Interchangeable Brake Shoe Specification

Report

CH01-00891 – ISRAEL RAILWAYS Ltd.

Technical Specification for Brake Shoes
Prepared Checked Released

U. Koppatsch R. Urban U. Koppatsch

Document Number Release Date Revision Revision Date Status

08-03-00283 12.03.2020 0.00 12.03.2020 Released

PROSE GmbH
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12099 Berlin
Germany

www.prose.one

Phone +49 30 7544 90 837

[email protected]

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Distribution
Company/Department/Name Remarks

Revision Index
Prepared checked Released Date

08-03-00283 U. Koppatsch R. Urban U. Koppatsch 12.03.2020

Rev.
Rev.
Rev.
Rev.
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Modifications
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This document discloses subject matter in which the PROSE Ltd., Winterthur (Switzerland) or one of it’s subsidiary companies, has proprietary
rights. Neither receipt nor possession thereof confers any right to reproduce or disclose the document, any part thereof, any information
contained therein, or any physical article or device, or to practise any methods or process, except by written permission from or written
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1 Preamble ............................................................................................................................. 4
1.1 Definitions ........................................................................................................................... 4
2 Brake Shoe Specification....................................................................................................... 5
2.1 Vehicles ............................................................................................................................... 5
2.2 Brake Shoes in Use Today ..................................................................................................... 6
2.3 General Requirements .......................................................................................................... 7
2.3.1 Normative References .................................................................................................................... 7
2.3.2 Operation........................................................................................................................................ 7
2.3.3 Environment ................................................................................................................................... 8
2.4 Proof of Interchangeability ................................................................................................... 8
2.4.1 Pre-Selection................................................................................................................................... 8
2.4.2 Proof of Stopping Distance (only composite brake shoes) ............................................................ 8
2.4.3 In-Service-Test (only composite brake shoes) ................................................................................ 9
2.4.4 Coefficient of Friction ..................................................................................................................... 9
2.4.5 UIC Requirements on Interchangeability (grey cast only) ............................................................ 10
2.5 Approval ............................................................................................................................ 10
3 Summary............................................................................................................................ 11
A Bibliography ....................................................................................................................... 12
B Vehicles of ISR .................................................................................................................... 13
C Drawings of Brake shoes ..................................................................................................... 15
D Material Characteristic Sheets ............................................................................................ 20

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1 Preamble
Israel Railways (ISR) is interested to identify interchangeable brake shoes for vehicles equipped
with tread brakes. Thus, alternative brake shoes shall be qualified for the use at vehicles of ISR.
This document provides the specification for the brake shoes to be searched for.
The main characteristics to be evaluated should be (e.g. EN 16452 [1]):
• brake shoe design;
• instantaneous and mean dynamic friction coefficients;
• static friction coefficient;
• wet friction behaviour;
• metal pickup formation behaviour;
• behaviour under conditions simulating a locked brake, with an applied braking force;
• brake shoe and wheel tread wear at different loads and service braking conditions;
• friction behaviour under severe winter conditions;
• influence on signalling systems (track circuits);
• brake shoe material properties.
In none of the categories the new brake shoes shall show lower performance than the brake shoes
in use today.

Various local and historical terms have become established for the wear material of the tread
brake. For this document, ISR requested the use of the term "brake shoe".
However, it was not possible to avoid using different terms in some cases. This is always the case
when official titles of standards are involved.

1.1 Definitions

Term Description

Technical term for brake systems which apply the braking force with
tread brake
brake shoes to the running surface of the wheels

Property of contacting materials; here: the coefficient of friction

coefficient of friction
between brake shoe and wheel

Behaviour of the coefficient of friction between brake shoe and wheel

friction performance
as a function of speed, humidity, temperature, etc.

brake shoe In this document: the wear material of the tread brake

elastic materials (for brake shoes), usually a combination of metal

composite material
fibers, rubber-resin compounds and additional additives

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Phosphorus content of grey cast iron brake shoes (P10 = 1%

P10, P14, P30
phosphorus); more phosphorus = higher coefficient of friction

K, L, LL different UIC friction classes for brake shoes

2 Brake Shoe Specification

This specification defines requirements for brake shoes that are intended to replace the brake
shoes in use today at vehicles of ISR.

2.1 Vehicles
ISR provided the data for locomotives [2], [3], [4].
According to this information the following vehicles are equipped with brake shoes made of
composite material:

CAR series CAR - type Quantity

G12 Loco 27
G26CW-2 Loco 12
G26C-W Loco 11
JT42BW-Bo.Bo Loco 8
JT42CW-Co.Co. Loco 48
NGT26-CW Loco 11
Table 1: Overview of Locos with brake shoes

For the above-mentioned vehicles brake shoes are in use which have a friction performance
according to AAR RP-559. There are two types of brake shoes in use which are described by the
drawings [5] and [6] (see also annex C) and the material characteristic sheets [7] and [8] (see
annex D).

Furthermore, there is a fleet of 1'378 freight wagons and 45 service vehicles equipped with brake
shoes according to ISR specification M-04-240 [9]. This document is about grey cast iron brake
shoes. The content of ISR specification M-04-240 [9] is based on the UIC leaflets UIC832 and
UIC542.
Additional vehicle data, necessary for the supplier to identify a suitable product can be find in the
vehicle tables in annex B.

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2.2 Brake Shoes in Use Today

Today the following brake shoes are in use (Source: E-Mails from ISR [10], [2]):
• Shoe Cobra 14"
o Drawing-No. V-573 [5] (see Figure 2)
o Dimension in inches (does not correspond to UIC versions)
o Friction Material W-663 (composite) [7] (see Figure 7)
o Friction coefficient: 0.13 – 0.26
o friction performance acc. to AAR RP-559
o Recommended field of application: locomotives
o equivalent UIC friction class: L/LL
o supplier: Wabtec (USA)
o average mileage: 12'500 km
• Shoe Cobra 250 mm
o Drawing No. V-648 [6] (see Figure 3)
o Dimensions in mm and identical to version "Bg" according to UIC 542
o Friction material: W-620 (composite) [8] (see Figure 8)
o Friction coefficient: 0.22 – 0.33
o friction performance acc. to AAR RP-559
o Recommended field of application: locomotives
o equivalent UIC friction class: K
o supplier: Wabtec (USA)
o average mileage: 12'500 km
• Cast Iron Brake Shoes according to "Technical Specification M-04-240" [9]
o Types: AF-2 and DX-2
o based on UIC 832
o friction material: cast iron P14 (phosphorus content 1.35 – 1.55%)
o Drawing Numbers:
▪ AF-2: TW 284.00.1 A (see Figure 4)
▪ DX-2: MDD 190.00.3 A (see Figure 5)
o additional information on cast iron brake shoes: see handwritten modified
drawing DX-2 [11] in the annex C (see Figure 6)
o Dimensions in mm
o presumed field of application: freight wagons and service vehicles
o average mileage: 15'000 km

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2.3 General Requirements

All materials used in the manufacture of the friction material and the resulting wear products shall
comply with the relevant environmental health regulations applicable at the time of use.
The noise caused by brake application shall be not higher than today.
It is intended to replace the brake shoes per vehicle by substitute brake shoes. The supplier may
allow to replace the brake shoes also per bogie, per axle or per wheel, which would be of
advantage for the maintenance procedure and the handling of the brake shoes.
The new brake shoes to be procured must correspond to the different brake shoes previously used
regarding their specific friction characteristics and mechanical interfaces. It must be possible to
use the newly procured brake shoes 1:1 in exactly the same way as the brake shoes previously
used on the existing vehicles without any conversion.

2.3.1 Normative References

There are two main categories of brake shoes which are also represented by different standards:
Brake shoes made from cast iron:
Normative references are the UIC leaflets
• UIC 832; Technical specification for the supply of brake-shoes made from phosphoric iron
for tractive and trailing stock [12]
• UIC 542; Brake Parts – Interchangeability [13]
Brake shoes made from composite material:
According to the information available from the ISR [10], composite brake shoes must comply with
AAR standard AAR RP-559 with respect to their coefficients of friction. The mechanical interfaces
are specified by the drawings [5] and [6].
Additional information
Furthermore, the following documents are relevant for assessment of brakes:
• UIC 544-1, Brakes – Braking Performance [14]
• EN 14198 Railway applications - Braking - Requirements for the brake system of trains
hauled by locomotives [15]
• FprEN 15329 Railway applications - Braking - Brake block holder and brake block key [16]

2.3.2 Operation
Typical operation at ISR is characterized by:
• Passenger service up to 160 km/h,
• Locomotives are also in service for freight trains.
• All passenger trains remain in its configuration during operation.
• No shunting and re-configuration occurs during operation.
• The service of ISR is solely national service.
In general, the application at ISR is quite unique. Some trains do not stop at every station, but
timetables do not define a significant split in regional and long-distance traffic.
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2.3.3 Environment (important for composite brake shoes)

Climate and Environmental Conditions
Term Unit Value
Height Above Sea Level m - 400 to +800
Max. Temperature °C 47 (shadow)
Min. Temperature °C -5
Rain mm/year 400 - 800
Relative humidity % 10 to 90
Sunshine h/year 3300 h
UV Radiation MJ/m² per year 360 - 600

2.4 Proof of Interchangeability

Cast iron brake shoes can always be interchanged without any field testing. Procurement must be
carried out in accordance with the specifications in UIC 832 [12].
Composite brake shoes are generally interchangeable within the same friction level (e.g. UIC
friction levels K, L, LL) and the same geometrical shape. Since the specific material composition of
a composite brake shoe is not specified, its suitability for use under certain conditions may vary.
In the present case, the friction characteristic of the composite brake shoes to be procured must
correspond to the material characteristic sheets [7] and [8].
The supplier must be able to refer to test results under similar operating conditions as those
occurring at ISR (see section 2.3.2 and 2.3.3).

2.4.1 Pre-Selection
For pre-selection the supplier shall show that the proposed brake shoe is suitable for the intended
service and that the proposal fulfils the requirements.
The parking brake performance of composite brake shoes could be proven by comparison of test
bench results.
ISR will provide brake shoes in use today to enable brake shoe suppliers to perform the comparing
dynamometer tests.
Based on documents by suppliers, ISR will do a pre-selection. If the proposed brake shoe shows
good performance, it might be selected for stopping distance test and in-service test.

2.4.2 Proof of Stopping Distance (only composite brake shoes)

The conduction of a stopping distance test is only necessary if no fully approved product can be
found.
The stopping distance is the most important parameter of the performance of the new brake
shoes. The comparison of mean coefficient of friction gained by test bench results might not give
enough precise confirmation. Therefore, such stopping distance test will be done at least for a
selection of most critical load and speed.

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2.4.3 In-Service-Test (only composite brake shoes)

The performance of an in-service-test is only necessary if no fully approved product can be found.
The test will then be done with a range of pre-selected brake shoes. The in-service-test will finally
show, if alternative brake shoes are available which cover the full range of applications. Or it will
show if a range of brake shoes could be defined, each to be preferred for a specific type of vehicle.
One possibility of testing the brake shoes is described in UIC leaflet UIC 541-4 [17]. As the brake
shoes used up to now comply with US standards, it is recommended to follow a corresponding US
regulation.

2.4.4 Coefficient of Friction

Brake shoes belong to classes of different levels of friction. That means that brake shoes which
belong to the same class do have a coefficient of friction which is similar within a defined tolerance
range.
In general, the coefficient of friction of the brake shoes is an essential parameter for design and
overall performance of the brake system. The coefficient of friction of the new brake shoes must
be “the same” as of the brake shoes currently in use.
• If the coefficient of friction is too low, the brake system will not reach the required
performance in terms of stopping distance.
• If the coefficient of friction is too high
o the brake system might exceed the available adhesion force between wheel and
rail. The result will be more likely wheel flats.
o the brake system might overload brake mechanics, structure of the vehicle and
the wheelset by higher forces.
Thus, the transition project must take specific care, that the coefficient of friction of alternative
brake shoes is in good accordance with the coefficient of friction of the shoes currently in use.
In the case of locomotives, it should also be considered whether the vehicles have wheel slide
protection.

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2.4.5 UIC Requirements on Interchangeability (grey cast only)

The leaflet UIC542 [13] requests for interchangeability of cast iron brake shoes as shown in the
following Figure 1.

Figure 1: extract from [13]

Furthermore, of course, brake shoes should only be replaced with brake shoes of the same friction
level. The friction values of cast iron brake shoes depend on the phosphorus content of the
material. This is specified by the manufacturer using the codes P10, P14 and P30. P10 means 1%
phosphorus. The higher the phosphorus content, the higher the coefficient of friction. ISR only
uses brake shoes of type P14.

2.5 Approval
In case of appropriate and convincing performance, the proposed new brake shoe will be taken to
the list of brake shoes approved for the use at the specific type of vehicle.

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3 Summary
The brake shoe supplier is asked to provide an offer based on the specification in this document.
After a pre-qualification based on documentation to be provided by the brake shoe supplier, ISR
either selects certified products or (if such products are not available) performs an in-service test
to obtain data for an economic assessment of a transition.
The steps will be:
• Bid by brake shoe suppliers, based on the specifications of chapter 2 of this document.
• Brake shoe supplier will need to support the following steps
o pre-selection by documents,
o choose of certified product
or
o stopping distance test,
o in-service-test.
• ISR will do a final economic evaluation, considering performance parameters and price.

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A Bibliography

[1] EN 16452 - Railway Applikations - Brake - Brake Blocks, Technical Committee CEN/TC 256, 2019-
06.
[2] Assaf, Milad; Israel Railways, E-Mail to U. Koppatsch (PROSE), Subject: "RE: PROSE CH01-00891;
ISR Brakeshoe Specification"; Date: 2019-12-09.
[3] Assaf, Milad; Israel Railways, E-Mail to U. Koppatsch (PROSE), Subject: "RE: PROSE CH01-00891;
ISR Brakeshoe Specification"; Date: 2020-02-03; Time: 14:17.
[4] Assaf, Milad; Israel Railways, E-Mail to U. Koppatsch (PROSE), Subject: "RE: PROSE CH01-00891;
ISR Brakeshoe Specification"; Date: 2020-02-03; Time: 14:49.
[5] SHOE COBRA 14 IN.; Drawing-No. V-573, Laurinburg, North Carolina: Railroad Friction Products
Corporation, 2003.
[6] SHOE COBRA 250mm; Drawing-No. V-648, Laurinburg, North Carolina: Railroad Friction Products
Corporation, 2009.
[7] MATERIAL CHARACTERISTICS SHEET MCS-035-m; W-663, Laurinburg, North Carolina: Railroad
Friction Products Corporation.
[8] MATERIAL CHARACTERISTICS SHEET MCS-052-m; W-620, Laurinburg, North Carolina: Railroad
Friction Products Corporation.
[9] Technical Specification for the supply of Brake Shoes for passenger and freigt wagons; Technical
Specifications No. M-04-240, Ports & Railways Authority, 2007.
[10] Assaf, Milad; Israel Railways, E-Mail to U. Koppatsch (PROSE), Subject: "RE: PROSE CH01-00891;
ISR Brakeshoe Specification"; Date: 2019-12-11.
[11] Assaf, Milad; Israel Railways, Drawing "Brake Shoe DX-2", handwritten modified, Israel Railways,
28.01.2020.
[12] UIC Leaflet 832 - Technical specification for the supply of brake-shoes made from phosphoric iron
for tractive and trailing stock, Paris: Union Internationale Des Chemins De Fer, 2015.
[13] UIC Leaflet 542 - Brake Parts - Interchangeability, Paris: Union Internationale Des Chemins De Fer,
2015.
[14] UIC Leaflet 544-1 - Brakes - Braking Performance, Paris: Union Internationale Des Chemins De Fer,
2014.
[15] EN 14198 Railway applications - Braking - Requirements for the brake system of trains hauled by
locomotives, Technical Committee CEN/TC 256, 2019-02.
[16] FprEN 15329 Railway applications - Braking - Brake block holder and brake block key, Technical
Committee CEN/TC 256, 2017-05.
[17] UIC Leaflet 541-4; Brakes - Composite brake blocks - General conditions for certification and use,
Paris: Union Internationale Des Chemins De Fer, 2018.
[18] UIC Leaflet 541-4 / Appendix M; List of certified composite brake blocks, Paris: Union
Internationale Des Chemins De Fer, 2010.

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Report

LOCOS EQUIPPED WITH BRAKE SHOES IN IR FLEET - DATE 10.06.2019*

Table 2:
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Brake Brake Brake Brake Brake Nr. of
Basic Maximum Minimum Axis in max. speed Type of Info: Nr. of
CAR series CAR - type Weight [t] Weight [t] Weight [t] Weight [t] Weight [t] Bogies discs per
Weight [t] Weight [t] Weight [t] each bogie [km/h] shoe today vehicles
axle
Mode P Mode <R> Mode R (red) Mode R+Mg (red) Mode G
G12 Loco no data no data no data no data no data 76,5 no data no data 2 2 block no data no data 27

G26CW-2 Loco N/A N/A N/A N/A 45 - 50 116 no data no data 2 2 block no data no data 12
Vehicles of ISR

G26C-W Loco N/A N/A N/A N/A 45 - 50 98,84 no data no data 2 2 block no data no data 11
0.00

JT42BW-Bo.Bo Loco 72 N/A N/A N/A 67 89,5 no data no data 2 2 block 110 no data 8
Revision

JT42CW-Co.Co. Loco 114 N/A N/A N/A 85 112 no data no data 2 3 block 140 no data 48

NGT26-CW Loco 90 N/A N/A N/A N/A 122 no data no data 2 3 block no data no data 11
* source: E-Mail from Milad Assaf; 2019-12-11

Data of Locos with brake shoes

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FREIGHT WAGONS and SERVICE WAGONS EQUIPPED WITH BRAKE SHOES IN ISR FLEET
Braking wheight Max Non
Max Load Speed Balance Permit Max Tara
Qtty length
Empty side to Load
Manual Auto (KM/H) wheight wheight
side (ton)
Freigth Wagons
- 51 24 70 29 1:1.1 60 84 21,5 15,04
- 44 25 70 33 1:1.1 60 84 21,5 15,04
- 49 26 70 58 1:1.1 60 84 21,6 15,04
- 51 27 70 1 no data 60,5 84 23,5 13,7
- 59 28 80 68 1:1.2 65 90 25 15,14
- 50 27 80 59 1:1.2 66 90 24 14,04
- 50 27 70 204 1:1.1 60 84 22,7 14,04
- 52 29 80 56 1:1.2 65 90 24,7 14,29
- 59 28 80 52 1:1.2 65 90 24,5 15,04
- 59 28 80 24 1:1.2 66 90 24 15,04
- 52 28 80 15 1:1.2 54 80 26 14,04
- 52 28 80 15 1:1.2 57 80 23 12,74
- 48 24 80 20 1:1.2 58 80 21,5 12,24
- 56 20 80 60 1:1.2 63 80,7 17,7 19,64
- 56 20 80 75 1:1.2 63 80,8 17,8 19,64
- 51 23 80 182 1:1.2 70 90 19,7 19,74
- 58 22 80 74 1:1.2 72 90 18 13,86
- 72 21,2 80 160 1:1.25 72 90 18 19,64
- 72 no data 80 100 01:03 73 90 17 13,5
- 48 24 70 30 1:1.1 60 80 23,5 20,64
- 48 24 70 17 1:1.1 61 80 19 14,04
40 - 25 60 17 1:1.1 50 72 20,5 16,24
40 - 26 60 2 1:1.1 50 72 20 19,24
- 40 19 80 25 1:1.1 61 80 16 13,5
42 - 21 60 2 1:1.1 50 72 18 16,15
Service Wagons
- 48 24 60 18 no data 60 no data 23,5 20,64
no data no data no data 60 1 no data 70 no data 20 16,5
- 41 25 60 1 no data 50 no data 25 16,24
no data no data no data 60 1 no data 62 no data 21,5 19,24
42 - 21 70 1 no data 72 no data 18 16,14
31 - 16 60 1 no data 58 no data 18 13,34
31 - 16 60 1 no data 68 no data 18 16,15
40 - 25 60 2 no data 70 no data 20,5 16,24
no data no data no data 60 2 no data 58 no data no data 18,61
31 - 16 40 2 no data 60 no data 18 13,34
42 - 25 50 15 no data 50 no data 22,5 16,24
Table 3: Data of freight wagons and service wagons with brake shoes

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C Drawings of Brake shoes

Figure 2: brake shoe drawing V-573

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Figure 3: brake shoe drawing V-648

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Figure 4: Brake Shoe AF-2 (extract from [9])

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Figure 5: Brake Shoe DX 2 (extract from [9])

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Figure 6: Brake Shoe DX 2 with handwritten modifications [11]

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D Material Characteristic Sheets

Figure 7: Material Characteristic Sheet MCS-035-m [7]

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Figure 8: Material Characteristic Sheet MCS-052-m [8]

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