Rail Sizes Chart and Mounting Clips

Selecting the correct rail profile is the foundation of safety and efficiency for any track-based system, whether for overhead cranes, mining operations, or industrial transport. A definitive rail sizes chart is the primary tool engineers and procurement specialists use to ensure compatibility between the track, the wheels, and the mounting hardware. Without precise adherence to these dimensions, systems face increased wear, derailment risks, and structural failures.

The Rail Sizes Chart

In the world of track maintenance and construction, relying on visual estimation is impossible. A rail sizes chart provides the exact geometric properties required to identify specific rail sections. Rails are categorized by their weight per yard (in US standards) or kilograms per meter (in Metric standards), but weight alone does not tell the full story.

Two rails might share a similar weight but possess vastly different cross-sectional geometries. For instance, an 85 lb ASCE rail has a different profile height and base width compared to an 85 lb Canadian Pacific section. Consult a detailed rail sizes chart to verify the four critical dimensions:

1. Height: The total vertical distance from the base to the top of the head.
2. Base Width: The width of the bottom flange that sits on the tie or plate.
3. Head Width: The width of the top surface where the wheel makes contact.
4. Web Thickness: The thickness of the vertical section connecting the head and base.

Common Rail Standards and Their Specifications

To effectively use a rail sizes chart, one must understand the governing bodies that standardize these profiles. The most common standards found in North American and international industrial charts include ASCE, AREA, and DIN.

ASCE Rails (American Society of Civil Engineers)

ASCE rails are typically “T-rails” used in lighter duty applications. You will frequently see these on rail sizes chart documents for sections weighing between 12 lbs/yd and 85 lbs/yd.

• Applications: These are the standard for mining tracks, light industrial sidings, and automated storage and retrieval systems (AS/RS).
• Profile Characteristics: ASCE rails generally have a height that roughly equals their base width, giving them a balanced, square proportion compared to taller high-speed rails.

AREA / ARA Rails (American Railway Engineering Association)

When the application demands heavy loads, such as mainline freight or heavy industrial transport, AREA (now often referred to under AREMA) specifications apply.

• Applications: Class I railroads, heavy rapid transit, and heavy port sidings.
• Profile Characteristics: These rails (90 lbs/yd up to 140+ lbs/yd) feature taller webs and broader heads to withstand high axle loads and high speeds. The “RE” suffix (e.g., 115 RE) is common in this category.

Crane Rails (CR / DIN Standards)

Crane rails differ significantly from transport rails. They are designed for massive vertical loads at slow speeds.

• DIN 536: This European standard specifies rails with a wide base and a low center of gravity (e.g., A45, A75, A100).
• American Crane Rail: Profiles like 104 lb or 175 lb Crane Rail feature very wide heads to accommodate the wide treads of crane wheels, ensuring better load distribution.

Detailed Rail Sizes Chart and Specifications

The following specification table provides data on the most common rail sections used in industrial and commercial applications. Use this rail sizes chart to cross-reference measurements taken from the field.

Rail Section	Weight (lb/yd)	Weight (kg/m)	Height (inches)	Base Width (inches)	Head Width (inches)	Web Thickness (inches)
ASCE SECTIONS
20 lb ASCE	20.0	9.9	2 5/8	2 5/8	1 11/32	1/4
30 lb ASCE	30.0	14.9	3 1/8	3 1/8	1 11/16	21/64
40 lb ASCE	40.0	19.8	3 1/2	3 1/2	1 7/8	25/64
60 lb ASCE	60.0	29.8	4 1/4	4 1/4	2 3/8	31/64
80 lb ASCE	80.0	39.7	5	5	2 1/2	35/64
85 lb ASCE	85.0	42.2	5 3/16	5 3/16	2 9/16	9/16
AREA / RE SECTIONS
90 lb ARA-A	90.0	44.6	5 5/8	5 1/8	2 9/16	9/16
100 lb RE	100.0	49.6	6	5 3/8	2 11/16	9/16
115 lb RE	115.0	56.9	6 5/8	5 1/2	2 23/32	5/8
132 lb RE	132.0	65.5	7 1/8	6	3	21/32
136 lb RE	136.0	67.5	7 5/16	6	2 15/16	11/16
CRANE RAIL SECTIONS
104 lb CR	104.0	51.6	5	5	2 1/2	1
135 lb CR	135.0	67.0	5 3/4	5 3/16	3	1 1/4
175 lb CR	175.0	86.8	6	6	4 1/32	1 1/2

Note: Dimensions are nominal. Wear and manufacturing tolerances may result in slight variances.

Rail Clips Types and Mounting Specifications

While the rail supports the load, the rail clips ensure the track stays aligned. Selecting the wrong clip is a frequent cause of premature rail failure. The choice of clip must correspond directly to the base width found in the rail sizes chart.

Rigid vs. Adjustable Clips

• Rigid Clips: These are simple steel plates, often bolted or welded directly to the support. They are cost-effective but offer no adjustability. If the rail aligns poorly during installation, rigid clips cannot compensate, leading to side-wear on wheels.
• Adjustable Clips: Modern industrial installations favor adjustable clips (often with a rubber “nose”). These allow for lateral adjustment (typically 3mm to 15mm) during installation to ensure perfectly straight rails. The rubber nose applies a downward force that holds the rail in place while allowing for slight longitudinal movement caused by thermal expansion.

Crane Rail Clips

Crane rails usually experience higher lateral forces than train tracks. Specialized crane rail clips (such as the Gantrail or Molyneux types) are engineered to withstand these side-thrusts.

• Self-Locking: Many high-end clips feature a self-locking mechanism that prevents vibration from loosening the bolts—a critical feature for overhead cranes.
• Weldable Base: These clips typically consist of a bottom component welded to the girder and a top component bolted to the bottom one. This ensures the mounting point is permanently fixed while the clip itself remains removable for maintenance.

Standard Railway Clips (E-Clips)

For standard railway ties (sleepers), the E-Clip (Pandrol clip) is the global standard.

• Spring Steel: Made from high-quality spring steel, these clips are driven into a cast iron shoulder embedded in the concrete tie.
• Elastic Fastening: Unlike bolted clips, E-clips provide a constant elastic tension that resists the vibrational loosening inherent in railway traffic. They require no maintenance (retightening) once installed.

How to Identify Rail Sections Using a Rail Sizes Chart

Field identification of worn rail is a common challenge. A rail might be worn down by 1/4 inch on the head, making it difficult to match with a “new” profile on a rail sizes chart. Follow this process for accurate identification:

1. Clean the Web: Look for the “Mill Marks” or raised lettering rolled into the web of the rail. This code often explicitly states the weight and section (e.g., “115 RE” or “85 AS”). This is the most reliable method.
2. Measure the Base First: The base of the rail experiences the least wear. Measure the width of the base accurately. This dimension alone can often narrow down the possibilities on the rail sizes chart to just two or three options.
3. Measure Web Thickness: Use calipers to measure the web thickness. This dimension rarely changes due to wear.
4. Estimate Original Height: Measure the current height and inspect the wear pattern on the head. If the rail looks flattened, add an estimated wear allowance (typically 1/8″ to 1/4″) before comparing it to the chart.

Installation and Maintenance of Rail Systems

Proper installation extends beyond just picking the right size. The interaction between the rail and the clip is vital.

Matching Clip to Base Width:
If a clip is designed for a 5-inch base (like an 80 lb ASCE), using it on a 5 1/8-inch base (like a 90 lb ARA-A) will result in improper seating. The clip will not apply force to the correct part of the rail foot, potentially snapping the clip or allowing the rail to slide. Always confirm the “Base Width” column in your rail sizes chart matches the clip specifications.

Torque and Welding:

• For bolted clips, adhere strictly to torque specifications. Over-torquing can strip threads or crack the clip; under-torquing leads to loose rails.
• For weldable clips, use low-hydrogen electrodes (e.g., E7018) and ensure the girder surface is clean. Do not weld the clip while the rubber nose is in contact with the hot metal; insert the rubber component only after the weld has cooled.

Thermal Expansion:
Rails expand and contract with temperature changes. Clips should hold the rail down firmly but not necessarily restrict longitudinal movement unless they are acting as a fixed point anchor. Adjustable clips with rubber noses are excellent for managing this thermal cycle, preventing the rail from buckling.

Frequently Asked Questions

How do I measure rail size correctly?
To accurately identify a rail, measure the Base Width and the Height. Then, measure the Head Width and Web Thickness. Compare these four measurements against a standard rail sizes chart. Always prioritize the Base Width measurement as it is least affected by wear.

What is the difference between ASCE and AREA rails?
ASCE rails (American Society of Civil Engineers) are typically lighter sections (up to 85 lbs) used for industrial and mining applications. AREA rails (American Railway Engineering Association) are heavier (90 lbs and up), have taller profiles, and are designed for mainline railroads carrying heavy freight at speed.

Can I weld crane rail clips?
Yes, many crane rail clips are specifically designed to be welded. These consist of a weldable lower base and a bolted upper clamp. Welding the base to the crane girder provides a robust, permanent fixture point that handles high lateral loads better than bolted connections.

What does the “lb” in rail size mean?
The “lb” designation refers to the weight of the rail per linear yard. For example, a “115 lb rail” weighs 115 pounds for every yard of length. This weight is a proxy for the rail’s cross-sectional area and overall strength.

Are international rail sizes compatible with US clips?
Not necessarily. International rails (like DIN or UIC standards) often have different base geometries and head profiles than US rails (ASCE/AREA). While the weight might be similar, the shape is different. Always verify compatibility using a rail sizes chart before purchasing clips for international rail sections.