Focus on fasteners

As demand climbs among freight and passenger railroads, suppliers are providing improved fastening solutions to help hold things together.

{besps}July15_fasteners{/besps} {besps_c}0|1fasteners.jpg| Customer input was a main driver in the development of Pandrol’s FASTCLIP FE1505.{/besps_c} {besps_c}0|2fasteners.jpg| Lewis Bolt & Nut products being evaluated at TTCI in Pueblo, Colo.{/besps_c} {besps_c}0|3fasteners.jpg| Amsted RPS says 2015 has been a year of steady growth for the company.{/besps_c}

As demand climbs among freight and passenger railroads, suppliers are providing improved fastening solutions to help hold things together.

Railroads want products that provide cost savings and safety. Fastening system providers say that comes from products that last the life of the rail and boast ease of installation along with a host of other features.

Amsted RPS

John Stout, vice president of sales and marketing, says 2015 has been a year of steady growth for Amsted RPS as the company’s offerings continue to evolve to serve the needs of its customers.

“The Amsted RPS team takes tremendous pride in supporting our customers by delivering innovative new product solutions, like our ME Series for concrete tie fasteners and MACRO Armor for rail seat repairs. At the same time, we offer the broadest range of traditional fastening products, such as our rail anchors, System Wide bonded direct fixation fasteners and e-clips with unmatched quality and service,” said Stout.

“Our broad portfolio of fasteners and our in house state-of-the-art test lab has enabled our engineering team to fully understand the benefits and limitations of the current fastening designs,” said Jose Mediavilla, director of engineering.

Amsted RPS says it has translated this knowledge to develop the next generation of products to improve durability, maintainability and cost and points to its e-clip fastening system for concrete ties as an example of this.

Amsted RPS manufactures the e-clip in its Atchison, Kan., facility with a low stress bending process that the company says couples higher fatigue performance with advanced designs for the integrated rail pad, abrasion plate and insulator. The result, says Amsted RPS, is a product that leverages the structural might of the concrete tie and reduces the bearing pressure on the plastic components, which means less in-field maintenance and lower total cost.

The company says it has been working in the passenger space for more than 25 years to develop products that reduce ground borne vibration, while reducing the stiffness of the track structure. Amsted RPS calls the EGG direct fixation fastener the “go to” fastener for transit systems in need of a highly resilient fastener to mitigate noise transfer to adjacent buildings and structures. The company explains it has leveraged this experience into the development of the new Phantom ADFF6 direct fixation fastener for transit applications.

Scott Osler, director of transit sales, said “The Phantom ADFF6’s innovative design provides for a lightweight fastener with a standard anchor bolt pattern while having a stiffness profile that is on par or better than the most high resilient fasteners available.”

Amsted RPS says it has provided freight railroads with ballast mat for more than 20 years to protect concrete bridge decks, reduce ballast degradation, reduce ground born vibration and reduce the impact loads on bridges to extend the useful life of the structure. The company notes that when ballast mat is not feasible, its next generation Under Tie Pad (UTP) is available to provide resilience under the tie. Amsted RPS partnered with edilon)(sedra to bring its UTP to the North American market. The UTP is made of elastromer material and is available in either attrition or attenuation performance categories. Amsted RPS says both categories of UTP have been proven to extend the life of ballasted track and bridge decks.

Additionally, Amsted RPS offers the Loadmaster fastener to freight railroads for use on slab, steel deck and timber deck bridges to reduce the track modulus of the bridge and more closely match the track on the approaches to prevent low bridge ends and reduce maintenance.

“We have taken a two-pronged approach to improving the performance of concrete tie fastening systems: First, seek out, test and integrate new materials that provide improved impact and wear resistance to extend maintenance intervals and increase track availability. MACRO Armor is one such example that has extended the asset life of numerous concrete ties that would have required removal and replacement with traditional products. Secondly, we have employed new clip designs and modern manufacturing techniques for our ME (Skl) Series and e-clip Series of fasteners to impart less stress during the forming process and prevent tool marks from creating possible stress risers. In addition, Amsted RPS utilized a proprietary process to produce clips with minimal to no decarburization. Having no decarburization allow us to produce a more cost-efficient clip with a significantly higher fatigue limit compared to other Skl and e-clips available in North America,” said Stout.

L.B. Foster Company

According to Bill Treacy, general manager, Transit Products for L.B. Foster Company, 2015 looks to be another good year for the company’s fastener business.

“We continue to wind up deliveries for the Honolulu Area Rapid Transit project, which was the largest single order in company history. But we are also seeing a solid flow of other opportunities among a variety of North American transit agencies. For example, our efforts have recently shifted to the Dulles 2 project in the Washington, D.C., area. We are excited to continue to support projects that enhance the growth of our nation’s infrastructure. These projects come from three key areas: Ongoing maintenance programs, rehabilitation of existing lines and new lines and expansions. L.B. Foster continues to win its share of projects in all of these areas and I would expect to do so in the future,” said Treacy.

Looking longer term, Treacy added, “The use of heavy, commuter and light-rail modes of mass transit is growing. According to data from American Public Transportation Association, in 2014, ridership on those three forms of public transportation grew by 3.3 percent, hitting another all-time record for passenger trips. And over the past decade, that growth averaged 3.8 percent per year. With a younger population and the need for alternative forms of transportation like passenger rail, we expect that the use of mass transit will increase.”

He continued, “Opportunities will also evolve from the need to maintain the State of Good Repair (SGR) with the many aging rail transit systems in the U.S. But creative solutions to maintain SGR in the face of funding difficulties will be needed. Successful passage of the next transportation bill could help to clear up transit agency funding, as it appears that transit agencies do not have a clear view of the future. The current legislation, MAP-21, expired at the end of last September and we are working with the second extension of that bill. Right now, there is much uncertainty for sources to fund the next bill and its length, with seemingly conflicting rhetoric coming out of Washington, D.C.”

Treacy explained L.B. Foster’s technical efforts revolve around the development of new products for specific applications, which helps the company continue to meet the needs of transit agencies.

“For example, we are focusing on opportunities to extend the life of infrastructure components in severe environmental conditions like tunnels. Through the novel use of coatings we have several solutions involving application to specific elements of the fastener to dramatically reduce corrosion and significantly extend the life of the fastener under adverse environmental conditions. We can also develop unique solutions for heavy-haul rail applications. For example, some open deck railroad bridge approaches require resilient fastener solutions which we can provide,” he noted.

“We continue to collaborate with other global product teams within L.B. Foster to bring new initiatives and market opportunities forward,” said Treacy. “We also continue to establish a growing presence in global transit markets. Overall, we have a lot of optimism over the future of our fastening products and technologies as we consider the growth opportunities throughout the world and leverage internal collaboration to develop unique technical and product solutions.”

Lewis Bolt

Lewis Bolt & Nut Company says it continues to focus on innovation by creating new products or enhancing existing ones due to the Class 1 railroads’ need and desire for products that speed the repair or maintenance process while maintaining the safest possible environment in which to do the work.

Dave Barry, vice president of sales, points to the patented Lewis Evergrip® and Permagrip® spikes as examples of this.

“The Evergrip, because of its many advantages over traditional track or screw spikes, has become the largest selling screw spike in North America. Today, Lewis Bolt continues this theme with the introduction of the new patent pending Quick-Set® Hook Bolt System. This innovative new design completely eliminates the need to drill holes (which often form cracks and reduce tie life) for hook bolt installation. In addition, no longer is it necessary to lie on the tie deck and attempt to feed the bolts up through the holes. This is difficult, as well as unsafe. The new Quick-Set System is installed quickly and safely between the ties. The Hook Bolt, angled inward 15 degrees to keep the deck from moving laterally, fits through the accompanying bracket and is attached with a flat washer and nut. To install, you simply reach down, engage the flange while holding the bracket. Next, tighten the initial nut and flat washer, and follow with a Lewis Everlok® nut. High Strength Lewis Recessed Head Timber Screws are then inserted through bracket into the timbers. Your installation is now complete. The new design fully engages the flange so installation is as desired every time. It’s extremely easy to inspect by walking the deck and looking at the engaged system. Average installation time is approximately five minutes per bolt,” said Barry.

Pandrol

“Pandrol continues to see strong demand for its fastening systems in 2015. We supply products to more than 400 railways in over 100 countries. To date, Pandrol has manufactured more than two billion resilient fasteners worldwide and is the North American and global market leader,” states Allen Goff, vice president of Sales and Marketing for Pandrol USA.

“We are constantly working with our customers to address their needs with existing products, while evaluating new concepts to improve performance and develop ideas for creating future solutions,” said Goff.

“For example, Pandrol has developed its next generation of rail fastening assembly in response to our customers request for products to last the life of the rail. This new assembly is identified as FASTCLIP FE1505. The new design incorporates a recessed rail seat and two-piece integral pad that significantly extends the life of the components while maintaining the benefit of a slide on/slide off captive fastening system. The FE1505 is currently in track on test and is performing well,” said Goff.

He also notes demand for the VICTOR product line has grown significantly in the past year. VICTOR was developed for wood ties and utilizes a standard AREMA rolled steel tie plate equipped with a choice of premium elastic fasteners based on the customer’s preference.

“The increased market demand has prompted Pandrol to increase capacity by adding a second production line that has already been put into service. We have also expanded the product line to include both an 18-inch and 16-inch version set up for either screw or cut spike hole patterns,” said Goff.

Pandrol has also developed a new fastening assembly that the company says has taken the well-known ‘e’-clip to the next level.

“The new ‘e’-clip RE design offers all the familiar advantages of the original ‘e’-clip fastener, while incorporating a number of improvements. The new RE assembly provides faster installation times with fewer components while significantly increasing product life,” said Goff.

He continued, “In addition, Pandrol has introduced a new protective coating as an option to mechanical galvanizing that provides excellent protection while being environmentally friendly for all areas where corrosion is a concern.”

A few years ago, Pandrol established a plant in Bridgeport, N.J., in order to manufacture all of its plastic components in house. Goff says this move improved product availability and quality along with response times in developing new ideas to address customer needs.

“The plant is equipped with state-of-the-art production molding machines with one unit dedicated to rapid R&D prototyping, while robotics are used to reduce handling expense and improve efficiencies,” explained Goff.

“We recently acquired a three-dimensional printer that allows us to design, evaluate and review concepts with our customers. This process speeds up the turnaround time of getting a final product in track. Controlling the overall process from concept to final product provides greater flexibility in delivering the correct solution to the customer. However, we realize a product is not complete until it passes the true test of actually performing in daily service under real operating conditions,” he said.

Vossloh Fastening Systems

“Cost savings and safety are the decisive procurement arguments when it comes to infrastructure projects. Therefore, Vossloh’s new and further developed products emphasize extended life cycle and, hence, enhanced cost effectiveness,” explained Ron Martin, vice president and general manager, Vossloh Fastening Systems.

Martin says the rail fasteners developed by Vossloh for U.S. heavy-haul tracks contain weather-resistant special components (for use in sandy or wet areas, for example) that not only protect the track, but also the entire track superstructure from material fatigue and ensure stability even under high loads and in sharp curves.

“Thanks to easy installation and flexible subsequent equipment options, they minimize initial investments, as well as current operating and maintenance costs,” said Martin.

Martin sees the use of innovative materials, such as nylon components, as contributors to high economic efficiency. He offers the example of the sand penetration resistant design of the abrasion plate of the fastening system W 40 HH AP, which is made of fiberglass-reinforced polyamide, is abrasion-resistant and can be loaded with high contact pressure.

Martin notes that a high portion of durable nylon in the area of urban transport ensures corrosion protection and electrical insulation.

“In comparison to steel, lighter nylon material provides logistical advantages, easier installation and enhances occupational safety. This also helps in the reduction of metal theft,” said Martin.
He explains the company’s commitment to the North American market with the establishment of a plant in Waco, Texas, which makes state-of-the-art technologies locally available, meeting the requirements of the Buy American Act.

“The present customers of Vossloh already know and have benefited from the advanced abilities of our systems in helping to extend rail and tie life,” said Martin. “Additionally, the limited maintenance requirements of the track in general lead to better track stability, less rail movement and less wear on track material. The ease of the new designs being used and the method of load distribution have shown the system has superior abilities in these areas.”

Martin calls the Class 1 railroads annual investment for expansion, modernization and maintenance of their infrastructure remarkable and says Vossloh offers its customers a mutually complementary range of products and services from a single source, specifically tailored to their needs.

One of those needs is finding a deterrent to Rail Seat Abrasion (RSA). Martin says Vossloh’s system is one of the best and provides more firm holdings position of the rail for lateral and vertical rail movement.

“Taking into account the added performance to alleviate combined lateral and horizontal stresses and you’ll find the best performing system on the market. These advanced systems have shown to extend the life of the fastener to up to three rail cycles in some cases,” said Martin.

Vossloh says it has developed a new generation of fastening systems and components with the aim of prolonging the life cycle of the track.

“The height-adjustment plates have a new symmetrical design to ease installation; Vossloh’s new inclined pad is a low-cost alternative for W-switches with inclined rail on uninclined concrete ties for various track types. In this way, costly indirect fasteners with ribbed plates can be replaced,” said Martin. “The innovative screw/dowel combination NG with its smart load distribution ensures a significant reduction in lateral forces occurring. This leads to less stress on the ties and hence enhanced safety and cost-effectiveness.”