Rail classification (weight)

Rail is graded by weight over a standard length. Heavier rail can support greater axle loads and higher train speeds without sustaining damage than lighter rail, but at a greater cost. In North America and the UK, rail is graded in pounds per yard (usually shown as pound or lb), so 130-pound rail would weigh 130 lb/yd (64.5 kg/m). The usual range is 115 to 141 lb/yd (57.0 to 69.9 kg/m). In Europe, rail is graded in kg/m and the usual range is 40 to 60 kg/m (80.6 to 121.0 lb/yd). The heaviest rail mass-produced was 155 pounds per yard (76.9 kg/m) and was rolled for the Pennsylvania Railroad. The UK is in the process of transition from the imperial to metric rating of rail.

Joining rails

Rails are produced in fixed lengths and need to be joined end-to-end to make a continuous surface on which trains may run. The traditional method of joining the rails is to bolt them together using metal fishplates, producing jointed track. For more modern usage, particularly where higher speeds are required, the lengths of rail may be welded together to form continuous welded rail (CWR).

Jointed track

Jointed track is made using lengths of rail, usually around 20 m (66 ft) long (in the UK) and 39 or 78 ft (12 or 24 m) long (in North America), bolted together using perforated steel plates known as fishplates (UK) or joint bars (North America).

Fishplates are usually 600 mm (2 ft) long, used in pairs either side of the rail ends and bolted together (usually four, but sometimes six bolts per joint). The bolts may be oppositely-oriented so that in the event of a derailment and a wheel flange striking the joint, only some of the bolts will be sheared, reducing the likelihood of the rails misaligning with each other and exacerbating the seriousness of the derailment. (This technique is not applied universally, British practice being to have all the bolt heads on the same side of the rail.) Small gaps known as expansion joints are deliberately left between the rail ends to allow for expansion of the rails in hot weather. The holes through which the fishplate bolts pass are oval to allow for movement with expansion.

British practice was to have the rail joints on both rails adjacent to each other, while North American practice is to stagger them.

Because of the small gaps left between the rails, when trains pass over jointed tracks they make a "clickety-clack" sound. Unless it is well-maintained, jointed track does not have the ride quality of welded rail and is less desirable for high speed trains. However, jointed track is still used in many countries on lower speed lines and sidings, and is used extensively in poorer countries due to the lower construction cost and the simpler equipment required for its installation and maintenance.

A major problem of jointed track is cracking around the bolt holes, which can lead to the rail head (the running surface) breaking. This was the cause of the Hither Green rail crash which caused British Railways to begin converting much of its track to Continuous Welded Rail.

Insulated joints

Where track circuits exist for signalling purposes, insulated block joints are required. These compound the weaknesses of ordinary joints. Specially-made glued joints, where all the gaps are filled with epoxy resin, increase the strength again.

As an alternative to the insulated joint, audio frequency track circuits can be employed using a tuned loop formed in approximately 20 m of the rail as part of the blocking circuit. Another alternative is the axle counter, which can reduce the number of track circuits and thus the number of insulated rail joints required.

Continuous welded rail

Most modern railways use continuous welded rail (CWR), sometimes referred to as ribbon rails. In this form of track, the rails are welded together by utilising flash butt welding to form one continuous rail that may be several kilometres long, or thermite welding to repair or splice together existing CWR segments. Because there are few joints, this form of track is very strong, gives a smooth ride, and needs less maintenance; trains can travel on it at higher speeds and with less friction. Welded rails are more expensive to lay than jointed tracks, but have much lower maintenance costs. The first welded track was used in Germany in 1924 and the US in 1930[5] and has become common on main lines since the 1950s.

Flash butt welding is the preferred process which involves an automated track-laying machine running a strong electrical current through the touching ends of two unjoined pieces of rail. The ends become white hot due to electrical resistance and are then pressed together forming a strong weld. Thermite welding is a manual process requiring a reaction crucible and form to contain the molten iron. Thermite-bonded joints are also seen as less reliable and more prone to fracture or break.

If not restrained, rails would lengthen in hot weather and shrink in cold weather. To provide this restraint, the rail is prevented from moving in relation to the sleeper by use of clips or anchors. Anchors are more common for wooden sleepers, whereas most concrete or steel sleepers are fastened to the rail by special clips which resist longitudinal movement of the rail. There is no theoretical limit to how long a welded rail can be. However, if longitudinal and lateral restraint are insufficient, the track could become distorted in hot weather and cause a derailment. Distortion due to heat expansion is known in North America as sun kink, and elsewhere as buckling. In North America a rail broken due to cold-related contraction is known as a pull-apart. Attention needs to be paid to compacting the ballast effectively, including under, between, and at the ends of the sleepers, to prevent the sleepers from moving. In extreme hot weather special inspections are required to monitor sections of track known to be problematic.

After new segments of rail are laid, or defective rails replaced (welded-in), the rails can be artificially stressed if the temperature of the rail during laying is different than what is desired. The stressing process involves either heating the rails causing them to expand,[6] or stretching the rails with hydraulic equipment. They are then fastened (clipped) to the sleepers in their expanded form. This process ensures that the rail will not expand much further in subsequent hot weather. In cold weather the rails try to contract, but because they are firmly fastened, cannot do so. In effect, stressed rails are a bit like a piece of stretched elastic firmly fastened down.

CWR rail is laid (including fastening) at a temperature roughly midway between the extremes experienced at that location (this is known as the "rail neutral temperature"). This installation procedure, along with normal track structure strength, is intended to prevent tracks from buckling in summer heat or pulling apart in winter cold. In North America, because broken rails are typically detected by the signaling system; they are seen as less of a problem than heat kinks which are not detected.

Joints are used in continuous welded rail when necessary, usually for signal circuit gaps. Instead of a joint that passes straight across the rail, the two rail ends are sometimes cut at an angle to give a smoother transition. In extreme cases, such as at the end of long bridges, a breather switch (referred to in North America and Britain as an expansion joint) gives a smooth path for the wheel while allowing the end of one rail to expand in relation to the next rail.

Rail support (sleeper/tie)

A railroad tie (also called a cross-tie in North American usage, or a railway sleeper outside North America) is a rectangular object on which the rails are supported and fixed. The tie has two main roles: to transfer the loads from the rails to the track ballast and the ground underneath, and to hold the rails to the correct width apart (to maintain the rail gauge). They are generally laid transverse (perpendicular) to the rails.