NRL2TRK001 Mod 19 Issue 6 Track Inspection Handbook PDF

Ref: NR/L2/TRK/001/mod19
Issue: 6
Date: 01 December 2012
Compliance date: 02 February 2013
Track Inspection Handbook
This document is the property of Network Rail. It shall not be reproduced in whole or part nor disclosed to a third
party without the written permission of Network Rail.
 Copyright 2012 Network Rail.
Uncontrolled copy once printed from its electronic source.

Published and Issued by Network Rail, Kings Place, 90 York Way, London. N1 9AG.
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Issue: 6
Contents
1 Scope 4
2 Definitions 4
3 Inspection 4
3.1 Safe for traffic 4
3.2 Method of inspection 4
3.3 Basic visual track inspection 4
3.4 Patrolling diagram 5
3.5 Defects to be identified by a patroller 5
4 Defects at fishplated joints 5
4.1 Broken, cracked, incorrect or damaged fishplates 5
4.2 Bolts missing from joints 5
4.3 “Fly-fished” joints 5
Table 1 - Minimum action to be taken for broken, cracked, incorrect or damaged
fishplates in a running line 6
Table 2A –Minimum action to be taken for joints with missing fishbolts 7
Table 2B – Minimum action to be taken for rail joints with all the bolts missing from
either rail end (‘fly-fished’ joint) 7
5 Broken rails 8
5.1 Immediate action 8
5.2 Authority to remove line blockage 8
5.3 Competent person 8
5.4 Broken rail action tables 8
Table 3 – Transverse break through plain rail or weld 9
Table 4 – Any part of the railhead broken away 9
Table 5 – Lower part of the rail broken away 10
Table 6 – Longitudinal split 11
6 Rail head damage (not arc damage) 11
6.1 Immediate action 11
6.2 Authority to remove line blockage 11
6.3 Rail head damage action table 11
7 Rail arc damage 11
Table 7 – Railhead damage 12
8 Loss of rail foot width 12
Table 8 – Minimum action for loss of rail foot width 12
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Page 2 of 47
Issue: 6
9 Adjustment switches 13
Figure 1 – Adjustment switch baseplate detail 13
Table 9 – Adjustment switch setting dimensions 13
Table 10 – Action for sub-standard switch tip support 14
Table 11 – Action for rail foot not fully supported at the end of the machining 14
10 Level Crossings 15
11 Maintenance tolerances and intervention limits 15
12 Priorities for track defects identified during inspection. 15
13 Actions for defective stretcher bars. 16
13.1 Fixed stretcher bars 16
13.2 Adjustable stretcher bars 16
13.3 Lock stretcher bars 16
13.4 Identification of stretcher bars and stretcher bar fastenings 16
13.5 Recording and reporting of stretcher bars defects 16
Appendix A - Maintenance tolerance and Intervention limit tables 17
Table A.1 – Ballast; maintenance tolerance and intervention limit 17
Table A.2 – Maximum number of ineffective sleepers per 60ft length 17
Table A.3 – Fastenings; maintenance tolerance and intervention limit 17
Appendix B - Work Priority Tables 18
Table B.1 Track Geometry 19
Table B.2 Joints 20
Table B.3 Rails 20
Table B 4 Sleepers 21
Table B.5 Rail Fastenings 21
Table B.6 Pads and insulators 22
Table B.7 Longitudinal timbers 22
Table B.8 Ballast 23
Table B.9 Check rails 24
Table B.10 S&C 24
Appendix C - Defective fixed stretcher bar action tables 27
Appendix D – Pictorial guidance for defects on fixed stretcher bar assemblies 29
Appendix E - Defective adjustable stretcher bar action tables 36
Appendix F – Pictorial guidance for defects on adjustable stretcher bar assemblies 38
Appendix G - Defective lock stretcher bar action table 44
Appendix H - Pictorial guidance for defects on lock stretcher bar assemblies 45
Appendix I – Identification of stretcher bars and stretcher bar fastenings 47
Page 3 of 47
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Issue: 6
1 Scope
This module of NR/L2/TRK/001 contains extracts from other modules within this
standard. It also includes additional tables and photographs to provide guidance
when undertaking inspections.
Mandatory requirements are detailed in the module of NR/L2/TRK/001 as referenced
at the end of each section/clause.
This guidance includes:
a) inspection;
b) defects at fishplated joints;
c) broken rails;
d) rail head damage (arc damage and non-arc damage);
e) loss of rail foot width;
f) adjustment switches;
g) level crossings
h) maintenance tolerances and intervention limits;
i) priorities for track faults observed during inspection;
j) actions for defective stretcher bars and missing or loose fastenings.
The reference at the end of the section/clause indicates where full details can be
found.
2 Definitions
See Glossary (NR/L2/TRK/001/mod01).
3 Inspection
3.1 Safe for traffic
If the track is not safe for traffic, apply either a speed restriction or block the line. The
speed restriction or line blockage will remain in place until the necessary repairs have
been completed.
NR/L2/TRK/001/mod02
3.2 Method of inspection
Unless an alternative method has been agreed, track inspections are undertaken in
daylight, on foot, walking within the length of the sleepers.
A maximum of two tracks can be inspected at one time.
NR/L2/TRK/001/mod02
3.3 Basic visual track inspection
Basic visual track inspections, undertaken by competent persons, identify defects
which, if uncorrected, could affect the safety or reliable operation of the railway.
NR/L2/TRK/001/mod02
Page 4 of 47
Issue: 6
3.4 Patrolling diagram

A uniquely referenced patrolling diagram is provided for each basic visual inspection.
The diagram is part of the track patroller’s method statement for carrying out visual
inspection.
Track patrol diagrams show the lines to be inspected and the route to be taken by the
patroller through any S&C within the patrol length.
NR/L2/TRK/001/mod02
3.5 Defects to be identified by a patroller
The patroller reports defects which could affect the safety of trains, due to
deterioration with time, weather exposure and /or the passage of traffic in the
following 4 weeks.
The Patroller will either mark and rectify the defect (if the defect is of a minor nature
and can be rectified within their normal duties – e.g. replacing clips, tightening bolts or
keeping flangeways clear) or mark the defect and report it to the Section Manager
[Track] (SM[T]) on TEF3015.
The Patroller may need to take appropriate action to protect trains by reporting the
defect to the Signaller.
The Patroller will also identify, where practical, other defects that require repair. The
patroller is not normally required to carry measuring equipment (track gauges etc) but
can make competent visual assessment of track component conditions and the
amount of movement (voiding, chair / baseplate shuffle etc.).
Because basic visual inspections are carried out frequently, the patroller will be able
to monitor these defects and report any deterioration to the SM[T].
Significant isolated geometry defects (top, alignment and twist) can be observed
visually and will be reported to the SM[T] who will make arrangements to take
measurements.
When measurements have been taken, the SM[T] will determine the timescales for
corrective action to be taken.
4 Defects at fishplated joints

4.1 Broken, cracked, incorrect or damaged fishplates
Where broken, cracked, incorrect or damaged fishplates are found, take action as
detailed in Table 1.
NR/L2/TRK/001/mod04
4.2 Bolts missing from joints
Where fishbolts are missing from a rail joint, take action as detailed in Table 2A.
NR/L2/TRK/001/mod04
4.3 “Fly-fished” joints
If all the bolts are missing from either rail end (a “fly-fished” joint), take action as
detailed in Table 2B.
NR/L2/TRK/001/mod04
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Page 5 of 47
Issue: 6
Table 1 - Minimum action to be taken for broken, cracked, incorrect or damaged fishplates in
a running line
Defect Immediate action (Patroller) Follow-up action (SM[T])

One or both fishplates cracked None required Replace both fishplates within
24 hours
One fishplate broken Impose a 20 mph ESR Replace both fishplates within
24 hours
Both fishplates broken (see note 2)
(see note 1) Impose a 5 mph ESR and fit
and clamp plates to the joint Replace both fishplates within
the sleepers will support and when the clamps plates have 24 hours
hold the rail ends in line and to been fitted, raise speed to a Complete TEF3064
gauge 20 or 50 mph ESR
(see note 3)
Both fishplates broken Block the line
(see note 1) Or Replace both fishplates within
but (see note 2) 24 hours
the sleepers will not support Provide additional or alternative replace sleepers.
and hold the rail ends in line support to the rails and fit clamp
and to gauge Complete TEF3064
plates.
Open with a 20 mph ESR
Broken fishplates on the joints Block the line Replace all fishplates
in both rails Complete TEF3064
Fishplate with flame cut holes Impose 5 mph ESR Replace both fishplates within
24 hours
Incorrect lift plates;
Replace both fishplates within
Step > 2mm Impose a 20 mph ESR
48 hours
Step ≤ 2mm None required Replace both within 7 days
Incorrect fishplates None required Replace both fishplates within
(see note 4) 7 days
Fishplate(s) deformed or None required Replace both fishplates within
damaged 48 hours
Notes:
1 Where a joint is present in the opposite rail, it shall be complete, well supported and with intact fishplates.
2 If the gap between the rail ends at the rail joint is greater than 50mm, take action as for a broken rail.
3 The speed shall not exceed 20 mph unless ALL of the following apply:
a) abutting rail heads are in line;
b) there are no voids under the two sleepers each side of the joint (that is four sleepers in total);
c) the clamping system is approved by Network Rail for use at 50 mph;
d) the fishplates are correct in terms of rail section and lift.
4 ‘Incorrect fishplates’ in this context describes the use of:
a) fishplates for the wrong rail section;
b) wrong or mismatched junction fishplates;
c) a pair of incorrectly fitted fishplates (e.g. fitted the wrong way round).
Copy of NR/L2/TRK/001/mod04, Table 4
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Issue: 6
Table 2A –Minimum action to be taken for joints with missing fishbolts
Defect Immediate action Follow-up action

One fishbolt missing Confirm all other Replace fishbolt;
fishbolts are tight within 7 days if line speed greater
than 60mph,
within 14 days if line speed is
60mph or less
All bolts missing from both rail ends Block the line Fit new fishbolts
All bolts missing from one rail end See Table 3

(fly-fished joint)
Table 2B – Minimum action to be taken for rail joints with all the bolts missing from
either rail end (‘fly-fished’ joint)
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Gap between Is a Watchman Immediate action Follow-up action
1, 2
rail ends present?
≤ 50mm Yes Impose a 20mph speed restriction. Fit new bolts within
3, 4
Confirm remaining bolts are tight 48 hours
≤50mm No Impose a 5mph speed restriction. Inspect after 24 hours.
Confirm remaining bolts are tight Fit new bolts within
3, 4
48 hours
51 to 75mm Yes Impose a 5mph speed restriction. Fit new bolts within
3, 4
Confirm remaining bolts are tight 48 hours
51 to 75mm No Block the line (until rectified) Fit new bolts
> 75mm Not applicable Block the line (until rectified) Fit new bolts
Notes:
1 The watchman, if appointed, shall remain on site throughout the period when trains are running.
2 The watchman shall monitor for any deterioration in the joint (reduced support or gap widening) and action
as advised by the SM[T].
3 If repairs are not completed within 48 hours, the line shall be blocked.
4 Repair may require rail replacement.
Page 7 of 47
Issue: 6
5 Broken rails
5.1 Immediate action
On discovery of a broken rail, block the line (by contacting the signaller).
The line shall remain blocked if either of the following apply:
a) the break is in a switch or crossing rail which is free to move;
b) the break is within 2 metres of heavy or severe rolling contact fatigue (RCF).
NR/L2/TRK/001/mod08
Report the break to the SM[T].
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5.2 Authority to remove line blockage
To determine whether the line blockage can be lifted, the break has to be inspected
and assessed by a competent person (see below).
NR/L2/TRK/001/mod08
5.3 Competent person

There are two levels of competency:
a) rail defect nominee (RDN);
b) rail defect examiner (RDE).
A RDN is only permitted to allow trains to pass over broken rails at a maximum
speed of 5mph.
NR/L2/TRK/001/mod08
5.4 Broken rail action tables

The following tables show the immediate action required and the circumstances
under which trains may be passed over the break.
The competent person applies mitigation (including any emergency speed restriction
required) in accordance with Tables 3 to 6.
The tables are extracts from the tables contained in NR/L2/TRK/001/mod08.
Page 8 of 47
Issue: 6
Table 3 – Transverse break through plain rail or weld
On discovery of a broken rail block the line.

The line shall remain blocked if any of the following apply:
 the break is in an S&C rail which is free to move (but see Note 7);
 the break is in a rail within 2 metres of heavy or severe rolling contact fatigue (RCF);
 there are any cracks extending into the rail web;
 If the break is > 50mm out of vertical (assessed over full depth of rail).
Gap At a joint OR 2m and <3m

Equipment Through a <2m from a 3m from a
between <2m from a from a weld or
fitted weld weld weld or joint
rail ends joint joint
Block the 10mph 10mph 10mph 10mph
10mm
Line Note 8 Note 8 Note 8 Note 8
None >10mm
Block the Block the Block the
and 5mph 5mph
Line Line Line
(but a 50mm
watchman >50mm
shall be Block the 5mph Block the Block the 5mph
and
present) Line Note 2 Line Line Note 2
75mm
>75mm B l o c k t h e L i n e
Notes:
See end of Table 4
Extract from NR/L2/TRK/001/mod08, Table 3
Table 4 – Any part of the railhead broken away

 the break is in a rail within 2 metres of heavy or severe rolling contact fatigue (RCF);
 the break or any cracks extend into the rail web.
Length of At a joint OR 2m and <3m

Equipment Through a <2m from a 3m from a
piece <2m from a from a
fitted weld weld weld or joint
missing joint weld or joint
None Block the Block the Block the

50mm 5mph 5mph
Line Line Line
(but a >50mm, Block the 5mph Block the Block the 5mph
watchman 75mm Line Note 2 Line Line Note 2
shall be
present) >75mm B l o c k t h e L i n e
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Page 9 of 47
Issue: 6
Notes (these apply to Tables 3 & 4):

1. Before allowing trains to pass over broken rails, confirm that the two adjacent sleepers, and the fastening
systems, on each side of the break (four in total) are sound, and the ballast beneath them well packed and of
equal consolidation.
2. Do not allow wheels less than 450mm diameter to pass over the break.
3. n/a
4. n/a
5. n/a
6. n/a
7. Only the route containing the broken/damaged moving rail need be blocked. Secure the rail to prevent fouling
of the open route or any signalling equipment.
8. Holders of the Rail Defect Nominee (RDN) competency are only permitted to open the line at 5mph.
Table 5 – Lower part of the rail broken away

 If both sides of the foot are broken;
 the break extends to the rail web;
 a crack from the break extends into the rail web.
Width of Length of At a joint 2m and <3m 3m from a

Equipment Through a <2m from a
piece piece OR <2m from a weld or
fitted weld weld
missing missing from a joint weld or joint joint
None 25mm 50mm Replace rail within 4 weeks [3H]
>50mm 20mph
None 25mm and
Replace rail within 48 hours [3A]
100mm
(but a
watchman Block the 5mph Block the Block the 5mph
>25mm 100mm
shall be
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Line Note 3 Line Line Note 3

present)
Any width >100mm B l o c k t h e L i n e
Notes:
1. Confirm that the two adjacent sleepers, and the fastening systems, on each side of the break (four in total) are
sound, and the ballast beneath them well packed and of equal consolidation.
2. Minimum action code (MAC) shown in brackets [..]. See NR/L2/TRK/001/mod07 for MAC definitions.
3. Replace rail within 24 hours for Category 1A, 1, 2 or 3 lines. Replace within 48 hours for Category 4, 5 or 6 lines.
4. n/a
5. n/a
6. Only the route containing the broken/damaged moving rail need be blocked. Secure the rail to prevent fouling of
the open route or any signalling equipment..
Page 10 of 47
Issue: 6
Table 6 – Longitudinal split

This table applies where a piece of rail is detached. See
NR/L2/TRK/001/mod07 for action where the rail is split, but not detached.
DETACHED PIECE B
Is the split in the running YES
OF RAIL (FROM A L
edge side of the rail head?
LONGITUDINAL O
SPLIT) C
Is the rail free to move YES
DISCOVERED NO K
YES (i.e. a switch rail)?
T
NO
Is the split in an S&C rail? H
Longitudinal Is the rail bolted to and E
YES
position of split supported by S&C blocks NO
is not NO and another form of L
support? I
significant N
YES
Is the split at a joint? E
NO
5mph ESR
6 Rail head damage (not arcing damage)

6.1 Immediate action
On discovery of rail head damage (excluding arcing damage), block the line (by
contacting the signaller).
NR/L2/TRK/001/mod08
Report the damage to the SM[T] and wait for further instructions.
6.2 Authority to remove line blockage

To determine whether the line blockage can be lifted, the damaged rail has to be
inspected and assessed by a competent person (see section 5.3).
NR/L2/TRK/001/mod08
6.3 Rail head damage action table

Table 7 shows the immediate action required and the circumstances under which
trains may be passed over the damaged rail.
The table is from NR/L2/TRK/001/mod08.
7 Rail arcing damage

Report arcing damage to the SM[T] and record on TEF3015.
Action tables are in NR/L2/TRK/001/mod08.
Page 11 of 47
Issue: 6
Table 7 – Railhead damage
Is the rail damaged or distorted YES

DAMAGED RAIL either vertically or laterally by BLOCK THE LINE
DISCOVERED more than 25mm?
NO
5mph ESR
Is the rail damaged or distorted YES Clamp if possible
either vertically or laterally by
Longitudinal Appoint Watchman
more than 10mm?
position of Rectify within 48 hours
damage is not
NO
significant 20mph ESR
Clamp if possible
Appoint Watchman
Rectify within 48 hours
Notes:
1. Localised breaking away (e.g. chipping) or lipping on either the running edge or the back edge of a
rail is not classified as rail head damage.
2. Holders of the Rail Defect Nominee (RDN) competency are only permitted to open the line at 5mph.

8 Loss of rail foot width
Where loss of rail foot width is observed, take action as detailed in Table 8.
NR/L2/TRK/001/mod09
Table 8 – Minimum action for loss of rail foot width
Action Minimum
Total loss to width
Action Code
of rail foot Immediate (see note 1) Follow up (MAC)
6mm to 12mm Change rail within 13 weeks 3C
Impose 20mph ESR

13mm to 18mm change rail within 4 weeks 1H
within 4 hours
Impose 20mph ESR
19mm to 25mm Change rail within 7 days 1B
immediately
Impose 5mph ESR
more than 25mm change rail within 48 hours 5A
immediately
Note:
1 Block the line if the loss in foot width renders the rail fastenings ineffective.
Page 12 of 47
Issue: 6
9 Adjustment switches
Check adjustment switch setting (gap dimension Y). Required gap dimensions are
shown (for various rail temperatures) in Table 9.
Check switch tip support (dimension X). If support is inadequate, take action as
shown in Table 10.
Check that the whole width of the rail foot at the end of the machining (rail foot cut
out) is fully supported.
If support is inadequate, take action as shown in Table 11.
NR/L2/TRK/001/mod16
Baseplate
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Edge of rail head
cut out
Switch tip
X Y
Figure 1 – Adjustment switch baseplate detail
Table 9 – Adjustment switch setting dimensions
Rail temperature Gap opening (Y) Tolerance

ºC mm mm
–4 to 2 125 ± 25
3 to 7 119 ± 25
8 to 13 112 ± 25
14 to 18 106 ± 25
19 to 27 100 ± 25
Page 13 of 47
Issue: 6
Table 10 – Action for sub-standard switch tip support
Switch tip support (X) Action
< 60mm Plan work to correct

Impose 20mph ESR
< 30mm
(until corrected)
Table 11 – Action for rail foot not fully supported at the end of the machining
Baseplate Baseplate
Edge of rail foot Edge of rail foot

Switch tip cut out Switch tip cut out
Track category Fault Action Timescale
All Dimension Z <30mm Adjust rails or bearer spacing to 13 weeks

provide increased support
whole width of the rail foot Adjust rails or bearer spacing to

1A, 1 or 2 Within 7 days
no longer fully supported provide full support
whole width of the rail foot Adjust rails or bearer spacing to

3, 4, 5, or 6 Within 30 days
no longer fully supported provide full support
Page 14 of 47
Issue: 6
10 Level Crossings
Routine basic visual track inspection will include, at level crossings, checks for the
following:
a) signs of deterioration or defects in any part of the track system concealed by the
crossing surface (e.g. poor top which could be caused by ballast or sleeper
failure);
b) any worsening of the track condition which is affecting, or may affect, the safe use
of the crossing (by rail or road vehicles);
c) deterioration of the level crossing surface system, including loose components,
broken or cracked deck panels and damage;
d) loose deck units which rock or tilt under load from road traffic (which may indicate
incorrect seating/support of the deck panels);
e) gaps and steps between the deck panels likely to be a hazard to the crossing
users (especially cyclists, pedestrians and those on horseback);
f) flangeways (to confirm they are clear and free from silt, rubbish, etc.);
g) damage or deterioration to the trespass guards;
h) correctly functioning telephones at unmanned level crossings.
Report any observed defect which is likely to render the level crossing unsafe.
Take immediate action where necessary to protect rail traffic and the users.
NR/L2/TRK/001/mod02
11 Maintenance tolerances and intervention limits

Appendix A contains a number of tables providing maintenance tolerances and
intervention limits.
12 Priorities for track defects identified during inspection.

Appendix B contains a number of tables providing guidance on priorities to be applied
to defects identified during inspection.
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Page 15 of 47
Issue: 6
13 Actions for defective stretcher bars.

13.1 Fixed stretcher bars
Appendix C contains tables providing details of initial action required by track staff
(usually the patroller) for:
a) missing or loose fastenings;
b) cracked fixed stretcher bars;
c) broken fixed stretcher bars.
Full details of actions required for fixed stretcher bar defects can be found in
NR/L3/TRK/1202/A.
Appendix D contains a pictorial guide for defects on fixed stretcher bar assemblies.
13.2 Adjustable stretcher bars

Appendix E contains tables providing details of action required for:
b) cracked adjustable stretcher bars;
c) broken adjustable stretcher bars.
Full details of actions required for adjustable stretcher bar defects (to be undertaken
by S&T staff) can be found in NR/L3/SIG/10179.
Appendix F contains a pictorial guide for defects on adjustable stretcher bar
assemblies.
13.3 Lock stretcher bars

Appendix G contains tables providing details of action required for:
b) cracked adjustable stretcher bars;
c) broken adjustable stretcher bars.
Appendix H contains a pictorial guide for defects on lock stretcher bar assemblies.
13.4 Identification of stretcher bars and stretcher bar fastenings

Appendix I contains diagrams showing the numbering / location convention to be
used to uniquely identify:
a) each stretcher bar within a set of switches and
b) the fastenings on each stretcher bar.
13.5 Recording and reporting of stretcher bars defects

Record any defects observed on TEF3099 and hand this form to the SM[T].
Page 16 of 47
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Issue: 6
Appendix A - Maintenance tolerance and Intervention limit tables
Table A.1 – Ballast; maintenance tolerance and intervention limit
Parameter Maintenance tolerance Intervention limit
Slurried beds Two consecutive beds/ sleepers. If one site is greater than 5m
(i.e. the ballast surrounding If sites are between 6m and 18m in length or three sites
the sleeper is unable to give apart, rectify before development between 6m and 18m apart
vertical or lateral support) of a third site (which can cause
cyclic top)
voided sleepers 7mm
Table A.2 – Maximum number of ineffective sleepers per 60ft length

Number consecutive
Line speed Number in
mph length track radius track radius
>800m ≤800m
60 6 2 1
65 to 100 3 1 1
105 to 125 2 1 1
Notes:
1. Ineffective sleepers shall not be present either side of a fishplated or welded joint.
2. Each group of ineffective sleepers shall be separated from the next group by at least two
sound sleepers.
Table A.3 – Fastenings; maintenance tolerance and intervention limit
Parameter Maintenance tolerance Intervention limit
Number of missing or 4 bullhead 6 bullhead

ineffective fastenings in any 8 flatbottom 12 flatbottom
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60ft of track
Number of consecutive rail 2, 3,
seats with any fastenings with each group separated by with each group separated by
missing or ineffective, or with at least two sleepers with all at least two sleepers with all
broken baseplates or chairs fastenings in place fastenings in place
Pads or insulators missing or 0; 0;
ineffective shall meet local signalling shall meet local signalling
requirements, shall be in one requirements, shall be in one
piece and not worn through piece and not worn through
Page 17 of 47
Issue: 6
Appendix B - Work Priority Tables

The following tables provide guidance on priorities to be applied to defects identified
during inspection.
Priorities used in the tables are:
M0 requires inspection and measurement by SM[T], fix within 10 days;
M1 Rectify within 4 weeks;
M9 Under normal operating conditions plan to rectify within 39 weeks;
M12 Under normal operating conditions plan to rectify within 52 weeks;
M24 Under normal operating conditions plan to rectify within 104 weeks.
The priorities in shaded boxes are normally applied by the Section Manager [Track].
Page 18 of 47
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Issue: 6
Appendix B Compliance date: 02 February 2013
Table B.1 Track Geometry

Priority
Parameter Limit Work item description
Cat 1A Cat.1/2 Cat.3/4 Cat.5/6
Cyclic top (significant dips or voids 6m to 18m apart)
Routes that carry 2 M1 M3 M3 M3

Lift and pack
freight at greater
than 30mph 3 or more M1 M1 M1 M1
If identified by track recording
Non freight 2 M1 M3 M12 M24 coach refer to
carrying routes or NR/L2/TRK/001/mod11 for
line speed less timescales for rectification
than 30mph 3 or more M1 M1 M6 M12
Dips at joints (dip measured over 1m)

3mm M1 M3 M9 M12
At a weld Lift and pack
4mm M0 M1 M3 M6
At an IBJ 2mm M0 M1 M1 M3 Lift and pack
Check dip angle output from track recording. Shim joint/rail end and straighten,
At any other joint 10mm lift and pack as appropriate
Action as specified in NR/L2/TRK/001/mod11
Voiding
Adjustment
switch, IBJ or Up to 7mm M1 M3 M3 M6
S&C (within 3m of Life and pack.
switch toes or
8mm or more M0 M1 M1 M3
crossing nose)
Plain line and Up to 14mm M1 M3 M3 M6

beyond 3m of
Lift and pack.
toes or crossing 15mm or
in S&C M0 M1 M1 M1
more
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Page 19 of 47
Issue: 6
Table B.2 Joints

Priority
Insulated block joints
Battered or Lift and pack, assess for
Rail ends M1 M1 M3 M6
crippled replacement
(see also dipped
joints) Lipped M1 M1 M3 M6 Remove lipping.
Worn or
M1 M3 M3 M6 Monitor and renew.
Insulators and damaged
end posts Broken or
M0 M0 M1 M1 Renew.
missing
Rail adjusting
More than 5
If rail temperature Rail adjust prior to hot weather.
o consecutive Report to SM[T]
is 20 C or less If not completed apply mitigation.
closed joints
More than 5
If rail temperature
o consecutive Report to SM[T] Rail adjust prior to winter.
is 30 C or more
wide joints.
Incorrectly spaced sleepers
At an IBJ M1 M3 M3 M6
At a fishplated or
M3 M6 M6 M12
welded joint
Table B.3 Rails

Priority
Rail lubricators
Adjust and clean lubricators.
Uncontrolled
M1 M3 M3 M3 Immediate action if grease is
grease flow
spilling onto the railhead.
All speeds
No grease M1 M1 M3 M3 Fill and adjust
Unserviceable M1 M3 M6 M12 Overhaul or renew.
Visible rail defects
Wheel burns
Arrange ultrasonic testing.
Corrugation
Report to SM[T] Repair in accordance with MAC
Spalling, Scaling (see NR/L2/TRK/001/mod07).
or Shelling
Arrange visual and ultrasonic
Rolling contact inspection.
Visible
fatigue/gauge Report to SM[T]
cracking Repair in accordance with MAC
corner cracking
(see NR/L2/TRK/001/mod07).
Page 20 of 47
Issue: 6
Table B 4 Sleepers
Priority
Ineffective sleepers In any 60ft of track (i.e. unable to provide vertical support or hold gauge)
2 M1 M3 M6
Number of
Ineffective 3 M0 M1 M3 M12 Monitor until sleepers replaced.
sleepers Install temporary restraint if
4 M0 M1 M6 appropriate.
(each group If over a significant distance, put
separated by at 5 M0 M3
Apply ESR or other in place control measures and
least 2 sound 6 mitigation. M3 plan for renewal.
sleepers)
Resleeper ASAP
7 or more M1
Ineffective sleepers at joint (fishplated or weld)
If ineffective
1 M0 M1 M1 M3
sleeper at a joint
Maximum number of consecutive ineffective sleepers (not at a joint or a weld)
2 M1 M1 M1 M3 Replace sleepers.
Consecutive
Impose ESR appropriate to the
Ineffective 3 M0 M0 M0 M1
highest traffic loading on the
sleeper
4 Impose ESR M0 route.
Table B.5 Rail Fastenings

Priority
Maximum number of missing or ineffective fastenings in any 60ft of track (not consecutive)
Up to 4 M3 M6 M12 M24
Replace fastenings.
Bullhead 5 or 6 M1 M3 M6 M12
Identify cause (missing pads,
More than 6 M0 M0 M1 M1 voiding, poor sleepers).
Change sleepers as required.
Up to 8 M3 M6 M12 M24 Impose 20mph ESR if M0 criteria
Flatbottom 9 to 12 M1 M3 M6 M12 reached and fastenings cannot be
permanently replaced.
More than 12 M0 M0 M1 M1
Maximum number of consecutive rail seats with missing or ineffective fastenings
Replace fastenings or change
Each group 2 M1 M1 M3 M3 sleepers.
separated by a
minimum of 2 fully Impose a 20mph ESR if
fastened sleepers 3 M0 M0 M1 M1 fastenings cannot be permanently
replaced.
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Issue: 6
Table B.6 Pads and insulators

Priority
Pads and insulators (not on steel sleepers)
Worn, broken, 11% to 25% M3 M6 M12 M24

displaced or
missing. 26% to 50% M1 M3 M6 M6
Assessed over Re-pad & re-nylon
10 lengths Over 50% M1 M1 M3 M3
Consecutive
6 or more M1 M1 M1 M3
sleepers
Pads and Insulators (on steel sleepers)
Missing or Replace as soon as possible to
N/A M1 M1 M1 M1
ineffective avoid track circuit failure.
Worn, damaged or missing ferrules
Badly worn
but M3 M6 M12 N/A
serviceable
Worn/damaged Replace ferrules
Worn right
through or M1 M3 M6 M12
missing
Table B.7 Longitudinal timbers

Parameter Limit Priority
Work item description
Tie rods and holding down bar straps
Loose N/A M0 M0 M0 Tighten during patrol.
Loose and
Report to Section Manager
unserviceable/
[Track] for immediate gauge
inaccessible or N/A M0 M0 M0
check; tighten or replace within
unable to tighten
24 hrs.
on patrol
Wedges (lateral packing)
Loose or missing N/A M0 M0 M0 Tighten/replace during patrol.
Page 22 of 47
Issue: 6
Table B.8 Ballast

Priority
Ballast shoulder profile
Rectify before the onset of hot
Deficient shoulder weather OR
profile or
See NR/L2/TRK/001/mod03 for ballast profile specification Apply mitigations in line with
insufficient crib
ballast calculated CRT (see
NR/L2/TRK/001/mod14).
Excess Ballast
Timber sleepers Rail foot and
Regulate/clear ballast and inspect
or bearers and fastenings M1 M1 M1 M1
fastenings.
radius < 800m buried
Regulate and clear ballast and
Other sleeper Rail foot and inspect fastenings.
types and fastenings M3 M3 M6 M12 NOTE: PLPR cannot operate
locations buried successfully if fastenings covered
by ballast.
Clogged and/or polluted ballast
Associated with
3 consecutive
L2 track fault or M1 M3 M9 M12 Dig out and re-ballast.
beds
poor geometry
Slurried beds or voiding sleepers;
1 site or consecutive Correct before number of beds
M1 M3 M3 M6
voiding ≤7mm beds increases.
between 6m Correct before the development

2 sites M1 M1 M3 M6 rd
& 18m apart of a 3 site.
between 6m Cyclic top risk. Apply 30mph ESR
3 sites M1 M1 M1 M3
& 18m apart as required.
greater than Correct before number of beds
1 site M1 M1 M1 M3
5m long increases.
within 3m of
>7mm
switch toes or M0 M1 M1 M3 Rectify as soon as possible.
voiding
crossing nose
Associated with Repair L2 in accordance with

L2 track fault NR/L2/TRK/001/mod11.
M0 M1 M3 M3
(identified by TRV Rectify wet bed in accordance
or similar) with these timescales.
Joint is Immediate 50mph ESR or
Associated with a
dipped, worn M0 M0 M1 M3 20mph ESR if joint is not
joint or IBJ
or loose supported (e.g. voiding badly).
Page 23 of 47
Issue: 6
Table B.9 Check rails

Priority
Check rails in plain line
Significant wear on running rail Measure check rail dimensions.

where check rail exists or badly M1 M3 M6 M12 Restore to within the limits
worn check rail 1391mm (+1mm, -8mm).
Check rails in S&C
Significant wear on running rail Measure check rail dimensions.

where check rail exists or badly M1 M3 M6 M12 Restore to within the limits
worn check rail. 1391mm (+1mm, -3mm).
Table B.10 S&C

Priority
Switch tip positions
Dimensions
more than Adjust to the correct position to be
Switch tip position M6 M12
15mm in 90mm +/-6.
– switches A-E Switches
(specification
90mm from the Dimensions
centre line of the more than
Adjust to the correct position to be
first slide plate) 20mm in M3 M6 M12
90mm +/-6.
F and longer
switches
When measuring the switch tip positions and these dimensions, the cross gauge must be square to
the rails and the switch tips never more than 12mm out of square.
7mm or more Adjust to the correct position
Switch tip position from (specification 115mm from
M3 M6 M12
– switch diamonds specified knuckle, 90mm for certain BH
position diamonds)
Gauge stops and Sole Plates
Gauge stop
Track gauge Block line until temporary gauge retention
cracked or Replace soleplate
not retained fitted.
missing
Gauge stop
Track gauge
cracked or Fit tie bars Replace soleplate within 4 weeks.
retained
missing
Soleplate Track gauge Block line until temporary gauge retention Replace / repair soleplate within
damaged not retained fitted. 7 days.
Soleplate Track gauge Replace / repair soleplate within
Fit tie bars
damaged retained 4 weeks.
Page 24 of 47
Issue: 6
Table B.10 S&C (continued)

Priority
Switch or stock rail wear
Sidewear, NR/L2/TRK/0053 detailed

flattening of inspection required?
Notify SM[T]
switch, sharp
edges or lipping SM[T] to assess and arrange.
Full check in accordance with

Flange back Any visible NR/L3/TRK/1202 required?
Notify SM[T]
contact sign
SM[T] to assess and arrange.
Crossing
Wear or damage
3mm or more
in wheel transfer See NR/L2/TRK/1054 Weld repair; lift and pack.
deep
area
Timber bearers
5mm to 8mm M3 M6 M12 Pull through or renew timbers.

Baseplate shuffle Wide gauge actions and
9mm or more M1 M3 M6 M6 timescales take priority over these
where applicable (see
NR/L2/TRK/001/mod11).
3mm or 4mm M3 M6 M12
Action to be to M1in all cases if the
Indentation shuffle is on a bearer within 1.8m
5mm or more M1 M3 M6 M12 of the toe.
Unable to
Rotten timber M1 M3 M6 M12 Renew timber.
retain screws
Concrete Bearers
Broken at
M1 M3 M6 M6 Repair or renew.
housing
Damaged
Badly
M3 M6 M12 M12 Renew.
cracked
Baseplates & chairs
1 M3 M3 M6 M12
2 or more
M1 M1 M3 M6
consecutive
Broken
baseplates/chair/ At switch tips Replace
housing or crossing M1 M3 M6 M6
nose
At IBJ, joint
M1 M3 M6 M6
or weld
Chipped/scor
Nylon slide chairs M1 M3 M6 M12 Renew pads.
ed/ Broken
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Page 25 of 47
Issue: 6
Table B.10 S&C (continued)

Priority
Pads and insulators and ferrules
Worn but
M3 M3 M6 M12
serviceable
Worn/ damaged/
Worn right Renew
missing
through / M3 M3 M3 M6
missing
Fastenings
1 broken/
missing or M3 M3 M6 M12
loose
2 consecutive
broken or M1 M1 M3 M6
Stud bolts missing Renew bolts
Isolated
loose stud M3 M3 M6 M12
bolts
More than
M0 M0 M3 M6
25% loose
At 2
consecutive M1 M3 M6 M12 Monitor; renew
Loose, broken or timbers
missing chair
screws/spikes At 3 or more
Renew or fit coils/ maintenance
consecutive M1 M1 M3 M6
fastenings
timbers
Isolated
Patroller replace if safe to do so.
loose, broken M1 M3 M6 M12
Report to SM[T]
Clip/keys or missing
More than For M0, impose 20mph ESR.
M0 M0 M1 M3
25% loose Renew/replace within 24 hours.
Page 26 of 47
Issue: 6
Appendix C - Defective fixed stretcher bar action tables Compliance date: 02 February 2013
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Page 27 of 47
Issue: 6
Appendix C Compliance date: 02 February 2013

Page 28 of 47
Appendix D – Pictorial guidance for defects Issue: 6
on fixed stretcher bar assemblies Date: 01 December 2012
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Page 29 of 47
Appendix D Issue: 6
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Page 30 of 47
Appendix D Issue: 6
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Page 31 of 47
Appendix D Issue: 6

Page 32 of 47
Appendix D Issue: 6

Page 33 of 47
Appendix D Issue: 6

Page 34 of 47
Appendix D Issue: 6

Page 35 of 47
Issue: 6
Appendix E - Defective adjustable stretcher bar action tables Compliance date: 02 February 2013
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Page 36 of 47
Issue: 6
Appendix E Compliance date: 02 February 2013
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Page 37 of 47
Issue: 6
Appendix F – Pictorial guidance for defects Date: 01 December 2012
on adjustable stretcher bar assemblies Compliance date: 02 February 2013
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Page 38 of 47
Issue: 6
Appendix F Date: 01 December 2012
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Page 39 of 47
Issue: 6

Page 40 of 47
Issue: 6

Page 41 of 47
Issue: 6
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Page 42 of 47
Issue: 6

Page 43 of 47
Issue: 6
Appendix G - Defective lock stretcher bar action table Compliance date: 02 February 2013
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Page 44 of 47
Appendix H - Pictorial guidance for defects Issue: 6
on lock stretcher bar assemblies Date: 01 December 2012
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Page 45 of 47
Appendix H Issue: 6
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Page 46 of 47
Issue: 6
Appendix I – Identification of stretcher bars and stretcher bar fastenings Compliance date: 02 February 2013
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Page 47 of 47

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3.4 Patrolling diagram

4 Defects at fishplated joints

Defect Immediate action (Patroller) Follow-up action (SM[T])

Copy of NR/L2/TRK/001/mod04, Table 4

Table 2A –Minimum action to be taken for joints with missing fishbolts

Defect Immediate action Follow-up action

All bolts missing from one rail end See Table 3

Copy of NR/L2/TRK/001/mod04, Table 5

51 to 75mm No Block the line (until rectified) Fit new bolts

Copy of NR/L2/TRK/001/mod04, Table 6

5.3 Competent person

5.4 Broken rail action tables

Table 3 – Transverse break through plain rail or weld

On discovery of a broken rail block the line.

Gap At a joint OR 2m and <3m

Extract from NR/L2/TRK/001/mod08, Table 3

Table 4 – Any part of the railhead broken away

On discovery of a broken rail block the line.

Length of At a joint OR 2m and <3m

None Block the Block the Block the

Extract from NR/L2/TRK/001/mod08, Table 4

Notes (these apply to Tables 3 & 4):

Extract from NR/L2/TRK/001/mod08, Table 4

Table 5 – Lower part of the rail broken away

On discovery of a broken rail block the line.

Width of Length of At a joint 2m and <3m 3m from a

None 25mm 50mm Replace rail within 4 weeks [3H]

Line Note 3 Line Line Note 3

Extract from NR/L2/TRK/001/mod08, Table 5

Table 6 – Longitudinal split

Copy of NR/L2/TRK/001/mod08, Table 6

6 Rail head damage (not arcing damage)

6.2 Authority to remove line blockage

6.3 Rail head damage action table

7 Rail arcing damage

Table 7 – Railhead damage

Is the rail damaged or distorted YES

Copy of NR/L2/TRK/001/mod08, Table 7

Table 8 – Minimum action for loss of rail foot width

6mm to 12mm Change rail within 13 weeks 3C

Impose 20mph ESR

Copy of NR/L2/TRK/001/mod09, Table 9

Figure 1 – Adjustment switch baseplate detail

Table 9 – Adjustment switch setting dimensions

Rail temperature Gap opening (Y) Tolerance

Extract from NR/L2/TRK/001/mod16, Table 1

Table 10 – Action for sub-standard switch tip support

Switch tip support (X) Action

< 60mm Plan work to correct

Extract from NR/L2/TRK/001/mod16, Table 5

Edge of rail foot Edge of rail foot

Track category Fault Action Timescale

All Dimension Z <30mm Adjust rails or bearer spacing to 13 weeks

whole width of the rail foot Adjust rails or bearer spacing to

whole width of the rail foot Adjust rails or bearer spacing to

Copy of NR/L2/TRK/001/mod16, Table 6

11 Maintenance tolerances and intervention limits

12 Priorities for track defects identified during inspection.