RIS RIS-1701-PLT. Rail Industry Standard for Portable and Transportable Plant Used for. Infrastructure Work Issue 1 October 2008

Transcription

1 RIS This document is a voluntary standard, produced by RSSB at the request of the industry. Duty holders may choose to mandate it through internal instructions/procedures or contract conditions. Published by Rail Safety and Standards Board Evergreen House 160 Euston Road London NW1 2DX Copyright 2008 Rail Safety and Standards Board Limited RIS-1701-PLT Portable and Transportable Plant Used for Infrastructure Work Issue 1 October 2008 Rail Industry Standard

2 Issue Record Issue Date Comments One October 2008 Original document Replaces GM/RT1310 Superseded or replaced documents The following Railway Group document is replaced, either in whole or in part as indicated: Superseded or replaced documents GM/RT1310 issue two Design Requirements and Acceptance of Portable / Transportable Infrastructure Plant and Equipment Sections superseded Date when sections are superseded All 06 June 2009 GM/RT1310 ceases to be in force and is withdrawn with effect from 06 June Supply Controlled and uncontrolled copies of this Rail Industry Standard may be obtained from the Corporate Communications Department, Rail Safety and Standards Board, Evergreen House, 160 Euston Road, London NW1 2DX, telephone or enquiries@rssb.co.uk. Railway Group Standards and associated documents can also be viewed at Page 2 of 29 RAIL SAFETY AND STANDARDS BOARD

3 Contents Section Description Page Part 1 Introduction Purpose and structure of this document Scope of this document Application of this document Health and safety responsibilities Copyright Approval and authorisation of this document 6 Part 2 Acceptance of Items of Portable and Transportable Plant Product acceptance of portable and transportable plant Engineering acceptance of portable and transportable plant Modification of portable and transportable plant Process overview 9 Part 3 General Requirements for Portable and Transportable Plant within Scope of Appendix A Limitation on use Colouring Lighting Pollution Electromagnetic compatibility Handling of portable and transportable plant Protection from electrification systems Electric powered portable and transportable plant Noise and vibration Damage to infrastructure Product maintenance Operating instructions 15 Part 4 Specific Requirements for Particular Types of Portable and Transportable Plant Manually propelled railborne portable and transportable plant Portable and transportable plant for handling rail Portable and transportable plant for handling sleepers and track sections Portable and transportable plant intended to be temporarily fixed to track Attachments Track jacks Cable detection equipment Automatic warning devices (AWD) 25 Appendices 26 Appendix A Plant Required to Comply with Parts 3 and 4 of this document 26 Appendix B Outline Flow Diagram of Portable and Transportable Plant Acceptance Process 27 Definitions 28 References 29 Tables Table 1 Rail wheel profiles 19 Table 2 Stopping distances 20 RAIL SAFETY AND STANDARDS BOARD Page 3 of 29

4 Figures Figure 1 Figure 2 Exceedance allowed at lower gauge (up to 1000 mm above rail level) for railborne portable and transportable plant over 20 kg 17 Exceedance allowed at lower gauge (up to 1000 mm above rail level) for railborne portable and transportable plant 20 kg and less 17 Figure 3 Lamp iron dimensions 18 Figure 4 Load lifting point labels 23 Page 4 of 29 RAIL SAFETY AND STANDARDS BOARD

5 Part 1 Introduction 1.1 Purpose and structure of this document This Rail Industry Standard has been published by Rail Safety and Standards Board (RSSB) to provide a voluntary standard for the acceptance for use on Network Rail managed infrastructure of portable and transportable plant used for infrastructure work This document details requirements for portable and transportable plant on, or that could affect, Network Rail managed infrastructure The document is set out in the form of standard requirements followed by guidance notes. Guidance notes are marked by a grey bar in the margin with the letters GN and sequential numbering, to differentiate them from the standard requirements to which they relate. 1.2 Scope of this document This Rail Industry Standard covers the acceptance for use on Network Rail managed infrastructure of all new and modified portable and transportable plant (as defined in this document) used for all infrastructure related activities This Rail Industry Standard includes the engineering requirements and fitness for purpose of portable and transportable plant to control rail specific risks Rail vehicles which are covered by RIS-1530-PLT and GM/RT2400 are excluded from the scope of this standard, although ancillary equipment and attachments for these vehicles are included in the scope of this standard. 1.3 Application of this document Rail Industry Standards are not mandatory unless or until a duty holder specifies all or part of them in company procedures or contract conditions. Where this is the case the duty holder will specify the nature and extent of application Specific compliance requirements and dates have not been specified since these will be the subject of the internal procedures or contract conditions of the companies which choose to adopt this standard. 1.4 Health and safety responsibilities Users of documents published by RSSB are reminded of the need to consider their own responsibilities to ensure health and safety at work and their own duties under health and safety legislation. RSSB does not warrant that compliance with all or any documents published by RSSB is sufficient in itself to ensure safe systems of work or operation or to satisfy such responsibilities or duties. 1.5 Copyright Copyright in the Railway Group documents is owned by Rail Safety and Standards Board Limited. All rights are hereby reserved. No Railway Group document (in whole or in part) may be reproduced, stored in a retrieval system, or RAIL SAFETY AND STANDARDS BOARD Page 5 of 29

6 transmitted, in any form or means, without the prior written permission of Rail Safety and Standards Board Limited, or as expressly permitted by law RSSB members are granted copyright licence in accordance with the Constitution Agreement relating to Rail Safety and Standards Board Limited In circumstances where Rail Safety and Standards Board Limited has granted a particular person or organisation permission to copy extracts from Railway Group documents, Rail Safety and Standards Board Limited accepts no responsibility for, and excludes all liability in connection with, the use of such extracts, or any claims arising therefrom. This disclaimer applies to all forms of media in which extracts from Railway Group documents may be reproduced. 1.6 Approval and authorisation of this document The content of this document was approved by: Plant Standards Committee on 14 August This document was authorised by RSSB on 19 August Page 6 of 29 RAIL SAFETY AND STANDARDS BOARD

7 Part 2 Acceptance of Items of Portable and Transportable Plant 2.1 Product acceptance of portable and transportable plant All new or modified items of portable and transportable plant shall be submitted to Network Rail Asset Management Acceptance Services to establish whether formal product acceptance is required All items of portable and transportable plant that require formal product acceptance by Network Rail for the operational use of portable and transportable plant shall be formally submitted to Network Rail Asset Management Acceptance Services in accordance with NR/CS/ACC/029. GN001 GN002 GN003 GN004 GN005 GN006 Network Rail's product acceptance relates to the type, safety and quality of work of the portable and transportable plant in its intended use and its effect on the infrastructure. The infrastructure manager gives product acceptance for the first of class. All subsequent members of the identical class do not need to be submitted for product acceptance because the design is already accepted. To be identical there should be no changes in design, construction or use of an item of portable and transportable plant that will affect the intended use, Plant Acceptance Body (PAB) certificate, called Plant Acceptance Body Engineering Assessment Certificate, limitations or any criteria specified within the scope of this standard. The infrastructure manager gives product acceptance for the first of class against the criteria that it does not damage the infrastructure, fitness for purpose and whether they require the portable and transportable plant design for use on Network Rail managed infrastructure. The safety and rail specific aspects are dealt with in this document. Where formal product acceptance is not required, written notification is given by Network Rail Asset Management Acceptance Services. This written notification will be provided in the form of a formal Product Acceptance Certificate and will clearly state that the product has been reviewed and identified as not requiring to undergo formal engineering acceptance by a PAB. Any such certificate will be endorsed with a seven year expiry date as with any other Product Acceptance Certificate. Network Rail Asset Management Acceptance Services issues a product acceptance certificate for all portable and transportable plant achieving formal product acceptance. All subsequent items of portable and transportable plant of identical design and construction by the same manufacturer are covered by the original product acceptance certificate, providing that the intended use remains the same. If the plant suppliers consider that it is unreasonable to have an existing item of equipment compliant with current standards, but still wish to have the equipment in operation for railway use, then an application should be made for derogation against this standard to the authority that mandates this standard. The derogation application should state the reasons why it is impracticable to make the equipment compliant; why it should remain in active operation for rail work; which requirements of which standard cannot be met; and what detailed mitigation will be applied in respect of the non-compliances The Product Acceptance Certificate for the design of a new piece of equipment shall be dated for a maximum life of seven years, at which time the equipment design shall be reviewed for compatibility and compliance with the applicable standards current at the time of the review. RAIL SAFETY AND STANDARDS BOARD Page 7 of 29

8 GN007 GN008 When an item of equipment receives a Product Acceptance Certificate for the first time, the certificate is given a life of seven years. At the end of the certificate life, the equipment design is either reviewed to the standards current at the time of re-certification, or the equipment design will have its formal approval for the supply of new equipment for use on railways withdrawn. It is the manufacturer s (and / or supplier s) responsibility to ensure that a design is re-submitted before the expiry date. Items of portable and transportable plant are not permitted to be supplied as new items after the expiry date of the Product Acceptance Certificate Product Acceptance Certificates issued as a result of reassessment to current standards shall be dated for a maximum life of seven years from date of reassessment Where a manufacturer significantly modifies an existing accepted design, the design shall be resubmitted to Network Rail Asset Management Acceptance Services to establish whether formal product acceptance is required. A Product Acceptance Certificate issued as a result of any engineering change shall be dated to the same expiry date of the previously accepted design unless the whole design has been re-assessed to the current standard. GN009 GN010 GN011 GN012 The manufacturer, when submitting equipment for re-assessment due to a modification during the life of an existing Product Acceptance Certificate, has a choice to make. He can either have the equipment assessed against the full requirements of this standard and have a new Product Acceptance Certificate valid for seven years, or have only the modification assessed against standards applicable to the modification and receive a new Product Acceptance Certificate dated to the expiry date of the original certificate. It is recommended that the manufacturer consults with a PAB (or Network Rail) to ascertain which is the most beneficial or cost effective decision in each case. A significant modification is where changes in design, construction or use of an accepted item of portable and transportable plant are made and that will affect the intended use, PAB certificate limitations or any criteria specified within the scope of this document. The manufacturer is responsible for providing the infrastructure manager with documented evidence to prove that the change is not significant the default position should be that a proposed modification is submitted. The requirements of Part 2.1 of this standard do not apply to equipment currently in use on the railway (that is with grandfather rights ) that has not undergone formal product approval in accordance with a mandated standard and not been issued a Product Acceptance Certificate, unless the infrastructure manager identifies a requirement for re-assessment to be undertaken. The Product Acceptance Certificate is dated for a set life of the design. Manufacturers are not permitted to supply new items of this design of portable and transportable plant after the expiry date of the Certificate. Individual items of portable and transportable plant, having been supplied, have no set life on them and can continue to be used indefinitely or until the infrastructure manager (Network Rail) has banned their use on the managed infrastructure. 2.2 Engineering acceptance of portable and transportable plant Before Network Rail Asset Management Acceptance Services issues a product acceptance certificate for the items of portable and transportable plant listed in Appendix A, a PAB or other Network Rail approved specialist body shall carry out an engineering assessment to confirm that it complies with requirements in Part 3 and Part 4 of this document. Page 8 of 29 RAIL SAFETY AND STANDARDS BOARD

9 GN013 GN014 GN015 GN016 Proof of compliance with Part 3 and Part 4 of this document is by issue of a Plant Acceptance Body Engineering Assessment Certificate. The certificate will also indicate any limitations on the use of the plant. This certificate is passed to Network Rail Asset Management Acceptance Services who (subject to the product being accepted) will issue the Product Acceptance Certificate with the restrictions given by the PAB plus any additional restrictions found necessary by Network Rail's own internal assessments. Plant acceptance bodies are appointed by Network Rail by its own process set out in NR/SP/ELP/ A list of current PABs can be obtained from Network Rail Asset Management Acceptance Services. Items of portable and transportable plant which are not listed in Appendix A still have to be submitted to Network Rail Asset Management Acceptance Services in accordance with 2.1. They will be considered against applicable internal Network Rail company specification or other appropriate requirements. Where portable and transportable plant is a conversion of an existing item which had its own CE marking (or equivalent road vehicle acceptance), the converter is responsible for compliance with the appropriate European directives. 2.3 Modification of existing portable and transportable plant by owner or operator Before submission to Network Rail Asset Management Acceptance Services all proposed modifications by the owner or operator to an item of portable and transportable plant (including changes / revisions to Operating and Maintenance Instructions) shall either a) be supported by the original manufacturer b) or where the manufacturer is reluctant to accept additional liability or no longer available the owner or operator shall justify the engineering change Details of all proposed modifications by the owner or operator to an item of portable and transportable plant (including changes / revisions to Operating and Maintenance Instructions) shall be submitted to Network Rail Asset Management Acceptance Services for review as set out in Where Network Rail, Asset Management Acceptance Services consider that formal approval of the modification in accordance with the requirements of this standard is not required then this shall be confirmed to the applicant in writing. GN017 GN018 The owner or operator should also consider where the portable and transportable plant is serviced, maintained, overhauled or any other function provided by an external supplier, that the supplier is aware that any changes to the existing design will require to be notified. The owner or operator should notify Network Rail Asset Management Acceptance Services of any proposed design change in writing, and allow Network Rail, to object to the proposal, require further product or engineering acceptance, or accept the proposal. 2.4 Process overview GN019 A simplified overview process for acceptance of items of portable and transportable plant is shown as a flow diagram in Appendix B. RAIL SAFETY AND STANDARDS BOARD Page 9 of 29

10 Part 3 General Requirements for Portable and Transportable Plant within Scope of Appendix A 3.1 Limitation on use Portable and transportable plant that is not permitted to be used outside of a possession shall have this limitation stated on the Plant Acceptance Body Engineering Assessment Certificate. GN020 It is good practice for portable and transportable plant that is not permitted to be used outside of a possession, that is on the open line during red zone working, to be clearly labelled Not to be used outside of a possession. 3.2 Colouring Every item shall be predominantly coloured yellow. GN021 GN022 The extent of yellow colour should be as complete as reasonably practical relative to the item design and its manufacture. The item should present predominantly yellow colour along the track. In most cases this is all sides of the item of portable or transportable plant. The colour should be yellow as specified by any of the following paint colours: a) RAL 1003, RAL 1004, RAL 1018, RAL 1021, or RAL 1023 from the RAL Classic Colour Collection b) BS 4800 Item 08E51 c) BR81 Item 202 d) NCS (natural colour system) target value Y10R or Y11R e) EC in the Eurocolour table. GN023 Conformance should be assessed by a visual comparison and no measurement of the colour when applied to the vehicle is necessary Any handrail used to gain access to the portable and transportable plant shall be white The push bar and brake handle on trolleys shall be white The control device or handle for any mechanism used for locking shall be red. 3.3 Lighting Where the portable and transportable plant is provided with its own lighting, it shall be able to be used without interfering with the operation of railway signalling or dazzling train crew or plant operatives. GN024 The lighting referred to in is likely to be work lighting (that is lighting to illuminate the working area), but could include any lighting that may be fitted to indicate the presence of the portable and transportable plant. Page 10 of 29 RAIL SAFETY AND STANDARDS BOARD

11 GN025 Lighting should either be in a fixed position which cannot interfere with signalling or dazzle drivers or the operator of the portable and transportable plant, or be adjustable to avoid this as necessary. 3.4 Pollution The portable and transportable plant shall be designed so that it minimises the emission of gases, liquids, dust, vapour and any waste products which may produce pollution Where such pollution is produced, then the use of the portable and transportable plant in tunnels, cuttings and confined spaces shall be assessed by the PAB and any limitations in use shall be stated on the Plant Acceptance Body Engineering Assessment Certificate. Network Rail shall state them on the product acceptance certificate The use of petrol engines in tunnels and equivalent confined spaces is not permitted therefore a product acceptance certificate for portable and transportable plant with a petrol engine shall prohibit its use in tunnels. GN026 Petrol engines should not be used in confined areas because of carbon monoxide produced in exhaust. Carbon monoxide has the propensity to displace oxygen in the blood and is undetectable to human senses The portable and transportable plant shall be designed so that any fluid connections designed to be disconnected during normal use, assembly and packing away shall not release any fluid. 3.5 Electromagnetic compatibility Portable and transportable plant shall be designed to be electromagnetically compatible with the railway infrastructure. GN027 GN028 GN029 GN030 Where portable and transportable plant is a conversion of an existing item which had its own CE marking (or equivalent road vehicle acceptance) and an electrical system of 28 V or less, then, providing no electrical parts are added, no further EMC testing is required. If electrical equipment is added, then provided that the equipment added has already been separately successfully tested and CE marked, again no further testing is required. Where previously untested portable and transportable plant exists with an electrical system of 28 V or less, then the portable and transportable plant should either be tested to automotive EMC test ISO or railway vehicle EMC test BS EN If electrical equipment of 28 V or less is to be added to an existing design then the portable and transportable plant to be added can either be independently tested to ISO or the complete portable and transportable plant tested to ISO Where a previously untested portable and transportable plant exists with an electrical system of greater than 28 V, then the portable and transportable plant should be tested to railway vehicle EMC test BS EN or BS EN RAIL SAFETY AND STANDARDS BOARD Page 11 of 29

12 3.6 Handling of portable and transportable plant Portable and transportable plant shall a) if it is designed to be manually lifted and carried it shall have provision for adequate manual handling b) if it is not designed to be manually lifted and carried there shall be suitable designated mechanical lifting points Portable and transportable plant that is not designed to be manually lifted and carried shall be clearly marked that it shall not be manually handled. GN031 The portable and transportable plant should be assessed as to whether or not it can be carried in the railway environment (noting that this will be likely to include access on steep steps, walking along ballast etc). A generally accepted figure is that one person should not be expected to lift and carry more than 20 kg (this could be 25 kg for a single lift). Therefore there should be sufficient carry handles or lifting points on each item of portable and transportable plant to ensure that the required number of persons can safely carry the item. Additional handles / lifting points could be required to maintain equilibrium of the portable and transportable plant If the portable and transportable plant has the potential to be used outside of a possession, during red zone working, then the portable and transportable plant shall be designed so that it can be easily removed from the track. GN032 The explanation of possessions and red zone working is set out in module T7 of the Rule Book (GE/RT8000/T7) If the portable and transportable plant has the potential to be used outside of a possession, then the potential to be used in red zone (or not), the length of time and the number of persons required for the removal off the track shall be assessed by the PAB and stated on the Plant Acceptance Body Engineering Assessment Certificate. GN033 The actual use of any item of portable and transportable plant in a red zone will depend on each occasion it is planned to be used (the geography, weather condition etc will affect the ability to move to a position of safety). The time taken to move to a position of safety will have to be calculated by the user on each occasion. The assessment called for here, by the PAB, is the time and effort required to remove from the track, that is does it have the potential to be used for red zone working. 3.7 Protection from electrification systems Overhead line electrification The Plant Acceptance Body Engineering Assessment Certificate for all portable and transportable plant shall be endorsed 'Not to be used under live OLE' unless the following, as applicable, are achieved: a) The portable and transportable plant shall be designed (or fitted with a means) to prevent any part, including moveable parts, of it infringing the clearances set out in GE/RT8025 during designed use. b) All fixed platforms or work surfaces designed for personnel access under OLE that are higher than 1.4 m above rail level, including all access and egress (normal and emergency) routes, shall be covered by a suitable Page 12 of 29 RAIL SAFETY AND STANDARDS BOARD

13 canopy. The canopy shall prevent personnel from coming into inadvertent contact with live OLE and shall either be non-conducting or be bonded as set out in GM/RT2304. GN034 GN035 The height of 1.4 m applies to the top of the platform surface (that is where the operatives feet are placed) and does not include the additional height of handrails, kickboards etc. Consideration should be given to the provision of a canopy where the platform is below 1.4 m above rail level if this is reasonably practicable Elevating work platforms or fixed platforms which are precluded from having a canopy fitted because of their intended use shall be fitted with electrification warning signs and methods of restricting access Third rail electrification The Plant Acceptance Body Engineering Assessment Certificate for all portable and transportable plant shall be endorsed 'Not to be used on live third rail electrification' unless the following is achieved: Fourth rail electrification a) The portable and transportable plant shall be designed to protect the operator from contact with the conductor rails while operating it, and the portable and transportable plant shall not infringe the clearances set out for third rail in GE/RT8025 unless specifically designed for use in proximity to the conductor rail The Plant Acceptance Body Engineering Assessment Certificate for all portable and transportable plant shall be endorsed 'Not to be used on live third and fourth rail electrification' unless the following is achieved: a) The portable and transportable plant shall be designed to protect the operator from contact with the conductor rails while operating it and the portable and transportable plant shall not infringe the clearances set out for fourth rail in GE/RT8025 unless specifically designed for use in proximity to the conductor rails Marking of portable and transportable plant All portable and transportable plant which has a restriction applied in 3.7.1, and / or shall be marked 'Not to be used on live third rail and / or fourth rail or OLE electrification' as applicable. 3.8 Electric powered portable and transportable plant Plugs and sockets shall be selected so that it is not possible to by-pass any lookout warning device fitted to the portable and transportable plant. GN036 Plugs sockets and cabling should be specified to suit the outdoor railway environment (in terms of weather protection, electrical rating, impact resistance, tamper proofing etc.). Colour and design should be to BS EN Electric powered portable and transportable plant shall be limited to a maximum 110 v ac or dc. RAIL SAFETY AND STANDARDS BOARD Page 13 of 29

14 3.8.3 Electrical tools shall be double insulated. Generators shall be centre tapped to earth (CTE) or alternatively the output shall be protected by a 30 ma residual current device (RCD). GN037 Generators should be provided with the facility to bond the earth connection to ground. 3.9 Noise and vibration Where the portable and transportable plant is to be accepted for use in red zones and there is a risk of the lookout warning not being heard by the operator owing to the noise of the portable and transportable plant then, except as indicated in 3.8.2, portable and transportable plant shall be fitted with an in-built warning system operable by a lookout, meeting the requirements of Where it is not reasonably practicable to fit such an in-built warning system the need for the provision of a touch lookout shall be stated on the Plant Acceptance Body Engineering Assessment Certificate. GN038 GN039 GN040 Where the portable and transportable plant has a noise source the manufacture should state the actual noise pressure level and noise power level. The manufacturer should state in the operating manual the actual whole body vibration and hand-arm vibration levels measured in m/s 2 and giving a degree of uncertainty for the measurements. Further guidance on noise requirements and measurement, whole body vibration and hand-arm vibration is set out in GM/GN Damage to infrastructure Portable and transportable plant shall be designed to ensure no unacceptable damage occurs to the infrastructure. GN041 GN042 GN043 Infrastructure includes the rail, sleepers, ballast, formation, buildings and structures. Network Rail specialist engineers are the arbiter of what comprises unacceptable damage. This does not apply to damage to the rail caused by equipment specifically designed for the handling of rail which has been designated scrap and will not again be used on the railway infrastructure Product maintenance All portable and transportable plant shall have a written maintenance plan provided by the manufacturer. GN044 GN045 GN046 The PAB should assess the maintenance plan provided by the manufacturer to ensure that it includes applicable railway specific requirements and completely details what is to be done and when. The plan should cover the item of plant concerned, be suitable and sufficient for the anticipated life and use of the plant and contains the current known industry best practice. This could also include eventual disposal methods of the portable and transportable plant. M&EE Code of Practice COP0010 defines certain maintenance processes on specific items of portable or transportable plant as safety critical; these processes should be Page 14 of 29 RAIL SAFETY AND STANDARDS BOARD

15 specifically highlighted in the maintenance plan. There are also other M&EE Codes of Practice (for example COP0013, COP0018 etc) which contain maintenance recommendations Operating instructions Where applicable portable and transportable plant shall have written railway specific operating instructions provided by the manufacturer. GN047 Legislation requires that a documented operating procedure is produced, the requirement here is that the operating instructions are tailored for use in the railway environment as applicable. This requirement should also include a suitable training syllabus for the equipment operator. RAIL SAFETY AND STANDARDS BOARD Page 15 of 29

16 Part 4 Specific Requirements for Particular Types of Portable and Transportable Plant 4.1 Manually propelled railborne portable and transportable plant General All manually propelled railborne portable and transportable plant shall meet the requirements of BS EN 13977:2005, except as set out below: a) Brakes - all railborne manually propelled portable and transportable plant shall meet the requirements set out in of this document and not as set out in BS EN section 5.4. b) Electrical power supplies shall be limited to 110 V ac and dc, not as set out in BS EN section c) Portable and transportable plant permitted to be used outside of a possession, during red zone working, shall comply with the requirements for the electrical resistance across rails set out BS EN section Portable and transportable plant that is only to be used within a possession shall have an electrical resistance between rail wheels of <0.5 Ω, measured across wheel tread surface on wheels on opposite rails (normally on the same axle alignment). d) The height limit of gauge set out in BS EN section is permitted to be exceeded for scaffold trolleys (tunnel inspection trolleys, painter's trolleys etc) but shall be accompanied by an outline safe system of work and the maximum permissible height shall be stated by the manufacturer, if necessary at differing levels of cant. This limitation shall be stated on the Plant Acceptance Body Engineering Assessment Certificate. e) The profile gauge set out in BS EN section 5.16 is permissible to be exceeded in the area around the wheelset, as shown in Figure 1 and Figure 2 of this document depending on weight of the item of railborne portable and transportable plant. The Plant Acceptance Body Engineering Assessment Certificate shall be endorsed 'Not for use on switches and crossings with a raised check rail' when Figure 2 is used. GN048 The use of profile shown in Figure 2 could cause a conflict at switches and crossings with check rails above rail level, this is the reason for the endorsement. Page 16 of 29 RAIL SAFETY AND STANDARDS BOARD

17 RAIL LEVEL This area intended for rail wheel Figure 1 Exceedance allowed at lower gauge (up to 1000 mm above rail level) for railborne portable and transportable plant over 20 kg Figure 2 Exceedance allowed at lower gauge (up to 1000 mm above rail level) for railborne portable and transportable plant 20 kg and less GN049 GN050 The manufacturer should take into account the maximum allowable wear on wheels and suspension equipment to ensure clearances are achieved throughout the life of the manually propelled railborne portable and transportable plant. The gauge shown in Figure 2 includes no allowance for raised check rail to 60 mm above rail head level. The Plant Acceptance Body Engineering Assessment Certificate should be endorsed with any restrictions. RAIL SAFETY AND STANDARDS BOARD Page 17 of 29

18 GN051 It is recommended that manually propelled railborne portable and transportable plant should be built to keep within the static coordinates of the W6a gauge, as defined in Appendix A of GE/RT8073. The dynamic movements of the vehicle should not exceed the figures shown by more than 25 mm at 1000 mm above rail level and 75 mm at 3080 mm above rail level There shall be the provision to attach a lamp at both ends of the item of manually propelled railborne portable and transportable plant, GN052 A trolley used under T2 protection is required to display either a red flag or red light (Rule Book Module T2 15.5). GN053 A bracket acceptable for attaching a lamp is shown in Figure 3. 7 mm 50 mm 150 mm 11 mm Figure 3 Lamp iron dimensions The maximum uniformly distributed load (UDL) of an individual item of manually propelled railborne portable and transportable plant shall not exceed 1 tonne. Manually propelled railborne portable and transportable plant for moving lengths of rail (commonly known as Ironmen ) are permitted to be treated as individual items for their total UDL when working together. GN054 Ironmen are convenient to permit a greater number of personnel to move the item along the track because they can comfortably have personnel distributed around each item. Therefore it is permitted to add together the UDL of each ironman being used. Trolleys which are designed to link together should limit the UDL for the total configuration to that of the lowest individual component because there is no additional scope for comfortable additional manpower when pushing the trolleys linked together Rail wheels In addition to BS EN 13977, the wheels shall not damage the rail or its connections, and shall be suitable for the weight of the manually propelled railborne portable and transportable plant Unless the manually propelled railborne portable and transportable plant is specifically designed to bend rails, the stresses exerted on the rails by the rail wheels of the manually propelled railborne portable and transportable plant when working shall not exceed 350 N/mm 2. Page 18 of 29 RAIL SAFETY AND STANDARDS BOARD

19 All manually propelled railborne portable and transportable plant with rail wheels shall be assessed by the PAB, to ensure that under all operating modes they ride along the track without the propensity to derail, including the ability to negotiate track twists. GN055 GN056 BS EN section 5.3 gives requirements for the manually propelled railborne portable and transportable plant in its worst case operating condition to ride successfully on a range of track configurations, which should be verified by the PAB. The track configurations shown in BS EN should be augmented with a track twist test equivalent to a slope of 1 in 150 of one rail up to a maximum of 20 mm. Additionally the PAB should test and assess the item of manually propelled railborne portable and transportable plant for its ability to negotiate switches and crossings under all operational modes Where a standard wheel profile, as shown in Table 1, is not utilised (this could include double flanged, flat rollers etc) the manufacturer shall state the exact profile used and all wear limits in the maintenance plan documentation. GN057 The PAB should assess the ability of the item of manually propelled railborne portable and transportable plant with non-standard wheel profiles to ensure they do not exhibit the propensity to derail on all track conditions at 3 mph (5 km/h). This should include switches, crossings, dipped joints, track twists, curves and canted track. Tread profile Drawing number / specification Flange thickness details (mm) As new W Minimum (Worn) Flange height details As new (mm) Y Maximum (Worn) P1 S8-C P10 F-C Table 1 Rail wheel profiles Brake system Except as set out in all manually propelled railborne portable and transportable plant fitted with three or more rail wheels (or rollers) shall be fitted with a fail safe brake system, which shall be capable of stopping and holding the item of manually propelled railborne portable and transportable plant, complete with any load it is designed to carry / use, on a gradient of 1 in 27. The system shall not be capable of being locked in the release position and shall self apply to prevent the manually propelled railborne portable and transportable plant running away. GN058 Where a low friction pad is used (normally on slow speed manually propelled railborne portable and transportable plant) to aid stability, this should be counted as a wheel or roller within the scope of A high friction pad, which will stop the movement of the plant in accordance with Table 2, should not be counted as a wheel or roller The braking system of manually propelled railborne portable and transportable plant shall be designed to cope with an overload of twice the permitted load. The maintenance instructions shall be written to retain this capability. RAIL SAFETY AND STANDARDS BOARD Page 19 of 29

20 GN059 The testing to prove the original brake system ( ) and stopping distances ( ) should be undertaken with a load of twice the stated maximum working load. GN060 The manufacturer should provide written maintenance instructions to maintain the braking system's ability to meet , and during its working life Where an item of manually propelled railborne portable and transportable plant is designed, and proven, to be incapable of running away (for example by lack of dynamic stability) this is sufficient mitigation to negate the need for brakes Manually propelled railborne portable and transportable plant shall meet the stopping distances shown in Table 2 in maximum laden and tare conditions. Gradient Stopping distance at 3 mph (5 km/h) dry rail (m) Stopping distance at 3 mph (5 km/h) wet rail Level in Table 2 Stopping distances (m) GN061 GN062 GN063 It should be emphasised that all items of manually propelled railborne portable and transportable plant need to meet the 1 in 27 stopping and holding requirements to comply with and The maximum speed of manually propelled railborne portable and transportable plant is 3 mph (as set out in RIS-1700-PLT). The speed is controlled by staff discipline, it would be advantageous to have an engineering means to limit speed, but this is not mandated. Additionally to over-speeding, there is also a risk of an adverse affect on the braking performance caused by overload of the manually propelled railborne portable and transportable plant. It would also be advantageous to have an engineering control of load limiting, but this is not mandated Manually propelled railborne portable and transportable plant shall, as far as reasonably practicable, be designed to prevent interference and damage to any mechanisms and actuators used in the operation of the brake, which could subsequently impede or reduce the effectiveness of the operation of the brake. GN064 It should be emphasised that the design of brake mechanisms should be protected from interference and inadvertent damage Where brakes are applied / released by manual operation then these shall be ergonomically assessed for their operational characteristics. GN065 Assistance in the ergonomic assessment of equipment can be obtained from Network Rail s Ergonomics & Human Factors Specialist Team Bonding For manually propelled railborne portable and transportable plant, electrical bonding shall either: a) Comply with the requirements of GM/RT2304 (GM/RC2514 sets out good practice in this area). Page 20 of 29 RAIL SAFETY AND STANDARDS BOARD

21 or b) Manually propelled railborne portable and transportable plant shall meet the requirement that there shall be no unacceptable electrical risks caused by the inability of any induced voltages to discharge to earth through the running rails. or Manual propulsion c) The manually propelled railborne portable and transportable plant shall be accepted for use on Network Rail managed infrastructure with the operating restriction of being allowed to be placed on track, or operated under OLE or in a conductor rail area, only when an overhead line permit or a conductor rail permit has been obtained. In this case the manually propelled railborne portable and transportable plant shall be marked 'Not to be used on live third and fourth rail or OLE electrification' as applicable The design of manually propelled railborne portable and transportable plant shall take into account the capabilities of the people required to propel (pull or push) it. GN066 GN067 When deciding the maximum weight of the manually propelled railborne portable and transportable plant and any permitted load consideration should be given to the manpower required to propel it along the track. Advice on the number of persons normally required to push wheeled vehicles is given in M&EE code of practice COP0018. Additional advice for design considerations regarding the handling and operation of manually propelled railborne portable and transportable plant can be obtained from Network Rail s Ergonomics & Human Factors Specialist Team. 4.2 Portable and transportable plant for handling rail Maximum rail stress Unless the portable and transportable plant is specifically designed to bend or stress rails (for example rail joint straightener), the stresses exerted on the rails being handled by the portable and transportable plant shall not exceed 175 N/mm Portable and transportable plant for handling sleepers and track sections Damage Lifting devices for handling concrete sleepers shall not rely solely on friction between device and sleeper Lifting devices for handling concrete and steel sleepers shall not exceed 20 N/mm 2 compression onto the sleeper. 4.4 Portable and transportable plant intended to be temporarily fixed to track Clamping devices Where it is necessary for the portable and transportable plant to be clamped to the rail or sleeper to allow it to carry out its designed function, it shall not damage RAIL SAFETY AND STANDARDS BOARD Page 21 of 29

22 the rail, sleeper, fastenings or connections. These clamping devices shall also be of sufficient strength to withstand the vibrations and forces generated by the operation of the portable and transportable plant All clamping devices shall be easily put in place and always secure the portable and transportable plant or its support to the rail or sleeper only Where an item of portable and transportable plant is designed to be clamped to rail during red zone working the clamping device shall be designed to remain secure when subjected to the foreseeable vibration caused by passing trains. Each obstructionless item of portable and transportable plant that complies with shall be marked 'permitted for use in red zone working' Cutting bits and tools If the portable and transportable plant is to be accepted for use in red zone working, then the method of retaining any cutting bits and tools within the portable and transportable plant shall be such that: a) If they become trapped, they can be quickly released from the portable and transportable plant and the plant easily removed clear of the track, with the trapped tool or bit remaining obstructionless or b) The portable and transportable plant and the trapped tools do not present an obstruction to trains. GN068 When using the obstruction-less design in b) the PAB should consider the potential for a tool or plant to vibrate loose during the passage of a train and then present an obstruction. 4.5 Attachments Attachments shall be assessed in relation to the specific type of plant to which they are to be attached. The assessment shall include: a) Material strength of host item of plant to support the attachment, including the means of physical attachment and any other associated accessory to facilitate this connection (such as hook, pin, shackle). b) Stability of host item of plant / attachment combination against overturning. c) Stability of host item of plant / attachment combination against derailment when moving along the track. d) Requirements for hydraulic, pneumatic and electrical supply. e) Fitment of attachment does not adversely obscure the view of the operator to see along the track in the direction of travel or of the work area. f) Fitment of the attachment does not adversely obscure the marker or tail lights of the host machine (unless replicated by additional lights on the attachment). Page 22 of 29 RAIL SAFETY AND STANDARDS BOARD

23 g) The means of ensuring the attachment continues to be retained by the host item of plant, that is the attachment itself cannot be inadvertently released and can only be released by deliberate action(s). GN069 GN070 It is permissible for the PAB assessment to be undertaken by physical testing, picture or video evidence, design review of engineering drawing etc or combinations. The PAB should, as far as they are able, check the compatibility between likely host items of plant hydraulic and/or air pressure supply and flow rate and the attachment being assessed. Similarly the compatibility with likely host item of plant electrical supplies should be assessed The attachment shall be labelled with requirements for: a) Hydraulic (minimum and maximum pressure and flow rate) b) Pneumatic (minimum and maximum pressure and flow rate) c) Electrical supply (frequency, voltage (ac or dc), maximum current and, where relevant, earthing arrangement) If the attachment has an area that could be used to lift a load then this shall be approved by the attachment manufacturer as a load lifting point All load lifting points shall be marked as a load lifting point, and labelled with maximum safe working load. GN071 Every load lifting point should be clearly labelled on the attachment. Suggestions for labels are set out in Figure 4. LOAD LIFTING POINT SWL 5 tonne Figure 4 Load lifting point labels Attachments for lifting shall be designed such that it is impossible to release the load whilst it is suspended unless there is a deliberate action by the operator Load lifting points shall be designed with a factor of safety of 5 to yield. GN072 Lifting devices should only be able to release the load it is carrying when the load has been lowered to the ground, or the operator makes a conscious action (normally this is expected to be at least two separate control movements) to release the load. Designs for lifting usable rails and sleepers should never allow release whilst the load is suspended Attachment for lifting operations, where hydraulically powered, shall be fitted with burst hose protection lock valves to prevent inadvertent release of the load in case of a hydraulic failure. RAIL SAFETY AND STANDARDS BOARD Page 23 of 29

24 GN073 GN074 GN075 GN076 Where lock valves are fitted they should close automatically to prevent fluid leaving the cylinders until they are opened by an external force. Burst hose protection devices should rely upon controlled servo pressure to release the valve and not main system pressure. The position of the burst hose protection device should be considered for its vulnerability during routine operation of the attachment when fitted to a vehicle. If necessary, protection should be provided for the device to avoid mechanical damage. The manufacturer should provide any necessary test facility on the attachment and provide any necessary instruction for testing of burst hose protection devices in the maintenance instructions 4.6 Track jacks Classification and registration Track jacks shall conform to one of the following classifications: a) Type 1 (obstructionless) One that will not protrude above rail height or come within 50 mm of the running edge (when lifting the rail) and can be lowered from full height within 10 seconds (under load). b) Type 2 One that will cause an obstruction to traffic (that is one falling outside the scope of Type 1) when placed under the rail but with a quick release mechanism enabling the jack to be immediately lowered from full height and be removed from under the track within a maximum of 10 seconds. c) Type 3 One that will cause an obstruction to traffic (that is one falling outside the scope of Type 1) when placed under the rail but cannot be quickly lowered from full height. d) Type 4 One that has been designed for track slewing Each jack shall be marked with the following: a) A unique identification number stamped on the casing. b) Safe working load stamped on the casing. In the case of a toe jack, the safe working load of both head and toe shall be separately identified. GN077 GN078 All track jacks should be registered so that they can be uniquely identified with their maintenance and examination records. Advice on the Maintenance, Operation and Testing of Track Jacks is given in M&EE Code of Practice COP0013 and Section 7 of RIS-1700-PLT Safe Use of Plant for Infrastructure Work. Page 24 of 29 RAIL SAFETY AND STANDARDS BOARD