L1 CHE STD 022 v2 Rail Grinding

Engineering Standard
Track
MTST 033100-08
RAIL GRINDING
Version: 2
Issued: February 2015
Approved By:
Paul O’Halloran
Chief Engineer
PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
TRACK ENGINEERING STANDARD
RAIL GRINDING
MTST 033100-08 L1-CHE-STD-022 Version: 2 Effective from 3rd February 2015
Approval
Amendment Record
Approval Date Version Description

22/11/2012 1 Initial issue under MTM.
Universal profile (MTM profile) for milling added. Document re-
numbered from L2-TRK-STD-001 with modifications in section
2.0 Scope and added section 8.0 Rail Milling.
03/02/2015 2 In section 10.2 Template Fabrication, amended the template

fabrication tolerance from +/- 0.1mm to +/-0.025mm.
Appendix 4 added.
Approving Manager: Chief Engineer Approval Date: 03/02/2015 Next Review Date: 03/02/2018
PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 37
RAIL GRINDING
Table of Contents
1. Purpose .............................................................................................................................. 5
2. Scope ................................................................................................................................. 5
3. Abbreviations .................................................................................................................... 5
4. Definitions.......................................................................................................................... 6
5. References & Legislations .............................................................................................. 14
6. Responsibilities ............................................................................................................... 14
7. Safety and Environmental............................................................................................... 14
8. Rail Milling ....................................................................................................................... 14
9. Rail Grinding .................................................................................................................... 15
9.1 Types of Rail Grinding ...............................................................................................................15
9.1.1 Corrective or Defect Grinding ........................................................................................15
9.1.2 Transitional Grinding ......................................................................................................15
9.1.3 Preventive or Cyclic Grinding ........................................................................................15
9.1.4 Special Grinding.............................................................................................................15
10. Rail Profiles ..................................................................................................................... 15
10.1 Templates ..................................................................................................................................15
10.2 Template Fabrication .................................................................................................................19
10.3 Calibration ..................................................................................................................................19
10.4 Template Application .................................................................................................................19
10.4.1 Placement ....................................................................................................................19
10.4.2 Tolerance to Template .................................................................................................21
10.4.3 Allowance for Rail Rotation ..........................................................................................21
10.4.4 Allowance for Transposed Rail ....................................................................................21
10.4.5 Gauge Corner Relief ....................................................................................................21
10.4.6 Field Side Relief ...........................................................................................................22
11. Metal Removal for Grinding ............................................................................................ 22
11.1 Metal Removal for Corrective Grinding ......................................................................................22
11.2 Metal Removal for Preventive/Transitional Grinding .................................................................23
11.2.1 Plain Track ...................................................................................................................23
11.2.2 Turnouts .......................................................................................................................23
12. Surface Finish.................................................................................................................. 24
12.1 Grinding Facets ..........................................................................................................................24
12.2 Other Surface Irregularities ........................................................................................................24
13. Competencies .................................................................................................................. 26
14. Related Documents ......................................................................................................... 27
15. Records ............................................................................................................................ 27
16. Appendices ...................................................................................................................... 27
16.1 Appendix 1 – Tangent Rail Template and Contact Region .......................................................28
RAIL GRINDING
16.2 Appendix 2 – High Rail Templates and Contact Region ...........................................................30

16.3 Appendix 3 – Low Rail Templates and Contact Region ............................................................34
16.4 Appendix 4 – Template Co-ordinates for Universal Profile (MTM Profile) of Rails in Tangent
and Curves ..........................................................................................................................................36
List of Tables
Table 1: X-Y Co-ordinates of Tangent (TGT) Template ...................................................................................28
Table 2: X-Y Co-ordinates of High Rail (H1) Template ....................................................................................30
Table 3: X-Y Co-ordinates of High Rail (H2) Template ....................................................................................32
Table 4: X-Y Co-ordinates of Low Rail (L1) Template ......................................................................................34
Table 5: X-Y Co-ordinates of Universal (MTM) Rail Template ........................................................................36
List of Figures
Figure 1: Contact Band (indicated by arrow) ...................................................................................................... 6
Figure 2: Directions in Rail.................................................................................................................................. 7
Figure 3: Flaking Defect on Rail Head ................................................................................................................ 7
Figure 4: Regions in Rail .................................................................................................................................... 8
Figure 5: Gauge Corner Cracking ...................................................................................................................... 9
Figure 6 - Typical arrangement of a milling cutter head for rail milling .............................................................10
Figure 7: Short Pitch Corrugations in Rail ........................................................................................................11
Figure 8: Shelling in the Gauge Corner of Rail .................................................................................................12
Figure 9: Components of a Turnout ..................................................................................................................13
Figure 10: Example of Metal Removal Requirements in Worn Rails in Tangent Track Using the TGT
Template ...........................................................................................................................................................16
Figure 11: Example of Metal Removal Requirements in Worn High Rails in Curved Track Using the H2
Template ...........................................................................................................................................................17
Figure 12: Example of Metal Removal Requirements in Worn Low Legs in Curved Track Using the L1
Template ...........................................................................................................................................................17
Figure 13: Example of Metal Removal Requirements in Worn High Rails with Severe Corrugations in Curved
Track Using the H2 Template ...........................................................................................................................18
Figure 14: H1 and H2 High Leg Grinding Profiles ............................................................................................18
Figure 15: Example of Holding Bar for Template .............................................................................................20
Figure 16: Unacceptable Gauge Corner Undercutting (Arrow Points to Gauge Corner) .................................22
Figure 17: Gauge Corner Checking Defects Left in the Rails after Grinding (Arrow Points to the Gauge
Corner) ..............................................................................................................................................................23
Figure 18: New 60kg/m Rail in Turnout with Tangent (TGT) Template ...........................................................24
Figure 19: Acceptable Standard of Finish from Grinding .................................................................................25
Figure 20: Unacceptable Severe Grinding Scratches (Arrow Points to Gauge Corner) ..................................25
Figure 21: Unacceptable Cyclic Grinding Scratches ........................................................................................26
Figure 22: Tangent (TGT) Template and Nominal Running Surface Contact ..................................................29
Figure 23: High Rail (H1 and H2) Templates and Nominal Running Surface Contact ....................................33
Figure 24: Low Rail (L1) Templates and Nominal Running Surface Contact ...................................................35
Figure 25: MTM Rail Template ........................................................................................................................37
RAIL GRINDING
1. Purpose
The primary objective of this document is to define the maintenance standards for the
grinding of running rails with the express purpose of increasing the life of track and
structures assets as well as rolling stock assets.
This document describes the Rail Grinding requirements for the Melbourne Metropolitan
Rail Network, contained within the Infrastructure Lease managed by MTM. Rail Grinding
will increase the life of both track and rolling stock assets by optimising the wheel/rail
interface.
Importantly, the document also establishes rail profiles that shall be used on track within the
Melbourne Metropolitan Rail Network and the quality of grinding to be achieved.
NOTE: This Standard has, in part, been compiled from various industry standards
considered by MTM Engineering to be best practice in the development of standards,
criteria and requirements for rail grinding to be applied within MTM.
2. Scope
This document provides details of the background and implementation processes
associated with Rail Grinding, and include:
 Common definitions applied in Rail Grinding
 Types of Rail Grinding
 Rail Profiles and associated Templates and Tolerances
 Metal Removal for Grinding
 Surface Finish Requirements
NOTE: The requirements specified by this Standard shall be applicable to alternative
methods of achieving desired rail profiles e.g. Rail Milling.
 A potential “universal” rail profile (identified as the MTM profile) has been developed for
milling, which basically combines the characteristics of the current H2 high rail template
towards the gauge side, and the current Tangent template towards the field side. Refer
to Appendix 4 and section 8.
3. Abbreviations
H1 High leg profile for curves with radius less than 800m
H2 Transitional high leg profile for curves with radius less than 800m
L1 Low leg profile for curves with radius less than 800m
Leq Sound exposure level expressed in decibels (dBs)
MGT Million Gross Tonnes
MTM Metro Trains Melbourne Pty Ltd
Ra Average Roughness as per AS 2382
TGT Tangent profile, for tangent track and curves greater than 800m
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4. Definitions
Authorised MTM The Infrastructure Delivery Manager or his delegated
Representative representative.
Checking Locations Specific points marked on the rail where the achievement of the
defined rail profile and / or metal removal is checked and monitored.
Contact Band The contact position of the wheels on the rail as evidenced by the
shiny worn surface as shown in Figure 1. This generally applies to
wheel contact occurring on the running surface region of the rail.
Figure 1: Contact Band (indicated by arrow)

Corrective or Defect Grinding carried out to remove specific defects in the rail. Such
Grinding defects may occur over a long track section (rail corrugations or
extensive rolling contact fatigue) or over short track sections (wheel
burns or isolated rolling contact fatigue defects).
Digital Rail Profile An electronic device used to measure and check the profile of the
Measuring Device rail with the information being collected and stored for later analysis.
These can be both automated running inline with a vehicle or
manual handheld types. Generally, the manual version is placed on
top of the rail and via either a inbuilt laser or tracing wheel, the
actual profile is measured providing an overall outlay to be
compared against predefined rail templates. Within the rail industry
there are a variety of versions available depending on the operator
requirements but in affect complete the same function.
RAIL GRINDING
Directions in Rail
Figure 2: Directions in Rail
Flaking Flaking is a surface condition that propagates from the shear

stresses applied to the rail head at the wheel contact areas of the
low leg. It appears as a mosaic or snakeskin like pattern on the rail
head. In the latter stages of growth these cracks begin to 'spall',
mainly in the centre of the rail head, and can be continuous over
the rail length (refer to Figure 3).
Figure 3: Flaking Defect on Rail Head

Field Side The side of the rail opposite the gauge face (refer to Figure 4)
RAIL GRINDING
Field Side Running Surface Region Gauge Corner

50 Region 40 mm Region
Gauge
40
Corner
4545°
C/L
Outside
30
of
Track Inside of
Tr ack
20
10
0
-40 -30 -20 -10 0 10 20 30 40
Figure 4: Regions in Rail

Field Side Relief Clearance between the wheel profile and the rail profile to reduce
wheel / rail contact on the head of the rail in the field side region.
Gauge Bar A rod or bar section which sits between and normal to the rails to
provide a superelevated reference for the application of the
template.
Gauge Corner The top corner of the rail above the gauge face (refer to Figure 4)
Gauge Corner Clearance between the wheel profile and the rail profile to reduce
Relief wheel / rail contact on the head of the rail in the gauge corner
region.
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Gauge Corner A surface condition that propagates from the shear stresses applied
Cracking or to the gauge corner contact region of the high rail in curves. It
Head Checks results in the deformation of the rail surface, and could be
described as being like ‘fish scales’. The head checks generally
occur at about 2-5 mm intervals and can grow to the same depth,
gradually spreading across the rail head. Once this occurs they can
break out as ‘spalls’. If left in track, head checking will deteriorate
further into a shelling flaw, and in turn, possibly a transverse defect
(refer to Figure 5).
Figure 5: Gauge Corner Cracking

Gauge Face The zone of the rail head facing the inside of the track. In the tighter
curves the gauge face may be worn due to contact with the wheel
flange.
Grinding The party conducting rail maintenance / grinding activities on behalf
Operator of MTM.
Grinding Facet Flat ridges left on surface of the rail by grinding stones after
grinding passes.
Hi Leg The high rail in canted track.
Lipping Overhanging metal due to plastic flow (rail flow) of the steel rail.
Low Leg The low rail in canted track.
Rail Milling A process that removes material away from a given area on the rail
head to a pre-defined profile by the use of rotating cutting heads.
Unlike conventional rail grinding, which consist of an array of
grinding wheel each removing a set amount, a standard rail milling
operation consists only of one set of milling cutters and a pair of
grinding wheels used to clean up the machining marks. There is
also the by-product of metal swarf (filings) which is collected inline
by the machine. In essence either rail grinding or milling operations
can be used to re-profile the rail. Typical rail milling cutter is shown
in Figure 6.
RAIL GRINDING
Figure 6 - Typical arrangement of a milling cutter head for

rail milling
Preventive or Grinding carried out to a regular schedule for the purpose of
Cyclic maintaining the rail profiles, preventing or inhibiting the growth of
Grinding defects, and maintaining the surface condition of the rail
(particularly in terms of corrugations and local vertical irregularities),
with a minimum metal removal of 0.1-0.2 mm from the rail contact
surface each grinding cycle.
Profile Grinding carried out to create the desired rail profile which provides
Grinding the correct contact band on the rail surface and wheel/rail interface.
Best practice indicates that profile grinding may occur across the
network. This may be based upon MGT and Rail condition as part
of the agreed to Asset Management Strategy.
Rail Cyclic (wave-like), generally vertical, irregularities on the running
Corrugation surface of the rails. Corrugations form from either the differential
wear caused by a repetitious sliding action of the wheel on the rail,
whether through acceleration, braking or lateral motion across the
rail, or from plastic flow of the rail material due to excessive contact
stresses and the combined resonance of the wheel set unsprung
mass and the track. Corrugations are generally 0.1mm to 0.5 mm in
depth, although sometimes can be larger, and may be:
Short pitch - from about 30 mm to 90 mm in wavelength, which are
associated with the lighter axle load passenger traffic (refer to
Figure 7);
RAIL GRINDING
Figure 7: Short Pitch Corrugations in Rail

Long pitch - from about 200 mm to 450 mm in wavelength or more,
this is typically associated with heavier axle load freight traffic.
Rail Flow Plastic flow of the rail surface material, which may occur on high,
low and tangent rails, both on the field and gauge sides. It results
from exceeding the yield strength of the material, which can occur
because of various reasons including higher tractive effort and poor
matching of wheel and rail profiles (including wheel hollows).
Rail Grinding A template used to fit over the head of ground rail to show the
Template relationship of the ground rail to the defined rail profile.
Rolling This is a generic term used to describe a range of defects which are
Contact due to excessive wheel / rail contact stresses and which may be of
Fatigue (RCF) the following types:
 Gauge Corner Cracking / Head Checks
 Flaking
 Shelling
Running The zone on top of the rail head which makes contact with the
Surface wheel tread (refer to Figure 4).
Records Objective evidence of having satisfied this Standard through
measurement, calibration, certification and inspections.
Shall Is used as the descriptive word to express a requirement that is
mandatory to achieve conformance to the Standard.
Shelling An internal defect (approximately 2 mm to 8 mm below the gauge
corner), that normally initiates at oxide inclusions or 'stringers' of
such inclusions that may be present in the rail steel. It is typically
confined to the gauge corner radii of rails on the high side of curves
(refer to Figure 8). Shelling cracks form on a horizontal or
longitudinal plane consistent with the profile of the rail on the gauge
corners. The cracks can continue to grow on that plane, and then
either spall out into a shell or turn down and form transverse defects
which can continue to grow on a transverse plane and in time will
lead to rail failure if not detected. The longitudinal separation from
which these transverse defects propagate is not always visible. The
presence of lubricants (water and grease) can enhance the growth
of shells, particularly in the presence of head checking.
RAIL GRINDING
Figure 8: Shelling in the Gauge Corner of Rail

Should Is used as the descriptive word to express a requirement that is
recommended in order to achieve compliance to the Standard.
“Should” can also be used if a requirement is a design goal but not a
mandatory requirement.
Squats Starts as a subsurface tear caused by either rolling stock applying
tractive forces to the rail or lateral creep forces. Squats first appear
as a dark shadowy area within the running surface. Surface cracking
appears over time and surface metal can break out.
Transitional Grinding carried out over several cycles to transfer from a corrective
Grinding to a preventive grinding regime.
Tread/Wheel A condition where there is a worn hollow in the wheel treads.
Hollowing Generally tread/wheel hollowing is not observed in passenger rolling
stock.
Turnout A track feature allowing trains to change running lines. A typical
turnout is shown in Figure 9.
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Guard Rail
Points
Closure Rail Nose

Nose
Vee
Stock Rail
Wing Rail
Figure 9: Components of a Turnout

Crossing - Made up of the wing rails, the vee, nose and part of the
closure rails.
Wing Rail - Non-running rail. Extension of the closure rail past the
crossing to guide bogie wheels (Refer to Figure 9).
Closure Rail - The running rail in a turnout between the points and the
crossing (Refer to Figure 9).
Points - Moving running rail section of a turnout (Refer to Figure 9).
Vee - Section of crossing where two opposing running rails intersect
(Refer to Figure 9).
Nose - The apex of the vee.
Guard Rail - Non-running rail. Guides bogies wheels through crossing
for through running trains (Refer to Figure 9).
Stock Rail - Outer running rails, runs continuous throughout the
turnout (Refer to Figure 9), referred to as the Straight and Set
(curved) stock rails.
Wheel Burns Structural discontinuities that occur on the running surface of both
rails (directly opposite) and are due to the localised slip of a wheel
set. This can cause either severe localised deformation or
overheating and the transformation of the rail material into a hard and
brittle martensitic microstructure. The contamination of the running
surface of the rails, by for example lubricants, greatly enhances the
development of wheel burns.
RAIL GRINDING
5. References & Legislations

L0-SQE-MAN-002 Safety Management System Manual
L0-SQE-PRO-014 Safety and Environmental Requirements for Contractors Working
On MTM Premises
AS 2377-2002 Acoustics - Methods for the measurement of rail bound vehicle
noise
AS 2382 -1981 Surface Roughness Comparison
Book of Rules and Operating Procedures 1994
6. Responsibilities
General responsibilities for the application of this Standard are set out in the MTM
Management System Manual and the relevant personnel position descriptions.
All personnel who are assigned a task related to this Standard shall be trained, suitably
qualified and competent to carry out that task.
7. Safety and Environmental

The general requirements in relation to safety are included in MTM’s Safety Management
System Manual (L0-SQE-MAN-002).
At all times, track inspections shall be carried out in accordance with the current Book of
Rules & Operating Procedures 1994, and all relevant Track and Safe working circulars.
L0-SQE-PRO-014 Safety and Environmental Requirements for Contractors Working on
MTM Premises outline the requirements of contractors operating within MTM’s premises.
8. Rail Milling
Rail milling is a new process available to the Australian Rail Industry for the removal and
rectification of rail defects. The milling process removes defects by cutting out the defects.
Refer to Fig 6. for details. The metal waste known as swarf (fillings) shall be collected inline
and stored on the milling machine for disposal.
The milling process application shall provide;
 Removal of surface defects with a processing depth of 0.3 – 1.0 mm, in one pass and
includes the treatment of the entire rail head surface profile.
 Environmentally friendly: no emissions, no dust, no dirt and low noise.
 High accuracy of traverse and longitudinal profile.
 No thermal damage to the rail head.
 Milling process does not produce sparks eliminating the risk of track fires.
 The process does not require cutting fluid that may cause environmental damage.
 No need to remove track lubricators as the milling machine runs within the allowable
rollingstock outline for MTM trains.
RAIL GRINDING
9. Rail Grinding
9.1 Types of Rail Grinding

There are four principle types of rail grinding as follows;
9.1.1 Corrective or Defect Grinding

Corrective grinding primarily aims to remove the rail defects that have developed
(including corrugations, gross plastic flow and rolling contact fatigue defects). This
entails aggressive grinding procedures that aim to remove a considerable amount of
metal (at least 0.5 mm and up to 6 mm) at long intervals that are generally
determined by the severity of the defects.
9.1.2 Transitional Grinding

Transitional Grinding is less intensive than corrective grinding but more intensive
than preventive or cyclic grinding. It aims to provide a partial corrective grind in
preparing the rail for an eventual preventive or cyclic grind; this is usually carried out
over several cycles.
9.1.3 Preventive or Cyclic Grinding

Preventive grinding primarily aims to eliminate or at least control rail defects and
maintain the surface condition and the preferred rail profiles. This entails the
removal of small amounts of metal (minimum 0.2mm) at more frequent and
controlled intervals.
9.1.4 Special Grinding

Special Grinding entails the application of grinding in order to achieve specific
objectives that usually lie outside the scope of the aforementioned three grinding
types, e.g. establishing rail profiles to reduce the rate of wheel hollowing or to
provide a very smooth rail contact surface in order to reduce noise generated at the
wheel/rail contact.
10. Rail Profiles
10.1 Templates
The rail profiles have been specifically developed by MTM to suit the wheel profiles and the
rolling stock using the Melbourne Metropolitan Rail Network.
As part of the design profiles, the contact band widths and location positions are
determined (Refer to Appendix 1-3). The designed rail profiles have been converted into
matching templates for use with the rail grinding operation.
The rail profiles also address particular problems that have occurred (e.g. rail defects, asset
life extension), and form part of a transitional grinding strategy.
The details of the template designs are given in Appendix 1, 2 & 3, and their application
shall be as follows:
 Tangent (TGT) Applied to all rails in curves with radii equal to or greater than 800m
and is also the nominated profile for turnouts. Refer to Appendix 1
RAIL GRINDING
 High Rail (H1) Applied to the high leg in curves with radii less than 800m. Refer to
Appendix 2
 High Rail (H2) Applied to the high leg in curves with radii less than 800m, as part of
the transitional grinding strategy. Refer to Appendix 2
 Low Rail (L1) Applied to the low leg in curves with radii less than 800m. Refer to
Appendix 3
It should be noted that in initial Profile Grinding, the High Rail (H2) profile shall be applied to
the high leg in curves.
Figure 10, Figure 11, Figure 12 and Figure 13 provide examples of the modified profiles in
relation to actual worn rails.
NOTE: In Figures 10-13, the Field Side and Gauge Side are located on the right hand side
and left hand side of the figures respectively.
Figure 14 illustrates the difference between the H1 and H2 profiles. It can be seen that the
H2 profile leads to a greater amount of metal removal in the gauge corner region. This is
required to control the gauge corner checking defects that are currently present on the high
rails.
It shall be the responsibility of the Grinding Operator to assess the metal removal and
hence the grinding requirements. Several guidelines have been provided in Section 11.
Also described in Section 11, in certain track sections, there will be a requirement to
remove a considerable amount of metal primarily from the running surface of the rails, to
control rail corrugations. In all of these cases, the grinding shall be completed by the
implementation of the appropriate rail profile, which shall conform with all of the standards
applied to the normal preventive grinding practice.
It shall be noted that the measurement of metal removal, profiles and tolerances during /
after grinding shall be conducted by the Grinding Operator using either a non-contact profile
measuring system or a Digital Rail Profile Measuring Device. However, mechanical
templates (as per Section 10.4) may be used during the grinding as a means of checking
that the design profiles are achieved.
Figure 10: Example of Metal Removal Requirements in Worn

Rails in Tangent Track Using the TGT Template
RAIL GRINDING
Figure 11: Example of Metal Removal Requirements in Worn High Rails in

Curved Track Using the H2 Template
Figure 12: Example of Metal Removal Requirements in Worn Low Legs in

Curved Track Using the L1 Template
RAIL GRINDING
Figure 13: Example of Metal Removal Requirements in Worn High Rails with
Severe Corrugations in Curved Track Using the H2 Template
H1
0
-50 -40 -30 -20 -10 0 10 20 30 40
Field Side Gauge Side

-2
H2
Y Axis Coordinates (mm)
-4
MTM H1
MTM H2
-6
-8
-10
-12
X Axis Coordinates (mm)
Figure 14: H1 and H2 High Leg Grinding Profiles
RAIL GRINDING
10.2 Template Fabrication

When mechanical rail templates are used, the templates shall be constructed of hardened
steel (or a product of equivalent or superior strength, wear resistance, dimensional stability
and durability) to a tolerance of  0.025mm at the profile surfaces. Tolerances at the fixing
points for connection to the gauge bar shall be adequate to ensure that overall
superelevated profile tolerances (as detailed in below paragraph) are not compromised.
The template name, date of manufacture and designed contact band details shall be
permanently scribed on the face of the template. The template shall be manufactured with
the 1 in 20 (2.86) rail cant included, noting that the co-ordinates for the various templates
given in Appendix 1 are for vertical rails and do not include the allowance for rail cant.
A gauge bar shall be used with the rail template. The gauge bar provides fixing holes which
shall match those on the template. The gauge bar shall provide a reference to the other rail
to give a super-elevated reference plane for the application of the template to within  0.2
degrees (i.e. a deviation of less than 2.6 mm from a 1.5m straight edge). The gauge bar
shall be made of mild steel, aluminium or other product of equivalent or superior strength,
dimensional stability and durability. The gauge bar shall be insulated so that there is no
electrical contact between the rails during its application.
Figure 15 illustrates an example of a gauge bar to hold the profile template and applied for
quality control purposes during rail grinding.
10.3 Calibration
Template calibration shall be checked at initial fabrication and thence six-monthly. The
template shall be within 0.05 mm at manufacture and thence within 0.1 mm of the designed
profile. Calibration should be carried out with the template fitted to the gauge bar or with a
suitably designed calibration block that will allow the proper alignment and matching of the
template and the calibration block.
If a calibration block is used it shall be within 0.05 mm of the design geometry.
To ensure that the gauge bar has not been deformed, it shall also be checked against a
straight edge at monthly intervals. The gauge bar needs to be within the original
specification of  0.2 degrees (i.e. a deviation of less than 2.6 mm from a 1.5m straight
edge).
Any other equipment (including the vehicle mounted non-contact system), used for the
application of or verification of templates, must meet equivalent calibration and repeatability
requirements.
10.4 Template Application
10.4.1 Placement
The rail template shall be affixed to the gauge bar.
With the non-template end of the gauge bar resting on the other rail, the template
shall be placed onto the rail to be checked and moved down and across to
maximise the contact of the template on to the rail.
NOTE: It is important that no excessive force be placed by the operator on the
template or gauge bar, which may lead to their distortion or accelerated wear.
RAIL GRINDING
Figure 15: Example of Holding Bar for Template
RAIL GRINDING
10.4.2 Tolerance to Template
10.4.2.1 Plain Track

The rail shall be ground so that the profile matches the template.
Tolerance shall be checked by measuring the visible gap between the
rail and the template using a feeler gauge no wider than 4 mm at the
end. The maximum allowable gaps between rail profile and template
shall be as follows:
 For high legs in curves with radii < 800m – 0.20 mm within the
nominal contact band as shown in Appendix 1 (i.e. a 0.25 mm feeler
gauge must not pass between the template and the ground rail head
covered by the template).\
 For high legs on curves with radii ≥ 800m - 0.35 mm in the gauge
corner region of the high rails (i.e. a 0.40 mm feeler gauge must not
pass between the template and the ground rail head covered by the
template)
 For tangent and low legs - 0.20 mm within the nominal contact
bands on, as well as 0.35 mm outside of the nominal contact bands
To provide appropriate referencing for the above measurements, the rail
templates should contain scribe marks indicating the position of the
nominal contact bands as shown in Appendix 1.
10.4.2.2 Turnouts
Rail template tolerance requirements for turnouts are as per Section
10.4.2.1 with the following exceptions;
 All rail flow on the gauge side of rails shall be removed.
10.4.3 Allowance for Rail Rotation

An allowance for potential rail rotation which may be due to rail seat wear and/or
applied wheel loads has not been made.
10.4.4 Allowance for Transposed Rail

MTM do not transpose rail, as such, an allowance for transposed rail has not been
made.
10.4.5 Gauge Corner Relief

Generally any required gauge corner relief is built into the templates. Consequently,
gauge corner undercutting, that leads to two point wheel / rail contact conditions in
the sharper curves (with radii less than 800 m), as illustrated in Figure 16, and
which exceeds the specified tolerances in this region shall not be accepted.
Figure 16 also shows that the grinding facet produced at the gauge is greater than
the maximum allowable limit of 4 mm (refer to Section 12.1).
However, in special circumstances where approved by an Authorised MTM
Representative, the rail condition may warrant the use of an additional gauge corner
relief, to extend the rail life.
RAIL GRINDING
The usage of up to 0.6 mm gauge corner relief as measured by the gap between rail
and template may be approved in these circumstances. The grinding facet limits as
specified in Section 12.1 must still be observed.
Figure 16: Unacceptable Gauge Corner Undercutting (Arrow Points to Gauge Corner)
10.4.6 Field Side Relief

Generally any required field side relief is built into the templates. Additional relief
requirements may be specified but only up to the tolerances stipulated (refer to
Section 10.4.2).
11. Metal Removal for Grinding
11.1 Metal Removal for Corrective Grinding

Allowance may be made for some gauge corner cracking/checking to remain after grinding
(refer to Figure 17).
To minimise the amount of metal removal, major rail rectification (e.g. repair and build up of
the nose at crossings), should be undertaken prior to rail grinding works.
RAIL GRINDING
Figure 17: Gauge Corner Checking Defects Left in the Rails after Grinding (Arrow
Points to the Gauge Corner)
11.2 Metal Removal for Preventive/Transitional Grinding
11.2.1 Plain Track

When rail (including new rail) is ground under the preventive grinding regime a
minimum amount of metal shall be removed.
In conjunction with restoration of the rail profile to the designed template as
specified in Section 10.1, a minimum of 0.2 mm of metal shall be removed from all
surfaces where there is wheel contact, the exception being the gauge face of the
high rails (at an angle >45º to the horizontal) in the sharper curves where gauge
face wear has been occurring.
11.2.2 Turnouts
Figure 18 provides an illustration of the tangent profile (TGT) in relation to a new 60
kg rail. Considerable amount of material needs to be removed particularly from the
gauge corner region of the new rails. Rails in turnouts are not canted, as with Plain
track rails, and hence do not match the wheel profiles.
For new rails, grinding shall not extend beyond 10mm on the field side of the rail
centre line, as illustrated in Figure 18.
The TGT profile exhibits an undercut in the gauge corner region, to ensure that
wheel / rail contact is made near the centre of the running surface, rather than the
gauge corner region, of the turnout rails.
Excessive grinding of the stock rail towards the tip of the switch shall be avoided.
This can occur due to the double grinding the stock rails, with the switch both closed
and open.
RAIL GRINDING
TGT Template
Field 10mm max

Side Gauge
Side
Figure 18: New 60kg/m Rail in Turnout with Tangent (TGT) Template
12. Surface Finish
12.1 Grinding Facets

The grinding process leaves visible facets on the head of the rail and gauge face. These
facets shall be controlled if excessive contact stress points shall be avoided. The allowable
maximum facet width shall be:
 4 mm in the gauge corner region
 8 mm elsewhere on the ground surface
12.2 Other Surface Irregularities

There shall be a minimum standard of finish arising from the normal rail grinding process,
an example is shown in Figure 19. Surface defects identified prior to grinding (such as
dipped welds or wheel burns) may not be able to be dealt with as part of the normal
grinding operation. Such locations should be noted for separate dealing. Otherwise the
requirements are as follows, in terms of possible grinding machine induced characteristics:
 There should be no sharp ridges especially at the interface of facets
 There should be no gouging on the rail surface and sharp scratches, as illustrated in
Figure 20
 There should be no indentations or longitudinal anomalies in the rail
 There should be no overheating (bluing) of the rail surface
 There should be no severe cyclic grinding scratch marks, as illustrated in Figure 21.
Such scratch marks have the potential to develop into short pitch corrugations
RAIL GRINDING
Figure 19: Acceptable Standard of Finish from Grinding
Figure 20: Unacceptable Severe Grinding Scratches (Arrow Points to Gauge Corner)
RAIL GRINDING
Figure 21: Unacceptable Cyclic Grinding Scratches
 Short pitch corrugations (30-90 mm in wavelength) shall be removed completely, and

the remaining longitudinal unevenness along the rail running surface shall be less than
0.05 mm when measured at the centre of the running surface over any 500mm length,
using a suitable measuring system. Generally, the assessment of corrugations shall be
conducted at the checking location. However, additional measurements may be
conducted at any location within a ground section in which visual examination may
indicate the presence of cyclic irregularities after grinding
 In the first grinding cycles, the longer pitch corrugations (about 200-450 mm in
wavelength) shall be reduced
 In subsequent grinding cycles the longer pitch corrugations shall also be removed,
unless otherwise directed by an Authorised MTM Representative, so that the remaining
longitudinal unevenness along the rail running surface shall be less than 0.1 mm over a
1m wavelength
 The roughness over the running surface of the rails shall be no rougher than a Ra of
10.0µm, when measured over a distance of 25mm
Note: Any measurements of surface roughness (as measured along the rail) need to
adopt established and calibrated procedures as specified in AS 2382 – Surface
Roughness Comparison.
There shall be no increase in the maximum level of wheel-rail noise ( 5%), measured
using the procedures detailed in AS 2377 (2002), arising from the rail grinding operation
(measured after 1-2 MGT of traffic). In this context, noise refers to either sound
pressure levels or Leq levels taken at a minimum distance of 10 m from the track, at one
(1) second intervals and averaged during the passage of traffic.
13. Competencies
N/A
RAIL GRINDING
14. Related Documents

MTPR 033100-05 Internal Rail Defects- Definition and Remedial Action
MTPR 033100-14 Surface Rail Defects- Definition and Remedial Action
15. Records
N/A
16. Appendices
Appendix 1 - Tangent Rail Template and Contact Region
Appendix 2 - High Rail Templates and Contact Region
Appendix 3 - Low Rail Template and Contact Region
Appendix 4 - New MTM Template in tangent Track and Curves
RAIL GRINDING
16.1 Appendix 1 – Tangent Rail Template and Contact Region

Table 1: X-Y Co-ordinates of Tangent (TGT) Template
X Y X Y X Y X Y
-40.00 -3.42
-35.00 -2.72 -10.5.0 -0.31 10.75 -0.18 23.00 -1.71
-34.50 -2.65 -10.00 -0.29 11.00 -0.20 23.25 -1.76
-34.00 -2.58 -9.50 -0.26 11.25 -0.21 23.50 -1.81
-33.50 -2.52 -9.00 -0.24 11.50 -0.23 23.75 -1.86
-33.00 -2.45 -8.50 -0.22 11.75 -0.24 24.00 -1.91
-32.50 -2.39 -8.00 -0.20 12.00 -0.26 24.25 -1.96
-32.00 -2.32 -7.50 -0.18 12.25 -0.28 24.50 -2.02
-31.50 -2.25 -7.00 -0.16 12.50 -0.30 24.75 -2.07
-31.00 -2.19 -6.50 -0.14 12.75 -0.32 25.00 -2.13
-30.50 -2.12 -6.00 -0.13 13.00 -0.34 25.25 -2.19
-30.00 -2.06 -5.50 -0.11 13.25 -0.36 25.50 -2.25
-29.50 -1.99 -5.00 -0.10 13.50 -0.38 25.75 -2.32
-29.00 -1.93 -4.50 -0.08 13.75 -0.40 26.00 -2.39
-28.50 -1.87 -4.00 -0.07 14.00 -0.42 26.25 -2.46
-28.00 -1.81 -3.50 -0.06 14.25 -0.45 26.50 -2.53
-27.50 -1.75 -3.00 -0.05 14.50 -0.47 26.75 -2.61
-27.00 -1.69 -2.50 -0.04 14.75 -0.49 27.00 -2.69
-26.50 -1.63 -2.00 -0.03 15.00 -0.52 27.25 -2.78
-26.00 -1.57 -1.50 -0.02 15.25 -0.55 27.50 -2.86
-25.50 -1.52 -1.00 -0.02 15.50 -0.57 27.75 -2.95
-25.00 -1.46 -0.50 -0.01 15.75 -0.60 28.00 -3.04
-24.50 -1.41 0.00 -0.01 16.00 -0.63 28.25 -3.14
-24.00 -1.35 0.50 0.00 16.25 -0.66 28.50 -3.24
-23.50 -1.30 1.00 0.00 16.50 -0.69 28.75 -3.34
-23.00 -1.25 1.50 0.00 16.75 -0.72 29.00 -3.44
-22.50 -1.20 2.00 0.00 17.00 -0.75 29.25 -3.55
-22.00 -1.15 2.50 0.00 17.25 -0.78 29.50 -3.66
-21.50 -1.11 3.00 0.00 17.50 -0.81 29.75 -3.77
-21.00 -1.06 3.50 0.00 17.75 -0.85 30.00 -3.89
-20.50 -1.01 4.00 -0.01 18.00 -0.88 30.25 -4.01
-20.00 -0.97 4.50 -0.01 18.25 -0.91 30.50 -4.14
-19.50 -0.93 5.00 -0.02 18.50 -0.95 30.75 -4.27
-19.00 -0.88 5.50 -0.02 18.75 -0.99 31.00 -4.41
RAIL GRINDING
X Y X Y X Y X Y
-18.50 -0.84 6.00 -0.03 19.00 -1.02 31.25 -4.55
-18.00 -0.8 6.50 -0.04 19.25 -1.06 31.50 -4.70
-17.50 -0.76 7.00 -0.05 19.50 -1.10 31.75 -4.85
-17.00 -0.72 7.50 -0.06 19.75 -1.14 32.00 -5.02
-16.50 -0.68 7.75 -0.07 20.00 -1.18 32.25 -5.19
-16.00 -0.65 8.00 -0.07 20.25 -1.22 32.50 -5.36
-15.50 -0.61 8.25 -0.08 20.50 -1.26 32.75 -5.55
-15.00 -0.58 8.50 -0.09 20.75 -1.30 33.00 -5.74
-14.50 -0.54 8.75 -0.09 21.00 -1.34 33.25 -5.95
-14.00 -0.51 9.00 -0.10 21.25 -1.39 33.50 -6.16
-13.50 -0.48 9.25 -0.11 21.50 -1.43 33.75 -6.38
-13.00 -0.45 9.50 -0.12 21.75 -1.47 34.00 -6.61
-12.50 -0.42 9.75 -0.13 22.00 -1.52 34.25 -6.83
-12.00 -0.39 10.00 -0.14 22.25 -1.57 34.50 -7.10
-11.50 -0.36 10.25 -0.16 22.50 -1.61 34.75 -7.37
-11.00 -0.34 10.50 -0.17 22.75 -1.66 35.00 -7.64
Note: The TGT profile has been specified for a free standing rail centreline using the above
coordinate system incorporating the rail centreline. Therefore when producing rail
Figure
profile templates A1 (a):
a cant Tangent (TGT)
adjustment (2.86) clockwise
of 1:20Template and Nominal Running
rotation shall be added
Surface Contact
so that the profile is referenced perpendicular to the track plane.
Rail Centreline
Contact Band
0
-45 -40 -35 -30 -25 -20 -15 -10 -5 -1 0 5 10 15 20 25 30 35 40
Y Axis Coordinates
Y axis Coordinates (mm)
-2
-3
-4
-5
Not to Scale -6
-7
-8 Rail Contact X
-9
X AxisCoordinates
X Axis Coordinates(mm)
Figure 22: Tangent (TGT) Template and Nominal Running Surface Contact
RAIL GRINDING
16.2 Appendix 2 – High Rail Templates and Contact Region

Table 2: X-Y Co-ordinates of High Rail (H1) Template
X Y X Y X Y X Y
-40.00 -2.34 -13.75 -0.19 8.25 -0.30 20.25 -1.51
-35.00 -1.84 -13.25 -0.17 8.75 -0.32 20.50 -1.55
-34.75 -1.82 -12.75 -0.15 9.25 -0.35 20.75 -1.60
-34.25 -1.77 -12.25 -0.14 9.75 -0.38 21.00 -1.64
-33.75 -1.72 -11.75 -0.12 10.25 -0.40 21.25 -1.68
-33.25 -1.67 -11.25 -0.11 10.50 -0.42 21.50 -1.73
-32.75 -1.62 -10.75 -0.09 10.75 -0.43 21.75 -1.78
-32.25 -1.57 -10.25 -0.08 11.00 -0.45 22.00 -1.84
-31.75 -1.52 -9.75 -0.07 11.25 -0.47 22.25 -1.89
-31.25 -1.47 -9.25 -0.06 11.50 -0.48 22.50 -1.95
-30.75 -1.43 -8.75 -0.05 11.75 -0.50 22.75 -2.02
-30.25 -1.38 -8.25 -0.04 12.00 -0.52 23.00 -2.08
-29.75 -1.33 -7.75 -0.03 12.25 -0.54 23.25 -2.15
-29.25 -1.28 -7.25 -0.02 12.50 -0.56 23.50 -2.22
-28.75 -1.23 -6.75 -0.02 12.75 -0.58 23.75 -2.29
-28.25 -1.18 -6.25 -0.01 13.00 -0.60 24.00 -2.37
-27.75 -1.13 -5.75 -0.01 13.25 -0.62 24.25 -2.45
-27.25 -1.09 -5.25 0.00 13.50 -0.64 24.50 -2.53
-26.75 -1.04 -4.75 0.00 13.75 -0.66 24.75 -2.61
-26.25 -0.99 -4.25 0.00 14.00 -0.69 25.00 -2.70
-25.75 -0.95 -3.75 0.00 14.25 -0.71 25.25 -2.79
-25.25 -0.91 -3.25 0.00 14.50 -0.74 25.50 -2.88
-24.75 -0.86 -2.75 0.00 14.75 -0.76 25.75 -2.98
-24.25 -0.82 -2.25 -0.01 15.00 -0.79 26.00 -3.09
-23.75 -0.78 -1.75 -0.01 15.25 -0.82 26.25 -3.20
-23.25 -0.74 -1.25 -0.01 15.50 -0.84 26.50 -3.31
-22.75 -0.71 -0.75 -0.02 15.75 -0.87 26.75 -3.43
-22.25 -0.67 -0.25 -0.03 16.00 -0.90 27.00 -3.56
-21.75 -0.63 0.25 -0.04 16.25 -0.93 27.25 -3.69
-21.25 -0.60 0.75 -0.04 16.50 -0.96 27.50 -3.83
-20.75 -0.56 1.25 -0.05 16.75 -0.99 27.75 -3.97
-20.25 -0.53 1.75 -0.07 17.00 -1.03 28.00 -4.12
-19.75 -0.50 2.25 -0.08 17.25 -1.06 28.25 -4.28
RAIL GRINDING
X Y X Y X Y X Y
-19.25 -0.47 2.75 -0.09 17.50 -1.09 28.50 -4.45
-18.75 -0.44 3.25 -0.10 17.75 -1.13 28.75 -4.62
-18.25 -0.41 3.75 -0.12 18.00 -1.16 29.00 -4.80
-17.75 -0.38 4.25 -0.14 18.25 -1.20 29.25 -4.99
-17.25 -0.35 4.75 -0.15 18.50 -1.23 29.50 -5.18
-16.75 -0.33 5.25 -0.17 18.75 -1.27 29.75 -5.39
-16.25 -0.30 5.75 -0.19 19.00 -1.31 30.00 -5.60
-15.75 -0.28 6.25 -0.21 19.25 -1.35 31.00 -6.56
-15.25 -0.25 6.75 -0.23 19.50 -1.39 32.00 -7.64
-14.75 -0.23 7.25 -0.25 19.75 -1.43 33.00 -8.72
-14.25 -0.21 7.75 -0.27 20.00 -1.47 34.00 -9.80
35.00 -10.87
RAIL GRINDING
Table 3: X-Y Co-ordinates of High Rail (H2) Template

X Y X Y X Y X Y
-40.000 -2.340 -13.750 -0.190 8.250 -0.300 20.250 -1.820
-35.000 -1.840 -13.250 -0.170 8.750 -0.320 20.500 -1.860
-34.750 -1.820 -12.750 -0.150 9.250 -0.350 20.750 -1.905
-34.250 -1.770 -12.250 -0.140 9.750 -0.380 21.000 -1.950
-33.750 -1.720 -11.750 -0.120 10.250 -0.400 21.250 -1.995
-33.250 -1.670 -11.250 -0.110 10.50 -0.420 21.500 -2.040
-32.750 -1.620 -10.750 -0.090 10.750 -0.450 21.750 -2.090
-32.250 -1.570 -10.250 -0.080 11.000 -0.480 22.000 -2.140
-31.750 -1.520 -9.750 -0.070 11.250 -0.505 22.250 -2.190
-31.250 -1.470 -9.250 -0.060 11.500 -0.530 22.500 -2.240
-30.750 -1.430 -8.750 -0.050 11.750 -0.555 22.750 -2.295
-30.250 -1.380 -8.250 -0.040 12.000 -0.580 23.000 -2.330
-29.750 -1.330 -7.750 -0.030 12.250 -0.605 23.250 -2.385
-29.250 -1.280 -7.250 -0.020 12.500 -0.630 23.500 -2.440
-28.750 -1.230 -6.750 -0.020 12.750 -0.660 23.750 -2.500
-28.250 -1.180 -6.250 -0.010 13.000 -0.690 24.000 -2.550
-27.750 -1.130 -5.750 -0.010 13.250 -0.725 24.250 -2.610
-27.250 -1.090 -5.250 0.00 13.500 -0.760 24.500 -2.670
-26.750 -1.040 -4.750 0.00 13.750 -0.800 24.750 -2.750
-26.250 -0.990 -4.250 0.00 14.000 -0.840 25.000 -2.830
-25.750 -0.950 -3.750 0.00 14.250 -0.875 25.250 -2.900
-25.250 -0.910 -3.250 0.00 14.000 -0.910 25.500 -2.970
-24.750 -0.860 -2.750 0.00 14.750 -0.950 25.750 -3.060
-24.250 -0.820 -2.250 -0.010 15.000 -0.990 26.000 -3.150
-23.750 -0.780 -1.750 -0.010 15.250 -1.025 26.250 -3.220
-23.250 -0.740 -1.250 -0.010 15.500 -1.060 26.500 -3.340
-22.750 -0.710 -0.750 -0.020 15.750 -1.105 26.750 -3.450
-22.250 -0.670 -0.250 -0.030 16.000 -1.150 27.000 -3.560
-21.750 -0.630 0.250 -0.040 16.250 -1.190 27.250 -3.690
-21.250 -0.600 0.750 -0.040 16.500 -1.230 27.500 -3.830
-20.750 -0.560 1.250 -0.050 16.750 -1.275 27.750 -3.970
-20.250 -0.530 1.750 -0.070 17.000 -1.320 28.000 -4.120
-19.750 -0.500 2.250 -0.080 17.250 -1.355 28.250 -4.280
-19.250 -0.470 2.750 -0.090 17.500 -1.390 28.500 -4.450
RAIL GRINDING
X Y X Y X Y X Y
-18.750 -0.440 3.250 -0.100 17.750 -1.430 28.750 -4.620
-18.250 -0.410 3.750 -0.120 18.000 -1.470 29.000 -4.800

-17.750 -0.380 4.250 -0.140 18.250 -1.505 29.250 -4.990
-17.250 -0.350 4.750 -0.150 18.500 -1.540 29.500 -5.180
-16.750 -0.330 5.250 -0.170 18.750 -1.580 29.750 -5.390
-16.250 -0.300 5.750 -0.190 19.000 -1.620 30.000 -5.600
-15.750 -0.280 6.250 -0.210 19.250 -1.660 31.000 -6.560
-15.250 -0.250 6.750 -0.230 19.500 -1.700 32.000 -7.640
-14.750 -0.230 7.250 -0.250 19.750 -1.740 33.000 -8.720
-14.250 -0.210 7.750 -0.270 20.000 -1.780 34.000 -9.800
35.000 -10.870
Note: The H1 and H2 profile has been specified for a free standing rail centreline using
the above coordinate system incorporating the rail centreline. Therefore when
producing rail profile templates a cant adjustment of 1:20 (2.86) clockwise
rotation shall be added so that the profile is referenced perpendicular to the track
plane.
Contact Band
0
-45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40
H1
-1
(mm)
-2
H2
Coordinates
-3
(mm)
-4
Coordinates
-5
-6
Axis
YY Axis
MTM H1 -7
MTM H2 -8 Not to Scale
-9
-10
-11
-12
X XAxis Coordinates
Axis Coordinates (mm) (mm)
Figure 23: High Rail (H1 and H2) Templates and Nominal Running Surface Contact
RAIL GRINDING
16.3 Appendix 3 – Low Rail Templates and Contact Region

Table 4: X-Y Co-ordinates of Low Rail (L1) Template
X Y X Y X Y X Y X Y
-40.00 -3.43 -12.50 -0.45 9.25 -0.09 19.25 -0.99 30.75 -5.26
-35.00 -2.78 -12.00 -0.42 9.50 -0.10 19.50 -1.02 31.00 -5.48
-34.50 -2.72 -11.50 -0.39 9.75 -0.11 19.75 -1.06 31.25 -5.70
-34.00 -2.65 -11.00 -0.36 10.00 -0.12 20.00 -1.10 31.50 -5.94
-33.50 -2.58 -10.50 -0.34 10.25 -0.13 20.25 -1.14 31.75 -6.20
-33.00 -2.52 -10.00 -0.31 10.50 -0.14 20.50 -1.18 32.00 -6.46
-32.50 -2.45 -9.50 -0.29 9.25 -0.09 20.75 -1.22 32.25 -6.73
-32.00 -2.39 -9.00 -0.26 9.50 -0.10 21.00 -1.26 32.50 -7.00
-31.50 -2.32 -8.50 -0.24 9.75 -0.11 21.25 -1.30 32.75 -7.27
-31.00 -2.25 -8.00 -0.22 10.00 -0.12 21.50 -1.34 33.00 -7.54
-30.50 -2.19 -7.50 -0.20 10.25 -0.13 21.75 -1.39 33.25 -7.81
-30.00 -2.12 -7.00 -0.18 10.50 -0.14 22.00 -1.43 33.50 -8.08
-29.50 -2.06 -6.50 -0.16 10.75 -0.16 22.25 -1.48 33.75 -8.34
-29.00 -1.99 -6.00 -0.14 11.00 -0.17 22.50 -1.53 34.00 -8.61
-28.50 -1.93 -5.50 -0.13 11.25 -0.18 22.75 -1.58 34.25 -8.88
-28.00 -1.87 -5.00 -0.11 11.50 -0.20 23.00 -1.63 34.50 -9.15
-27.50 -1.81 -4.50 -0.10 11.75 -0.21 23.25 -1.69 34.75 -9.42
-27.00 -1.75 -4.00 -0.08 12.00 -0.23 23.50 -1.75 35.00 -9.69
-26.50 -1.69 -3.50 -0.07 12.25 -0.24 23.75 -1.82
-26.00 -1.63 -3.00 -0.06 12.50 -0.26 24.00 -1.88
-25.50 -1.57 -2.50 -0.05 12.75 -0.28 24.25 -1.95
-25.00 -1.52 -2.0 -0.04 13.00 -0.30 24.50 -2.02
-24.50 -1.46 -1.50 -0.03 13.25 -0.32 24.75 -2.10
-24.00 -1.41 -1.00 -0.02 13.50 -0.34 25.00 -2.17
-23.50 -1.35 -0.50 -0.02 13.75 -0.36 25.25 -2.25
-23.00 -1.30 0.00 -0.01 14.00 -0.38 25.50 -2.34
-22.50 -1.25 0.50 -0.01 14.25 -0.40 25.75 -2.42
-22.00 -1.20 1.00 0.00 14.50 -0.42 26.00 -2.51
-21.50 -1.15 1.50 0.00 14.75 -0.45 26.25 -2.60
-21.00 -1.11 2.00 0.00 15.00 -0.47 26.50 -2.70
-20.50 -1.06 2.50 0.00 15.25 -0.49 26.75 -2.80
-20.00 -1.01 3.00 0.00 15.50 -0.52 27.00 -2.91
-19.50 -0.97 3.50 0.00 15.75 -0.55 27.25 -3.02
-19.00 -0.93 4.00 0.00 16.00 -0.57 27.50 -3.14
RAIL GRINDING
X Y X Y X Y X Y X Y
-18.50 -0.88 4.50 -0.01 16.25 -0.60 27.75 -3.26
-18.00 -0.84 5.00 -0.01 16.50 -0.63 28.00 -3.39
-17.50 -0.80 5.50 -0.02 16.75 -0.66 28.25 -3.52
-17.00 -0.76 6.00 -0.02 17.00 -0.69 28.50 -3.66
-16.50 -0.72 6.50 -0.03 17.25 -0.72 28.75 -3.81
-16.00 -0.68 7.00 -0.04 17.50 -0.75 29.00 -3.97
-15.50 -0.65 7.50 -0.05 17.75 -0.78 29.25 -4.13
-15.00 -0.61 8.00 -0.06 18.00 -0.81 29.50 -4.30
-14.50 -0.58 8.25 -0.07 18.25 -0.85 29.75 -4.47
-14.00 -0.54 8.50 -0.07 18.50 -0.88 30.00 -4.66
-13.50 -0.51 8.75 -0.08 18.75 -0.91 30.25 -4.85
-13.00 -0.48 9.00 -0.09 19.00 -0.95 30.50 -5.05
Note: The L1 profile has been specified for a free standing rail centreline using the above coordinate
system incorporating the rail centreline. Therefore when producing rail profile templates a cant
adjustment of 1:20 (2.86) clockwise rotation shall be added so that the profile is referenced
perpendicular to the track plane.
Figure A3: Low Rail (L1) Template and Nominal Running Surface
Contact
Rail Centreline
Contact Band
0
-45 -40 -35 -30 -25 -20 -15 -10 -5 -1 0 5 10 15 20 25 30 35 40
Y Axis Coordinates (mm)
-2
-3
-4
-5
-6
-7
Rail Contact X
Not to Scale -8
-9 Run-Off
-10
-11
X Axis Coordinates (mm)
Figure 24: Low Rail (L1) Templates and Nominal Running Surface Contact
RAIL GRINDING
16.4 Appendix 4 – Template Co-ordinates for Universal Profile (MTM Profile) of Rails in
Tangent and Curves
Table 5: X-Y Co-ordinates of Universal (MTM) Rail Template
X Y X Y X Y X Y
-40.00 -3.43 -16.50 -0.72 2.50 0 21.50 -1.11
-35.00 -2.78 -16.00 -0.68 3.00 0 22.00 -1.19
-34.50 -2.72 -15.50 -0.65 3.50 0 22.50 -1.28
-34.00 -2.65 -15.00 -0.61 4.00 0 23.00 -1.36
-33.50 -2.58 -14.50 -0.58 4.50 -0.01 23.50 -1.43
-33.00 -2.52 -14.00 -0.54 5.00 -0.02 24.00 -1.52
-32.50 -2.45 -13.50 -0.51 5.50 -0.03 24.50 -1.62
-32.00 -2.39 -13.00 -0.48 6.00 -0.04 25.00 -1.72
-31.50 -2.32 -12.50 -0.45 6.50 -0.04 25.50 -1.82
-31.00 -2.25 -12.00 -0.42 7.00 -0.05 26.00 -1.89
-30.50 -2.19 -11.50 -0.39 7.50 -0.07 26.50 -2.00
-30.00 -2.12 -11.00 -0.36 8.00 -0.08 27.00 -2.10
-29.50 -2.06 -10.50 -0.34 8.50 -0.09 27.50 -2.23
-29.00 -1.99 -10.00 -0.31 9.00 -0.10 28.00 -2.35
-28.50 -1.93 -9.50 -0.29 9.50 -0.12 28.50 -2.47
-28.00 -1.87 -9.00 -0.26 10.00 -0.14 29.00 -2.63
-27.50 -1.81 -8.50 -0.24 10.50 -0.18 29.50 -2.77
-27.00 -1.75 -8.00 -0.22 11.00 -0.22 30.00 -2.91
-26.50 -1.69 -7.50 -0.2 11.50 -0.25 30.50 -3.09
-26.00 -1.63 -7.00 -0.18 12.00 -0.27 31.00 -3.27
-25.50 -1.57 -6.50 -0.16 12.50 -0.30 31.50 -3.45
-25.00 -1.52 -6.00 -0.14 13.00 -0.34 32.00 -3.60
-24.50 -1.46 -5.50 -0.13 13.50 -0.37 32.50 -3.83
-24.00 -1.41 -5.00 -0.11 14.00 -0.39 33.00 -4.04
-23.50 -1.35 -4.50 -0.1 14.50 -0.43 33.50 -4.25
-23.00 -1.3 -4.00 -0.08 15.00 -0.46 34.00 -4.53
-22.50 -1.25 -3.50 -0.07 15.50 -0.50 34.50 -4.83
-22.00 -1.2 -3.00 -0.06 16.00 -0.55 35.00 -5.14
-21.50 -1.15 -2.50 -0.05 16.50 -0.60 35.50 -5.60
-21.00 -1.11 -2.00 -0.04 17.00 -0.65 36.50 -6.56
-20.50 -1.06 -1.50 -0.03 17.50 -0.69 37.50 -7.64
-20.00 -1.01 -1.00 -0.02 18.00 -0.74 38.50 -8.72
-19.50 -0.97 -0.50 -0.02 18.50 -0.77 39.50 -9.80
-19.00 -0.93 0.00 -0.01 19.00 -0.82 40.50 -10.87
-18.50 -0.88 0.50 -0.01 19.50 -0.86
-18.00 -0.84 1.00 0 20.00 -0.91
-17.50 -0.8 1.50 0 20.50 -0.98
-17.00 -0.76 2.00 0 21.00 -1.03
Note: The MTM profile has been specified for a free standing rail centreline using the
above coordinate system incorporating the rail centreline. Therefore when producing rail
profile templates a cant adjustment of 1:20 (2.86) clockwise rotation must be added so
that the profile is referenced perpendicular to the track plane.
RAIL GRINDING
Figure 25: MTM Rail Template

L1 CHE STD 022 v2 Rail Grinding

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L1 CHE STD 022 v2 Rail Grinding

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Engineering Standard

Issued: February 2015

Approval Date Version Description

03/02/2015 2 In section 10.2 Template Fabrication, amended the template

16.2 Appendix 2 – High Rail Templates and Contact Region ...........................................................30

Figure 1: Contact Band (indicated by arrow)

Figure 2: Directions in Rail

Flaking Flaking is a surface condition that propagates from the shear

Figure 3: Flaking Defect on Rail Head

Field Side Running Surface Region Gauge Corner

Figure 4: Regions in Rail

Figure 5: Gauge Corner Cracking

Figure 6 - Typical arrangement of a milling cutter head for

Figure 7: Short Pitch Corrugations in Rail

Figure 8: Shelling in the Gauge Corner of Rail

Closure Rail Nose

Figure 9: Components of a Turnout

5. References & Legislations

7. Safety and Environmental

9.1 Types of Rail Grinding

9.1.1 Corrective or Defect Grinding

9.1.2 Transitional Grinding

9.1.3 Preventive or Cyclic Grinding

9.1.4 Special Grinding

10. Rail Profiles

Figure 10: Example of Metal Removal Requirements in Worn

Figure 11: Example of Metal Removal Requirements in Worn High Rails in

Figure 12: Example of Metal Removal Requirements in Worn Low Legs in

Field Side Gauge Side

Figure 14: H1 and H2 High Leg Grinding Profiles

10.2 Template Fabrication

10.4 Template Application

Figure 15: Example of Holding Bar for Template

10.4.2 Tolerance to Template

10.4.2.1 Plain Track

10.4.3 Allowance for Rail Rotation

10.4.4 Allowance for Transposed Rail

10.4.5 Gauge Corner Relief

10.4.6 Field Side Relief

11. Metal Removal for Grinding

11.1 Metal Removal for Corrective Grinding

11.2 Metal Removal for Preventive/Transitional Grinding

11.2.1 Plain Track

Field 10mm max

12. Surface Finish

12.1 Grinding Facets

12.2 Other Surface Irregularities

Figure 19: Acceptable Standard of Finish from Grinding

Figure 21: Unacceptable Cyclic Grinding Scratches

 Short pitch corrugations (30-90 mm in wavelength) shall be removed completely, and

14. Related Documents

16.1 Appendix 1 – Tangent Rail Template and Contact Region

16.2 Appendix 2 – High Rail Templates and Contact Region

Table 3: X-Y Co-ordinates of High Rail (H2) Template

-18.250 -0.410 3.750 -0.120 18.000 -1.470 29.000 -4.800

MTM H2 -8 Not to Scale

16.3 Appendix 3 – Low Rail Templates and Contact Region

Figure 25: MTM Rail Template

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