RT6001, with permissible or enhanced permissible speeds up to and
including 140mph and carrying vehicles with axle loads up to and including
25.5 tonnes.
3 Definitions
All technical terms used in this document, other than those given below, have
the meanings defined in GC/RC5603.
Broken rail
A rail that has either:
a vertical or diagonal fracture through the full cross section;

a piece broken out of it;
rail head damage or distortion which exceeds 10mm either vertically or
laterally over a length of 150mm or less.
Defective rail
A rail that is not broken, but which contains a crack (visible or invisible), localised
spreading of the rail head or some other defect requiring the rail to be either
removed prematurely from the track or repaired to prevent it from breaking in
service.
Emergency bridging piece

A device used to temporarily bridge a large gap between two broken rail ends in
order to permit a vehicle to pass in an emergency. The wheels of the vehicle run
over the emergency bridging piece. Compare with temporary rail clamping
system.
ESR
Emergency speed restriction.
Rolled AMS rails

Rails rolled from austenitic manganese steel.
Rolled non-AMS rails

Rails rolled from steel other than austenitic manganese steel.
Temporary rail clamping system

Fishplates held together with clamps to form a temporary rail joint. The
temporary rail clamping system may also be applied to a rail at some breaks and
defects to hold the rails to line and level. Emergency clamped fishplates are a
particular type of temporary rail clamping system. The wheels of the vehicle run
over the rail head. Compare with emergency bridging piece.
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Track category
The classification of a section of track by usage and speed, so that requirements
relating to design, maintenance, renewal and inspection of the track may be
specified and applied. The procedure for categorising track is given in
GC/RT5023.
4 Introduction
This document quotes, verbatim and boxed, sections 8.1, 8.2, 8.3, 8.4 and 8.5 of
GC/RT5022 and gives recommendations which will generally enable the
requirements of these sections of the Railway Group Standard to be met with
respect to the actions to be taken on discovery of a broken or defective rail.
The recommendations were previously set out as mandatory requirements in the

appendices to Railway Group Standards GC/RT5019 (Issue 2) and GC/RT5020
(Issue 2). There are only minor differences between the recommendations of
this document and the previously mandated requirements, principally to take
account of tache ovale type defects originating from gauge corner cracking or
head checking.
The infrastructure controller should add to or modify the recommended actions

given in this document when necessary to reflect the identification of new types
of rail defects or changes in the behaviour of currently known types of defect (for
example, increases in numbers appearing or accelerated growth rates).
5 Recommended Action
to be Taken upon the
Discovery of Broken Rails
GC/RT5022 section 8.1

Action to be taken upon the discovery of broken rails
A procedure shall be in place that specifies the minimum action to be taken upon
the discovery of broken rails.
The procedure shall only be for the use of people who are trained and competent
in the application of the procedure or by track engineers who can demonstrate
competence through relevant knowledge and experience.
Other people who have received special training and hold valid certificates are
permitted to authorise trains to pass over broken rails in accordance with a
separate procedure set out in the Rule Book, GO/RT3000.
The minimum actions shall be selected from one of the following options:
block the line;

impose a 5mph speed restriction;
impose a 20mph speed restriction;
replace the broken rail with a temporary rail (see section 8.5.1) and impose
a 50mph speed restriction.
The specified minimum actions shall vary to suit the following factors:
the type of rail break;

the size of the gap between rail ends;
the position of the break in relation to welded or fishplated joints;
whether equipment is fitted to the break to permit trains to pass and its type
(see section 8.5);
the type and axle load of trains likely to pass over the break;
whether wheels with a diameter of less than 750mm are likely to pass over
the break (generally, wheel diameters of less than 750mm are confined to
on-track machines, wheel skates and a limited number of low floor height
freight vehicles);
whether a watchman has been posted.
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The minimum action shall be varied during the course of events if required to suit
changing conditions (for example, the fitting of equipment to the break to permit
trains to pass or the deterioration of sleepers supporting the broken rail).
The procedure shall require the line to be blocked if:
the break passes through a bolt hole;

the break is at a welded joint that is within 3m of another welded or
fishplated joint;
the break is a transverse break and is more than 50mm out of vertical
between the head and foot of the rail;
the break is in an S&C rail that is free to move (for example a switch rail);
the gap between rail ends exceeds the capability of available temporary rail
clamping systems or emergency bridging pieces;
the condition and packing of the two adjacent sleepers on each side of the
break are insufficient to support the rail;
the condition of the fastenings of the two adjacent sleepers on each side of
the break are insufficient to retain the rail in position.
The procedure shall require a watchman to be posted if equipment (for example

a temporary rail clamping system) is not fitted to the break. See also section
8.5.1.
The procedure shall only permit trains to pass over a broken rail at 20mph if the
following conditions are met:
the break has been fitted with a temporary rail clamping system designed for
use at a speed of at least 20mph;
the break is not within 3m of a welded or fishplated joint;
the gap between rail ends does not exceed 50mm wide.
The procedure shall require the broken rail to be removed from the track within
24 hours of its discovery in lines in track categories 1A, 1, 2 and 3 and within
48 hours of its discovery in track categories 4, 5 and 6.
When a broken rail is discovered, the actions required by the procedure shall be
implemented.
Recommended minimum actions to be taken upon the discovery of broken rails

are set out in Appendix A.
Discovery of Rail Defects

Action to be taken upon the discovery of rail defects
the discovery of a defective rail.
The minimum actions shall include requirements for:
imposition of speed restrictions;

fitting of a temporary rail clamping system;
removal of defects within stated timescales;
weld repair of defects within stated timescales;
grinding of rails to remove or reduce the size of small and incipient surface
defects;
removal of lipping from rails;
re-testing of defects at stated intervals.
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the type of rail defect;

the size of the rail defect, inferred from non-destructive test results where it
cannot be measured directly;
whether the defect is isolated or whether multiple defects exist;
the grade of rail steel;
the position of the defect in relation to welded or fishplated joints;
the type and axle load of trains likely to pass over the defect;
whether a temporary rail clamping system is fitted to the defect to support
the rail head (see section 8.5);
whether a watchman has been posted;
the condition of the adjacent sleepers and fastenings;
local conditions.
The minimum actions shall be formulated to minimise the likelihood of the rail
breaking before it has been removed or repaired. Where a likelihood remains of
the rail breaking before it is removed or repaired, the minimum actions shall be
designed to reduce the consequences of the rail break.
If a rail defect is discovered of a type that may be repeated in the length of rail as
manufactured (for example, piping), the procedure shall require consideration to
be given to replacing the complete rail between adjacent joints.
The procedure shall require rails removed because of defects to be clearly

marked to prevent their accidental re-use.
When a defective rail is discovered, the actions required by the procedure shall
be implemented.
Recommended minimum actions to be taken upon the discovery of defects in

rolled non-AMS rails are set out in Appendix B.

rolled AMS rails are set out in Appendix C.

cast rails and crossings are set out in Appendix D.
Discovery of Cracked or
Broken Fishplates

Action to be taken upon the discovery of cracked or broken fishplates
the discovery of a cracked or broken fishplate.
The minimum actions shall specify the requirements for:
imposition of speed restrictions;

fitting of temporary rail clamping systems;
replacement of the broken or cracked fishplates within stated timescales.
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whether the fishplate is broken or cracked;

whether one or both fishplates are affected;
the condition and packing of the adjacent sleepers on each side of the joint;
where present, the condition of the joint in the opposite rail;
the presence of rail defects close to the joint;
local conditions.
Both fishplates at a joint shall be replaced, even if only one of the fishplates has
been broken or cracked. All other components used to form the joint shall also
be replaced at the time the fishplates are changed.
The procedure shall require the cracked or broken fishplate to be permanently

replaced within 24 hours of its discovery in lines in track categories 1A, 1, 2 and
3 and within 48 hours of its discovery in track categories 4, 5 and 6.
The procedure shall require the underlying cause of the broken or cracked
fishplates to be investigated and, where the cause is identified, action to be
taken to prevent a recurrence.
When a cracked or broken fishplate is discovered, the actions required by the

procedure shall be implemented.
Recommended minimum actions to be taken upon the discovery of broken or

cracked fishplates are set out in Appendix E.
8 Flame Cut Holes in

Rails and Fishplates

Flame cut holes in rails and fishplates
Holes shall not be produced in rails or fishplates by flame cutting.
If a flame cut hole is found in a standard grade group rail in a running line, a
20mph speed restriction shall be imposed and the rail changed within 36 hours.
A temporary rail clamping system shall be fitted where possible.
If a flame cut hole is found in a higher grade group rail, the line shall be blocked
until the rail is changed.
If a flame cut hole is found in a fishplate, a 20mph speed restriction shall be

imposed until the fishplate is changed.
This section of GC/RT5022 is self-explanatory and therefore there are no

associated recommendations.
9 Equipment Used to
Pass Trains over Broken
or Defective Rails
GC/RT5022 section 8.5.1

General requirements for equipment used to pass trains over broken or
defective rails
The infrastructure controller shall specify procedures for using equipment
designed to permit trains to pass over broken or defective rails. The procedures
shall include requirements for the use of:
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temporary rail clamping systems;

very short pieces of sawn or disc cut rail held in the gap of a broken rail by a
temporary rail clamping system to provide continuity of running surface
(applicable to broken rails only);
emergency bridging pieces (applicable to broken rails only);
short lengths of rail with a temporary rail joint at either end to replace a
broken rail (applicable to broken rails only).
The general requirements for the use of such equipment shall be as set out in
section 6.6.1 for temporary rail joints.
Use of very short pieces of sawn or disc cut rail held in the gap of a broken rail
by a temporary rail clamping system shall be subject to the following
requirements:
the temporary clamping system shall be securely clamped to the adjacent

rail ends;
the piece of rail shall be of the same nominal section as the broken rail;
the maximum permitted speed shall be 5mph;
a watchman shall be posted;
any additional requirements specified by the manufacturer of the temporary
clamping system shall be complied with.
Use of emergency bridging pieces shall be subject to the following requirements:

a watchman shall be posted;
any additional requirements specified by the manufacturer shall be complied
with.
Use of short lengths of rail with a temporary rail joint at either end to replace a
broken rail shall be subject to the following requirements:
the short rail shall be supported by at least three sound, well packed
sleepers;
the initial gap at each temporary rail joint shall not exceed 10mm;
the temporary joint shall not be a fly-fished joint;
the other requirements for temporary rail joints set out in 6.6 are met.
the joints are inspected after 24 hours and a permanent repair is effected
within 48 hours.
A maximum permitted speed of 50mph is permitted over a short length of rail

meeting the conditions above provided the temporary joints are replaced with
fishplated joints complete with all fishbolts.
All equipment used to pass trains over broken or defective rails shall be
inspected after use to confirm the equipments continuing fitness for purpose.
GC/RT5022 section 8.5.2

Acceptance of equipment used to pass trains over broken or defective rails
Equipment for forming temporary rail joints shall be accepted for use on Railtrack
Controlled Infrastructure in accordance with the requirements of GI/RT7002.
This section of GC/RT5022 is self-explanatory and therefore there are no

associated recommendations.
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Appendix A
Recommended Action to be Taken on
Discovery of Broken Rails
A1 Charts Giving
Minimum Actions
Type of break See chart

No:
Transverse break through a plain rail or A1.1
weld
Any part of the railhead broken away A1.2
Lower part of the rail broken away A1.3
Longitudinal split A1.4
Railhead damage A1.5

(Localised breaking away of lipping on
either of the running edge or the back edge
of a rail is usually of insufficient severity to
warrant classification as rail head damage.)
All charts are to be read in conjunction with the notes given at the end of this
Appendix.
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A1.1 Minimum action to be taken on discovery of a broken rail -
Transverse break through a plain rail or weld
Equipment Gap between At a At a welded <1.8m from a PDQG 3m from a

fitted rail ends fishplated joint welded joint <3m from a welded or
joint or welded or fishplated
<1.8m from a fishplated joint
fishplated joint
joint
None PP Block the line Impose 5mph Block the line Block the line Impose 5mph
ESR ESR
Note 1,2,3,6 Note 2,3
> 50mm and Block the line Impose 5mph Block the line Block the line Impose 5mph
PP ESR ESR
Note 1,2,3,4,6 Note 2,3,4,6
> 75mm Block the line Block the line Block the line Block the line Block the line
Temporary rail PP Block the line Impose Impose 5mph Impose 5mph Impose
clamping 20mph ESR ESR ESR 20mph ESR
system Note 1,2,3 Note 2,3,8, Note 2,3 Note 2,3
> 50mm and Block the line Impose 5mph Impose 5mph Impose 5mph Impose 5mph
PP ESR ESR ESR ESR
Note Note Note 2,3,4,6,7 Note 2,3,4,6,7
1,2,3,4,6,7 2,3,4,6,7,8
> 75mm and Block the line Impose 5mph Impose 5mph Impose 5mph Impose 5mph
PP ESR ESR ESR ESR
Note 1,2, Note 2,3, Note 2,3, Note 2,3,
3,5,6,7,10 5,6,7,8,10 5,6,7,10 5,6,7,10
>165mm Block the line Block the line Block the line Block the line Block the line
Emergency PP Impose 5mph Impose 5mph Impose 5mph Impose 5mph Impose 5mph
bridging piece ESR ESR ESR ESR ESR
Note 6,7 Note 1,6,7 Note 6,7,8 Note 6,7 Note 6,7
> 50mm and Impose 5mph Impose 5mph Impose 5mph Impose 5mph Impose 5mph
PP ESR ESR ESR ESR ESR
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Any part of the railhead broken away
Equipment Length of At a At a welded <1.8m from a PDQG PIURPD

fitted piece fishplated joint welded joint <3m from a welded or
missing joint or welded or fishplated
fishplated joint
joint
None PP Block the line Impose 5mph Block the line Block the line Impose 5mph
ESR ESR
Note 1,3,6 Note 3
>50mm and Block the line Impose 5mph Block the line Block the line Impose 5mph
PP ESR ESR
Note 1,3,4,6 Note 3,4,6
> 75mm Block the line Block the line Block the line Block the line Block the line
system Note 1,3 Note 3,8 Note 3 Note 3
>50mm and Block the line Impose 5mph Impose 5mph Impose 5mph Impose 5mph
PP ESR ESR ESR ESR
Note 1,3,4 Note 3,4,8 Note 3,4 Note 3,4
> 75mm and Block the line Block the line Block the line Block the line Block the line
PP
>50mm and Impose 5mph Impose 5mph Impose 5mph Impose 5mph Impose 5mph
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Lower part of the rail broken away
Equipment Length of At a At a welded <1.8m from a PDQG PIURPD

fitted piece fishplated joint welded joint <3m from a welded or
missing joint or welded or fishplated
fishplated joint
joint
None PP Block the line Block the line Block the line Block the line Block the line
OR Impose OR Impose
5mph ESR 5mph ESR
Note 1,6,9 Note 3,6,9
> 50mm and Block the line Block the line Block the line Block the line Block the line
PP OR Impose OR Impose
5mph ESR 5mph ESR
Note 1,6,9 Note 3,6,9
system Note 1 Note 3,8 Note 3 Note 3
PP ESR ESR ESR ESR
Note 1,6 Note 3,6,8 Note 3,6 Note 3,6
PP ESR ESR ESR ESR
Note 1,6,7 Note 3,6,7,8 Note 3,6,7 Note 3,6,7
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A1.4 Minimum action to be taken upon discovery of a broken rail -
Longitudinal split
Split rail Is the split in the Block the line

running edge YES
side of the rail
head?
Is the rail free to
YES move (eg a
NO switch rail)?
YES
Is the split in an
S&C rail?
NO
Is the rail bolted

YES to and supported NO
NO by S&C blocks or
another form of
support?
Is the split at a
joint? YES
Impose 5mph
NO ESR
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Railhead damage
Damaged rail Is the rail Block the line

damaged or YES
distorted either
vertically or
laterally by more
than 25mm?
NO
Impose 5mph
Is the rail ESR
damaged or YES
distorted either
vertically or
laterally by more
than 10mm?
Impose
NO 20mph ESR
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A2 Notes to Charts in
Appendix A
A2.1 Notes referenced in charts A1.1 to A1.5 inclusive
1. Block the line if the break at a welded joint is within 3m of another welded
or fishplated joint.
2. Block the line if the break is more than 50mm out of vertical from head to
foot of rail.
3. Block the line if the break passes through a bolt hole.
4. No wheels less than 450mm diameter should pass over the break.
5. A short length of sawn or disk cut rail of suitable full rail section should be
clamped in position to provide wheel support and guidance.
6. A watchman should be present.
7. The time limit for the arrangement specified is either 24 hours for Category
1A, 1, 2 or 3 lines or 48 hours for Category 4, 5 or 6 lines.
8. If the adjacent welded joint is alumino-thermic, then this welded joint should
also be clamped.
9. Block the line if the break is in the foot on both sides of the foot. Impose
5mph ESR if the break is in the foot on one side of the foot.
10. Only clamping systems designed for gaps over 75mm should be used.
These systems should be approvedl for this specific application. They
should be used strictly in accordance with manufacturers instructions and
the type approval certificate.
A2.2 General notes on recommended actions
a. On lines electrified by either the conductor rail or overhead systems

temporary bonds should be fitted around the break in accordance with the
infrastructure controllers procedures.
b. Bridging pieces and temporary rail clamping systems should be used in

accordance with the infrastructure controllers procedures for using the
equipment required by GC/RT5022 section 8.5.1.
c. The condition and packing of the two adjacent sleepers on each side of the
break should be sufficient to support the rail.
d. The condition of the fastenings on each side of the break should be

sufficient to retain the rail in position.
e. The size of the gap between rail ends or the length of pieces missing should
be measured (not estimated).
f. Block the line if the break is in an S&C rail that is free to move (for
example, a switch rail). The minimum actions set out in the tables only
apply to breaks in S&C where the break is in a rail that is bolted to and
supported by S&C blocks or another form of support.
g. Block the line if any cracks extend from the break into the web.
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Appendix B
Recommended Actions to be Taken on
Discovery of Defects in Rolled non-AMS
Rails
B1 Table of Minimum
Actions
The table is to be read in conjunction with the notes given at the end of this
Appendix.
Defect no Location Within Anywhere See notes

fishplate in a rail
limits of a except
bolted within
joint fishplate
limits of a
bolted
joint
1 Any visible crack except as noted below 1A 1A S
2 Any crack passing through a bolt hole 1A 1A S
3 Horizontal crack in head extending to more than 15mm below 1A 1A T
running surface and / or more than 25mm long
4 Horizontal crack in head extending to less than 15mm below 3B 3D -
running surface and less than 25mm long
5 Horizontal crack in web, including upper and lower fillet radii 1A 1A S
6a Two or more tache ovale type defects with less than 5m 1A 2A Q,T&X
between defects in the same rail; action based on worst
defect
Signal amplitude: > 100% full screen height
6b Two or more tache ovale type defects with less than 5m 1A 2B O,Q&T
defect
Signal amplitude: =100% -50% full screen height
6c Two or more tache ovale type defects with less than 5m 3B 3G O
defect
Signal amplitude: = 50% - 25% full screen height
7a Single or multiple tache ovale type defects more than 5m 1A 2B T
apart within the same rail; action based on worst defect
Signal amplitude: > 100% full screen height
7b Single or multiple tache ovale type defects more than 5m 1A 2C O&T
Signal amplitude: =100% -50% full screen height
7c Single or multiple tache ovale type defects more than 5m 3B 3G O&Y
Signal amplitude: = 50% - 25% full screen height
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fishplate in a rail
limits of a except
bolted within
joint fishplate
limits of a
bolted
joint
8a Squat length >50mm 1A 2A T
With detectable tache ovale type defect extending to more
than 15mm below rail surface
8b Squat length >50mm 1A 2F or 2C O,Q,T&Y
With detectable tache ovale type defect extending to no more
8c Squat length >50mm 1A 2F or 2C O,Q,T&Y
Tache ovale type defect cannot be detected
8d Squat length 50mm and less 1A 2B O&T
8d Squat length 50mm and less 1A 2F or 2C O,Q,T&Y
8e Squat length 50mm and less 3C 3F or 3G O,Q,T&Y
No detectable tache ovale type defect
9a Isolated wheelburns 3B 3F Y
9b Continuous wheelburns - - N
10a Vertical Longitudinal cracking, head or web 1A 1A U
Visible crack or bulging
10b Vertical Longitudinal cracking, head or web 3G 3G U&Y
Neither visible crack nor bulging
11 Hydrogen shatter cracks 3G 3G Y
12 Gauge corner cracking with no detectable tache ovale type - - Z
defect
13 Cracks in machined rails in S&C - - V
14 Visible crack in weld collar - 2B T&W
15 Untestable defect - - P
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B2 Notes and Codes

Used in Table of
Minimum Actions
B2.1 Minimum action codes
Code Minimum action to be taken

1 Impose 20 mph ESR and fit temporary rail clamping system where
possible
2 Fit temporary rail clamping system
3 No emergency action required
B2.2 Timescale for action codes
Code Time scale of action to be taken

A Remove defect within 36 hours
B Remove defect within 7 days
C Remove defect within 13 weeks
D Weld repair within 7 days and retest within 14 days of completion of
weld repair
F Weld repair to Engineers specified timescale
G Retest to Engineers specified timescale
H Remove defect within 4 weeks
B2.3 Notes
Code Notes
L Report battered rail ends as Untestable where applicable
N Wheelburns cannot be ultrasonically tested; track having continuous
wheelburns should be rerailed
O Interpretation of timescales within bands of action. The definitive
date for removal should consider:
where the defect is located;
annual tonnage over the defect;
axle weights;
permissible and enhanced permissible speeds;
local track conditions.
P Rails reported as untestable because of rail head shape or ballast
scars should be considered for reprofiling and retesting
Q When assessing multiple defects for corrective action then any
action taken should be based upon the largest defect present
S Where it is discovered that a crack is extending into the rail head
and / or foot then an ESR of 5mph should be imposed
T If it is not possible to fit temporary rail clamping system then the
minimum action is to impose a 20mph ESR and change rail within 36
hours
18 RAILTRACK
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GC/RC5522
Issue One
Code Notes
U Bulging means an increase of 2mm or more in the width of head /
web
V S&C: In S&C layouts where, because of the complexities of the
design of the units or because there are delays in the supply of
replacements, it is not possible to adhere strictly to the minimum
actions stipulated, then the action to be taken should ensure that the
risk to trains is as low as reasonably practicable
W Replace with a wide gap weld if possible (wide gap weld not
available for AMS). If this is not possible, fit temporary rail clamping
system and replace weld within 7 days
X Appoint a watchman
Y Engineers specified timescale should not exceed the laid down
frequency of ultrasonic inspection
Z Report extent and location for consideration of rail grinding
RAILTRACK 19
Withdrawn Document
GC/RC5522
Issue One
Appendix C
Recommended action to be taken on
discovery of defects in rolled AMS rails
C1 Table of Minimum
Actions
Appendix.

fishplate in a rail
limits of a except
bolted within
joint fishplate
limits of a
bolted
joint
21a FB Rails 3B 2H O&T
Visible transverse crack in foot and / or lower web
Crack fully contained in zones 1 & 2 as indicated in sketch
21b FB Rails 1A 1A -
Crack fully contained in zone 3 as indicated in sketch
21c BH Rails 1A 1A -
Crack visible on top surface of rail foot
21d BH Rails 3B 2H O&T
Crack not visible on top surface of rail foot
22a Any rail containing a crack or cracks passing through a bolt 1A 2A T
hole where any crack is greater than 25mm in length or there
are more than four cracks (of any length) at any bolt hole
22b Any rail containing a crack or cracks passing through a bolt 3H 3H O
hole where the longest crack is between 10mm and 25mm in
length and there are not more than four cracks (of any
length) at any bolt hole
22c Any rail containing a crack or cracks passing through a bolt 3C 3G Y
hole where every crack is less than 10mm in length and there
are not more than four cracks (of any length) at any bolt hole
23 Horizontal crack in head extending to more than 15mm below 1A 1A L
running surface
24 Horizontal crack in head extending to 15mm or less below 3C 3F L&Y
running surface
25a Horizontal crack in web, including upper and lower fillet radii 1B 2C O&T
Length > 25mm
25b Horizontal crack in web, including upper and lower fillet radii 3G 3G Y
Length < 25mm
20 RAILTRACK
Withdrawn Document
GC/RC5522
Issue One

fishplate in a rail
limits of a except
bolted within
joint fishplate
limits of a
bolted
joint
26a Two or more tache ovale type defects with less than 5m 1A 1A X
between defects in the same rail; based on worst defect
>100% full screen height
26b Two or more tache ovale type defects with less than 5m 1A 2B T
100%- 50% full screen height
26c Two or more tache ovale type defects with less than 5m 3C 3G O&Y
50% full screen height and less
27a Isolated tache ovale type defects 1A 2B O&T
Visible transverse crack in head
27b Isolated tache ovale type defects 1A 2B O&T
Not visible >50% full screen height
27c Isolated tache ovale type defects 3C 3G O&Y
Not visible 50% full screen height and less
28a Squat length >50mm 1A 2B O&T
28b Squat length >50mm 3C 3F Y
28c Squat length >50mm 3C 3F Y
28d Squat length 50mm or less 1A 2B O&T
28e Squat length 50mm or less 3C 3F Y
28f Squat length 50mm or less 3C 3F Y
29a Isolated wheelburns 3C 3F O&Y
29b Continuous wheelburns - - N
30a Vertical longitudinal cracking, head or web 1B 1B U
Visible crack or bulging
30b Vertical longitudinal cracking, head or web 3G 3G U&Y
Neither visible crack nor bulging
RAILTRACK 21
Withdrawn Document
GC/RC5522
Issue One

fishplate in a rail
limits of a except
bolted within
joint fishplate
limits of a
bolted
joint
31 Gauge corner cracking - - Z
32 Cracks in machined rails in S&C - - V
33 Visible crack in weld collar - 2A T&W
34 Untestable - - P
22 RAILTRACK
Withdrawn Document
GC/RC5522
Issue One
C2 Notes and Codes

Used in Table of
Minimum Actions
C2.1 Sketch showing locations of zones referred to in table in section C1.
,'dd *
( )
*'dd *'dd
C2.2 Minimum action codes
Code Minimum action to be taken

1 Impose 20 mph ESR and fit temporary rail clamping system where
possible
2 Fit temporary rail clamping system
3 No emergency action required
C2.3 Timescale for action codes
Code Time scale of action to be taken

A Remove defect within 36 hours
B Remove defect within 7 days
C Remove defect within 13 weeks
D Weld repair within 7 days and retest within 14 days of completion of
weld repair
F Weld repair to Engineers specified timescale
G Retest to Engineers specified timescale
H Remove defect within 4 weeks
RAILTRACK 23
Withdrawn Document
GC/RC5522
Issue One
C2.4 Notes
Code Notes
L Report battered rail ends as Untestable where applicable
N Wheelburns cannot be ultrasonically tested; track having continuous
wheelburns should be rerailed
O Interpretation of timescales within bands of action: The definitive
date for removal should consider:
where the defect is located;
annual tonnage over the defect;
axle weights;
permissible and enhanced permissible speeds;
local track conditions.
P Rails reported as untestable because of rail head shape or ballast
scars should be considered for reprofiling and retesting
Q When assessing multiple defects for corrective action then any
action should be based upon the largest defect present
S Where it is discovered that a crack is extending into the rail head
and / or foot then an ESR of 5mph should be imposed
T If it is not possible to fit temporary rail clamping system then the
minimum action is to impose a 20mph ESR and change rail within 36
hours
U Bulging means an increase of 2mm or more in the width of head /
web
V S&C: In S&C layouts where, because of the complexities of the
design of the units or because there are delays in the supply of
replacements, it is not possible to adhere strictly to the minimum
actions stipulated, then the action to be taken should ensure that the
risk to trains is as low as reasonably practicable
W Replace with a wide gap weld if possible (wide gap weld not
available for AMS). If this is not possible, fit temporary rail clamping
system and replace weld within 7 days
X Appoint a watchman
Y Engineers specified timescale should not exceed the laid down
frequency of ultrasonic inspection
Z Report extent and location for consideration of rail grinding
24 RAILTRACK
Withdrawn Document
GC/RC5522
Issue One
Appendix D
Discovery of Defects in Cast Rails and
Crossings
D1 Tables of Minimum
Actions
The tables are to be read in conjunction with the notes given at the end of this
Appendix.
D1.1 Cast AMS monobloc crossings only

Within fishplate limits
Defect Description of defect Minimum action to be taken

No
41 Transverse crack emanating from behind the fishplates and
extending to a position:
41A more than 25mm from the Impose 20mph ESR
running surface Appoint watchman
41B within 25mm of the running Impose 5 mph ESR
surface Appoint watchman
42 Horizontal longitudinal crack in the top fillet extending to a position:
42A not more than 25mm beyond the Inspect daily
fishplates and is not upturning
42B more than 25mm beyond the Impose 20mph ESR
fishplates, or is upturning Appoint watchman
anywhere along its length to a
position more than 25mm from
the running surface
42C within or beyond the fishplates Impose 5mph ESR
and is upturning to within 25mm Appoint watchman
of the running surface
43 Vertical transverse crack extending from the running surface to a
depth:
43A not more than 15mm Inspect twice a week
43B between 15mm and 25mm Inspect daily
43C between 25mm and the bottom Impose 20mph ESR
corner of the rail head Appoint watchman
43D hidden by the fishplates Impose 5mph ESR
Appoint watchman
44 Longitudinal vertical crack in the box section at the end of the vee
(1 in 24 and 1 in 28 crossings only):
44A less than 50mm in length Inspect weekly
44B more than 50mm in length Inspect twice a week
RAILTRACK 25
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GC/RC5522
Issue One

No
45 Longitudinal crack in the apron and:
45A not hidden by the fishplates Inspect weekly
45B partially hidden by the fishplates Impose 5mph ESR
Appoint watchman
46 Transverse crack in the foot extending to a position:
46A not hidden by the fishplates Inspect daily
46B hidden by the fishplates Impose 5mph ESR
Appoint watchman
Figure 1
Minimum actions for cracks discovered within fishplate limits
(,dd+*8%@ejg\Zkkn`Z\Xn\\b
),dd+*9%@ejg\Zk[X`cp+(9%,dg_<JIN +):%,dg_<JIN
+*:%)'dg_+(8%)'dg_<JIN +)9%)'dg_<JIN
<JIN
+*;%,dg_+)9%)'dg_<JIN
<JIN +)8%@ejg\Zk[X`cp
),dd
=`j_gcXk\
c`d`k
N 48ggf`ekXNXkZ_dXe
Notes to figure 1
1. In all cases where a transverse crack is found to extend from the running
surface to a position hidden by the fishplates, the circumstances should be
investigated to establish whether the crack is associated with another defect
that might compromise the safe passage of trains.
2. If there is more than one transverse crack extending from the running
surface to a position hidden by the fishplates, the line should be blocked.
26 RAILTRACK
Withdrawn Document
GC/RC5522
Issue One
D1.2 Cast monobloc, cast centre and cast vee AMS crossings only
Leg-ends

No
depth:
47C between 25 and 75mm or into a Impose 20mph ESR
bond hole Appoint watchman
47D More than 75mm Impose 5mph ESR
Appoint watchman
48A not more than 50mm from the Inspect twice a week
foot tip
48B between 50mm from the foot tip Inspect daily
and to the top of the lower fillet
radius curve (35mm into the
web, measured from the
underside of the foot)
48C between 35 and 50mm from the Impose 20mph ESR
underside of the foot Appoint watchman
48D more than 50mm from the Impose 5mph ESR
underside of the foot Appoint watchman
Figure 2
Minimum actions for cracks discovered within leg-ends but outside
fishplate limits
(,dd +.8%@ejg\Zkkn`Z\Xn\\b
),dd +.9%@ejg\Zk[X`cp +.:
)'dg<JIN
.,dd :fie\i
+.:%)'dg_<JIN
+/;%,dg_<JIN
+.;%,dg_<JIN
+/:%)'dg_ .,dd
<JIN
=`j_gcXk\c`d`k
+/9%@ejg\Zk[X`cp
*,dd
,'dd
N 48ggf`ekXNXkZ_dXe =ffkk`g
+/8%@ejg\Zkkn`Z\Xn\\b
RAILTRACK 27
Withdrawn Document
GC/RC5522
Issue One
D1.3 All cast crossings in AMS and bainitic steels

Change of section

No
depth:
49A not more than 15mm Inspect weekly
49B between 15mm and 25mm Inspect twice a week
49C between 25mm and 75mm Inspect daily
49D more than 75mm or turns into Impose 20mph ESR
top fillet of web Appoint watchman if crack turns
into top fillet of web
50A not more than 50mm from the tip Inspect twice a week
50B between 50mm from the foot tip Inspect daily
and 35mm up the side wall
50C between 35mm and 75mm up Impose 20mph ESR
the side wall
50D more than 75mm up the side Impose 5mph ESR
wall or turns into the web Appoint watchman
28 RAILTRACK
Withdrawn Document
GC/RC5522
Issue One
D1.4 All cast crossings in AMS and bainitic steels

Monobloc

No
51 Crack on one foot extending into a core pocket and to a position up
the side wall (from the underside of foot):
51C more than 75mm Impose 20mph ESR
Appoint watchman
52 Crack on foot extending across full width of casting and to a position
on any one side (from underside of foot):
52A not more than 35mm Inspect daily
52B between 35mm and 75mm Impose 20mph ESR
Appoint watchman
52C more than 75mm Impose 5mph ESR
Appoint watchman
53 Transverse crack on the vee extending to a depth below the running
surface:
53C between 25mm and base of the Inspect daily
flangeway
53D having crossed the base of the Appoint watchman
flangeway and reached the wing
rail / rails
53E if associated with a crack in the Impose 20mph ESR
wing rail Appoint watchman
54 Vertical transverse crack on wing rail extending to a depth below the
running surface:
54C between 25mm and base of the Inspect daily
flangeway or between 25mm
and 75mm down the sidewall
54D more than 75mm Impose 20mph ESR
55 Depression of the running Impose 20mph ESR
surface, other than in the wheel Appoint watchman
transfer area, of more than 3mm
depth measured over 1m or
associated with cracking of the
sidewall
RAILTRACK 29
Withdrawn Document
GC/RC5522
Issue One

No
56 Flaking or shelling of the wheel Inspect weekly
contact surface
57 Misshapen crossing nose profile Inspect twice a week
58 Metal breaking out within the wheel transfer area of the vee:
Defect Defect Defect length
depth width
(notes 1& up to 26mm to > 150mm
2) 25mm 150mm
58A 5 - 10mm <50% or Inspect Inspect Impose

35mm daily daily 20mph
ESR
Appoint
watchman
58B >50% or Inspect Impose Impose
35mm daily 20mph 20mph
ESR ESR
Appoint Appoint
watchman watchman
58C 10 - 15mm <50% or Inspect Impose Impose
35mm daily 20mph 5mph ESR
ESR Appoint
Appoint watchman
watchman
58D >50% or Inspect Impose Impose
35mm daily 5mph ESR 5mph ESR
Appoint Appoint
watchman watchman
58E > 15mm <50% or Inspect Impose Block the
35mm daily 5mph ESR line
Appoint
watchman
58F >50% or Impose Block the Block the
35mm 20mph line line
ESR
Appoint
watchman
D2 Notes to Tables of
Minimum Actions
1. Where the casting width is less than 70mm the limiting defect width will be
50% of that width.
2. Where the casting width is 70mm or more then the limiting defect will be
35mm.
3. Weld repairs should be undertaken on any casting where metal has broken
out.
4. Weld repairs should be undertaken as soon as possible to prevent further

propagation.
30 RAILTRACK
Withdrawn Document
GC/RC5522
Issue One
Appendix E
Discovery of Cracked or Broken Fishplates
E1 Table of Minimum
Actions
Appendix.
Defect Minimum action if fishplates cannot

be changed immediately
Both broken fishplates at a fishplated Impose 5mph and fit temporary rail
joint clamping system.
After fitting, section 6.6 of GC/RT5022
applies.
One broken fishplate at a fishplated Impose 20mph ESR.
joint Replace both fishplates within
24 hours (Category 1A, 1, 2 and 3
lines) or 48 hours (Category 4, 5 and
6 lines).
One or both cracked fishplates at a Replace both fishplates within
fishplated joint 24 hours (Category 1A, 1, 2 and 3
lines) or 48 hours (Category 4, 5 and
6 lines).
E2 Notes to table of
minimum actions
1. These minimum actions apply to all types of fishplates between all rail
sections.
2. The table sets out the minimum action. The situation at any particular joint
should be reviewed by a competent person and if necessary more restrictive
conditions applied.
3. Where present, the joint in the opposite rail should be complete, well
supported and with intact fishplates to enable trains to be passed over the
joint. If both joints have broken fishplates then the line should be blocked
until the fishplates are replaced.
4. Where there is any doubt as to the ability of the two sleepers either side of
the joint to hold the rail(s) to line, level and gauge where the fishplates are
broken, then it will be necessary to either (a) provide additional or alternative
support to the rails or (b) block the line until the fishplates are changed and
the defective sleepers are replaced. This is especially important where the
track is supported on concrete sleepers.
5. Both fishplates at a joint shall be replaced, even if only one of the fishplates
has been broken or cracked. All other components used to form the joint
shall also be replaced at the time the fishplates are changed. (GC/RT5022
section 8.3).
6. The cause of the broken or cracked fishplates should be investigated and

where causes are identified, action should be taken to prevent a recurrence.
RAILTRACK 31
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GC/RC5522
Issue One
References
GA/RT6001 Railway Group Standards Change Procedures
GC/RC5603 Standard Definitions of Civil Engineering Terms
GC/RT5022 Rails and Rail Joints
GC/RT5023 Categorisation of Track
GO/RT3000 Master Rule Book
The Catalogue of Railway Group Standards and the Railway Group Standards
CD-ROM give the current issue number and status of documents published by
the Safety & Standards Directorate.
32 RAILTRACK

GCRC5522 Iss 1 - Recommended Action To Be Taken N Discovery of A Broken or Defective Rail

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Issue Date Comments

Railtrack Approved Codes of Practice are non mandatory documents detailing

Health and Safety

The recommendations of this document apply to all running lines on Railtrack

a vertical or diagonal fracture through the full cross section;

Emergency bridging piece

Rolled AMS rails

Rolled non-AMS rails

Temporary rail clamping system

The recommendations were previously set out as mandatory requirements in the

The infrastructure controller should add to or modify the recommended actions

GC/RT5022 section 8.1

block the line;

the type of rail break;

The procedure shall require the line to be blocked if:

the break passes through a bolt hole;

The procedure shall require a watchman to be posted if equipment (for example

Recommended minimum actions to be taken upon the discovery of broken rails

GC/RT5022 section 8.2

The minimum actions shall include requirements for:

imposition of speed restrictions;

the type of rail defect;

The procedure shall require rails removed because of defects to be clearly

Recommended minimum actions to be taken upon the discovery of defects in

Recommended minimum actions to be taken upon the discovery of defects in

Recommended minimum actions to be taken upon the discovery of defects in

GC/RT5022 section 8.3

The minimum actions shall specify the requirements for:

imposition of speed restrictions;

whether the fishplate is broken or cracked;

The procedure shall require the cracked or broken fishplate to be permanently

When a cracked or broken fishplate is discovered, the actions required by the

Recommended minimum actions to be taken upon the discovery of broken or

8 Flame Cut Holes in

GC/RT5022 section 8.4

If a flame cut hole is found in a fishplate, a 20mph speed restriction shall be

This section of GC/RT5022 is self-explanatory and therefore there are no

GC/RT5022 section 8.5.1

temporary rail clamping systems;

the temporary clamping system shall be securely clamped to the adjacent

Use of emergency bridging pieces shall be subject to the following requirements:

the maximum permitted speed shall be 5mph;

A maximum permitted speed of 50mph is permitted over a short length of rail

GC/RT5022 section 8.5.2

This section of GC/RT5022 is self-explanatory and therefore there are no

Type of break See chart

Any part of the railhead broken away A1.2

Lower part of the rail broken away A1.3

Longitudinal split A1.4

Railhead damage A1.5

A1.1 Minimum action to be taken on discovery of a broken rail -

Transverse break through a plain rail or weld

Equipment Gap between At a At a welded <1.8m from a PDQG 3m from a

A1.2 Minimum action to be taken on discovery of a broken rail -

Any part of the railhead broken away

Equipment Length of At a At a welded <1.8m from a PDQG PIURPD

A1.3 Minimum action to be taken on discovery of a broken rail -

Lower part of the rail broken away

Equipment Length of At a At a welded <1.8m from a PDQG PIURPD

A1.4 Minimum action to be taken upon discovery of a broken rail -

Equipment Gap between At a At a welded <1.8m from a PDQG 3m from a

Equipment Length of At a At a welded <1.8m from a PDQG PIURPD

Equipment Length of At a At a welded <1.8m from a PDQG PIURPD