Track Fastening Systems
User Guide - Edition 8
Other PANDROL publications available
Pandrol FASTCLIP
system literature
Pandrol FASTCLIP
‘FE’ system
Provides detailed
information on installing
PANDROL FASTCLIP.
The literature describing
the new generation of
FASTCLIP.
Pandrol VANGUARD
Pandrol ‘Re’ system
Provides detailed
information on Pandrol’s
very resilient track form
for the highest vibration
mitigation.
Literature describing
the new ‘Re’ system for
re-railing applications on
older sleepers.
Pandrol VIPA
Pandrol SFC
baseplates
Provides detailed
information on Pandrol’s
noise and vibration
isolation system.
Pandrol
FASTCLIP Track
Installation Guide
Providing practical
instructions for the
safe installation of
the FASTCLIP system.
01
Pandrol Track Fastening Systems User Guide - Edition 8
Provides detailed
information about
SFC single resilience
baseplates.
Track Report 2011
The journal of Pandrol
Rail Fastenings 2011.
This technical magazine
contains authoritative articles
written by railway experts
from around the world
about high-profile rail
projects. It is published
every 12 to 18 months.
Contents
Introduction
03
Clip Applications & Colour Coding
04
Insulator Applications & Colour Coding
09
Pad Identification
15
Baseplates for Timber Sleepers
18
Concrete & Steel Sleeper Assemblies
19
Special Applications
22
Identification of Pandrol Hand-Tools
27
Use of Hand-Tools
36
Machines for automated installation
and extraction of FASTCLIP systems.
40
Track Support baseplates for
Noise & Vibration mitigation
41
Anchorage Systems for Pandrol Baseplates
45
Identification Chart for Anchorage Components
47
www.pandrol.com
02
Introduction and how to contact PANDROL
This guide is intended for use by all those involved in the specification,
installation and maintenance of Pandrol products for Network Rail in
the UK. The products and systems are not applicable to other railways
as system details vary between customers.
History of the Company
Pandrol is owned by the Delachaux Group and has been established in the business
of resilient rail fastenings since 1937. Our first rail fastening was the Elastic Rail Spike,
the very first resilient rail fastening for timber sleepers.
This was manufactured at Worksop, largely for export, with factories being opened in
South Africa and Australia in the early 1950’s. In the early 1960’s European railways began
to move to concrete sleepers fitted with continuous welded flat bottom rail. The classic
‘Pandrol’ PR clip was introduced at this time, firstly in the UK and then around the world.
In the mid 1970’s the Pandrol ‘e’ clip was introduced offering a higher clamping force at
a lower component cost due to more effective use of the steel section. During this period
the number of factories world wide increased to twelve.
In the early 1990’s the Pandrol FASTCLIP system was introduced which combined the
traditional virtues of the Pandrol system with pre-assembly of the fastening at the sleeper
factory. This has led to major productivity gains wherever it has been introduced in
particular with the new generation of automated track relaying equipment such as the
TRT and NTC machines.
New information since Edition 7
This edition of the booklet has been revised and many new products and systems have
been added, including:
1. Pandrol ‘Re’ system
2. ZLR systems for ‘rail free’ applications
3. Glue-in and replacement shoulders
4. Clips around IBJ’s.
5. Clips around ‘Balise’ units
6. More efficient and safer hand-tools for FASTCLIP
7.Expanded section on vibration mitigation baseplates for slab track and steel bridges
This booklet is intended to answer the most frequently asked questions relating to our
products. However, if further information is needed, Pandrol’s Customer Support Engineers
can be contacted for advice on:
T. 01909 476101
F. 01909 500004
03
E. support@pandrol.com
www.pandrol.com
Pandrol Track Fastening Systems User Guide - Edition 8
Clip Applications & Colour Coding
FINISHES: Clips are available with either STANDARD or CORROSION PROTECTION (previously called
SHERARDISED) finishes. CORROSION PROTECTION (CP) finish should be used in the following areas:
• Wet tunnels
• Coastal areas
Note: 10kN = 1 Tonne
• Level crossings
• Adjacent to heavily salted roads and platforms
Standard Finish: Green 57/48048
CP Finish: Purple 57/48055
Type: FC 1504
Used on G44 and EG47
concrete sleepers also
Series 560, 560H, 600, HH10,
Mk2 and HH12 steel sleepers.
Nominal toe load per clip = 10kN
Standard Finish: Red 57/48033
CP Finish: Grey Gloss 57/48056
Type: FC 1501
Used on F41 and EF36 concrete
sleepers and Series 500 steel sleepers.
Nominal toe load per clip = 10kN
Standard Finish:
Cat. No. not allocated.
CP Finish: Blue 57/02029
Type: FC 1503
Used only for Pandrol Type SFC baseplates
for slab track.
Nominal toe load per clip = 10 kN
www.pandrol.com
04
Clip Applications & Colour Coding
FINISHES: Clips are available with either STANDARD or CORROSION PROTECTION (previously called
SHERARDISED) finishes. CORROSION PROTECTION (CP) finish should be used in the following areas:
• Wet tunnels
• Coastal areas
Note: 10kN = 1 Tonne
• Level crossings • Adjacent to heavily salted roads and platforms
Type: e-Plus - eP20127
Standard Finish: Red 57/48237
CP Finish: Grey Gloss 57/48307
Standard Finish: Green 57/48236
CP Finish: Blue Gloss 57/48308
Standard Finish: Yellow 57/48252
CP Finish: Purple Gloss 57/48309
Standard Finish: Red 57/48469
CP Finish: Matt Grey
Cat No. Not allocated
Used on F27, EF28 and W402 sleepers where
extra resilience and insulator durability is
required. Fitted with integral
Type 9903 toe insulator.
Nominal toe load per clip = 12.5kN
Type: e-Plus - eP20129
Used on NR60 S&C, also on EG49
sleepers with 60E1 rail.
Nominal toe load per clip = 12.5 kN
Type: e-Plus - eP20130
Left hand version of eP20129.
Nominal toe load per clip = 12.5kN
Type: Re Clip - Re1609
Used on F23 to F27, EF28, 5EF28, W402
sleepers for re-railing operations, used
in conjunction with pad type 14229. Clip
is fitted with integral toe insulator not
separately available.
Nominal toe load per clip = 9 kN
05
Pandrol Track Fastening Systems User Guide - Edition 8
Standard Finish: Red 57/48255
CP Finish: Matt Grey 57/48031
Type: e1809
For use in F40 sleepers with a Blue (HVN)
insulator. For use in all other sleepers with an
Orange (Nylon) insulator. Must not be used
with Grey Cast Iron ‘PAN’ Type Baseplates.
Nominal toe load per clip = 9kN
Standard Finish: Yellow 57/48256
CP Finish: Black Gloss 57/48043
Type: e1810
Left handed version of e1809.
Used in IBJ’s in various situations, see page
25. Nominal toe load per clip = 9kN
Standard Finish: Purple 57/48247
CP Finish: Bright Red Gloss:
57/48044
Type: e2001
High toe load clip for F27/EF28 sleepers, used
in difficult areas where insulator crushing or
creep is occurring. Must be used with white
insulator, either type 2433 or type 6924.
Nominal toe load = 12.5 kN
Standard Finish: Blue 57/48248
CP Finish: Grey Gloss 57/48045
Type: e2007
High toe load clip which is interchangeable
with either PR401A or e1809 clip types.
Should NOT be used in applications fitted
with orange insulator type 724a.
Also used with IBJ’s in NR60 S&C. See page
25. Nominal toe load = 12.5 kN
CP Finish: Green 57/48587
Type: e2071
Clip only used for Zero Longitudinal Restraint
(ZLR), to convert the following sleeper
types to ‘rail free’ assemblies: F23 to F27,
EF28, 5EF28, W402, F40 & 5F40, with other
specialist components.
(See separate section on page 23)
www.pandrol.com
06
Clip Applications & Colour Coding
FINISHES: Clips are available with either STANDARD or CORROSION PROTECTION (previously called
SHERARDISED) finishes. CORROSION PROTECTION (CP) finish should be used in the following areas:
• Wet tunnels
• Coastal areas
Note: 10kN = 1 Tonne
• Level crossings • Adjacent to heavily salted roads and platforms
Type: PR401A
Standard Finish: Red 57/48239
CP Finish: Matt Grey 57/48253
Standard Finish: Blue 57/48243
CP Finish: Grey Gloss 57/48234
Standard Finish: Purple 57/48245
CP Finish: Bright Red Gloss
57/48242
Standard Finish: Green 57/48244
CP Finish: Yellow Gloss 57/48249
For concrete sleepers and all PAN
plates EXCEPT obsolete PAN1 to PAN5 where
PR303 clips were used.
Nominal toe load per clip = 6.5kN
Type: PR402A
Left handed version of PR401A.
Nominal toe load per clip = 6.5kN
Type: PR427A
Maintenance replacement for PR303
in PAN 1 to PAN5 baseplates.
NOT suitable for other types of baseplate.
Nominal toe load per clip = 6.5kN
Type: PR428A
Maintenance replacement for left handed
PR304 in PAN 1 to PAN5 baseplates.
NOT suitable for other types of baseplate.
Nominal toe load per clip = 6.5kN
07
Pandrol Track Fastening Systems User Guide - Edition 8
Left-Handed Clips
Non-symmetrical clips (‘PR’, ‘e’, ‘e-PLUS’, & ‘Re’) are normally ‘right-handed’ and should be inserted into the shoulder
anchor point from the right-hand side of the shoulder, when facing the rail. Left-handed variants are required in
areas of restricted access around the shoulders, and are fitted from the opposite end of the shoulder
(i.e the left-hand side of shoulder). Left-handed clips are typically needed around IBJ’s and S&C layouts.
The equivalence chart below shows which clips are interchangeable between the standard right-handed
and left-handed variants.
Right-Handed Clips
Equivalent Left-Handed Clips
PR401A
PR402A
PR427A
PR428A
e1809
e1810
eP20129
eP20130
Standard Finish: Red 57/48450
CP Finish: Matt Grey 57/48046
Type: PANLOCK
Clip for Bull Head Rail
Catalogue No. 57/48781
A1 Spike
Original A1 Elastic Rail Spike.
Elastic spikes are only supplied in Standard finish. The A1 spike is red colour.
Catalogue No. 57/48785
AL23 Maintenance Spike
Maintenance replacement for A1 Spike
Elastic spikes are only supplied in Standard finish. The AL23 spike is supplied in two
parts. The inner part is black and the outer part is red, and fit together as shown.
www.pandrol.com
08
Insulator Applications & Colour Coding
FASTCLIP Type 8582
Catalogue Number: 57/48064
Sidepost Insulator (Blue)
16.4mm sidepost thickness. For use on the
FIELD side of the 56E1 rail when fitted to
G44, EG47, Series 560, 560H, 600, HH10
Mk2 and HH12 sleepers. Also used to replace
obsolete insulator type 9373 previously used
for hook-in shoulders with steel sleepers.
FASTCLIP Type 7551
Catalogue Number: 57/48021
Sidepost Insulator (White)
8mm sidepost thickness. Used on G44, EG47,
Series 560, 560H, 600, HH10 Mk2 and HH12
sleepers with 60E1 rail. Used on F41, 5F41,
5EF36 and Series 500 steel sleepers with 56E1
rail. Also used to replace obsolete insulator
type 8914 previously used for hook-in
shoulders with steel sleepers.
FASTCLIP Type 8690
Catalogue Number: 57/48066
Sidepost Insulator (Black)
10mm sidepost thickness. For use on the
GAUGE side of the 56E1 rail when fitted
to G44, EG47, Series 560, 560H, 600, HH10
Mk2 and HH12 sleepers. Also used to replace
obsolete insulator type 9374 previously used
for hook-in shoulders with steel sleepers.
FASTCLIP Type 8691
Catalogue Number: 57/48067
Sidepost Insulator (Green)
6mm sidepost thickness. Used in limited
areas where oversize 60E1 rail was
supplied. Used in place of the GAUGE side
Type 7551 sidepost Insulator.
09
Pandrol Track Fastening Systems User Guide - Edition 8
Catalogue Number: 57/48118
FASTCLIP Type 8277
Side post insulator (Yellow)
13mm sidepost thickness, for use on HH10
Mark 1 sleepers with Type 9922 hook in
shoulders.
Catalogue Number: 57/48111
e-PLUS Type 9132
Sidepost Insulator (Blue)
Used with eP20127 clip on F27, EF28, W402
sleepers and NR56V S&C.
Catalogue Number: 57/48294
e-PLUS Type 9875
Sidepost Insulator (White)
Used with eP20129 clips on F40
sleepers and NR60 S&C.
Catalogue Number: 57/48114
e-PLUS Type 9877
Gauge Management Insulator (Black)
10mm sidepost insulator, used for NR60 S&C.
Catalogue Number: 57/48115
e-PLUS Type 9876
Gauge Management
Insulator (Green)
6mm sidepost insulator, used for NR60 S&C
www.pandrol.com
10
Insulator Applications & Colour Coding
FASTCLIP Type 8494
Catalogue Number: 57/48020
Toe Insulator (White)
For use on all sleeper types fitted
with the FASTCLIP system.
e-PLUS Type 9903
Catalogue Number: 57/48113
Toe Insulator (White)
Previously coloured blue. Not supplied
separately, always supplied already fitted
to the e-PLUS clip types
Orange (Nylon) Type 724a
Catalogue Number: 57/48424
5mm sidepost thickness x 5mm blade
thickness. Used for: F23 , F24 series, EF25,
F27, EF28, EF29, EF32, EF33, F34, F35
concrete sleepers and 400 series, steel
sleepers with 56E1 or BS110A
or BS110A rails.
Blue (Nylon) Type 724a
Catalogue Number: 57/48423
5mm sidepost thickness 5mm blade thickness
used where 98lb and 109lb rail is installed.
Used for concrete sleeper types: F23, F24,
EF25, F27, EF28, EF29, EF33, F34, & F35, as
well as steel sleepers 400 Series. NOTE: This
insulator is not commonly available, and can
be replaced with Pandrol type 6924 provided
this is used with clip type e2001.
11
Pandrol Track Fastening Systems User Guide - Edition 8
Catalogue Number: 57/48027
Blue (GRN) Type 4452.
8mm sidepost thickness x 8mm blade
thickness used on: F40 and 5F40 sleepers
Catalogue Number: 57/48436
White (GRN) Type 2433
5mm sidepost x 8mm blade thickness
(previously coloured black) used with e2001
clip. Also used on F40 & 5F40 sleepers as part
of the range of gauge management insulators
to adjust the track gauge, by moving the
rail across the rail seat. This insulator can be
upgraded to use HVN by substituting insulator
type 6924, which is an identical size.
Catalogue Number: Not allocated
White Type 6924
White (HVN) type 6924, 5mm side post x 8mm
blade thickness used with e2001 clip. Also can
be used with NR56V S&C to replace composite
insulators. This HVN insulator is sufficiently
flexible to be used as a replacement for Blue
nylon insulator Catalogue No. 57/48423 with
either 98lb or 109lb rail, but can ONLY be used
with e2001 clips
Catalogue Number: 57/48434
Brown(HVN) Type 7583
12mm sidepost x 8mm blade thickness.
Used as part of the range of Pandrol insulators
to provide gauge management by adjusting
the position of the rail in the rail seat.
A separate data-sheet is available to advise the
methods and adjustment range achievable.
Gauge management can be provided for
concrete sleeper types: F40, & 5F40.
www.pandrol.com
12
Insulator Applications & Colour Coding
Red (HVN) Type 10274
Catalogue Number: 57/48082
Insulator for 56E1
rail on FIELD side of:
1. NRS1/NRS2/Combi baseplates
2. EG49 concrete sleepers
Yellow (HVN) Type 10275
Catalogue Number: 57/48081
Insulator for 56E1
on GAUGE side of:
1. NRS1/NRS2/Combi baseplates.
2. EG49 concrete sleepers
Green (HVN) Type 5720
Catalogue Number: 57/48060
Insulator for use with 60E1
rail using:
1) NRS1/NRS2/Combi baseplates
with 60E1 rail.
2) 6 Hole IBJ’s on NR60 S&C
3) EG49 Concrete sleepers
Composite
Catalogue Number: 57/48427
(Nylon with cast iron cover plate) for:
1. Concrete S&C bearers.
2. As a substitute for ORANGE (Nylon)
insulators where the wear rate is
unacceptable. NOTE. This insulator is not
commonly available, and can be replaced
with Pandrol type 6924 provided this is
used with clip type e2001.
13
Pandrol Track Fastening Systems User Guide - Edition 8
Catalogue Number: 57/48166
Composite (Black) Type 2786/1
6mm sidepost thicknesses
Catalogue Number: 57/48167
Composite (Blue) Type 2786/2
7.5mm sidepost thicknesses
Catalogue Number: 57/48168
Composite (Red) Type 2786/3
9mm sidepost thicknesses
Catalogue Numbers:
4mm = 57/48169 8mm = 57/48170 12mm = 57/48171
Composite Cover Plates
Composite cover plates Type 2787,
to provide 4, 8 and 12mm blade thicknesses
Catalogue Number depends upon insulators
and cover plates selected
Composite Insulators
For level and gauge adjustment
on slab track installations.
Plastic insulators and metal cover plates
are combined to give a variety of blade
and sidepost thicknesses.
www.pandrol.com
14
Pad Identification
PANDROL pads are an important part of the rail fastening system. Rail pads provide a conforming
layer between the rail seat and the rail, provide electrical resistance, and protect concrete sleepers
from impact loading.
Modern pads are 10mm thick. Low stiffness studded rubber pads are used for 25t axle loads on
concrete sleepers. Stiffened pads are used for 30t axle loads on concrete sleepers to prevent excessive
dynamic gauge widening. Steel sleepers use hard EVA pads of 10mm thickness.
Pad No. 14229
Catalogue Number: 057/48470
Studded EVA rail pad 8mm thick
bonded to HVN side insulators of
5.5mm thick.
Used with ‘Re1609’ clip for ‘re-railing’
to replace orange insulators on
older sleeper types F23 to F27, EF28,
5EF28, W402, HH10 (Mk1).
Pad No. 2061/3
Catalogue Number: 57/48521
Thickness: 5mm
Material: Flat EVA
Used with W402 sleepers and PAN
baseplates.
Can also be used with concrete
sleeper types: F23, F24 ,EF25, F27,
EF28, EF32, EF33, F34, F35.
Pad No. 9970
Catalogue Number: 57/48077
Thickness: 10mm
Material: Studded EVA
Used on FASTCLIP steel sleepers
with 60E1 rail.
Supersedes / interchangeable
with 7850.
15
Pandrol Track Fastening Systems User Guide - Edition 8
Catalogue Number: 57/48278
Pad No. 8531
Thickness: 10mm
Material: Studded EVA
Used on FASTCLIP steel sleepers
56E1 rail.
Catalogue Number: 57/48028
Pad No. 4548
Thickness: 10mm
Material: Studded Rubber
Used on F40 and 5F40 sleepers.
Catalogue Number: 57/48271
Pad No. 6650
Thickness: 10mm
Material: Studded Rubber
Used on FASTCLIP concrete
sleepers with 56E1 rail.
Catalogue Number: 57/48254
Pad No. 8854
Thickness: 10mm
Material: Studded Rubber
Used on FASTCLIP concrete
sleepers with 60E1 rail.
www.pandrol.com
16
Pad Identification
Pad No. 9286
Catalogue Number: 57/48441
Thickness: 8mm
Material: Studded Rubber
Used on F27 and EF28
sleepers when fitting
the e-Plus system.
Pad No. 9328
Catalogue Number: 57/48293
Thickness: 10mm
Material: Studded Rubber
Used on e-Plus RT60
and NR60 layouts.
Pad No. 5197
Catalogue Number: 57/48088
Thickness: 10mm
Material: Studded Rubber
Used on EG49 sleepers with
either 56E1 or 60E1 rails.
Pad No. 7031
Catalogue Number: 57/48613
Thickness: 10mm
Material: Studded Rubber
Used on NRS1, NRS2,
and Combi baseplates.
17
Pandrol Track Fastening Systems User Guide - Edition 8
Baseplates for Timber Sleepers
Baseplate
Types
Pandrol
Clips Used
Originally fitted with
PAN 1 to PAN 5 PR303, can be fitted
with PR427A x 2
PAN 1 to PAN PR401A x 2
12 and PAN 14
Number
of Pandrol
Housings
4
Either 2 or 4
CC PAN 1 - 44
PR401A x 1
PR402A x 1
2
HO PAN
PR401A X 1
PR402 X 1
2
PAN 14SG
e1809 x 2
4
Various other
baseplates
including:
V, VN, CV, RCV
PR401A x 2
Either 2 or 4
NRS1 & NRS2,
or Combi
baseplates
e2007
The Vortok Coil is used to refurbish
timber sleepers with worn screw spike
holes. The coils restore 90% of both
the original pull-out strength and
the torque of the screw to improve
the positioning and dynamic gauge
performance of the baseplates.
2
Comments
Baseplates no longer available.
Only 2 housings and clips should be used
Only 2 housings and clips should be used in any of these
baseplates. Note the extra housings should only be used
in the event of the first housings wearing or failing
Check rail baseplates
Only 2 housings should be used.
Only use ‘e’ clips with SGI grade cast-iron.
Only 2 housing should be used in any of these
baseplates.
Dual rail baseplate for either 56E1 or 60E1/2.
Other components:
• Pad Type 7031
• Insulator Types: 60E1 = 5720 56E1 = 10274 & 10275
Catalogue No’s: S tandard Coil 057/048034
Large Coil 057/048298
www.pandrol.com
18
Concrete & Steel Sleeper Assemblies
Sleeper Type(s)
Clip
Insulators
Pad
Design
Track Gauge
Current CONCRETE sleepers
G44, EG47
for 56E1 rails
FC1504 with
8494 toe
G44, EG47
for 60E1/2 rails
FC1504 with
8494 toe
Pad 6650, except:
• Curves less than 400m
radius, fit EVA type 8531
FIELD side: 8582 (Blue)
GAUGE side: 8690 (Black) • Low line speed, fit EVA
type 8531
Pad 8854, except:
• Curves less than 400m
radius , fit EVA type 9970
Both sides: 7751 (White)
• Low line speed, fit EVA
type 9970
1436mm
1438mm
Current STEEL sleepers
560H for
56E1 rails
NOTE. This sleeper is
fitted with hook-in
shoulder type 9482.
560H for
60E1 / 2 rails
NOTE. This sleeper is
fitted with hook-in
shoulder type 9482.
19
FC1504 with
8494 toe
FIELD side: 8582 (Blue)
Pad 8531
GAUGE side: 8690 (Black)
1436mm
FC1504 with
8494 toe
Both sides: 7751 (White) Pad 9970
1438mm
Pandrol Track Fastening Systems User Guide - Edition 8
Concrete & Steel Sleeper Assemblies
Sleeper
Type(s)
Clip
Insulators
Pad
Design
Track Gauge
Discontinued / serviceable older CONCRETE sleeper types
EG49 for
56E1 rails
e2007
FIELD side: 10274 (Red)
GAUGE side: 10275 (Yellow)
Pad 5197
1436mm
EG49 for
60E1/2
e2007
Both sides: 5720 (Green)
Pad 5197
1438mm
F41 & EF36
FC1501 with
8494 toe
Both sides: 7751 (White)
Pad 6650, except:
• Curves less than 400m
radius, fit EVA type 8531
• Low line speed, fit EVA
type 8531
1435mm
e1809
Both sides: 4452 (Blue)
Pad 4548
1432mm
1435mm
F40
5F40
Alternative assemblies for F23 to F27, EF28, EF29, EF33 sleepers:
Pad 5mm rubber,
or 7.5mm rubber
maintenance pad,
or EVA Pandrol type
2061/3.
1. S tandard
toe-loads
PR401A or
e1809
56E1 rail:
Both sides: 724a (Orange)
98lb or 109lb rails:
Both sides: 724a (Blue)
2. I ncreased
toe-loads
e2001
56E1 rails:
Pad 5mm rubber or EVA
Both sides: 2433 (GRN White),
pad type 2061/3
or 6924 (HVN White)
1432mm
3. e-PLUS system eP20127
56E1 rails:
Both sides: 9132
Pad 9286
1432mm
4. Pandrol
‘Re’ system
56E1 rails:
No separate insulator
Composite pad type 14229
1432mm
Re1609
1432mm
www.pandrol.com
20
Concrete & Steel Sleeper Assemblies
Sleeper Type(s)
Clip
Insulators
Pad
Design
Track Gauge
Discontinued / serviceable older STEEL sleeper types
HH10 (Mk 2), HH12,
for 56E1 rails
FC1504 with
Shoulder types:
8494 toe
• HH10 = shoulder 9922
• HH12 = shoulder 9482
FIELD side: 8582 (Blue)
GAUGE side: 8690 (Black)
Pad 8531
1436mm
HH10 (Mk 2), HH12,
FC1504 with
for 60E1/2 rails
• HH10 = shoulder 9922 8494 toe
• HH12 = shoulder 9482
Both sides: 7751 (White)
Pad 9970
1438mm
500 Series
FC1501 with
8494 toe
Both sides: 7751 (White)
Pad 8531
1435mm
W402 Series
HH10 (Mk1)
for 56E1 rail
PR401A
or e1809
56E1 rail:
Both sides: 724a (Orange)
Pad 5mm EVA
1435mm
Pandrol type 2061/3.
Both sides: 8277 (Yellow)
Pad 8531
Alternative assembly
converting HH10 (Mk1) FC1504 with
to FASTCLIP system
8494 toe
using shoulder type
9922
1435mm
Conversion of obsolete fastenings on very old concrete sleepers
The following obsolete
sleepers may be
converted to Pandrol
‘e’ clip assemblies:
• F10 using BJB
fastenings
• RNB6 also known as
KENITRA sleepers
• HEYBACK sleepers
21
Whilst conversions have been available and undertaken in large volumes in the past,
the components are no longer readily available, generally regarded as uneconomic,
and anyone attempting this process should contact Pandrol directly for advice.
Pandrol Track Fastening Systems User Guide - Edition 8
Special Applications
1. Replacement shoulders for concrete and steel sleepers, and concrete
slab track. This identifies the shoulders to be used for replacement in the
unlikely event of damage in track.
Shoulder Type
Shoulder type 8888R
Sleeper Type(s)
Catalogue No. Not allocated
Modification of standard shoulder.
Shoulder type 9922
Comments
G44, and EG47
HH10
This shoulder is ONLY available as
part of a complete supply and replacement service provided through the
approved specialist subcontractor
HOLEMASTERS.
Hook-in shoulder for 10mm thick
steel sleepers.
Catalogue No. 057/048072
Shoulder type 9482
HH12, 560H Series.
Hook-in shoulder for 12mm steel
sleepers.
Catalogue No. 057/048073
Shoulder type 7250
Concrete slab track
Standard finish:
Catalogue No. 057/048071
For slab track in tunnels:
Sherardised finish
Catalogue No. 057/048063
For use with 10mm pads and either:
‘e’ clip assembly using GRN insulator
type 4452 (blue)
Or
e-PLUS assembly using eP20129
www.pandrol.com
22
Special Applications
2. Zero longitudinal restraint (ZLR) assemblies to provide ‘rail free’
longitudinal movement of the rail.
Used to provide differential movement between the rails and long
bridge structures, or stressing relief for ground subsidence due to
mining activities.
ZLR assemblies use normal toe-load clips, but divert the clamping force
in other directions providing a gap over the rail foot and allowing the
rail to slide longitudinally in the gap. In the event of the rail moving
to close gap (such as ‘rail roll’) the nominal toe-load is immediately
available to prevent further overturning movement.
The components below can be used with existing sleeper
configurations to alter the fastening assembly into a ZLR assembly.
Sleeper
Type(s)
Pandrol
Assembly No.
F23 to F27,
EF28 5EF28,
and W402
15206
(covers all
sleeper types)
F40 and 5F40
23
15207
(covers all
sleeper types)
Components & Catalogue Nos.
EVA 5.5mm pad type 2061
Cast-iron cover plate
type 7015
Clip type e2071 NOTE:
Sherardised finish ONLY
Catalogue Number:
057/048521
Catalogue Number:
057/048586
Catalogue Number:
057/048587
EVA 10mm pad type
12697
Cast-iron cover plate
type 7015
Clip type e2071 NOTE:
Sherardised finish ONLY
Catalogue Number:
057/0485588
Catalogue Number:
057/048586
Catalogue Number:
057/048587
Pandrol Track Fastening Systems User Guide - Edition 8
Special Applications
Sleeper
Type(s)
Pandrol
Assembly No.
G44, EG47
and EG47-3R
15208 for
56E1 rail
15229 for
60E1 / 2 rail
Components & Catalogue Nos.
EVA 10mm pad type 8531
Sub-assembly 15227 comprising clip type FC1504
with ZLR insulator
Catalogue Number:
057/048287
Catalogue Number: 057/048589
NOTE: The ZLR insulator is BLACK
EVA 10mm pad type 9970
Sub-assembly 15227 comprising clip type FC1504
with ZLR insulator
Catalogue Number:
057/0485587
Catalogue Number: 057/048589
NOTE: The ZLR insulator is BLACK
www.pandrol.com
24
Special Applications
3. Insulated Block Joints
FASTCLIP with IBJ’S
6-hole IBJ on concrete sleeper type EG47.
6-hole IBJ on steel sleepers,
showing standard FASTCLIP components.
The clips fit snuggly into the recesses of the IBJ,
and clip extraction is carried out using
a rear-arch FASTCLIP extractor.
‘e’ Clips with older concrete sleepers
6-hole IBJ on older types of concrete sleepers.
The clips should be:
Right handed locations: e1809
Left handed locations: e1810
Both clip types are used with orange
or composite insulators , except for F40 sleepers
which use blue GRN type 4452 insulators.
Other clips with S&C layouts
NR60 details in e-PLUS (eP20129) layout. NOTE:
e-PLUS clips do not fit beneath the
IBJ bolts. The clips should be:
Right handed locations: e2007
Left handed locations: e1810
Both clip types are used with green
insulator type 5720
In layouts to NR56V design the IBJ will be mounted
on 8mm thick pads, and the clips should be:
Right handed locations: e2001
Left handed locations: e1810
Both clip types are used with orange
or composite insulators.
25
Pandrol Track Fastening Systems User Guide - Edition 8
Special Applications
4. Anchorage for ‘Balise’ mounting frames.
Vortok Balise Mounting System (BMS)
The Vortok BMS is fitted to either concrete or steel sleepers using the rail
clips to hold the beams in place between the shoulders of the sleepers.
The beams are used with either ‘e’ clip or FASTCLIP as shown below.
Balise units on FASTCLIP sleepers TYPES G44 / EG47, F41 & EF36
The frame sits beneath the rear arch of the standard FASTCLIP in each sleeper type.
‘e’ Clips with older concrete sleepers
The frame is anchored in
position using Pandrol clip type
e2001. The new clip should
replace the original clip on the
GAUGE side of the rail seat, and
is usually supplied as part of
the BMS system by Vortok.
www.pandrol.com
26
Identification of Pandrol Hand-Tools
The new range of FASTCLIP tools also for VIPA-SFC
The new tools, which react from the rail, are more efficient, faster and safer because they are not prone
to slipping from the shoulder reaction points. Additionally, the tools offer compatibility with a wide
range of Pandrol systems, including FASTCLIP ‘FC’ & FASTCLIP ‘FE’ and the Pandrol baseplate types VIPA-SP
& SFC baseplate. Finally, because the reaction point for the installation tool has been moved to the head
of the rail, the installer is able to lift sleepers (about 20mm) as part of the normal action of the tool,
lifting from the rear arches of the clip before driving the clip into the installed position.
Installer (FASTCLIP ‘FC’, ‘FE’, VIPA-SP, SFC)
FASTCLIP Installer LP18681
Catalogue No. 39/47850
Extractor (FASTCLIP ‘FC’, ‘FE’, VIPA-SP, SFC)
FASTCLIP Installer LP18679
Catalogue No. 39/47851
The original version of the sleeper
lifter can still be used in conjunction
the new installer where sleepers need
to be lifted more than 20mm.
The rear arch extractor remains
available to extract clips around IBJ’s.
Sleeper lifter for FASTCLIP ‘FC’, & ‘FE’
PANDROL No. LP12608
Catalogue No. 39/47852
27
Pandrol Track Fastening Systems User Guide - Edition 8
Rear arch extractor
for FASTCLIP ‘FC
PANDROL No. LP15177
Catalogue No. not allocated
Discontinued FASTCLIP and VIPA-SP tools.
The original versions of the FASTCLIP hand-tools are illustrated below, and these remain suitable for use.
Pandrol has discontinued the original versions from sale.
The original FASTCLIP tools have now been superseded with new tools which are more efficient,
faster to use and safer. Both of the new tools look different from the earlier tools, because they
react from the rail instead of from the shoulder in the sleepers. See the section on the opposite page.
The original versions of the VIPA-SP & SFC hand-tools are illustrated below, and these remain suitable
for use. Pandrol has discontinued the original versions shown below.
The original VIPA-SP tools have now been superseded with new tools which are more efficient, faster to
use and safer. See FASTCLIP hand-tools on the opposite page The new tools are compatible with FASTCLIP
‘FC’ and FASTCLIP ‘FE’ systems, as well as VIPA-SP & SFC baseplates, reducing the risk of the selecting the
incorrect tools.
www.pandrol.com
28
Hydraulic tools for VANGUARD and FASTCLIP
Vanguard Hydraulic Tool
PANDROL No. LP15647
Catalogue No. Not Allocated
Vanguard Installer & Extractor
Refer to separate Pandrol instructions for the use of the VANGUARD hydraulic tool.
FASTCLIP Hydraulic Tool
RAILTECH TYPE CDH 16
Catalogue No. Not Allocated
Rosenqvist Handy Clipper
(Network Rail Acceptance Certificate PA05/03211)
A versatile lightweight clipping/unclipping machine
dedicated to Pandrol FASTCLIP. With one man operation, the
Handy Clipper is easily transported to site and will fit in the
back of an estate car.
It incorporates automatic sleeper lifting of up to 10mm.
At maximum output 10 sleepers a minute can be achieved.
29
Pandrol Track Fastening Systems User Guide - Edition 8
Identification of Pandrol Hand-Tools
Catalogue Number: Not Allocated
PANPULLER Type D For PR, & e Clips
PANDROL No. LP7632
Especially for e2001 and e2007clips but NOT
for 4-shoulder baseplates. NOTE hook positions
for max efficiency:
Upper pivot: Clip installation
Lower pivot: Clip extraction
Catalogue No. 39/42748
PANPULLER Type C for PR, & e Clips
PANDROL No. LP1180
And for 4 shoulder baseplates
Catalogue No. Not allocated
e-PLUS PANPULLER LP12717
PANDROL No. LP12717
Colour: Red working head (matches the
appropriate e-PLUS clip type), and yellow
handle. For use with eP20127 clips for
retrofitting to sleeper types: F27, EF28, 5EF28,
and for the new S&C designs to NR56V.
Catalogue No. 39/42749
e-PLUS PANPULLER LP15923
PANDROL No. LP15923
Colour: White
The tool is used with the eP20129 green
or eP20130 yellow e-PLUS clips, mostly
with RT60 and NR60 S&C layouts.
www.pandrol.com
30
Replacement Hook for Types
C and D PANPULLER
Catalogue No. 39/42743
PANDROL No. 3-P2260
Replacement Hooks e-Plus
PANPULLER’S
LP12717 - Catalogue Number: Not Allocated
LP15923 - Catalogue Number: 39/42742
PANDROL No. LP12717
use replacement hook type 2P5931
PANDROL No. LP15923
use replacement hook type 3P16127
PANPULLER Hook Wear - Gauge
Catalogue No. 39/30100
PANDROL No. 3-P6536
Use of Wear Gauges
• Place curve of gauge into hook. Gauge can be used with out removing
the hook from the PANPULLER.
• Surfaces ‘A’ and ‘C’ in contact and gap at ‘B’ Hook suitable for use.
• Surfaces ‘B’ and ‘C’ in contact and gap at ‘A’ Hook unsuitable for use.
Replacement Hooks
for e-Plus PANPULLER:
Catalogue Number 39/42742
Pandrol Number 3P16127
Replacement Hooks
for Standard PANPULLER:
Catalogue Number 39/42743
Pandrol Number 3P2260
It is recommended for safety reasons that contractors should formally check and record the wear of the hooks at
intervals of 6 months using the wear gauge described above. The gauge is suitable for all types of PANPULLER
or e-PLUS PANPULLER. The wear gauge provides easy Go / No-Go assessment of when to replace the hook.
Worn hooks have a tendency to slip off the clips, which can present a significant risk to operators.
31
Pandrol Track Fastening Systems User Guide - Edition 8
Identification of Pandrol Hand-Tools
Catalogue No. 39/42900
PANSETTER for PR, e, e-PLUS
& Re clips
PANDROL No. 2-P9559
THE PANSETTER is suitable for all Network Rail
Sleepers fitted with PR, e & e-PLUS
Optional Handles Catalogue Nos. for tools with straight insulated handles.
All Pandrol hand-tools can be supplied with optional
insulated handles, which have recently been upgraded to
35mm diameter cylindrical handles with ‘T’ cross bars for
improved ergonomic and safer use. The photograph shows
a typical handle attached to a FASTCLIP sleeper lifter.
PANPULLER type ‘C’:
Catalogue No. 39/40129
PANSETTER:
Catalogue No. 39/40133
PANLOCK Puller:
Catalogue No. 39/40135
FASTCLIP installer:
Catalogue No. not allocated
FASTCLIP extractor:
Catalogue No. not allocated
FASTCLIP lifter:
Catalogue No. not allocated
Tools with cranked handles for operation in the 4-foot.
A further option is available on Pandrol hand-tools for
operation whilst standing in the 4-foot, typically needed
through platform areas, or in track with 3rd rail
electrification. Cranked handles alter the swept arc of the
handle to operate safely whilst standing in the 4-foot.
All the FASTCLIP tools have optional cranked handles.
www.pandrol.com
32
Identification of Pandrol Hand-Tools
Hand-tools for PANLOCK and Elastic Spikes
Hammers should NEVER be used for either insertion or extraction of PANLOCK.
Hammers may be used for the loosening of rusty PANLOCK, but NOT to fully extract.
Hammers can be used for the insertion of elastic spikes.
PANLOCK Puller
Catalogue No. 40/60549
PANDROL No. LP8452
Elastic Spike Extractor
Catalogue No. 39/17090
Elastic Spike extractor available from
Tool and Steel; Product code: TASTE112
33
Pandrol Track Fastening Systems User Guide - Edition 8
Identification of Pandrol Hand-Tools
Vortok Stressing Roller (VSR)
The VSR is a multi function stressing roller. It combines both the side and under roller requirements
for stressing rail. It also incorporates a lift function removing the need for track jacks.
The Vortok Stressing Roller
is available for:
• FASTCLIP (0094/018014)
• ‘e’ clip (0094/018013)
• FASTCLIP ‘FE‘ (Application Pending)
Catalogue No. 094/018014
Catalogue No. 94/018013
Side Roller LP16668 for Pandrol Vipa
Under Roller LP17469 for Pandrol Vipa
Hooks over the shoulder on the inside of the track
curve, and tightens using the screw to adjust the
ball-bearing to touch the web of the rail. Use at
least one roller every 10 rail seats, depending
upon the severity of the curve.
This simple wire roller fits on top of the rail pad
once the rail has been lifted out of the rail seat.
It is a low friction roller designed to provide an
even distribution of the tension from the hydraulic
stressing jacks.
Catalogue No. Not allocated
Catalogue No. Not allocated
www.pandrol.com
34
Identification of Pandrol Hand-Tools
Discontinued Rollers for FASTCLIP
PANDROL UNDER-ROLLER Type 1P10385 is now obsolete and should NOT be used for stressing with
FASTCLIP. Pandrol side rollers for dual rail sleeper types have been discontinued. However the original
side rollers should only be used with conventional under-rollers. Therefore the recommendation for
stressing is to use VSR equipment detailed on page 34.
Cat No. 0039/47855
Side Roller FC1500l - 56
Cream with BLUE handle for 113A
rail on FIELD side.
Cat No. 0039/47856
Side Roller - FC1500l - 44
Cream with BLACK handle for 113A
rail on GAUGE side.
Cat No. 0039/47857
Side Roller FC1500l - 52
Cream all over for CEN60
rail on either side of rail seat.
35
Pandrol Track Fastening Systems User Guide - Edition 8
Use of Hand-Tools
PANDROL PR and
e-CLIP & Re clip types
Installation Instructions
Instructions for PANPULLER LP1180
and e-Plus PANPULLER LP12717
• I nsert centre leg of clip into housing.
• P lace pivoted hook over the inside of the front arch of clip with
foot of PANPULLER behind clip housing and ensure lip of the
hook is under the front arch.
• Taking up a natural stance behind the PANPULLER, with both
hands on tee handle at top of PANPULLER, pull strongly towards
chest until refusal.
• The PANPULLER automatically pulls clip to the correct position
e-Plus PANPULLER -eP20129
Catalogue No. 39/42749
• e-Clip and ‘Re’ Clips
• e-Plus Clip
Pandrol Number - LP15923
Pull until refusal. PANPULLER does not act as a stop
due to shorter centre leg of clip.
When correctly installed the centre leg of ALL types
of e-PLUS clips, protrude beyond the shoulder to hold
the side-insulator in the correct position.
For instructions on the use of FASTCLIP tools and methods, refer to the separate booklet entitled:
PANDROL FASTCLIP Track Installation Guide
www.pandrol.com
36
Use of Hand-Tools
PANDROL PR and
e-CLIP & Re type clips
Extraction Instructions
Reverse the PANPULLER.
• Taking up a natural stance on the same side as for installation,
place hook on the outside of the front arch of the clip, the foot
of the PANPULLER resting on the baseplate/housing just above
the centre leg of clip (as illustrated).
• Standing behind PANPULLER with both hands on the tee
handle at the top of PANPULLER, give a strong firm push away
from your chest.
• If clips have been in situ for many years, it may be necessary to
use a hammer to loosen them taking safety precautions. If the
clips will not move then use the Rusty Clip Extractor can be used
for PR clips.
NOTE. It is mandatory to wear eye protection when removing or fitting any clips
where hammer assistance might be necessary.
Soft-faced hammers
Soft-faced hammers can be used to extract ‘PR’, ‘e’‘e-PLUS’ and ‘Re’ type clips, provided the following has been agreed
on each site. The use of hammers should only be attempted with the agreement of Network Rail, using suitably trained
and supervised track teams. The risks of the inappropriate use of soft faced hammers fall into 2 categories. ‘PR’, ‘e’ and
‘e-PLUS’ & Re type clips can generally withstand the use of hammers so the risks are:
1. ‘PR’, ‘e’ and ‘e-PLUS’ & Re type clips MUST be caught at the point of extraction to prevent clips flying.
See the boot of the operator in the photograph.
2. Poorly controlled hammers can injure personnel and damage other components
The photograph shows the typical use of a soft faced
hammer to extract any of the following clip types:
PR, e, Re, e-PLUS.
For instructions on the use of FASTCLIP tools and methods, refer to the separate booklet entitled:
PANDROL FASTCLIP Track Installation Guide
37
Pandrol Track Fastening Systems User Guide - Edition 8
Use of Hand-Tools
PANDROL PR ,
e, e-PLUS and Re Clips
Pansetter
Used for lifting the sleeper to the rail foot. It pushes the rail
over, leaving the correct gap between the rail foot and the
Pandrol housing, so that the insulator can be easily placed
in the correct position.
Catalogue Number 39/42900
Pandrol Number 2P9559
PANDROL PR
Rusty Clip Extractor
If the clips have not been disturbed for a long
time, rust can develop between the centre leg
of the clip and the inner face of the housing.
This problem has mainly occurred with concrete
sleepers in tunnels. With this situation,
considerable force may be needed to remove the
clips from their housings. By using such force the
concrete around the housing may break away,
making the sleeper unserviceable.
To overcome this difficulty, Pandrol has developed
the Rusty Clip Extractor to remove whole clips.
If the clip has broken then the tool will remove
the clip centre leg.
• Suitable for PR401A clips only.
• NOT suitable for use on slab track.
For instructions on the use of FASTCLIP tools and methods, refer to the separate booklet entitled:
PANDROL FASTCLIP Track Installation Guide
www.pandrol.com
38
Use of Hand-Tools
Pandrol Rail Fastenings for Bull Head Rail
PANDROL PANLOCK
PANLOCK Puller:
Catalogue Number 40/60549
Pandrol Number LP8452
Insulated PANLOCK Puller:
Catalogue Number 39/040135
Installation Instructions
• P lace PANLOCK in chair from right hand side with open
curled end to rail web.
• P lace PANLOCK-Puller head against rail head and on
top of chair jaw with lower arm under rail foot.
• E nsure curved toe of handle enters leading curve
of PANLOCK.
• Take up a firm stance with both hands on the tee
handle and pull until PANLOCK is fully installed when
PANLOCK-Puller toe will disengage from PANLOCK.
• Remove tool.
• Check PANLOCK is located centrally in chair.
PANDROL PANLOCK
IMAGE REQUIRED
Extraction Instructions
• P lace PANLOCK-Puller head against rail head and on top of
chair jaw with lower arm under rail foot.
• E nsure curved toe of handle enters right hand curve of
PANLOCK behind centre section.
• Take up a firm stance with both hands on the tee handle
and pull until PANLOCK is driven through the chair and out.
• Remove tool.
If the PANLOCK has been installed for a long time, it may be necessary to loosen the fastening
with a hammer prior to extraction with the PANLOCK Puller.
• NOTE. It is mandatory to wear eye protection when removing or fitting any clips where hammer
assistance might be necessary.
• For maximum effectiveness PANLOCKS should not be mixed with other bull head rail fastenings.
Also ensure the chair is square to the rail.
For instructions on the use of FASTCLIP tools and methods, refer to the separate booklet entitled:
PANDROL FASTCLIP Track Installation Guide
39
Pandrol Track Fastening Systems User Guide - Edition 8
Machines for automated installation
and extraction of FASTCLIP systems.
Most track renewal sites now use FASTCLIP machines to insert or remove the clips and achieve significant
productivity and efficiency gains.
FASTCLIP Clipping Machine Mark 4A:
• Petrol or Diesel Engine
• Sleeper Lifting Device
• Optional Unclipping Module
• Self Propelled
• Umbilical Remote Control
• Suitable for Concrete or Steel Sleepers
• Clipping Module
(4 clips simultaneously)
• Clipping Rates about 8 Sleepers per minute with
Sleeper Lifting
Rosenqvist CD500 High Output Clip Driver:
• Self-propelled high speed clipping machine
• Clipping and unclipping actions
• On & off tracking is self-powered.
• Clipping / Unclipping rate: up to 75 slprs/min
for stressing.
• Sleeper lifting capability for renewal work.
Rosenqvist CD400 Clip Driver:
• Sleeper lifter
• Clipping / Unclipping action
• Hydraulically operated attachment or self propelled
• Ideal for track renewal and stressing
• Clipping rates: 12 sleepers per Min for renewals.
25 sleepers per Min for stressing.
• Suitable for concrete or steel sleepers
• Fits 3rd rail conductor systems without removing
conductor rails
Rosenqvist CD200:
• Clipping and unclipping action.
• Sleeper lifting option
• Clipping and unclipping rates up to
12 sleepers per Min
www.pandrol.com
40
Track Support baseplates for
Noise & Vibration mitigation.
1. Baseplates and Modular Assemblies
Pandrol provides 3 different baseplate systems incorporating different levels of resilience for different
required levels of vibration mitigation. The stiffness can be engineered to achieved different levels of
resilience within limits, but generally Pandrol VANGUARD is the softest possible system, followed by
VIPA-SP then SFC baseplates the firmest. All of these systems can be supplied in different variants,
most of which are already Product Accepted by Network Rail. The baseplates can be installed on
concrete slab track or steel structures using a range of anchorage systems shown on the following pages.
Pandrol SFC:
Catalogue No. 057/001958
Assembly 14903 for 56E1
Pandrol SFC:
Catalogue No. 057/001959
Assembly 15082 for CEN60
Pandrol VANGUARD:
Not relevant to loose components
Assembly No. 10395 for CEN60
See pages 43 and 44 for description of loose components
Pandrol VANGUARD:
Assembly No. 10853 for 56E1
See pages 43 and 44 for description of loose components
41
Pandrol Track Fastening Systems User Guide - Edition 8
Not relevant to loose components
Catalogue No. 057/001960
Pandrol VIPA-SP:
Assembly 11308 for 56E1
Catalogue No. 057/001961
Pandrol VIPA-SP:
Assembly 10435 for CEN60
Catalogue No. 057/001955
Pandrol VIPA-SP:
Assembly 11321 for 56E1
Catalogue No. 057/001956
Pandrol VIPA-SP:
Assembly 13788 for 56E1
Catalogue No. 057/001957
Pandrol VIPA-SP:
Assembly 10601 for CEN60
www.pandrol.com
42
Track Support baseplates for
Noise & Vibration mitigation.
1. Vanguard Components
These tables depict the differing components needed for the most frequently used variant of the
VANGUARD range being the baseplate variant. Network Rail has formally accepted this variant for either
56E1 or 60E1 or 2 rails but the components are different to reach the differing rail sizes. The Network Rail
Product Acceptance certificate is: PA05/00569. This explains and illustrates the differing components.
Common Components for Both Rails
Baseplate Type 10396
Hook-In Shoulder Type 9705
Catalogue No. 057/060022
Catalogue No. 057/060023
Bump-Stop Pad Type 9766
VANGUARD Locking Wedge Type 9242
Catalogue No. 057/060024
Catalogue No. 057/0060026
VANGUARD Retention Clip Type 7920
Catalogue No. 057/048335
43
Pandrol Track Fastening Systems User Guide - Edition 8
Remaining Components Unique to Each Rail Size
Rail Size 56E1
Rail Size 60E1 or 60E2
Rubber Wedge Assembly 9456
Rubber Wedge Assembly 9769
Catalogue No. 057/048334
Catalogue No. 057/060027
Side Arm Type 9413
Side Arm Type 9765
Catalogue No. 057/048350
Catalogue No. 057/060025
www.pandrol.com
44
Anchorage Systems for Pandrol Baseplates
3. Anchorage Assemblies
The choice of anchorage assembly is determined by the installation method selected by the contractor.
The methods listed below describe the techniques used by contractors. The corresponding anchorage
should be specified as part of the Pandrol scope of supply to maintain the Product Acceptance validity.
Components List for Each Hold-Down Assembly
‘Bottom-up’ Method
Bottom-up method on concrete slab track
24 Stud Type:
M24 Nut Type:
2 Qty. Flat Washers:
2 Qty. Disc Springs:
11249
11368
11244
11242
Top-Hat Bush:
11032-24
Serrated Washer:
9978
Conforming Pad:
10401
Heights Adjusting
Shims Type:
10854
(Thickness available:
3, 5, 10mm)
Pandrol does NOT supply grout for the anchor stud
‘Top-Down’ Method
Drilled and grouted anchors, with poured
grout pad beneath baseplate
The ‘Top-down’ method uses the same components as above,
with the exception of swapping the Conforming pad, for a:
Construction shim: 11361
Pandrol does NOT supply grout for the anchor stud,
NOR the grout for beneath the construction shim
‘Bottom-up’ Method
Bottom-up method on steel deck
M24 Bolt Type:
M24 Nut Type:
2 Qty. Flat Washers:
2 Qty. Disc Springs:
45
13110
11368
11244
11242
Top-Hat Bush:
11032-24
Serrated Washer:
9978
Conforming Pad:
10401
Heights Adjusting
Shims Type:
10854
(Thickness available:
3, 5, 10mm)
Pandrol Track Fastening Systems User Guide - Edition 8
The anchorage assemblies shown below can be used with either method of top-down construction.
Installation and the choice is determined by other factors such as track curvature or height adjustment
limits required. Generally plastic inserts can used for track where curvature is greater than 400 metres,
and height adjustments less than 15mm.
‘Top-Down’ Method
Assemby with
M24 bolt, and
cast-iron insert.
Slab track concrete poured to beneath the baseplate
or set with concrete sleepers.
M24 Bolt Type:
9978
13110 Serrated Washer:
Cast Iron Insert:
11361
9744 Construction Shim:
Top-Hat Bush:
11032-24 (wet poured concrete)
2 Qty. Flat Washers: 11244 Conforming pad:
10401
2 Qty. Disc Springs: 11242 (on sleepers)
Height adjusting shims are NOT required using this
method, unless downward adjustment is later required
‘Top-Down’ Method
Assemby with
Anchor Screww
and plastic insert.
Slab track concrete poured to beneath the baseplate
or set with concrete sleepers.
Anchor Screw
9978
Serrated Washer:
22mm ø Type:
11361
10886 Construction Shim:
Plastic Insert:
10887 (wet poured concrete)
Top-Hat Bush:
10401
11032-23 Conforming pad:
2 Qty. Flat Washers: 11244 (on sleepers)
2 Qty. Disc Springs: 11242
Height adjusting shims are NOT required using this
method, unless downward adjustment is later required
NOTES.
1. The lengths of anchor studs, bolts, and screws can be calculated with the aid of separate data-sheets from Pandrol.
2. The factors of safety for the various Pandrol anchorage systems can be calculated by Pandrol from track and site
parameters. Contact Pandrol for details.
www.pandrol.com
46
4. Identification Chart for Anchorage Components
The anchorage components identified below form part of the scope of supply only with the relevant
Pandrol baseplates. These components are NOT supplied separately, and can only be warranted when
used within the defined Pandrol assembly.
Bolts, Studs and Nuts
Catalogue No. 57/01962
M24 Anchor Stud
Type 11249
Lengths from 225mm to 320mm
Catalogue No. 57/01970
M24 Bolts
Type 13110
Lengths from 140mm to 210mm
Catalogue No. 57/01972
Anchor Screw
Type 10886
For use with plastic inserts
Catalogue No. 57/01963
M24 Nut
Type 11368
NOTE: The standard finish on bolts, anchor studs, screws, and nuts is spun galvanised.
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Pandrol Track Fastening Systems User Guide - Edition 8
Inserts
Catalogue No. 57/01971
Cast-Iron
Type 9744
Note: The blue epoxy finish is optional.
Standard finish is natural cast-iron
Catalogue No. 57/01973
Plastic Insert
Type 10887
Washers and Disc Springs
Catalogue No. 57/01964
M24 Flat Washer
Type 11244
For use with plastic inserts
Catalogue No. 57/01965
M24 Disc Spring
Type 11242
NOTE: Washers are zinc plated, and disc springs are additionally passivated yellow colour.
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48
Identification Chart for Anchorage Components
Bushes and Serrated Washers
Catalogue No. 57/01947
Top-Hat
Type 11032-23
Catalogue No. 57/01966
Top-Hat
Type 11032-24
Catalogue No. 57/01998
Serrated Washer
Type 9978 (Top)
Serrated Washer
Type 9978 (Bottom)
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Pandrol Track Fastening Systems User Guide - Edition 8
Pads and Shims
Catalogue No. 57/01968
Catalogue No. 57/01969
Conforming pad
Type 10401
Height
Adjusting Shim
3mm thick for
preformed concrete
and steel decks
Type 10854-3
3mm thick
Catalogue No. 57/01974
Construction Shim
Catalogue No. 57/01948
Height
Adjusting Shim
Type 11361
Type 10854-5
10m thick for
poured concrete
and grout
5mm thick
1mm - Catalogue No. 57/01950
2mm - Catalogue No. 57/01951
Catalogue No. 57/01949
Steel Half-Shim
with Slotted Holes
Type 14954
Height
Adjusting Shim
Range:1,2mm thick
Type 10854-10
HDPE Half Shim
with Slotted Holes 3mm - Catalogue No. 57/01952
Type 14953
Range: 3, 5
10mm thick
10mm thick
5mm - Catalogue No. 57/01953
10mm - Catalogue No. 57/01954
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50
www.pandrol.com
Design by Andy Marsden: t. 07960 085647 e. andy.marsden76@gmail.com
Pandrol UK Limited
Gateford Road
Worksop
Notts S81 7AX
T. 01909 476101
F. 01909 500004