Policy

Principle

Standard

Task Instruction

Track Standard
Use of Track Materials

Purpose
This Standard defines the minimum requirements for track material standards for track renewals and
major maintenance.

Document Control
Document No.
T-ST-MM-5709
Issue No.
Issue 3.0
Date Effective
31/12/2022
Author
Andy Pearson
Prepared (P)
Mark Fleet (A)
Checked and
Track Technical Committee
Reviewed (R)
Approved By
Amended (A)
Authorised for
Professional Head of Track
Release By

Copyright
The information in this document is protected by Copyright and no part of this document may be
reproduced, altered, stored or transmitted by any person without the prior consent of KiwiRail.

The original version is held on KiwiRail DMS, and controlled copies are available through SharePoint or
Colligo. All other electronic copies and all printed versions are uncontrolled.

link to page 15 link to page 15

Use of Track Materials
1.  Revision Procedure and History
This is a ‘living’ document, that will be up dated every five years or whenever KiwiRail determines that
changes to it and processing requirements documented herein are appropriate.
If changes arise from the review this document will be reissued, however, if no changes arise from the
review, the current version of this document will remain in force.
Refer to the Briefing Note(s) for T-ST-MM-5709 Use of Track Materials
(at the end of this document) for full document changes.
Issue No
Prepared (P)
Authorised for Release By
Date Effective
Reviewed (R)
Amended (A)
1.0
Andy Pearson (P)
Professional Head of Track
1/07/2016
1.1
Andy Pearson (A)
Professional Head of Track
1/04/2017
2.0
Geoff Hayward(A)
Professional Head of Track
02/02/2018

1.1  Changes in this issue
Issue No
Section
Description
Page(s)
2.0
6
Tables 6.1, 6.2, 6.3 & 6.4 updated
10-11
6.5
Text updated
12
6.8
New section
12
App 1
Text updated
14
1.2  Withdrawn, closed and superseded
Old Reference
Title
Replaced by

2.  Associated Documents
Level
Number
Title
3
T-ST-AM-5301
Classification of Secondhand Materials

Track Standard: T-ST-MM-5709
Issue 3.0
Page ii
Effective Date: 31/12/2022

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Use of Track Materials
Acronyms and Definitions
Acronyms
Definition
CWR
Continuously Welded Rail
EMU
Electric Multiple Unit – type of passenger car
HH
Head Hardenend
HW
Heavy weight rail, shall mean 85, 90, 91 or 100 lb / yard, 50 kg/m
LNI
Local Network Instruction of the RORP
LW
Light weight rail, shall mean 53, 55 or 56 lb / yard
LWR
Long Welded Rail
MHT
Mill Heat Treated
MW
Medium weight rail, shall mean 70, 72 or 75 lb / yard
ROC
Rail Operating Code
RORP
Rail Operating Rules and Procedures
SC
Standard Carbon
SH
Secondhand

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Use of Track Materials
3.  Scope
To maintain the track asset in a fit for purpose condition it is important that materials used
for major maintenance and renewals are appropriate to the track standard required.
This  Standard  defines  the  requirements  for  track  materials  used  in  track  renewals  and
major  maintenance.  It  does  not  preclude  the  use  of  ‘like  for  like’  replacement  for  minor
maintenance to restore operational efficiency.
1)  Minor Maintenance Work
All materials shall be replaced with identical materials except that A clips shall
be  replaced  by  a  fastening  system  with  bedplates  in  A  and  B  Class  lines,  in
conjunction with major maintenance or renewals.
2)  Capital Works / Private Sidings
Track  Engineering  will  from  time  to  time  set  standards  for  the  installation  of
materials.  Details  of  approved  materials  will  form  part  of  the  annual  Capital
Track Renewals plan.
3.1  Use in the field
This document has been designed to be used in the field. It is expected that this document
wil  be opened in an iPad via ‘Briefcase’ and used as reference to complete the task. Note
as written on the front cover the controlled version is held on iKon. Printed copies of this
document are uncontrolled.
4.  Line Classification, Speed and Axle Load
The  railway  system  is  divided  into three  classes for the  purpose  of defining  standards for
construction, renewals and maintenance.
  Class A:  Principal Lines
  Class B:  Secondary Lines and Loops
  Class C:  Minor lines, Yards and Sidings

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Use of Track Materials
1.  Speed:
Each  line  is  given  a  speed  category  rating,  the  maximum  allowable  speeds  for  each
category being defined as:

Table 4.1 Speed category allowable speed – Km/h
Speed Category
Maximum
Comments
SC 1
110
EMU’s and Railcars only at maximum
SC 2
70

SC 3
50

SC 4
40
Includes loops
SC 5
25
Includes yards, sidings and terminals
The  classification  and  speed  category  for  each  line  or  portion  thereof  is  as  shown  in
Appendix 1  Classification and Speed Category.
Actual line speed may be less than those given above, and is shown in the RORP LNI.

2.  Axle Loads:
The maximum or allowable axle loads of rolling stock and locomotives for routes is shown
in the ROC.
Either speed and/or axle loads may be reduced to overcome infrastructure deficiencies.
Maximum  axle  loads  for  both  locomotives  and  rolling  stock  on  specific  line  classes  are
generally as shown in Table 5.2 together with guideline comments on material standards.
Note  that  Table  5.2  relies  on  rail,  sleepers  and  the  ballast/formation  layer  being  in  good
condition  (condition  three  or  above  as  per  document  T-ST-IN-5108).  Where  track
components are of a lesser standard then restrictions on axle loads and linespeed will be
required.

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Use of Track Materials
Table 4.2 Line classification, speed and axle load
Class
Axle
Comments
Loads
A
≥18 metric
Where Medium Weight (MW) rail still exists on these lines every
tonnes
opportunity must be taken to upgrade rail to Heavy Weight (HW) rail.
Speeds of 18 tonne/axle rolling stock and locomotives are reduced when
running on MW rail. Speeds of ≥18 tonne/axle (up to 22.5 tonnes) rolling
stock and locomotives are to be reduced if 91lb or 50kg CWR is not fitted
on concrete sleepers.
B
16.3
Rolling stock and locomotives may run at express freight speeds when on
metric
MW CWR. However, further speed reductions may be imposed due to the
tonnes
general track condition.
Where 100% HW rail exists on these lines 18 tonne/axle rolling stock and
locomotives may run. When there is a mix of HW and MW rail, speeds of
18 tonne/axle rolling stock and locomotives are reduced when running on
MW rail.
C
≤14.3
All rail is generally MW and other track conditions may determine running
metric
rights. Freight train speeds generally apply.
tonnes
Where LW rail still exists on these lines or joints are in short/ medium
lengths then speeds of rolling stock and locomotives are reduced.
5.  Track Material Standards
The following tables set out  the minimum standard for  which materials are to be used for
track renewals and major maintenance for various line classifications.
The  Asset  Engineer,  Production  Manager  or  Project  Manager  must  comply  with  these
standards  for  renewals  and  major  maintenance.  A  departure  may  be  granted  by  the
Professional  Head  –  Track  where  it  is  considered  appropriate  to  deviate  from  these
standards.
Any  line  that  requires  upgrading  may  be  treated  differently  to  their  existing  line
classification  for  example  the  Castlecliff Branch.  Such  lines may  be reclassified  when  the
requirement for upgrading is identified.

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Effective Date: 31/12/2022

Use of Track Materials
5.1  Class A: speed category 1 or 2
Table 5.1 Class A : speed category 1 or 2
Material
Renewal or major maintenance
Rail: new re-rail,
New 50kg with grade SC, MHT or HH as permitted. CWR must be formed
relay
where permitted.
Rail: closure rail,
First class, SH 91 lb or 50 kg, or new 50 kg rail.
hi-leg
Sleepers
Concrete, new Hardwood, new Composite, first class Hardwood/TPR.
Timber/Composite sleepers must not be installed in curves less than 400 m
radius.
50% sleeper renewal is permitted.
Ballast
300 mm depth. Clean well graded with formation strength of CBR > 30
Turnouts
50 kg NZR or equivalent only. Manganese frog 91lb for replacement of frog
only in 91 lb. Bearers shall be concrete.
Fastenings
P (N in some level crossing designs).
Insulated Joints
Six holed GIJ’s.
Fishplates
Six holed long fishplates.
5.2  Class B: speed category 1 or 2
Table 5.2 Class B: speed category 1 or 2
Material
Renewal or major maintenance
Rail: new re-rail, relay
New 50 kg with grade SC, MHT or HH as permitted. First class SH HW.

HW rail is to be formed into CWR and any MW rail shall be formed into at

least LWR.
Rail: closure rail, hi-leg
Where existing rail is MW then like for like is acceptable although every
opportunity to upgrade shall be taken but only as directed.
1st Class SH 91lb or 50kg, SH MW rail.
Sleepers
New Concrete, new Hardwood, new Composite, first class SH
Hardwood/TPR/Concrete. Timber or Composite must not be installed in
curves less than 400m radius.
50% sleeper renewal is permitted. Renewals percentage less than this
may be permitted to bring 50% of sleeper condition to grade two or
higher.
Ballast
>200mm depth. A maximum of 20% fouled / rounded with formation
strength of CBR > 20
Turnouts
50kg NZR or equivalent only, refurbished SH 91lb. Manganese frog 91lb
for replacement of frog only in 91lb. Bearers shall concrete or composite.
Fastenings
P, R and N (R & N on curves >400m radius and tangent track only).
Insulated Joints
Six holed GIJ’s, six holed bolted IJ’s, non-glued or bolted in MW rail.
Fishplates
Six holed long, standard like for like in MW rail.

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Effective Date: 31/12/2022

Use of Track Materials
5.3  Class B: speed category 3, 4 or 5
Table 5.3 Class B: speed category 3, 4 or 5
Material
Renewal or major maintenance
Rail: new re-rail, relay
1st class SH HW or SH MW. HW rail is to be formed into CWR and

MW rail formed into at least LWR.
Rail : closure rail, hi-leg
Where existing rail is MW then like for like is acceptable. Upgrades
shall be as directed.
Sleepers
SH 1st or 2nd class Hardwood/TPR, SH Concrete.
1st class Hardwood or new Composite in curves with radius less than
250m for SC3 and SC4 only.
50% renewal. Where there is already 25% in condition two or higher a
25% renewal may be permitted.
Ballast
>200mm depth. A maximum of 20% fouled / rounded with formation
strength of CBR > 20
Turnouts
50 kg NZR or Equivalent in high traffic areas, refurbished SH 91 lb or
70 lb frogs for like for like. Bearers may composite or SH 1st or 2nd
class Hardwood/TPR.
Fastenings
P, R and N (R & N on curves >400m radius and tangent track only).
Insulated Joints
Bolted six hole IJ in HW and four hole in MW. Six hole bolted IJ in
busy sidings and loops with 18 tonne / axle running rights.
Fishplates
Four holed long in HW, standard like for like in MW rail.
Note  this  includes  all  Loops,  Arrival  and  Departure  roads  and  busy  yards  on
Class A and B lines.
5.4  Class C: all speed categories
Table 5.4 Class C: all speed categories
Material
Renewal or Major Maintenance
Rail: new re-rail, relay
2nd class for SC5 & 3rd class for yards/sidings only SH MW formed

into LWR. Where existing rail is MW then like for like is

acceptable. No upgrading shall be undertaken except where ≤55
Rail: closure rail, hi-leg
lb rail exists.
SH MW rail, like for like is acceptable.Upgrades shall be as
directed.
Sleepers
Second class Hardwood/TPR. 25% Renewal permitted.
Ballast
<200mm depth. A maximum of 30% fouled / rounded with
formation strength of CBR < 15
Turnouts
Refurbished SH 91 lb or 70 lb. Frogs like for like. Bearers may be
SH 2nd class Hardwood/TPR.
Fastenings
R, N and A. Only use A on tangent track.
Insulated Joints
Non glued or bolted in medium weight.
Fishplates
Four holed long, standard like for like in MW rail.
Track Standard: T-ST-MM-5709
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Effective Date: 31/12/2022

Use of Track Materials
Note  this  includes  Loops  on  Class  C  lines  and  all  Yards  and  Sidings  not  previously
identified.
5.5  Head hardened rail
Head hardened rail shall be used on Class A lines on curves of radius 250 m and less, on
grades steeper than 1:83 and in specific environment conditions for example tunnels. Seek
clarification from Track Engineering in all cases.
KiwiRail currently purchases MHT rail which is an acceptable alternative to HH and SC rail
in all cases.
5.6  Use of galvanised fastenings and bedplates/sleepers
Galvanised  fastenings systems  including  bedplates for timber  or  concrete  sleepers  are  to
be used in any areas subject to a high risk of corrosion such as: tunnels, within 150 m of
the  high  water  mark  in  coastal  areas  and  level  crossings.  Seek  clarification  from  Track
Engineering in all cases.
5.7  General
Any  variations  to  these  requirements  must  be  authorised  by  the  Professional  Head  of
Track.
Where secondhand material is permitted then the classification must be in compliance with
document T-ST-AM-5301 Classification of Secondhand Materials.
5.8  Covering of fastening systems
As resilient fastenings (eg Pandrol) are very susceptible to corrosion induced fatigue, they
must not be used where the fastening system is covered by road metal or ballast such as
in  yards  or  tarmacked  level  crossings.  Galvanised  N  type,  without  spring  washers,  is  the
only permitted fastening system in these locations.

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Issue 3.0
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Effective Date: 31/12/2022

Use of Track Materials
Appendix 1 Classification and Speed Category
North Island Lines
Line
Speed Category
From
To
Class A: Principal Lines

NIMT
1
Wellington
Auckland
ECMT
1
Hamilton
Te Maunga

2
Te Maunga
Kawerau
Wairarapa Line
1
Wellington
Masterton
PNGL
2
Palmerston North
Napier
NAL
1
Westfield
Swanson
Kinleith Branch
2
Waharoa
Kinleith
Murupara Branch
2
Kawerau
Murupara
Mission Bush Branch
2
Paerata
Mission Bush
MNPL
2
Marton
Whareroa
Mt Maunganui Branch
2
Te Maunga
Mt Maunganui
Newmarket Line
2
Newmarket
Auckland
Onehunga Branch
1
Penrose
Onehunga
Manukau Branch
2
Wiri
Manukau
Johnsonville Line
2
Wellington
Johnsonville
Melling Branch
3
Melling Jcn
Melling

Track Standard: T-ST-MM-5709
Issue 3.0
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Effective Date: 31/12/2022

Use of Track Materials
North Island Lines, cont.

Line
Speed Category
From
To
Class B: Secondary Lines

NAL
2
Swanson
Waitakere
3
Waitakere
Whangarei
MNPL
2
Whareroa
New Plymouth
Wairarapa Line
3
Masterton
Woodville
MNPL
3
New Plymouth
Breakwater
Napier Port Branch
5
Napier Jcn
Napier Port
Wanganui Freight Branch
5
Aramoho
Wanganui
Castlecliff Branch
5
Wanganui
Castlecliff
Class C: Minor Lines

NAL
4
Whangarei
Otiria
Port Whangarei Industrial
5
Whangarei
Whangarei Port
Siding
Hautapu Branch
5
Ruakura
Hautapu
PNGL
4
Napier
Wairio
Waitoa Branch
5
Morrinsville
Waitoa
Gracefield Branch
5
Woburn
Hutt Wshops
Southdown Branch
5
Westfield
Southdown
Rotowaro Branch
5
Huntly
Rotowaro
Kapuni Branch (moth)
4
Te Roti Jcn
Kapuni
Dargaville Branch (moth)
4
Waiotira
Dargaville
SOL (moth)
2
Stratford
68.5 km
PNGL  (moth)
2
Wairio
Gisborne
Rotorua Branch (moth)
3
Putaruru
Rotorua
SOL (moth)
3
68.5 km
Okahukura
Waitara Branch (moth)
5
Lepperton Loop
Waitara
Makaraka Branch (moth)
5
Makaraka Jcn
Makaraka

Track Standard: T-ST-MM-5709
Issue 3.0
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Effective Date: 31/12/2022

Use of Track Materials
South Island Lines
Line
Speed Category
From
To
Class A: Principal Lines

MNL
2
Addington
8.4 km

1
8.4 km
Picton
2
Lyttelton
Middleton
MSL
1
Middleton
Invercargill
Midland Line
1
Rolleston
Greymouth
Class B: Secondary Lines

SNL
2
Stillwater
Inangahua
3
Inangahua
Ngakawau
Port Chalmers Branch
5
Sawyers Bay
Port Chalmers
Taieri Branch
4
Wingatui
3.5 km
Rapahoe Branch
4
Omoto
Rapahoe
Class C: Minor Lines

Hornby Branch
5
Hornby Jcn
Hornby
Hokitika Line
4
Greymouth
Hokitika
Westport Industrial
5
Westport Jcn
Westport
Finegand Branch
5
Balclutha
Finegand
Ohai Branch
4
Invercargill
Ohai
Bluff Branch
4
Invercargill
Bluff

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Issue 3.0
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Effective Date: 31/12/2022

Use of Track Materials
Briefing Note(s) for T-ST-MM-5709 Use of Track Materials
Date Effective
31/12/2022
Issue No.
Issue 3.0

Background
Amendments to section 6 Tables. New Section 6.8 and amendment to Appendix 1

Key changes / compliance
Amendments to line classifications and speed categories.

Implementation
This document should be cascaded down to all field staff impacted by this Task Instruction in the field.
All documents will have the Briefing Note inserted to each document during the next review process
or next published version iteration, whichever comes first.

Applicability
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Asset Engineers
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Field Asset Engineers
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Production Managers
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Field Production Managers
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Gangers
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Issue 3.0
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Effective Date: 31/12/2022

Use of Track Materials
Document History
Note page numbers relate to the document at the time of amendment and may not match page numbers in current document.
Issue No
Section
Description
Page(s)
1.0

First Publication

1.1
5
Table 5.2 minor changes
7
1.1

Briefing Note added to document
15
1.2
6.1 – 6.4
Ballast added and Turnouts updated in Tables 6.1 – 6.4
8 – 9
1.2

Document History new
15

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Issue 3.0
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Effective Date: 31/12/2022

Document Outline