1、UIC Code 712Rth edition, January 2002Translation4Rail defectsDfauts de railsSchienenfehlerLeaflet to be classified in Section : VII - Way and WorksApplication :With effect from 1 January 2002All members of the International Union of RailwaysThis leaflet applies to standard gauge linesRecord of updat
2、es1st edition, November 1956 Compilation of the Catalogue of rail flaws and breakages for the useof track personnel.Compilation of the Withdrawal form for damaged and flawed rails.Compilation of the Standard statistical plan.2nd edition, June 1957 Preparation of a leaflet on rail defects.3rd edition
3、, January 1979 Completion of UIC Leaflet 712 - Rail defects (June 1959).Revision of UIC Leaflet 712 - Rail defects (May 1965).Revision of UIC Leaflet 712 - Rail defects (June 1978).4th edition, January 2002 Several types of defects added; main body of text and handbookincorporated in the leafletThe
4、person responsible for this leaflet is named in the UIC Code712R712RWarningNo part of this publication may be copied, reproduced or distributed by any means whatsoever, includingelectronic, except for private and individual use, without the express permission of the International Union ofRailways (U
5、IC). The same applies for translation, adaptation or transformation, arrangement or reproduction byany method or procedure whatsoever. The sole exceptions - noting the authors name and the source - are“analyses and brief quotations justified by the critical, argumentative, educational, scientific or
6、 informative natureof the publication into which they are incorporated“ (Articles L 122-4 and L122-5 of the French Intellectual Property Code). International Union of Railways (UIC) - Paris, 2002Printed by the International Union of Railways (UIC)16, rue Jean Rey 75015 Paris - France, January 2002Dp
7、t Lgal January 2002ISBN 2-7461-0339-7 (French version)ISBN 2-7461-0340-0 (German version)ISBN 2-7461-0341-9 (English version)712RContentsSummary 11 - Introduction . 22 - Handbook of Rail Defects. 33 - Withdrawal form for broken, cracked or damaged rails 44 - Rail defect statistics . 5Appendix A - Ch
8、ecklist of headings to be used when compiling a withdrawal form 6Appendix B - Handbook of rail defects 7B.1 - Definition of rail defects 7B.2 - Definition of recommendations . 7B.3 - Definition of the location of defects. 8B.4 - General coding of rail defects. 8B.5 - Rail defect coding system. 10B.6
9、 - Classification and numbering of rail defects . 11712R1SummaryThis leaflet contains recommendations for identifying and classifying rail defects and compilingstatistics. These defects are coded, described and illustrated in the Handbook of Rail Defects.Appendix B defines a standard system for clas
10、sifying broken, cracked and damaged rails accordingto the location, appearance and cause of the defects. It also explains ways and means of detectingsuch defects and recommends measures to be taken when rail defects are discovered in the track.1 - IntroductionIrrespective of the rules specific to ea
11、ch railway, track maintenance will always involve the removal ofa number of rails (or sections of rail) because of breakages or damage resulting from manufacturingdefects and/or traffic loads.It is therefore essential to monitor the behaviour of rails in the track closely, so that users andproducers
12、 can focus their efforts to improve the quality of the rails and at the same time the conditionsfor their use.For monitoring to be consistent, reliable and suitable for computer processing, those responsible formaintenance and the design offices of technical departments are reliant on the quality of
13、 theinformation provided by the staff involved locally in rail maintenance and inspection operations on thetracks.The information gathered must therefore be as precise as possible and must be communicated usingclear, precise documents in easy-to-use form.To harmonise the methods used for identifying
14、, notifying and classifying rail defects and producingstatistics, whilst also providing a basis for a constructive comparison of experience, it is recommendedthat UIC member railways: - make use of the “Handbook of Rail Defects“,- draw up a “withdrawal form of broken, cracked or damaged rails“ and c
15、ompile “statistics onrail defects“.712R22 - Handbook of Rail DefectsThe Handbook is intended for use by staff working on the track; with this in mind, it has beencondensed wherever possible.The introduction to the Handbook includes:- a definition of rail defects,- a definition of the recommendations
16、,- a definition of the location of the defects,- the general coding system for rail defects.For each type of broken, cracked or damaged rail there is a page giving one or more photographs ofthe defect in question and an explanatory text detailing, for each defect:- its characteristics and appearance
17、,- means of detection,- recommendations of a general nature that each railway can adapt to its own specific requirements.Because of the nature of certain defects, it is not always possible to establish their origin clearly froma visual inspection alone.In cases such as these, the origin of the defec
18、t can only be determined by further examination in thelaboratory.Any reference to the assumed causes of the defect has no bearing on the railways position with regardto the supplier where the guarantee is concerned.Using the coding system selected, it will be possible to produce statistics rapidly b
19、y processing theinformation gathered directly by computer.The Handbook is published by UIC Headquarters and available to UIC member railways.712R33 - Withdrawal form for broken, cracked or damaged railsThis is a basic document designed for easy completion by each railway.It is recommended that the d
20、ifferent points listed in appendix A - page 6 be recorded for each defect.A withdrawal form is filled out for any rail or section of rail, including connecting rails on points andcrossings, laid new on main line tracks1which has to be withdrawn prematurely because of breakage,cracking or damage, wit
21、h the exception of the following cases:- rails removed routinely due to wear,- damage resulting from a traffic incident,- special quality rails (not to specification),- machined rails.However, each railway shall still have the option of producing a withdrawal form to its ownrequirements for the case
22、s mentioned above and for replacement rails.NB : Withdrawal forms should also be completed for broken, cracked or damaged rails which arerepaired by laying a new section of rail and welds repaired in the track by welding, despite thefact that they remain in the track once the operation is completed.
23、1. According to the definition given in the “International Railway Statistics“ published annually by UICHeadquarters, “main line tracks are tracks providing end-to-end line continuity and used for working regulartrains between stations or places indicated in the tariffs as independent points of depa
24、rture or arrival for theconveyance of passengers or goods“.712R44 - Rail defect statisticsThe information supplied by the withdrawal forms constitutes a database that can be used forcompiling statistics.712R5AppendicesAppendix A - Checklist of headings to be used when compiling a withdrawal formNB :
25、 Items marked with an asterisk (*) should be considered the basic minimum.GENERAL INFORMATIONBreakage * or Cracking or damage*PRECISE LOCATION OF THE DEFECT IN THE TRACKLine *Track *Rail *Kilometre point *DATEDate the defect was discovered *Date the defect was repaired or the broken rail removed *HO
26、W WAS THE DEFECT DETECTED ?Ultrasonic testingOther means of detectionCHARACTERISTICS OF THE LINE AND TRACKLayout: Straight line * or Curve *Curve radius *UIC group classification *Maximum speed *Year laidMethod of laying: Standard sections * - Continuous welded rail * - with baseplates - without bas
27、eplatesType of sleepers : Wooden - Concrete - Metallic - Slab trackLocation : Open line - Tunnel (name)Type of joint : Ordinary - Junctioned - Insulated - Glued insulatedCHARACTERISTICS OF THE RAILRail condition: New or ReusedRail profile *Length of railLength of replacement railRolling marks (in re
28、lief)Stamped marks (embossed)Steel grade *Manufacturing process *Total gross tonnage borne * CHARACTERISTICS OF WELDS OR RESURFACINGYear carried outWeld removed or repairedLength of replacement railProfiles of the rails on either side of the weldSteel grade of the rails on either side of the weldRes
29、urfacing: at rail end or away from rail endCODE NUMBER OF DEFECTAs per the Handbook of Rail Defects *ACTION TAKENRail removed on or rail despatched to DESCRIPTION OF THE DEFECTSketch showing where the defect was located, with indication of its size.712R6AppendicesAppendix B - Handbook of rail defect
30、sB.1 - Definition of rail defectsThe following defects may occur in rails in the track:- damaged rail;- cracked rail;- broken rail.B.2 - Definition of recommendationsTo make the recommendations more easily understandable, the following set expressions are used:Keep rail under inspectionApplicable in
31、 case of defects that do not, at this stage, represent a hazard for operation.Removal of the railRemoval of the rail on occasion of a periodical or scheduled maintenance check. Applicable to defects that do not represent an immediate hazard for operation but could develop intoa potential hazard afte
32、r the date of removal. Immediate removal of the railMandatory removal of the rail within a deadline to be set according to the characteristics of the defect,and the local conditions. This removal is the subject of a special intervention. Applicable to defects representing a hazard for operation, but
33、 where the track nevertheless can be runif appropriate mesures are taken.Prohibition of traffic and immediate removal of the railApplicable to defects that do not permit any further use of the track, not even if special and provisionalmeasures are taken.Damaged rail:a damaged rail is any rail which
34、is neither cracked nor broken, but which has otherdefects, generally on the rail surface.Cracked rail:a cracked rail is any rail which, anywhere along its length and irrespective of theparts of the profile concerned, has one or more gaps of no set pattern, apparent ornot, the progression of which co
35、uld lead to breakage of the rail fairly rapidly.Broken rail: a broken rail is any rail which has separated into two or more pieces, or a rail fromwhich a piece of metal becomes detached, causing a gap of more than 50 mm inlength and more than 10 mm in depth in the running surface.712R7AppendicesComm
36、ents- Some rail defects are liable to worsen with time; where this is the case, a range ofrecommendations is made to cover the potential hazardousness of the defect at any given stage.- In all cases, the defect must be kept under observation and the appropriate recommendationsapplied until the defec
37、t is eliminated.- Ultrasound scans can be used:to detect certain internal defects,to check for possible internal growth of defects that originated at the surface.- Visual inspection can be used:to detect and monitor defects originating at the surface, to monitor the growth of defects in the track.B.
38、3 - Definition of the location of defectsRail defects may be located at the rail ends, away from the rail ends or in welding zones.B.4 - General coding of rail defectsBroken, cracked and damaged rails are given a code that may comprise up to 4 digits:Rail end: The part of the rail located at the lev
39、el of the fishplates.Zone away from rail end:Zone comprising all parts of the rail located away from the rail ends and fromthe welding zones.Welding zone: The welding zone stretches 10 cm to either side of the centre-line of rail welds,in other words 20 cm in all. Any defect of internal origin occur
40、ring in the zoneshall be classified as a welding defect. Defects of external origin shall beclassified according to their own specific codes.Rail ends Welding zone20 cmFishplate length712R8AppendicesThe first digit indicates:1. defects in rail ends;2. defects away from rail ends;3. defects resulting
41、 from damage to the rail;4. weld and resurfacing defects.The second digit indicates:- the place in the rail section where the defect originated;- the welding method, in the case of weld and resurfacing defects.The third digit indicates:- the pattern of the defect in the case of a broken or cracked r
42、ail;- the nature of the defect in the case of a damaged rail;- the cause of the defect in the case of a damaged rail.The fourth digit allows for a further classification based on the type of defect as and whenrequired.The general coding system for rail defects and the classification of the different
43、 types of defect areshown in the tables on points B.5 - page 10 and B.6 - page 11.Each defect is given a number and is described on a sheet indicating the characteristics andappearance of the defect, saying how it can be detected and giving recommendations as to whatmeasures should be taken once it
44、has been discovered. 712R9AppendicesB.5 - Rail defect coding system1st digit 2nd digit 3rd digit 4th digit1. Transverse2. Horizontal3. Longitudinal vertical4. Corrosion5. Passing through a hole6. Not passing through a hole9. LapPattern, nature0. Wear1. Surface defects2. Shelling3. Crushing4. Local b
45、atter5. Wheel burns7. Cracking and localsubsidence of therunning surfaceOrigin, cause1. Bruising2. Faulty machining3. Permanent deformation1. Transverse2. Horizontal or shellingAdditionalcharacteristicsand differentiations(no 4th digit)Location0. Full section1. Rail head3. Web5. Foot2. Surface of ra
46、il headSituation1. Rail ends2. Zone away from rail ends3. Defects caused bydamage to railLocation0. Full sectionWelding method1. Electric flash-butt welding2. Thermit welding3. Electric arc welding4. Oxyacetylene (autogenous)5. Pressurised gas welding6. Induction welding7. Resurfacing8. Other weldin
47、g methods4. Welding and resurfacingdefectsPattern, natureAdditionalcharacteristicsand differentiationswelding712R10AppendicesB.6 - Classification and numbering of rail defects1 Defects in rail ends10 Full section100 Transverse break without apparent origin11/12 Head111 Progressive transverse crackin
48、g (kidney-shaped fatigue crack)112 Horizontal cracking113 Longitudinal vertical cracking121 Surface defects122 Shelling of running surface123 Crushing124 Local batter of running surface125 Wheel burns13 Web132 Horizontal cracking1321 at the web-head fillet radius1322 at the web-foot fillet radius133
49、 Longitudinal vertical cracking (piping)134 Corrosion135 Star-cracking of fishbolt holes139 Lap15 Foot153 Longitudinal vertical cracking154 Corrosion712R11Appendices2 Defects away from rail ends20 Full section200 Transverse break without apparent origin21/22 Head211 Progressive transverse cracking (kidney-shaped fatigue crack)212 Horizontal cracking213 Longitudinal vertical cracking220 Wear:2201 Short-pitch corrugation2202 Long-pitch corrugation2203 Lateral wear2204 Abnormal vertical wear221 Surface defects222 Shelling2221 Shelling of the running surface2222 Shelling of the gauge c
