Description
Cembre AR260D Double-Sided Rail Web Bush Connection Kit
The Cembre AR260D Double-Sided Rail Web Bush Connection Kit provides a permanent, low-resistance electrical connection through the rail web. Importantly, it allows two cable connections from opposite sides of the rail through a single rail web bush.
The AR260D suits 14–16.5 mm rail web thickness and requires a precision-drilled 19 mm rail web hole. It uses M12 electrical connections for railway signalling, traction return, bonding, earthing and track connection applications.
The AR260D is the double-sided version of the Cembre AR60D. While the AR60D provides one electrical connection, the AR260D provides connections on both sides of the same rail web bush. As a result, it can reduce the number of rail holes required where two conductors need to connect at the same location.
Unlike welded or externally clamped rail connections, the AR260D uses a conductive bush that expands mechanically within the rail web. Therefore, the system creates a durable metal-to-metal electrical interface without applying heat to the rail.
Cembre AR260D Double-Sided Rail Web Connection
The Cembre AR260D forms part of Cembre’s permanent rail electrical connection system. Cembre specifically designed the AR260D for applications requiring a double-sided rail connection.
First, the operator drills a precision 19 mm hole through the rail web. Next, the AR260D components are positioned in the hole. The appropriate Cembre hydraulic tooling then pulls a calibrated mandrel through the conductive bush.
As a result, the bush expands firmly against the internal surface of the rail web hole and creates the permanent electrical interface.
Once installed, the AR260D provides one electrical connection on each side of the rail. Consequently, two conductors can connect through a single rail web hole.
This configuration can provide a significant advantage where two bonding conductors or track connections are required. Instead of installing two separate single-sided contacts, the AR260D provides both connections through one rail hole.
Furthermore, the AR260D uses mechanical expansion rather than a thermal bonding process. Therefore, installation requires no welding or heating of the rail and creates no heat-affected zone.
Cembre AR260D Rail Bonding Applications
The Cembre AR260D double-sided rail web bush kit suits a wide range of railway electrical applications, including:
- Traction return bonding
- Rail continuity bonding
- Rail earthing and grounding
- Double-sided rail bonding
- Signal track circuit connections
- Substation rail connections
- Electrical drainage systems
- Rail bonding connections
- Track connections
- Railway electrical connections
- Applications requiring two conductors through a single rail web connection
Once installed, the permanent bush remains fixed within the rail web. However, maintenance crews can inspect, remove or replace either external cable connection without disturbing the permanent rail interface.
Consequently, the AR260D provides a maintainable connection for long-term railway infrastructure.
Cembre AR260D Technical Specifications
- Manufacturer: Cembre
- Part Number: AR260D
- Product Type: Double-sided rail web bush electrical connection kit
- Electrical Contact Type: Double
- Number of Connections: 2
- Rail Web Thickness: 14–16.5 mm
- Required Rail Hole: 19 mm
- Electrical Connection: M12
- Bolt: M12 x 70 stainless steel
- Bush Material: Tin-plated copper
- Installation Type: Cold mechanical expansion
- Connection Style: Permanent double-sided rail web electrical bush
- Copper Connection Tightening Torque: 80 Nm
- Aluminium Connection Tightening Torque: 50 Nm
- Typical Applications: Railway signalling, traction return, continuity bonding, earthing, grounding and double-sided track connections
For additional manufacturer specifications, visit the official Cembre AR260D product page.
Cembre AR260D vs AR60D Rail Web Connections
The main difference between the Cembre AR260D and AR60D is the number of available electrical connections.
The AR60D provides a single-sided rail connection with one external electrical connection.
In comparison, the AR260D provides a double-sided rail connection. Therefore, two electrical conductors can connect from opposite sides of the same rail web bush.
Both systems use the same fundamental Cembre mechanical rail connection principle. In addition, both suit 14–16.5 mm rail web thickness and use a 19 mm rail hole with M12 connections.
Where only one conductor is required, the AR60D generally provides the appropriate solution. However, where two connections are required at the same rail location, the AR260D provides both connections without requiring a second rail hole.
How the Cembre AR260D Rail Bush Connection Works
The AR260D creates its permanent electrical interface through controlled mechanical expansion of the conductive copper bush.
First, the operator drills a correctly sized 19 mm hole through the rail web using suitable Cembre rail drilling equipment.
Next, the AR260D bush and associated components are positioned within the rail web. The appropriate Cembre hydraulic installation tool then pulls the calibrated mandrel through the bush.
As the mandrel passes through, it expands the conductive copper against the internal surface of the rail hole. Consequently, the bush conforms closely to the rail and creates a gas-tight, metal-to-metal electrical interface.
This connection method provides excellent resistance to:
- Rail vibration
- Mechanical movement
- Moisture
- Weather exposure
- Atmospheric contaminants
- Long-term environmental degradation
Once installation is complete, cable lugs can connect to both sides of the AR260D. Meanwhile, the permanent electrical interface with the rail remains undisturbed.
Cembre AR260D Installation Tools and Accessories
Correct AR260D installation requires the appropriate Cembre drilling and hydraulic installation equipment.
In addition, the double-sided AR260D requires the AR260 Washer Kit during installation.
19 mm Rail Hole
The Cembre AR260D requires a 19 mm diameter hole through the rail web.
For best results, we recommend the Cembre CY190 19 mm Broach Cutter with compatible Cembre rail drilling equipment.
Using the correct cutter helps produce the accurately sized hole required for AR system installation.
AR260D Installation Mandrel
The AR260D uses either the:
The required mandrel depends on the installation tool configuration.
During installation, the hydraulic tooling pulls the calibrated mandrel through the bush. As a result, the copper bush expands against the wall of the 19 mm rail web hole and creates the permanent connection.
AR260 Washer Kit for Double-Sided Installation
Unlike the single-sided AR60D, the Cembre AR260D requires the AR260 Washer Kit for installation.
The kit incorporates the Ø38 mm installation washer required to correctly extrude the AR260 double-sided contact.
During installation, the operator fits the washer to the RHTEP-S Hydraulic Installation Head. The washer then provides the support required to correctly extrude the double contact and copper washer.
Importantly, Cembre includes the AR260 washer kit as standard with both the HTEP and B1300TEP-T rail contact installation tools.
Therefore, these tools can install both the single-sided AR60D and double-sided AR260D connection systems when configured with the appropriate accessories.
Engineering Supplies also supplies the AR260 Washer Kit separately for existing Cembre installation tools that require an additional or replacement kit.
Battery Hydraulic Installation Tool
For portable battery-powered installation, use the Cembre B1300TEP-T Battery Hydraulic Installation Tool.
For AR260D installation, use the B1300TEP-T with:
- RHTEP-S Hydraulic Installation Head
- OG13.2 or OG13.2T installation mandrel
- AR260 Ø38 mm Washer Kit
In addition, Cembre supplies the AR260 washer kit as standard with the B1300TEP-T.
Manual Hydraulic Installation Tool
Alternatively, use the Cembre HTEP Manual Hydraulic Installation Tool for manual hydraulic installation.
Cembre supplies the HTEP with the required AR260 Washer Kit. Therefore, the tool can install both AR60D and AR260D rail web connection systems when correctly configured.
Using the correct Cembre drilling equipment, mandrel, washer and hydraulic tooling helps provide a controlled and repeatable AR260D installation.
Benefits of the Cembre AR260D Double-Sided Rail Connection
Two Connections Through One Rail Hole
The AR260D allows electrical conductors to connect from both sides of the rail through a single permanent rail web bush.
As a result, applications requiring two connections may need fewer rail holes and individual rail contacts than two separate single-sided connections.
No Welding Required
The AR260D uses controlled mechanical expansion rather than a thermal bonding process.
Therefore, installation requires no welding equipment and introduces no heat-affected zone into the rail.
Permanent Rail Interface
Once installed, the conductive bush remains permanently connected to the rail.
However, maintenance crews can service either external cable connection independently from the permanent rail interface.
Low-Resistance Electrical Connection
Controlled expansion creates a large metal-to-metal contact area between the conductive copper bush and the rail web.
Consequently, the AR260D provides a stable, low-resistance electrical connection for demanding railway applications.
Resistance to Railway Environments
Cembre designs the AR system for railway applications where connections experience vibration, mechanical movement, moisture and environmental exposure.
Therefore, the AR260D suits demanding long-term railway infrastructure applications.
Maintainable Cable Connections
Maintenance crews can inspect, disconnect or replace either conductor without drilling another rail hole or disturbing the permanent rail bush.
As a result, the system simplifies ongoing maintenance and future cable replacement.
Repeatable Installation
Dedicated Cembre drilling equipment, installation mandrels, washers and hydraulic tooling allow operators to follow a controlled installation process.
Furthermore, using equipment designed as part of the same Cembre system helps simplify installation and tooling selection.
Cembre AR260D Frequently Asked Questions
What is the difference between the Cembre AR260D and AR60D?
The AR60D provides a single-sided rail web connection.
In comparison, the AR260D provides a double-sided connection and allows two cable connections from opposite sides of one rail web bush.
How many connections can be made to an AR260D?
The Cembre AR260D provides two electrical connection points, with one available from each side of the rail.
Therefore, two conductors can connect through a single permanent rail web bush.
What size hole does the Cembre AR260D require?
The Cembre AR260D requires a 19 mm diameter hole through the rail web.
For best results, use the Cembre CY190 19 mm Broach Cutter with compatible Cembre rail drilling equipment.
What rail web thickness suits the AR260D?
The Cembre AR260D suits rail web thicknesses from 14 mm to 16.5 mm.
Therefore, always confirm the rail web thickness before selecting the connection kit.
What size connection does the AR260D use?
The AR260D uses M12 connections.
Importantly, its double-sided design allows conductors to connect from both sides of the rail.
What tool installs the Cembre AR260D?
For battery-powered hydraulic installation, use the Cembre B1300TEP-T.
Alternatively, the Cembre HTEP provides a manual hydraulic option.
In addition, AR260D installation requires the appropriate OG13.2 or OG13.2T mandrel and AR260 Ø38 mm washer kit.
What is the Cembre AR260D used for?
Typical applications include:
- Traction return bonding
- Rail continuity bonding
- Railway earthing
- Rail grounding
- Signal track circuits
- Double-sided rail bonding
- Track connections
- Railway electrical connections requiring two conductors through one rail web connection
Does the AR260D require welding?
No.
The Cembre AR260D uses a cold mechanical expansion process. Therefore, installation requires no welding or heating of the rail.
Can the cables be replaced after installation?
Yes.
The permanent electrical bush remains installed within the rail web. However, maintenance crews can remove, service or replace either external cable connection without disturbing the permanent rail interface.
Does the Cembre AR260D require a special washer?
Yes.
Unlike the single-sided AR60D, the AR260D requires the AR260 Washer Kit during installation.
The kit includes the Ø38 mm installation washer used with the RHTEP-S installation head.
Importantly, Cembre supplies this washer kit as standard with the HTEP and B1300TEP-T installation tools. Engineering Supplies also supplies the kit separately when a replacement or additional washer kit is required.
Cembre AR260D Supply and Technical Support in Australia
Engineering Supplies supplies and supports the Cembre AR260D double-sided rail web bush connection kit together with the associated drilling, installation and checking equipment.
In addition, we can assist with:
- Cembre AR260D product supply
- Double-sided rail web bush selection
- Cembre rail drilling equipment
- CY190 19 mm rail broach cutters
- AR260D installation tooling
- AR260 washer kits
- OG13.2 and OG13.2T installation mandrels
- Battery and manual hydraulic installation tools
- Technical product information
- Rail connection product identification
- Complete Cembre rail connection systems
Therefore, customers can source both the AR260D and its associated drilling and installation equipment from Engineering Supplies.
Get a Quote
For pricing, availability or technical assistance with the Cembre AR260D Double-Sided Rail Web Bush Connection Kit, contact Engineering Supplies on (08) 9258 8444 or email sales@engsup.com.au.
Finally, Engineering Supplies supplies Cembre railway electrical connection systems, rail drilling equipment, hydraulic installation tooling and consumables throughout Australia.
