UIC Code 866

o
2nd edition, 01-01-85
Reprint of 01- 10-88

Technical specification
for the supply of cast manganese steel crossings

for switch and crossing work

International Union of Railways

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Leaflet to be classified in Volumes:

VII - Way and works

VIII - Technical specifications

Amendments
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o- INTRODUCTION

This specification sets out requirements in respect of

material quality and manufacturing, together with conditions
governing the acceptance of cast manganese steel crossings for
turnouts and diamonds.
When invitations to tender are issued this
f.pecification shall be accompanied by any other documentation
necessary for fulfilling the contract, with special reference
to application of the following articles in the specification:

1.2 - Manufacture
1.3 - Drawings and inspection gauges
1.4 - Markings
1.5 - Appearance and finish

1.6 - Repair

1.7 - Tolerances
2.3 - Tests (type of)
2.4 - Chemical analysis
3.1 - Manufacturer's guarantee and liability
Appendix

1 - MANUfACTURING CONDITIONS

l.:.l. - ~1ateri a 1

Castings for switch .and crossing work shall be

manufactured from austenitic higher manganese steel.
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1.2 - Manufacture

Unless otherwise specified in the invitation to tender.

methods used for smelting. casting and heat treatment shall be
left to the discretion of the supplier. who shall however
notify the purchasing railway of the processes in question.

Throughout the entire manufacturing process the

supplier shall use the best available techniques to ensure that
castings comply with this specification.

The necessary preheating prior to quenching shall be

carried out in a furnace equi pped with proper teq»erature
control and recording equipment (pyrometers). Temperature
recordings from the control equipment shall be available to the
purchasing railway at all times.

Castings quenched simultaneously shall be separated by

wedges.

1.3 - Drawings and inspection gauges

Basic drawings for the castings shall be provided by

the purchasing railway or the supplier. Before commencing
production the supplier shall submit manufacturing drawings to
the purchasing railway for approval, in accordance with terms
to be agreed by both parties.

Dimensional tolerances for manufacture, approximate

weight and the position of impact test-pieces shall be
indicated on the manufacturing drawings.

All inspection gauges shall be provided by the

supplier. They snClll be inspected by the purchasing railway
and if judged satisfactory be marked by it accordingly.
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The supplier shall submit a prototype of each casting

for approval if this is stipulated in the invitation to tender.

1.:.!!. - Markings

All car.tings shall be marked 1t:gibly with the

following :

- manufacturer's mark;
railway's mark;
- month and last two digits of the year of manufacture;
designation of the rail section and the angle of the
crossing, or solely an identification mark.
a continuous serial number for each type of casting.

All these marks shall be embossed by the foundry, and

no others shall be added without the prior authority of the
purchasing railway.

The arrangement and position of the marks shall be

shown on the drawings submitted to the purchasing railway for
approval; the characters shall be 20 to 40 mm in height.

1.5 - Appearance and finish

All castings shall be carefully cleaned of sand and all

loose oxide; casting gates, air-holes and sink-heads must be
removed. The castings shall be free of defects such as
shrinkage cavities, scabs, cold shuts, flakes, cracks,
bHsters, lack of metal, porosity and inclusions which might
adversely affect their suitability for use or their durability.
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They must have clean surfaces; any irregularities,

traces of joints, casting fins, etc. must be carefully ground
off.

Running surfaces and their connecting fillets, fishing

surfaces and all surfaces which make contact on assembly,
together with ends, shall be correctly shaped and calibrated.

The purchasing raUway shall stipulate which surfaces

are to be finished by mechanically-guided machining.

Fish-bolt holes shall in principle be drilled and have

a 1 mm chamfer at each end. Holes for holding-down screws and
electrical connections may be cast undersize and subsequently
opened out to correct size.

Any operation, whether carried out hot or cold, the

purpose of which is to conceal a fault, is forbidden and shall
cause the casting to be rejected.

When the customer railway's representative has examined

any faults, repair work shall be effected in accordance with
the provisions contained in the appendix.

Any dfscontinuities not eliminated within the maximum

depth permitted shall cause the casting to be rejected.

1.7 - Tolerances

Dimensional tolerances for manufacturing shall be given

in the drawings appended to the invitation to tender.
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Unless otherwise specified in the invitatiun to tender,

the dimensions of those Iwrts of the casting listed below shall
have the following tolerance ranges:
Body of the casting

length 5 mm
height 3 mm

- width of base, supported on baseplates 2mm

supported without baseplates 3 mm

fl"ngeways mm

surface flatness mm
- diameter of holes for sleeper screws 2 mm

End of casting (over half a fishplate length)

- height of railhead mm
- height of fishing table 1 mm

- overall height 2 mm

- width of railhead (in relation to web centre-line)

running edge 1 mm
outbide edge 2 mm

- width of base 2 mm

thickness of web 2 mm

position of web faces (in relation to the running

edge 2mm

angle of inclination of the fishing surfaces (in

relation to the theoretical inclination) 3.6 •
- diameter and position of fish-bolt holes 1 mm

Tolerances for straightening of running edges and for

their distance apart at ends shall be specified in the
invitation to tender.
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2 - ACCEPTANCE

2.1 - General

The supplier must be able to carry out all tests laid

down.

The preparation of test pieces and the tests themselves

shall be carried out at the supplie~s expense and he shall make
staff and equipment available to the purchasing railway's
representative as required.

The purchasing railway's representaHve shall be

entitled to monitor all stages of manufacturing by day or
night. to be present during all tests on castings ordered and
to be informed of test resul ts. He may underUlke any
inspections necessary to ensure that the agreed manufacturing
conditions have been observed.

2.2 - Submission for acceptance

Castings shall be submitted in delivery condition.

They must not have any paint. or even graphite or slate powder.
applied. Machined parts of fishing surfaces may be oiled at
the purchasing railway's request.

2.3 - Tests (type of)

Apart from verification checks for dimensions,

appearance and chemical analysis, and from the impact bending
test. castings may be inspected by means of non-destructive
tests.

The purchasing railway shall stipulate in the

invitation to tender which non-destructive tests are required,
e.g. radiographic, ultrasonic. dye penetrant, etc.
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~- Chemical analysis

2.4.1 - Verification check of chemical analysis

Depending on the purchasing railway's requirements.

chemical analysis may be accepted on the basis of a certificate
of analysis provided by the supplier or verified by analysis of
samples taken from test-pieces provided for the impact bending
test.

2.4.2 - Carrying out the analysis

Ana 1ysi s shall be carri ed out in accordance wi th the

national standards of the country of production.

If sample pi eces are analysed they shall in pri nci pl e

be of cubical form of size 30 x 30 x 50 mm. Three samples
shall be taken. i.e. :

one for the purchasing railway,

- one for the supplier,
one for a control analysis in the event of disagreement.

~ - Requi red results

Unless otherwise stipulated in the invitation to tender

the percentage content of the various elements shall comply
with the following conditions

carbon: 0.95 - 1.3;

- manganese: 11.5 - 14. The manganese content must be more
than 10 times the carbon content;
si 1 icon : < 0.65;
sulphur: <0.03;
phosphorus : < 0 .Ol! • The maximum may be set at 0.08 if
so stipulated in the invitation to
tender by the purchasing railway.
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The amount of other alloying elements (Cu, Ni, Cr,

etc.) may be stipulated in the invitation to tender.

The grain structure must be completely austenitic and

free from loose carbide.

~~ Impact bending test

This test may be carried out before the casting is

finished.

~~ ~aking and preparation of test~pfeces

Test~pieces for impact testing shall have a 30 x 30 mm

(tolerance! 1 mm) cross~section and be 200 mm in length. Four
pieces shall be taken, of which two shall be for the usual
acceptance tests and two for any extra tests. The test~pieces
shall be cast together with each casting and shall only be
separated from it after heat treatment and marking by the
purchasing raflway's inspector.

2.5.2 ~ Execution of tests

The impact test~pieces shall be of unmachined bar, the

edges of which may have a chamfer not exceeding 1 mm.

Prior to the test the bars shall be notched in a press

to a semi~circle (r = 1.5 mm; depth = 1.5 mm) on one face in
the presence of the inspector.

The test-pieces shall then be placed horizontally on

two knife-edge supports spaced 160 mm apart, notch downwards
and mid-way between the two supports. The knife-edge supports
shall have a radius of 2 mm. The test pieces must withstand 3
successive blows of a 50 kg weight falling freely from a height
of 3 m onto the surface opposite the notch. The part of the
falling weight coming into contact with the test-piece shall be
rounded to a radius of 50 mm.
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2.5.3 - Number of tests

Two impact tests shall be made for each casting.

2.5.4 - Required results

The test-pieces must withstand three impacts. They
may crack but the crack must not extend more than 7 mm up.

Both test-pi eces must comply wi th the above

dcceptance conditions for the casting to be acceptable.

2.5.5 - Extra tests - Further heat treatment

I f one or both of the impact tests gives

unsatisfactory results. the supplier may opt to request an
extra test to be performed

on the casting as it is,

- on the casting after further heat treatment: this, however,
shall be possible only on a casting in the unfinished state.

The extra test shall be carried out on the two

remalmng test-pieces, subject to the same conditions as set
out abovt: for the fi rst two tests. I f one of the two extra
tests gives unsatisfactory results the casting shall definitely
be rejected.

2.6 - Interpretation of test results

Acceptance of castings is subject to compliance with

dll conditions set out in this specification.
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2.7 - Dimensional appearance/finish check on the equipment

This shall be carried out on each item, and shall cover

the pOints referred to in Articles 1.5 - 1.7.

3 - GUARANTEE AND PATENT RICHTS

3.1 - Guarantee and manufacturer's liability

The manufacturer shall guarantee cast manganese steel

crossings for a period of three years from the date when they
are laid in the track; the validity of guarantee may not
however extend beyond four years after the date of delivery,
which shall be taken as the last day of the month marked on the
casting.

Any casting which during this period deteriorates other

than by normal wear or which exhibits faults not detected
during acceptance inspection at the works shall be replaced by
one of the same type free of charge by the manufacturer, or
alternatively the manufacturer shall pay compensation equal to
the value of the casting, calculated by applying the price paid
at the last order for castings of the same type.

The same guarantee shall be applicable to a casting

supplied free of charge in replacement of a faulty casting.

If the supplier so requests the faulty casting shall be

returned to him, in which case he is liable for payment of the
transport costs incurred.

The purchasing railway may stipulate an alternative

guarantee clause in the invitation to tender.

3.2 - Patent rights

The manufacturer shall be liable for any patent rights,

and shall fndemnify the purchasing railway from any claims in
thfs respect.
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APPENDIX

INSTRUCTIONS FOR THE REPAIR OF CAST MANGANESE

STEEL CROSSINGS
BY THE MANUFACTURER

INTRODUCTION

These instructions establish the rules allowing under

certain conditions for the removal and repair by arc welding of
localised casting defects, namely lack of metal, shallow
cracks, porosities, inclusions or cold shuts, Observed on any
new castings, whether as-cast or in the process of being
machined.

These provisions shall apply to common and obtuse

crossings.

Repair operations may (after examination of the defect

and depending on where it is situated) only be undertaken after
prior agreement :

- of the purchasing railway's representative, in the case of

defects the repair of which is authorised by virtue of these
instructions;

- of the purchasing railway in the case of defects the repair

of which is not authorised under the terms of these
instructions.

Failure to comply with these provisions shall on

principle result in rejection of the castings in question.
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APPENDIX

1 - DEFINITION OF REPAIR ZONES (1)

Zone 1 - Fishing tables

Zone 2 - Parts of running surfaces (head and

running edge) subject to impact
from wheeh

Zone 3 - Parts of running surfaces not

K\\\\1 subject to impact from wheels
- Active parts of the flangcways of
crossings
- End section

fZ//111 Zone 4 - Foot of crossing below the impact

zone in the centre

Zone 5 - All parts of the crossing apart

from zones 1 to 4.

2 - MAXIMUM DIMENSIONS OF DEFECTS FOR WHICH REPAIR

IS AUTHORISED, WITH RESTRICTIONS (1)

Authorised repairs may be mandatory or optional, as

stipulated in the attached figure.

(1) See drawings and table in the attached figure.

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APPENDIX

Authorised repairs may be cumulated, subject

to the restrictions set out in the paragraphs below. Authorised
repairs may not however be cumulated in the case of adjacent.
defects of the same type.

2.1 - Lack of Metal

2.1.1 - Maximum din~nsions

Lack of metal resulting from a

design/manufacturing fault in the casting mould (incorrect
geometry of the mould or core, deterioration of the impression,
etc.) with a surface area whose largest dimension is ",3Omm and
whose depth is ~ 8 RIft, without exceedi ng one thi rd of the
thickness.

A machi ni ng taul t may be counted as a defect

of this type.

2.1.2 - Restrictions

Repairs in zones 4 and 5 are optional.

2.2 - Cracks

2.2.1 - Cracks.§. 30 RIft in length

2.2.1.1 - Maximum dimensions

Any crack whose developed 1 ength i s ~ 30 mm

a nd whose depth when ground out i s ~ 8 mm wi thout e~eedi ng
one-third of the thickness.
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APPENDIX

2.2.1.2 - Restrictions

Repairs are authorised in zone 1, with the exception of

repairs to cracks in the connecting fillets between the web and
the fishing surfaces, or to cracks, usually star-shaped,
originating at the fish-bolt holes.

Repairs are not authorised in zone 2.

In zones 1, 3 and 5 only one repair is authorised on

the parts of the crossing within length L 2.

~ - Cracks between 30 and 60 mm in length

2.2.2.1 - Maximum dimensions

Any crack whose developed length is between 30 and 60

mm and whose depth when ground is~8 mm, without exceeding ~ne
third of the thickness.

2.2.2.2 - Restrictions

Repairs are not authorised in zones 1, 2, 3 and 4.

In zone 5 only one repair is authorised on the parts of

the crossing within length L 2.

2.3 - Surface defects

2.3.1 - Maximum dimensions

Porosities, inclusions, cold shuts whose largest

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APPENDIX

dimension is ~ 8 mm; thf' depth when ground out must not exceed
one-third of ~he thickness.

2.3.2 - Restrictions

Repairs are not authorised in zone 1.

Repairs in zones 4 and 5 are optional.

3 - CONDITIONS GOVERNING REPAIR

Conditions governing the preparation of repai r work,

the execution of this work and its finishing, shall be set out
in the invitation to tender.
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COMMONCROSSI NG REPAIR ZONES J L 1 : Length of top machining of nOSE (2) + 100 mm o
Impact zones
l L2: Length of fishing table (machinud part) Plat(l

Application of article 2
0 (Optional:
{
authorised (3) M (mandatory)
Repair {
not authorised : N.A.

L2
Types of defect
~ Zones 1 2 3 4
"",- r / / /
5

-l2 - -----...

l A,iWt ' )
c-c 2J
Lack of meta!jdepth";; 8 mm
without exce ing 1/3 of the
thickness) largest Climension
,.;;30mm
M M M 0 0

: c, d b ~ I....r
__'_____
~~ Cracks the depth
2.2.1 of which";; 8 mm
without exceeding
Length,.;; 30 mm M N.A. M
(4)(5) - - (4)
M M
(4)
f-
OBTUSE CROSSING REPAIR ZONES 1/3 of the thick-
30 mm";; L..;;60 mm' NA N. A. N. A. N. A. M
2.22 ness
(4)

Inclusions, porosities, cold shuts (largest

2.3 dimension";; 8 mm, depth ~ 1/3 N.A M M o o
thickness)

(1) Dimension to be specified in invitation to tender

(2) Shown on approved drawing
(3) Following examination and agreement by the purchasing railway's
representative
(4) One repair only authorised on the parts of the cro,;sing within
lengths L2
(5) NA in connecting fillets web/fishing surfaces, and in the case of
cracks originating at fish-bolt holes.
Apart from the restrictions set out in § 2, in particul"lr concerning
adjacent defects of the same type, authorised repairs may be cumufated.
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Application

With effect from 1 January 1985

All Railways in the Union

Record references

Headings under which the question has heen examined:

- Preparation of a specification for the supply of cast

manganese steel crossings for switch and crossing work.
(5th Committee - PWS, Paris, June 1957).

- Revi sion of Leaflet 866 "Technical specification for the

supply of cast manganese steel crossings for switch and
crossing work".
(Way and Works Committee, Paris, June 1984).