T HR CI 12071 ST

Standard

Guard Rails

Version 1.0
Issue date: 21 June 2019

© State of NSW through Transport for NSW 2019

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Version 1.0
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Important message
This document is one of a set of standards developed solely and specifically for use on
Transport Assets (as defined in the Asset Standards Authority Charter). It is not suitable for any
other purpose.

The copyright and any other intellectual property in this document will at all times remain the
property of the State of New South Wales (Transport for NSW).

You must not use or adapt this document or rely upon it in any way unless you are providing
products or services to a NSW Government agency and that agency has expressly authorised
you in writing to do so. If this document forms part of a contract with, or is a condition of
approval by a NSW Government agency, use of the document is subject to the terms of the
contract or approval. To be clear, the content of this document is not licensed under any
Creative Commons Licence.

This document may contain third party material. The inclusion of third party material is for
illustrative purposes only and does not represent an endorsement by NSW Government of any
third party product or service.

If you use this document or rely upon it without authorisation under these terms, the State of
New South Wales (including Transport for NSW) and its personnel does not accept any liability
to you or any other person for any loss, damage, costs and expenses that you or anyone else
may suffer or incur from your use and reliance on the content contained in this document. Users
should exercise their own skill and care in the use of the document.

This document may not be current and is uncontrolled when printed or downloaded. Standards
may be accessed from the Transport for NSW website at www.transport.nsw.gov.au.

For queries regarding this document, please email the ASA at

[email protected] or visit www.transport.nsw.gov.au

© State of NSW through Transport for NSW 2019

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Standard governance
Owner: Lead Civil Engineer, Asset Standards Authority
Authoriser: Chief Engineer, Asset Standards Authority
Approver: Executive Director, Asset Standards Authority on behalf of the ASA Configuration Control
Board

Document history
Version Summary of changes
1.0 First issue

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Preface
The Asset Standards Authority (ASA) is a key strategic branch of Transport for NSW (TfNSW).
As the network design and standards authority for NSW Transport Assets, as specified in the
ASA Charter, the ASA identifies, selects, develops, publishes, maintains and controls a suite of
requirements documents on behalf of TfNSW, the asset owner.

The ASA deploys TfNSW requirements for asset and safety assurance by creating and
managing TfNSW's governance models, documents and processes. To achieve this, the ASA
focuses on four primary tasks:

• publishing and managing TfNSW's process and requirements documents including TfNSW
plans, standards, manuals and guides

• deploying TfNSW's Authorised Engineering Organisation (AEO) framework

• continuously improving TfNSW’s Asset Management Framework

• collaborating with the Transport cluster and industry through open engagement

The AEO framework authorises engineering organisations to supply and provide asset related
products and services to TfNSW. It works to assure the safety, quality and fitness for purpose of
those products and services over the asset's whole-of-life. AEOs are expected to demonstrate
how they have applied the requirements of ASA documents, including TfNSW plans, standards
and guides, when delivering assets and related services for TfNSW.

Compliance with ASA requirements by itself is not sufficient to ensure satisfactory outcomes for
NSW Transport Assets. The ASA expects that professional judgement be used by competent
personnel when using ASA requirements to produce those outcomes.

About this document

This standard details the design and installation requirements for guard rails on the TfNSW
heavy rail network and was developed in consultation with TfNSW cluster representatives.

This document was developed from elements of the following TfNSW standards:

• ESC 310 Underbridges, version 2.2

• ESC 340 Tunnels, version 2.3

• T HR CI 12030 ST Overbridges and Footbridges, version 2.0

• T HR CI 12072 ST Track Slabs, version 1.0

• T HR CI 12075 ST Airspace Developments, version 1.0

• T HR CI 12080 ST External Developments, version 1.0

This document is a first issue.

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Table of contents
1. Introduction .............................................................................................................................................. 6
2. Purpose .................................................................................................................................................... 6
2.1. Scope ..................................................................................................................................................... 6
2.2. Application ............................................................................................................................................. 6
3. Reference documents ............................................................................................................................. 7
4. Terms and definitions ............................................................................................................................. 8
5. Risk and safety ........................................................................................................................................ 9
5.1. Risk assessment .................................................................................................................................... 9
6. Guard rail design ................................................................................................................................... 12
6.1. TfNSW designs .................................................................................................................................... 12
6.2. Design load .......................................................................................................................................... 13
6.3. Rail ....................................................................................................................................................... 13
6.4. Type ‘A’ rail clips .................................................................................................................................. 14
6.5. Screw spikes ........................................................................................................................................ 14
6.6. Threaded inserts .................................................................................................................................. 14
6.7. Anchor rods.......................................................................................................................................... 14
6.8. Prohibited configurations ..................................................................................................................... 14
7. Guard rail installation ............................................................................................................................ 15
7.1. General installation requirements ........................................................................................................ 15
7.2. Special installation ............................................................................................................................... 16
7.3. Guard rail installation not on underbridges .......................................................................................... 18
7.4. Guard rail installation on underbridges ................................................................................................ 19
7.5. Guard rail plates and fasteners for timber and FFU sleepers and transoms ...................................... 20
8. Maintenance ........................................................................................................................................... 20
9. Decommissioning and disposal........................................................................................................... 21
Appendix A Combined guard rail plate drawing ................................................................................. 22

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1. Introduction
Guard rails are used to mitigate high consequence events such as a derailed train falling off a
bridge or colliding with a structure adjacent to the track.

Guard rails are additional rails placed inside the running rails and typically have a tapered nose
(previously referred to as a vee) at an approach end to rail traffic.

The primary function of a guard rail on a rail track is to keep derailed or derailing bogies tracking
parallel to and close to the running rails.

The purpose of the nose is to direct the derailed wheels towards the gap between the running
rails and the guard rail.

2. Purpose
This standard specifies the life cycle (design, construction and installation, maintenance,
decommissioning and disposal) requirements for guard rails on the Transport for NSW (TfNSW)
Metropolitan Heavy Rail Network (formerly known as the RailCorp network). Refer to TS TOC 1
Train Operating Conditions (TOC) Manual – General Instructions, which defines the areas
associated with the network.

2.1. Scope
This standard provides the requirements for the installation of guard rails which may be used for
the following:

• containment of a derailed train on underbridges, pedestrian subways, flyovers and dives

• containment of a derailed train at existing overbridges and footbridges

• containment of a derailed train at existing buildings over and adjacent to the railway line

• containment of a derailed train in existing tunnels and at tunnels portals

Requirements for determining where guard rails are required are provided in Section 5.

2.2. Application
This standard applies to the design and installation of guard rails on the TfNSW Metropolitan
Heavy Rail Network.

In addition to the requirements of this standard, asset decisions shall consider the life cycle cost
considerations specified in T MU AM 01001 ST Life Cycle Costing.

This standard applies to the new guard rail installations and modifications to existing guard rails.

If, when using the standard, it is considered that the intent of stated requirements is not clear,
clarification should be obtained from the Asset Standards Authority (ASA).

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3. Reference documents
The following documents are cited in the text. For dated references, only the cited edition
applies. For undated references, the latest edition of the referenced document applies.

Australian standards

AS 1085.1 Railway track materials – Part 1: Steel rails

AS 1085.18 Railway track material – Part 18: Screw spikes and threaded inserts

AS/NZS 1111.1 ISO metric hexagon bolts and screws – Product grade C – Part 1: Bolts

AS/NZS 1214 Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread
series) (ISO 10684:2004, MOD)

Transport for NSW standards

ESC 220 Rail and Rail Joints

ESC 230 Sleepers and Track Support

ESC 302 Structures Defect Limits

ESC 340 Tunnels

ESG 100.17 Signal Design Principles – Track Circuits

MN A 00100 Civil and Track Technical Maintenance

T HR CI 12020 ST Underbridges

T HR CI 12030 ST Overbridges and Footbridges

T HR CI 12072 ST Track Slabs

T HR CI 12075 ST Airspace Developments

T HR CI 12080 ST External Developments

T MU AM 01001 ST Life Cycle Costing

T MU AM 01003 ST Development of Technical Maintenance Plans

T MU MD 20001 ST System Safety Standard for New or Altered Assets

T MU MD 20002 ST Risk Criteria for Use by Organisations Providing Engineering Services

TS TOC 1 Train Operating Conditions (TOC) Manual – General Instructions

Transport for NSW drawings

CV0168626 Guard Rail – Special Arrangement – For Bridges Fitted with “Alternative 1” Plates –
General Arrangement

CV0168627 Guard Rail – Special Arrangement –For Bridges Fitted with “Alternative 1” Plates –
Details of Concrete Sleepers
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CV0168632 Guard Rail – Special Arrangement – For Bridges Fitted with “Alternative 1” Plates –
Details of Guard Rail Nose

CV0179048 Guard Rails – Installation of Guard Rails on Ballast Top Underbridge – General
Arrangement

CV0179049 Guard Rails – Installation of Guard Rails on Transom Top Underbridge – General
Arrangement

CV0179050 Guard Rails – Installation of Guard Rails on Ballast Top Underbridge – Details of
Guard Rail Concrete Sleepers

CV0179051 Guard Rails – Installation of Guard Rails on Ballast Top and Transom Top
Underbridges – Detail of Tapered Nose Section

CV0558906 Typical Details – All Lines - Combined ALT 1 & Guard Rail – Details

CV0692290 Berry – Illawarra Line 140.220km – Broughton Creek Underbridge Custom Guard
Rail Plate – Steelwork

SG0406853 Standard Placement of Alstom Balise at Guard Rails – Sheet 1 of 2

SG0406919 Standard Placement of Alstom Balise at Guard Rails – Sheet 2 of 2

Other reference documents

SafeWork NSW, Safe design of structures code of practice

Work Health and Safety Act 2011

4. Terms and definitions

The following terms and definitions apply in this document:

AEO Authorised Engineering Organisation

ASA Asset Standards Authority

ATP automatic train protection

FFU fibre reinforced foamed urethane

four foot the area between the two rails of a single track

open ballasted track track comprising of rails, fastenings, sleepers and ballast. It does not
include track comprising of slab or embedded systems, or track on transom deck bridges.

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RIM rail infrastructure manager; in relation to rail infrastructure of a railway, means the person
who has effective control and management of the rail infrastructure, whether or not the
person—

(a) owns the rail infrastructure; or

(b) has a statutory or contractual right to use the rail infrastructure or to control, or provide,
access to it

TfNSW Transport for NSW

ZLR zero longitudinal restraint

5. Risk and safety

Safe design is mandated in the Work Health and Safety Act 2011 and shall be incorporated into
the design of guard rails. Guidance on the safe design of structures can be found in SafeWork
NSW's Safe design of structures code of practice.

The Authorised Engineering Organisation (AEO) shall establish and implement a design
process system that manages safety across the full life cycle of the structure. The design
process system shall be developed in accordance with T MU MD 20001 ST System Safety
Standard for New or Altered Assets.

The installation of guard rails shall take into account the safety considerations for construction,
operational, maintenance and decommissioning workers.

5.1. Risk assessment

The requirement for guard rail installation shall be based on risk assessment and as required by
the following TfNSW standards:

• T HR CI 12020 ST Underbridges

• T HR CI 12030 ST Overbridges and Footbridges

• T HR CI 12072 ST Track Slabs

• T HR CI 12075 ST Airspace Developments

• T HR CI 12080 ST External Developments

• ESC 340 Tunnels

Risk criteria are contained in T MU MD 20002 ST Risk Criteria for Use by Organisations
Providing Engineering Services.

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The risk assessment shall be site specific and shall consider as a minimum, the following
factors:

• site condition, including cuttings and embankments

• derailment history at the site

• type of structure; that is, the potential for collapse and damage to trains

• track clearance to support elements

• presence of hazards at the site, for example track turnouts

• track components in the approach direction of travel, for example, catchpoints, facing and
trailing turnouts, slips, diamonds or scissor crossovers

• track geometry; that is, straight or curved track

• track speed (and potential out of control train speed) at the location

• track type; that is class , sleeper type and rail size

• type of rolling stock

• rail traffic frequency

• future usage and growth in patronage

Risk assessments shall be submitted for acceptance of the rail infrastructure manager (RIM).

5.1.1. Existing guard rail installations

Some existing guard rail installations in the TfNSW network have been installed to previous
standards and do not comply with the requirements of this standard. These can include
installations with the following characteristics:

• guard rails with e-clip fasteners

• guard rails with rail plates and lock spikes

• guard rails with dog spikes and no rail plates

• guard rails with fasteners installed on alternate sides of the foot of the rail

• guard rails based on small or worn rail sections

• guard rails based on angles rather than rails

• guard rail approach nose tip with gap between rails

• guard rails with short extent

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It is not mandatory to immediately upgrade all existing guard rails to suit the requirements of this
standard. However, the RIM shall determine whether risk levels associated with not upgrading
to new requirements are acceptable.

A risk assessment of existing guard rail installations shall be undertaken to determine priority
locations for upgrades. Risk assessments shall be submitted for acceptance of the RIM.

The following process may be used by the RIM to determine the need for upgrading of existing
guard rail installations:

• identify all guard rail installations on the network to establish an inventory to include
location, site factors, extent and type of guard rail and anchors installed, details of structure
being protected

• develop a risk based process for identifying and prioritising installations for upgrading to
current standards, for example, ballasted track with concrete sleepers and e-clips used to
anchor the guard rails is considered lower risk than dog spiked guard rails in similar
locations

• establish a program for upgrading works

• upgrade existing installations to this standard when carrying out related work such as
sleeper or transom renewal

Where existing guard rail installations are determined not to be a priority for upgrading, the
following shall apply:

• where guard rail fasteners are not in accordance with Section 6, the fasteners shall be
upgraded during routine track reconditioning activities to comply

• on transom top bridge locations where guard rail fasteners and plates are not in
accordance Section 7.5, the RIM shall develop a strategy for retrofitting approved guard rail
plates and fasteners during routing transom replacement activities

5.1.2. Reduced guard rail clearance at existing sites

The guard rail clearance (or gap) between the running rail and the guard rail may be less than
that specified in Section 7.1 at existing guard rail sites provided all of the following conditions
are satisfied:

• the RIM determines that a narrower gap is required to avert collision by a derailed train
represented by the maximum applicable design kinematic rolling stock outline located in
the derailed position (including an appropriate margin for clearance nominated by the RIM )
with any part of the structure, or to reduce the risk of a derailed train falling off a bridge

• the narrower gap can effectively guide a derailed train

• a modified complying nose is incorporated

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• compliant guard rail fasteners and plates are installed

• signalling interface is not affected

• track transit space is not affected

6. Guard rail design

Design of guard rail installations is not normally undertaken as installation details shown on
standard drawings can be adopted in most instances.

Guard rail arrangements as shown on drawings listed in Table 1 that have current complying
arrangements are deemed to satisfy the guard rail performance requirements of this standard.

Where standard arrangements cannot be installed, the guard rail shall satisfy the requirements
specified in Section 6, and shall be installed in accordance with Section 7. Proposed guard rail
arrangements shall be submitted for approval by the RIM.

Guard rails and fastening systems shall be supplied and installed in accordance with this
standard.

Guard rails shall not be used for the following:

• to protect new over track structures

• to reduce collision loads specified in other TfNSW standards

6.1. TfNSW designs

TfNSW has a number of drawings associated with guard rail installation. Relevant drawings are
listed in Table 1:

Table 1 - Drawings for guard rails

EDMS No. Drawing Title

CV0168626 Guard Rail – Special Arrangement – For Bridges Fitted with “Alternative 1”
Plates – General Arrangement (refer to note 1)
CV0168627 Guard Rail – Special Arrangement – For Bridges Fitted with “Alternative 1”
Plates – Details of Concrete Sleepers
CV0168632 Guard Rail – Special Arrangement – For Bridges Fitted with “Alternative 1”
Plates – Details of Guard Rail Nose
CV0179048 Guard rails – Installation of Guard Rails on Ballast Top Underbridge – General
Arrangement (refer to note 2)
CV0179049 Guard Rails – Installation of Guard Rails on Transom Top Underbridge –
General Arrangement (refer to note 2)
CV0179050 Guard Rails – Installation of Guard Rails on Ballast Top Underbridge – Details of
Guard Rail Concrete Sleepers (refer to note 2)
CV0179051 Guard Rails – Installation of Guard Rails on Ballast Top and Transom Top
Underbridge – Detail of Tapered Nose Section

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EDMS No. Drawing Title

CV0558906 Typical Details – All Lines – Combined Alt 1 & Guard Rail – Details

Notes:

(1) drawing does not include guard rail plates which may be required (refer to
Section 7.5) and is provided for information only

(2) drawing does not include Type A clip (refer to Section 6.4) and is provided for
information only

The use of designs shown on drawings in Table 1is mandatory in the first instance; however
these drawings may not be compliant with this standard or suitable for all locations.

Where the designer proposes to adopt a standard design or detail for a specific location, the
designer shall asses the currency and suitability of the standard design for compliance with this
standard, and where necessary, shall specify modified or alternative designs.

Modified or alternative designs shall comply with all relevant TfNSW and Australian standards
(refer to Section 6). The use of non-standard arrangements shall be submitted for approval by
the Lead Civil Engineer, ASA.

6.1.1. Drawings for guard rail installation

The guard rail drawings that are listed in Table 1 are available from the Virtual Planroom
(TfNSW's engineering document management system used for storing and managing electronic
data and information) and show dimensional set out, detail and sizes of componentry, and fixing
details for double guard rails.

6.2. Design load

Where non-standard guard rail arrangements are adopted, each guard rail shall be designed for
a single ultimate horizontal force of not less than 80 kN, applied at the top of the guard rail
acting perpendicular to the guard rail face in either direction, and applied at any point along the
length of the guard rail, including the nose, to produce the worst effect.

The force shall be distributed through the rail down to the fasteners.

6.3. Rail
Rail used for guard rails shall be new rail manufactured to the requirements of AS 1085.1
Railway track materials – Part 1: Steel Rails or recycled rail categorised as Category 1 (white
rail) in ESC 220 Rail and Rail Joints.

The guard rail section shall be the same as the running rail or one section size less than the
running rail.

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6.4. Type ‘A’ rail clips

Approved Type ‘A’ rail clips shall be used for fastening guard rails for all track forms and rail
support types shall be supplied in accordance with ESC 230. Type ‘A’ rail clips are used to
provide greater restraint to the guard rail against rotation.

6.4.1. Zero longitudinal restraint type ‘A’ rail clip

Where zero longitudinal restraint (ZLR) clips are used on the running rails, approved ZLR Type
‘A’ rail clips shall also be used on the guard rails to the same installation pattern as on the
running rails.

6.5. Screw spikes

Screw spikes shall be minimum M24 and supplied in accordance with AS 1085.18 Railway track
material – Part 18: Screw spikes and threaded inserts and ESC 230.

6.6. Threaded inserts

Threaded inserts cast into concrete shall be in accordance with AS 1085.18 and ESC 230.

6.7. Anchor rods

Threaded rods, nuts and spring washers shall be M24 grade 4.6/S to AS/NZS 1111.1 ISO
metric hexagon bolts and screws – Product grade C – Part 1: Bolts and galvanised to
AS/NZS 1214 Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread
series) (ISO 10684:2004, MOD) and set in a proven high strength grout.

6.8. Prohibited configurations

Concrete upstand located between the running rails (four foot) with solid surface between
gauge faces as shown in Figure 1 is prohibited.

Figure 1 - Prohibited configuration of concrete upstand

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7. Guard rail installation

The typical arrangement for guard rails is two parallel rails (twin guard rails) installed in the track
four-foot area with a tapered nose segment on the train approach side (refer to Table 1 for
reference drawings).

Standard details for single guard rail installations have not been developed. Details for single
guard rail installations shall be submitted for approval by the Lead Civil Engineer, ASA.

7.1. General installation requirements

General requirements for guard rails are as follows:

• all guard rail installations and modifications shall be submitted for approved by the RIM

• guard rails shall only be installed at locations where a derailed train that is contained by the
guard rails can be directed clear of the adjacent structure

• the clearance between the gauge face of the running rail and adjacent face of guard rail
shall be 380 mm

• the top of the guard rail shall be no higher than the top of the adjacent running rail and no
more than 50 mm below the top of the running rail

• the guard rail installation shall have a continuous and connected rail profile from the tip of
the nose to the end of the installation

• each guard rail shall be fastened on both sides of the rail at the same spacing as the
running rail

7.1.1. Guard rail nose requirements

The guard rail nose is the tapered segment and an associated short parallel segment installed
at the approach end of guard rails.

All guard rails shall be fitted with a nose section on the approach end. Where rail traffic is
bi-directional, the nose section shall be installed at both ends.

Requirements for the nose are as follows:

• the guard rail nose shall comprise twin rails with a tapered segment of a minimum length
of 3.6 m followed by a parallel segment of 1 m in length (refer to drawing CV0179051)

• the minimum nose length shall be in addition to the specified approach length of parallel
guard rails

• the tip of the tapered nose shall be fastened by not less than two M24 bolts

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• the tapered tip of the nose shall not have a gap between the ends of the guard rails for the
length of the tip bolted connection

• the transition between the tapered segment and the parallel segment of rails shall be bent

Table 1 shows references to guard rail nose drawings and details.

7.1.2. Joints in guard rails

The number of joints in guard rails shall be minimised. Where joints are required, the following
shall apply:

• Welded rail joints are preferred to bolted rail joints.

• Where welding is used, rail welds shall be in accordance with ESC 220.

• Non-welded rail joints shall be standard fishplates and bolted with not less than four
standard fishbolts in accordance with ESC 220.

• Where modified fishplates are used, all bolts shall have the nuts on the inside. Fishplates
shall be modified by machining, not by oxy-acetylene cutting. The plates shall have slotted
holes for the bolts.

• Fishbolts shall be installed with the head of the bolt facing the running rail.

• No joints, other than insulated joints, are permitted along the nose.

• Rail joints should be located midway between rail fasteners and shall not be located within
100 mm of rail fasteners.

7.2. Special installation

Guard rail installations with special requirements include the following:

• where rail expansion joints exist on the running rail, specific design details for guard rail
expansion joints shall be provided and approved track fasteners shall be used

• where noise and vibration limiting track fasteners are used for the running rail, special
attention to detailing of the guard rail may be required

• at signalling interfaces, refer to Section 7.2.1

• for automatic train protection (ATP) interfaces (for example balises), refer to Section 7.2.2.

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7.2.1. Signalling interface

Approved isolation arrangements shall be made in track circuited and electrified areas.

The requirements for track circuit signalling interface for new installations and where
refurbishment of the guard rails is undertaken are as follows:

• design drawings shall specify that insulation and bonding arrangements and shall be in
accordance with the requirements of the Lead Engineer Signals and Control Systems, ASA

• the nose shall have an electrically insulated joint with approved components

• one insulated joint is required per nose

• there are three options for locating the insulated joint (refer to Table 1 for references to
drawings):

o midway along the nose section, or

o immediately behind the nose section, or

o located at a short distance from the nose section

• where guard rails exceed 50 m in length, additional isolation and bonding arrangements
may be required in accordance with the requirements of the Lead Signals and Control
Systems Engineer, ASA.

For further signalling interface information and requirements, refer to TfNSW standard
ESG 100.17 Signal Design Principles – Track Circuits.

7.2.2. ATP interface

An ATP four bolt mechanical isolation joint shall be used for electrical isolation of guard rails at
ATP locations.

Example details for electrical isolation of guard rails are provided on the following drawings:

• SG0406853 Standard Placement of Alstom Balise at Guard Rails – Sheet 1 of 2

• SG0406919 Standard Placement of Alstom Balise at Guard Rails – Sheet 2 of 2

For installations that cannot be accommodated by the referenced drawings, advice shall be
obtained from the Lead Signals and Control Systems Engineer, ASA on requirements for
suitable interface arrangements.

The final arrangement for guard rails at ATP interfaces shall be submitted for approval by the
Lead Signals and Control Systems Engineer, ASA and the Lead Civil Engineer, ASA.

An additional requirement for fastening ATP equipment to timber or fibre reinforced foamed
urethane (FFU) transoms on bridges is that abandoned holes drilled in timber or FFU transoms
shall be filled with a suitable filler material approved by the RIM.

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An additional requirement for fastening ATP equipment to concrete track slabs and concrete
bridge decks is that steel reinforcement detectors shall be used to locate the steel reinforcement
prior to drilling. Reinforcement shall be avoided and the arrangement shall be submitted for
approval by the RIM.

Requirements for fastening ATP equipment to sleepers supporting guard rails in open ballasted
track locations shall be obtained from the Lead Track Engineer, ASA.

7.3. Guard rail installation not on underbridges

Guard rails at locations not on underbridges shall only be installed where they have been
determined by risk assessment as necessary to provide appropriate protection for at risk
supports of existing structures such as overbridges, footbridges, tunnel walls and structures
adjacent to or over the tracks.

The guard rails shall also comply with the following requirements:

• guard rails shall extend parallel in advance of the vulnerable support on the train approach
side for a length determined by risk assessment, but not less than 20 m plus nose segment

• where rail traffic is bi-directional, the guard rail shall extend beyond the vulnerable support
on both ends by a length determined by risk assessment, but not less than 20 m, plus nose
segments installed on both ends

• where traffic is one-directional, the guard rails shall extend parallel for a minimum of 3 m
beyond the vulnerable support on the train departure end without the nose installed

7.3.1. Ballasted track with concrete sleepers

Additional requirements for guard rails on concrete sleepers are as follows:

• Drawings are listed in Table 1. Where there are no standard drawings available which have
details for Type A rail clips used to fasten the guard rail, the AEO shall develop a suitable
sleeper that uses the Type A rail clip for guard rail fastening.

• The sleeper design shall be submitted for approval by the Lead Track Engineer, ASA.

• Single guard rails shall not be used on ballasted track.

• Guard rail fasteners shall be approved threaded inserts cast into the concrete sleepers.

7.3.2. Ballasted track with timber or FFU sleepers

Additional requirements for guard rails on timber or FFU sleepers shall be in accordance with
Section 7.5.

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7.3.3. Direct fixation track slabs

Refer to Section 7.4.3 for guard rail installation requirements in direct fixed track.

7.4. Guard rail installation on underbridges

General guard rail requirements for underbridges are as follows:

• installation locations shall be in accordance with T HR CI 12020 ST

• for non-through type bridges the entire guard rail nose specified in Section 7.1.1 shall
extend on the train approach end of the bridge beyond the end of abutment,

• for through type bridges, guard rails shall extend parallel for a minimum of 3 m beyond the
end of abutment (and structure end) on the train approach end and then followed by the
nose section as specified in Section 7.1.1

• for through type bridges with approach slabs that have derailment kerbs or barriers, the
entire guard rail nose shall extend beyond the end of kerbs or barriers

• on the train departure end of the bridge, guard rails shall extend parallel for a minimum of
3 m beyond the end of abutment without the nose installed

• where traffic is bi-directional the nose shall be installed on both ends of the bridge

• the end of the abutment shall be taken as the hidden face of the ballast wall, or the end of
the deck where no ballast wall is present, measured along the centreline of track for non-
skewed bridges

• at skewed bridge ends, the guard rails shall account for the skew angle of the bridge end
so that the extension length of any guard rail is not less than the minimum length specified

• for bridges with approach slabs the nose shall not be located partially on the approach
slab, that is, it shall be fully on or off the approach slab

7.4.1. Ballast top underbridges

Guard rail installation on ballast top underbridges shall also comply with the requirements in
Section 7.3.1 for concrete sleepers and Section 7.5 for timber and FFU sleepers.

7.4.2. Transom top bridges

Guard rails on transom top underbridges shall be determined in accordance with
T HR CI 12020 ST and installed in accordance with this standard.

The approved combined guard rail plate shown in Appendix A should be used where practical
on all new transom top underbridges as there are benefits in noise and vibration reduction and
enhanced axle load distribution. Refer to Section 7.5 for further requirements.

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Guard Rails
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7.4.3. Direct fixation track bridges

The approved combined guard rail plate shown in Appendix A should be used where practical
on all new direct fixation track underbridges as there are benefits in noise and vibration
reduction, enhanced axle load distribution and reduction in the number of fasteners.

Where fasteners are cast directly into the bridge deck, steel reinforcement shall be detailed to
provide a minimum fifty mm clearance to fasteners. For existing bridge decks, steel
reinforcement detectors shall be used to locate the steel reinforcement prior to drilling and the
reinforcement shall be avoided where possible and the arrangement shall be submitted for
approval by the RIM.

Blackout holes formed into a concrete deck for guard rail fasteners shall incorporate threaded
inserts in accordance with Section 6.6, or grouted approved steel fasteners, using a proven high
strength grout.

7.5. Guard rail plates and fasteners for timber and FFU
sleepers and transoms
The following guard rails plate requirements apply to timber and FFU sleepers and transoms:

• each guard rail shall be plated on every sleeper and transom and fastened on both sides of
the rail

• each plate shall be fastened using not less than four M24 screw spikes

• type approved combined running rail and guard rail plate shown in Appendix A may be
used

• an acceptable separate guard rail plate which may be used is shown on drawing
CV0692290 Berry – Illawarra Line 140.220km – Broughton Creek Underbridge Custom
Guard Rail Plate – Steelwork

• abandoned holes shall be filled with a suitable filler material approved by the RIM

• the RIM shall advise where rail insulators are required with the Type A rail clips, if so,
compatible Type A rail clips and insulators shall be used (refer to Section 7.2.1)

8. Maintenance
Maintenance requirements for guard rails shall be specified by the RIM in the technical
maintenance plan (TMP). Requirements are to include examination tasks and frequencies,
damage limits, and repair standards.

In most cases, MN A 00100 Civil and Track Technical Maintenance and ESC 302 Structures
Defect Limits shall apply. However, it may be necessary to document site-specific maintenance
requirements.

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The requirements and high-level processes for the development of technical maintenance plans
are detailed in T MU AM 01003 ST Development of Technical Maintenance Plans.

9. Decommissioning and disposal

Decommissioning is the final process of withdrawing an asset from operational service on the
network.

Disposal is the process of physically removing an asset from the network, for example,
demolition of an underbridge followed by removal and recycling.

The decommissioning and disposal of an asset is the final stage of the asset life cycle. Proper
planning for this phase of the life cycle is an integral part of the strategic life cycle process.

The process for the disposal of guard rails, usually undertaken in conjunction with replacement,
shall include the following:

• Justification (safety, financial and so on) for disposal of the asset.

• Confirmation of stakeholder engagement regarding the proposed action. Such engagement

shall include, but not be limited to heritage, local council, RIM and environmental body
consultation.

• Agreement from all stakeholders to the decommissioning or disposal of the existing guard
rails.

Following decommissioning and disposal, the asset database shall be updated by the RIM to
reflect network changes.

Ninety-five per cent of construction and demolition waste by weight of the decommissioned
asset shall be diverted from landfill.

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Appendix A Combined guard rail plate drawing

Figure 2 - Approved combined guard rail plate - Delkor Rail drawing ALT192GAS04

© State of NSW through Transport for NSW 2019 Page 22 of 22