ISRAEL RAILWAYS
INFRASTRUCTURES DIVISION
TRACK AND ENVIRONMENT DEPARTMENT
SPECIFICATION FOR PRODUCTION AND SUPPLY
OF
GRAVEL BALLAST FOR RAILWAY TRACKS
E-01-0013
VERSION 1.1
FEBRUARY 2012
0. Introduction
The standard EN13450 is the basis for this technical specification. Consequently, the
criteria for grading, and the test methods and operating procedures, are based on the
aforesaid standard.
1. Production
The aggregate will be produced entirely from natural material, and not from blending of
raw materials from different geological sources.
2. Physical and mineralogical properties of rock for production of aggregate
The rock from which the aggregate is produced, will conform to the requirements set out in
the tables that follow.
Table 2.1 General, physical, and mineralogical properties of dolomitic / limestone dolomite
rock for production of aggregate - to be carried out by a laboratory, periodically and/or per
quantity of production, as defined in the table in Appendix A.
Property
Test method
Basalt
Granite
EN 1097-6 (*)
Dolomitic /
limestone
dolomite
Over 2.72
g/cm3
Over 2.65
g/cm3
Less than 1.5%
Bulk specific
gravity
Apparent
specific gravity
Water
absorption
Unconfined
compressive
stress
Mineralogical
restrictions
C29/C29M (*)
Over 2.85
g/cm3
Over 2.70
g/cm3
Less than 2%
Over 2.80
g/cm3
Over 2.68
g/cm3
Less than 1%
ASTM D712-04
(*)
Over 800
kg/cm2
Over 1000
kg/cm2
Over 1000
kg/cm2
According to
Table A.1
_____________
Dolomite
[CaMg(CO3)2]
content - over
25%
EN-932-3
EN-932-3
According to
Table A.1
ASTM C127 (*)
Minimum test
frequency
According to
Table A.1
(*) In all cases where a standard is mentioned, the requirements should be carried out
according to the most up-to-date version of that standard.
2.1 Sunburn - Sonnenbrand
If there is prior knowledge of signs of "sunburn" at the basalt quarry, quality tests will be
carried out according to the requirements of the European Standard EN 1367-3.
Note: "Sunburn" is a type of defect found at times in rock from basaltic sources which has
been affected by atmospheric conditions. It first appears in the form of grayish-white spots.
Minute cracks usually appear, radiating from the white spots, and eventually joining
together to from a network. This phenomenon weakens the mineral structure, and as a
result, the rock eventually crumbles into small particles.
Table 2.2 General physical and mineralogical properties of rock for production of mineral
aggregate. These will be carried out as preliminary tests by a geologist (Petrographic
classification according to standard EN 932-3 (*) )
Property
Basalt
Granite
Sunburn test
Dolomite/chalky
dolomite
n/a
Must be tested
n/a
Color/shade
Dark grey
Dark grey to black
Texture
Medium to fine
crystalline, free of
small pores, free of
lamination. No
fossils. No pseudobractious texture.
Few calcite veins
The rock will not be
vesicular, and will
have no large
crystals or signs of
exfoliation
Allowable
production method
Quarrying from
open faces only
Gathering and
quarrying from
open faces
Light grey to pink
for granite and
Taba gneiss.
Brown for Neshef
quartz porphyry
The rock will not
include large
crystals, and will
have no wear
layers. Taba gneiss
will have homogeneously
distributed
minerals, without
lamination.
Quarrying from a
face free from worn
materials
Minimum test
frequency
According to Table
A.1
According to Table
A.1
According to Table
A.1
According to Table
A.1
3. Harmful components
The ballast shall not contain any components or materials other than those detailed in this
specification.
4. Geometrical requirements
4.1 Size of gravel ballast for railway tracks
The size of gravel ballast for railway tracks is defined by a pair of millimetric screens. The
first number defines the lower limit of screen size, and the second number the higher limit.
Most of the gravel particles are between the two sizes.
The nominal size of gravel ballast for railway tracks is 50/31.5.
4.2 Grading
Grading of gravel ballast for railway tracks will be carried out according to standard EN
933-1(*). The frequency of testing is given in Table A.1. The limits of grading are as
follows:
Screen No.
(mm)
63
50
40
31.5
22.4
50/31.5
Percent passing through
[%]
100
70-99
30-65
1-25
0-3
≥ 50
Note: Situations may arise where samples are taken from the car and/or the line. In either
case, the same test methods and the same test requirements will apply. Due to
degradation of the ballast during transport, the maximum amount passing a 22.4
mm screen increases to 5%.
4.3 Fine particles.
The fine particle content will be defined according to standard EN 933-1(*). Testing
frequency as given in Table A1
Fine particle content should be as follows:
Screen no. (mm)
0.5
Maximum wt. passing through (%)
At production site
At railway storage piles
0.6
1.0
Note: 0.6% is the maximum permitted value in a sample of gravel ballast taken at the
production site of the raw material.
1.0% is the maximum permitted value in a sample of gravel ballast in stock yards at the
railway site.
4.4 Fines content
The fines content is defined according to standard EN933-1(*). This requirement, defined
below, will be specifically defined in the work specification at special application sites, such
as tunnels:
Screen no. (mm)
0.063
Maximum wt. passing through (%)
At production site
At railway storage pile
0.5
0.5
Note: 0.5% is the maximum permitted value in a sample of gravel ballast taken at the
production site of the raw material.
0.5% is the maximum permitted value in a sample of gravel ballast in stock yards at the
railway site.
4.5 Particle size
4.5.1 Flakiness index
The shape of the coarse particles making up the ballast will be defined according to the
requirements of standard EN 933-3(*). The flakiness index value should be equal to, or
less than, 20. Frequency of testing: as defined in Table A.1.
4.5.2 Shape index
The shape index is defined according to the requirements of standard EN 933 -4 (*). The
value of the shape index will be equal to, or less than, 25. Frequency of testing: as defined
in Table A.1.
4.6 Particle length
The particle size will be determined with a gauge and/or a pair of compasses/calipers.
The percentage w/w of particles of length equal to, or greater than, 100 mm (L ≥ 100 mm)
in a representative sample weighing at least 40 kg, will be equal to, or less than, 4.
Frequency of testing: as defined in Table A1.
5. Physical requirements
5.1 Resistance to fragmentation
The resistance to fragmentation of gravel railway ballast (Los Angeles Coefficient) under
the conditions defined in Appendix C of the standard EN 13450(*), is as defined in
standard EN 1097-2(*), paragraph 5. The value of the Los Angeles coefficient will be equal
to, or less than:
For dolomite / chalky dolomite: 17.5
For basalt and granite: 16
Frequency of testing: as defined in Table A.1.
5.2 Resistance to wear
Resistance to wear of gravel railway ballast (Micro Deval coefficient under conditions
defined in Appendix E of standard EN 13450(*)) defined as set out in Standard EN 10971(*). The value of the Micro-Deval coefficient shall be equal to, or less than:
For dolomite / chalky dolomite: 9
For basalt and granite: 9
Frequency of testing: as defined in Table A.1.
6. Factory production control
6.1 At every quarry, a production control program will be in place, whose function is to
oversee the quality of production and product, according to the procedures and the
requirements of the technical specification, and to be responsible for testing by a
laboratory certified by the competent authority, and to ensure that at all times, the gravel
meets with the quality requirements defined above.
6.2 In case any deviation from the requirements of the specification is observed, the
supplier must immediately cease production, correct all that requires correcting, and only
after ensuring that he is able to continue production of gravel ballast according to
standard, shall the supplier resume production.
6.3 The railway will not be supplied with any quantity whatsoever of gravel, on a sample of
which tests have shown that it does not meet with the requirements of this specification.
APPENDIX A TO THE TECHNICAL SPECIFICATION
PRODUCTION CONTROL AT THE QUARRIES
Introduction
This Appendix describes the production control program to be established at all quarries
producing aggregate for gravel railway ballast. Its objective is to ensure compliance of the
the product with the requirements of the specification.
The performance of the control program at each quarry will be evaluated according to the
principles set forth in the present Appendix.
A1. Organization
A.1.1 Responsibility and authority
The responsibility, the authority, and the mutual relationships between all the bodies
managing, carrying out, and testing the effect of production quality on finished product
quality, must be defined and established at each quarry, including those bodies requiring
organizational freedom and authority to:
I. Begin any activity which will prevent the occurrence of non-standard product
II. Identify, document, and deal with any deviation in product quality.
A.1.2 The representative of management in production quality control
At every quarry producing aggregate for gravel railway ballast, an individual will be
appointed, with the appropriate authority, to make sure that the instructions of the present
specification are fully carried out and maintained at all times.
A.1.3 Management control
The production control system of every quarry selected to meet the requirements of this
Appendix, shall be controlled and inspected at appropriate intervals by the management,
in order to ensure its continuing suitability and effectiveness. Documentation of all such
control inspections should be available.
A.2 Control processes
At every quarry, a set of instructions for production control procedures in the plant will be
established and kept up-to-date, so that production control requirements at the quarry will
be met.
A.2.1 Documents and control of information
Documents and control of information will include those documents and information which
are relevant to the present specification, and which cover the aspects of purchasing,
production, testing of materials, and documentation of quality control throughout the
quarry.
Any procedure dealing with documents and information, will be documented in the
instructions for control of production, which covers the processes and limits of
responsibility for approval, issuing, distributing and management of internal and external
documentation and information, and also the preparation, issuing, and documentation of
changes in documentation.
A.2.2 Information concerning raw material
Documentation will exist, detailing the character of the raw material, its source, and in
appropriate cases, one or more maps detailing the location and the plan of extraction.
it will be the manufacturer's responsibility to ensure, that in the event of dangerous
materials being identified, their content shall not exceed the permitted limits set at their
point of application.
A.3 Management of production
The production control system at every quarry will meet the following requirements:
a) Procedures will be available for identification and control of materials.
Note: Procedures for maintaining and adapting equipment for production, carrying out
of tests and/or trials on samples of material during the production process,
improvement of the production process during periods of bad weather, etc., may be
included.
b) Procedures will be available for identification and control, for all dangerous materials
identified in paragraph A.2.3, in order to ensure that their content shall not exceed the
permitted limits at their point of application.
c) Procedures will be available for ensuring that the material be stacked in a controlled
manner, and the storage places and their content identified.
d) Procedures will be available to ensure that the material taken from the ballast stock
yard shall not have deteriorated to a point where its suitability is in doubt.
e) The material shall be identifiable, up the point of marketing, in all respects to do with
its source and type.
A4. Inspection and testing
A.4.1 General
At every quarry, the installations, equipment, and qualified personnel for carrying out
inspection and testing, must be present.
A.4.2 Equipment
At every quarry, control, calibration, and maintenance of the equipment for testing,
measurement and inspection, shall be carried out.
Precision and frequency of calibration shall be according to standard EN 932-5 (*).
All use of equipment will be according to the documented procedures.
Equipment will have a single detection value.
Calibration results will be recorded and saved.
A.4.3 Frequency and place of sampling, testing, and inspection
The documents of production control will include a description of the frequency and the
nature of inspection. Frequency of sampling and testing, when required, will be according
to Table A1.
Notes:
 The frequency of tests is usually associated with periods of production. A period of
production is defined as a full week, month, or year of production work days.
 The requirements for production control in the plant may also include visual testing.
Any deviation found during such tests may lead to an increase in the frequency of
testing.
 When the measured value of a test is close to the specified limit, it may be necessary
to increase the frequency of testing.
 Under special conditions, the frequency of testing may be reduced to below the
frequencies specified in Table A.1. These conditions may include the following:
a) A high degree of mechanization in the production equipment
b) Long range experience of regularity of special properties
c) Highly suitable sources.
d) Continuous application over a long period of a quality management system which
includes abnormal measurements while inspecting and monitoring the production
process.
The manufacturer will prepare timetables for frequency of testing, taking into account the
minimum requirements set out in Table A1.
Reasons for reducing the frequency of testing will be documented in the production control
documents of the plant.
Table A1
Minimum testing frequencies (for general use)
Property
Test method
Minimum laboratory
test frequency at
quarry (**)(QC)
Once weekly and/or
every 2000 tons
1
Grading
EN 933-1 (*)
2
Fine particles
EN 933-1 (*)
Once weekly and/or
every 2000 tons
3
Fines
EN 933-1 (*)
Once weekly and/or
every 2000 tons
5
Particle shape
`EN 933-3 (*)
EN 933-4 (*)
Once monthly and/or
every 10000 tons
6
Particle length
EN 13450 (*)
Once monthly and/or
every 10000 tons
7
Resistance to
fragmentation (Los
Angeles)
EN 1097-2 (*)
Once weekly and/or
every 2000 tons
8
Resistance to wear
(micro Deval)
EN1097-1 (*)
Once monthly and/or
every 10000 tons
9
Unconfined
compressive stress
ASTM D2166-06
(*)
10
Water absorption
EN1097-6 (*)
On proof of compliance
with the threshold terms
of the tender
Once every three
months and/or every
20000 tons
11
Bulk specific gravity
C29/C29M (*)
12
Apparent specific
gravity
ASTM C127 (*)
On proof of compliance
with the threshold terms
of the tender
On proof of compliance
with the threshold terms
of the tender
Minimum test frequency by
Railway or its
representative (***) (QA)
Once monthly and/or every
10000 tons, and according to
special, specific request of
Railway
Once monthly and/or every
10000 tons, and according to
special, specific request of
Railway
Once monthly and/or every
10000 tons, and according to
special, specific request of
Railway
Once monthly and/or every
10000 tons, and according to
special, specific request of
Railway
Once monthly and/or every
10000 tons, and according to
special, specific request of
Railway
Once monthly and/or every
10000 tons, and according to
special, specific request of
Railway
Once monthly and/or every
10000 tons, and according to
special, specific request of
Railway
According to special, specific
request of Railway
Once a month and/or every
10000 tons, and according to
special, specific request of
Railway
On special, specific request
of Railway
On special, specific request
of Railway
13
Mineralogical
restrictions
14
Color
15
Texture
16
Allowable
production method
17
Sunburn sonnenbrand
According to the
requirement of the
technical
specification
According to the
requirement of the
technical
specification
According to the
requirement of the
technical
specification
According to the
requirement of the
technical
specification
EN 1367-3
On proof of compliance
with the threshold terms
of the tender
On special, specific request
of Railway
On proof of compliance
with the threshold terms
of the tender
On special, specific request
of Railway
On proof of compliance
with the threshold terms
of the tender
On special, specific request
of Railway
On proof of compliance
with the threshold terms
of the tender
On special, specific request
of Railway
Four tests per year
On special, specific request
of Railway
(**) All test results of the quarry's laboratory, which were carried out at the
frequency detailed in the table above, will be forwarded on the actual day of testing.
(***) The railway, or its representative, reserves the right at all times to enter the
quarry for Quality Assurance purposes.
A.5 Documentation
The results of production control at each quarry will be documented, including the location
of sampling points, dates and times, and products tested, and all other relevant
information, such as weather conditions.
When the product being tested and/or examined does not meet the requirements of the
specification, or if there is any indication that such a thing is about to occur, a note will be
added to the documentation, describing the steps taken to deal with the matter (for
example: the taking of an additional sample, or the taking of measurements with a view to
adjusting the production process).
The documentation will include all the documents required by this Appendix.
Documents will be saved during the entire period of the agreement, and for a period of at
least two years after termination of the agreement.
A.6. Control of non-conforming product
After any test or trial that indicates that the product does not conform to the specification,
one of the following procedures will be followed:
a) A repetition of processing, and/or
b) Routing of the material to a different application, to which it is suitable, and/or
c) Rejection and marking "not suitable".
All cases of non-conformity with the specification, will be documented by the manufacturer,
will be tested, and if necessary, corrective action will be taken.
NOTE: Corrective action may include:
a) Checking of the reason for non-conformity, including checking of the testing process
itself, and taking all the necessary corrective action.
b) Analysis of the process, performance, quality documents, service documents, and
customer complaints, in order to locate and prevent possible reasons for nonconformance.
c) Initiation of preventive activity, in order to confront the problems before they lead to
possible dangers.
d) Addition of more controllers, to ensure that effective preventive actions have been
taken.
e) Application and documentation of changes in the process arising from preventive
action.
A.7. Handling, storage and stipulations in the production areas.
All necessary arrangements will be made, to maintain the quality of the product during
handling and storage.
NOTE: These arrangements will take into account the following subjects:
a) Contamination of the product.
b) Segregation
c) Cleanliness of the handling equipment, and of storage areas.
A.8. Dispatching and packaging
A.8.1 Areas of responsibility for all matters concerning storage and transportation will be
defined in the production control system of each quarry.
NOTE: When the gravel ballast is carried on a truck, the container must be covered during
the entire period of transportation: this is in order to reduce contamination from the
environment, and other risks.
A.8.2 The methods employed for loading and dispatching will be such as will not lead to
contamination, or to a reduction in the quality of the aggregates, to the point where their
properties are significantly altered, before unloading from the truck. All necessary safety
precautions, taken to achieve this during handling and storage of the aggregates, will be
marked and indicated on the accompanying documents.
A.9 Personnel training
At all quarries, procedures for training all personnel involved in the plant's production
process, will be permanently maintained and saved. Appropriate training documentation
will be permanently saved.