How To Install Rail Pads Properly?

Rail pads can prevent rail sleeper abrasion and the crushing of the sleeper under the rail foot. Rubber rail pads are normally designed to a specified load-deflection characteristic. The initial stiffness of the rail pad is designed to be low so that that their deformations under the springs toe loads is quite substantial.

We have developed a range of high-performance elastic rail pads for stiffness requirements and various application areas-from trams through standard gauge railways to heavy haul lines, especially those for E-type rail fastening systems and SKL type rail fastening systems with material of HDPE/EVA/Rubber, with following properties respectively.

In the fast-paced environment of railway construction, the installation of the Rail Pad is often perceived as a rudimentary task-simply placing a rubber mat under the steel rail. However, field data analyzes by GNEE RAIL indicate that many premature track failures, such as sleeper abrasion or clip loosening, stem from improper pad installation. Correct installation protocols are essential to ensure the Rail Rubber Pad functions effectively as a vibration damper and protective interface. Here are the professional standards that must be observed.

1. Surface Preparation: The Foundation of Success

The most critical, yet frequently overlooked, step occurs before the Railroad Pad is even laid down: cleaning the concrete sleeper's rail seat. In a construction environment, grit, ballast dust, or remnants of old pads often accumulate on the sleeper surface. If not removed, these particles act like sandpaper under the dynamic load of trains, rapidly wearing through the new pad and damaging the concrete beneath.

GNEE RAIL emphasizes that the rail seat must be dry, flat, and debris-free. A clean interface ensures that the Rubber Track Pad achieves maximum friction grip, preventing lateral displacement (walking) during train operations.

2. Orientation and Geometric Fit

Modern fastening systems (such as Vossloh SKL or Pandrol E-Clip) often utilize Rail Elastic Pads with specific geometric features, such as locating tabs, horns, or side wings designed to fit between insulators or guide plates.

Installers must pay close attention to the orientation-ensuring the correct side faces up (often the grooved side for flexibility) and that the tabs align with the sleeper shoulders. Forcing a pad into a space where it doesn't fit causes buckling and stress concentration. GNEE RAIL's products are manufactured with precise dimensional tolerances to ensure a "drop-in" fit, eliminating the need for on-site trimming or forcing.

3. Clamping and Final Inspection

Once the rail is lowered onto the pad and the fastening clips are applied, a visual inspection is mandatory. The Rail Pad should extend slightly beyond the rail foot on both sides, indicating full coverage.

If the pad appears extruded or significantly more compressed on one side, it suggests rail tilting or improper cant. Correcting this immediately ensures the pad operates within its designed static stiffness range. A properly seated pad ensures the fastening system maintains the correct toe load.

Installation Support from GNEE RAIL

At GNEE RAIL, we deliver more than just boxes of Railway Pads; we deliver engineering assurance. Our shipments can include detailed installation guidelines specifying orientation and compatibility. Whether you are installing standard EVA pads or complex Under Sleeper Pads, our technical team is ready to support your contractors to ensure the job is done right the first time. Contact us for components that fit perfectly and perform reliably.