Description
Cembre AR60A-41 Double-Sided Rail Web Bush Connection Kit
The Cembre AR60A-41 Double-Sided Rail Web Bush Connection Kit provides a permanent, low-resistance electrical connection through thick rail webs, allowing electrical conductors to be connected from both sides of the rail.
Designed specifically for 40–44 mm rail web thickness, the AR60A-41 is installed into a precision-drilled 19 mm hole and provides an M12 double-sided electrical connection for railway traction return, continuity bonding, grounding, signalling and track connection applications.
The AR60A-41 extends Cembre’s proven AR rail web connection system to applications involving significantly thicker rail webs than standard AR60D and AR260D connections.
Rather than relying on welded or externally clamped connections, the AR system uses a conductive copper bush mechanically installed under controlled expansion within the rail web. This creates a permanent metal-to-metal electrical interface between the bush and the rail itself.
The result is a highly reliable electrical connection designed to maintain stable, low contact resistance while resisting vibration, weather exposure and atmospheric contaminants throughout the long service life expected of railway infrastructure.
AR60A-41 Double-Sided Rail Web Connection
The AR60A-41 is designed for railway applications requiring two electrical connections through a rail web between 40 mm and 44 mm thick.
A common application is bonding 40TAL heavy-haul rail with an approximately 43.5 mm web thickness, making the AR60A-41 particularly relevant to heavy-haul mining and iron-ore rail networks.
Once installed, the connection provides access from both sides of the rail, allowing conductors to be connected to opposite sides of the same permanent rail web bush.
This provides a practical solution where a double-sided track connection is required through a particularly thick rail section.
Because the connection is created mechanically rather than thermally, installation does not require welding or heating of the rail.
This avoids creating a heat-affected zone and eliminates the potential metallurgical changes associated with welded rail bonds, making the AR system well suited to demanding heavy-haul railway applications.
AR60A-41 Rail Bonding and Track Connection Applications
The AR60A-41 rail web bush kit is suitable for applications including:
- 40TAL heavy-haul rail bonding
- Heavy-haul mining rail networks
- Traction return bonding
- Rail continuity bonding
- Ground bonding
- Rail earthing and grounding
- Substation connections
- Electrical drainage
- Signal track circuit continuity
- Signal track circuit connections
- Double-sided track connections
- Thick rail web electrical connections
With a specified rail web range of 40–44 mm, the AR60A-41 is particularly suited to 40TAL rail applications with approximately 43.5 mm web thickness.
Once installed, the permanent bush remains mechanically connected to the rail while the external cable connections can be removed, inspected, replaced or upgraded without disturbing the rail interface.
Why Use the AR60A-41 Rail Web Connection?
Ideal for 40TAL Heavy-Haul Rail
The AR60A-41 is commonly used for electrical bonding of 40TAL heavy-haul rail, where the approximately 43.5 mm rail web thickness falls within the product’s 40–44 mm installation range.
This makes it particularly suited to heavy-haul mining and iron-ore railway infrastructure where substantially thicker rail sections are used than on conventional rail networks.
Designed for 40–44mm Thick Rail Webs
The defining feature of the AR60A-41 is its ability to provide a permanent electrical connection through rail webs between 40 mm and 44 mm thick.
This allows the system to be used on specialised heavy-haul rail sections that cannot accommodate standard AR60D or AR260D connections designed for conventional rail web thicknesses.
Cembre AR60A-41 Technical Specifications
Manufacturer: Cembre
Part Number: AR60A-41
Product Type: Double-sided rail web bush electrical connection kit
Electrical Contact Type: Double-sided
Number of Connection Sides: 2
Rail Web Thickness: 40–44 mm
Required Rail Hole: 19 mm
Electrical Connection: M12
Installation Type: Cold mechanical expansion
Connection Style: Permanent double-sided rail web electrical bush
Required Installation Kit: AR60.41-INST
Recommended Broach Cutter: Cembre CY190L
Compatible Hydraulic Installation Tools: Cembre HTEP and B1300TEP-T
Typical Applications: Traction return, continuity bonding, grounding, signalling and double-sided track connections through thick rail webs
How the AR60A-41 Rail Bush Connection Works
The reliability of the AR system comes from the permanent mechanical interface created between the conductive bush and the rail web.
A precision 19 mm hole is first drilled completely through the thick rail web using suitable Cembre rail drilling equipment.
The conductive bush is then positioned within the hole and installed using the appropriate Cembre hydraulic installation equipment together with the dedicated AR60.41-INST installation kit.
During installation, the bush is mechanically expanded against the internal surface of the drilled hole.
The controlled extrusion process allows the conductive material to conform closely to the rail, creating 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
Because the permanent rail interface is separate from the removable cable connections, conductors can subsequently be disconnected or replaced without disturbing the installed bush.
AR60A-41 Rail Drilling Requirements
The AR60A-41 requires a 19 mm diameter hole through a 40–44 mm thick rail web.
Because of the increased drilling depth compared with standard rail web connections, the recommended cutter is the:
- Cembre CY190L 19 mm Long Broach Cutter
The CY190L is specifically designed for applications requiring greater drilling depth than the standard CY190 broach cutter.
It should be used with compatible Cembre rail drilling equipment capable of drilling the required rail section.
Using the specified long 19 mm broach cutter helps produce the accurate rail web hole required for correct installation and controlled extrusion of the bush.
The completed hole should be checked using the appropriate Cembre checking equipment before installation of the electrical contact.
For further information on Cembre’s rail electrical contact technology, see the Cembre Rail Electrical Contact Systems page.
AR60.41-INST Installation Kit
Installation of the AR60A-41 requires the dedicated Cembre AR60.41-INST installation kit.
The AR60.41-INST must be used in addition to compatible Cembre rail contact hydraulic installation equipment and provides the specialised installation components required for the extended 40–44 mm rail web connection.
Standard AR60D or AR260D installation equipment alone is not sufficient for correct installation of the AR60A-41.
Engineering Supplies can supply the AR60.41-INST installation kit together with the bush kit and associated Cembre hydraulic installation tooling.
Battery Hydraulic Installation Tool
Cembre B1300TEP-T
The B1300TEP-T provides portable battery-powered hydraulic installation of Cembre AR rail web electrical contacts.
For installation of the AR60A-41, the B1300TEP-T must be used together with the dedicated AR60.41-INST installation kit.
The battery-powered system provides a controlled and repeatable installation process without requiring a welded rail connection.
Manual Hydraulic Installation Tool
Cembre HTEP
The HTEP provides a manually operated hydraulic installation option for Cembre AR rail web electrical contacts.
When installing an AR60A-41, the HTEP must also be used with the dedicated AR60.41-INST installation kit.
This allows existing Cembre HTEP users to install the specialised thick-web connection by fitting the correct AR60.41 installation components.
Why Use the AR60A-41 Rail Web Connection?
Designed for 40–44mm Thick Rail Webs
The defining feature of the AR60A-41 is its ability to provide a permanent electrical connection through rail webs between 40 mm and 44 mm thick.
This makes it suitable for specialised rail sections where standard 14–16.5 mm rail web connection systems cannot be used.
Double-Sided Electrical Connection
The connection allows conductors to be attached from both sides of the rail through a single permanent bush.
19mm Rail Web Connection
The system uses a precision 19 mm rail web hole, drilled using the recommended Cembre CY190L long broach cutter.
No Welding Required
The electrical interface is created through controlled mechanical expansion rather than a thermal bonding process.
This removes the requirement to heat or weld the rail during installation.
Permanent Low-Resistance Interface
Controlled expansion of the conductive bush creates a stable metal-to-metal electrical interface directly with the rail web.
Resistant to Vibration and Weather
The mechanical connection is engineered for the vibration, moisture, atmospheric exposure and demanding environmental conditions encountered in railway infrastructure.
Maintainable Cable Connections
External cable lugs and conductors can be inspected, disconnected or replaced without removing the permanent rail web bush.
Repeatable Installation
Using the specified Cembre drilling equipment, AR60.41-INST installation components and hydraulic tooling provides a controlled and repeatable installation process.
AR60A-41 vs AR260D Rail Web Connection
Both the AR60A-41 and AR260D are double-sided Cembre rail web electrical connections using a 19 mm rail hole and M12 electrical connections.
The major difference is the rail web thickness they are designed to accommodate.
The AR260D is designed for standard rail webs between 14 mm and 16.5 mm thick.
The AR60A-41 is designed for substantially thicker rail webs between 40 mm and 44 mm thick.
The AR60A-41 also requires the dedicated AR60.41-INST installation kit and the longer CY190L 19 mm broach cutter for drilling through the thicker rail section.
Where a double-sided electrical connection is required through a standard rail web, the AR260D is typically appropriate. Where the rail web is 40–44 mm thick, the AR60A-41 provides the corresponding Cembre connection system.
Cembre AR60A-41 Frequently Asked Questions
What rail web thickness suits the AR60A-41?
The AR60A-41 is designed for 40 mm to 44 mm rail web thickness.
What size hole is required?
A 19 mm diameter hole must be drilled completely through the rail web.
Which broach cutter is recommended?
The Cembre CY190L 19 mm Long Broach Cutter is recommended due to the increased drilling depth required for the 40–44 mm rail web.
Is the AR60A-41 single-sided or double-sided?
The AR60A-41 is a double-sided rail web connection, allowing electrical conductors to be attached from opposite sides of the same permanent rail web bush.
What size electrical connection does it use?
The bush kit uses M12 electrical connections.
Is a special installation kit required?
Yes.
Correct installation requires the Cembre AR60.41-INST installation kit in addition to a compatible Cembre HTEP or B1300TEP-T hydraulic installation tool.
Can I use an existing HTEP or B1300TEP-T?
Yes.
An existing compatible Cembre HTEP or B1300TEP-T can be used, provided it is fitted with the dedicated AR60.41-INST components required for this connection.
Why can’t I use a standard CY190 broach cutter?
The 40–44 mm rail web requires greater drilling depth than a standard rail web.
The CY190L long 19 mm broach cutter is therefore recommended to provide the necessary drilling depth.
Is the AR60A-41 a welded rail connection?
No.
The electrical interface is produced using controlled mechanical expansion of the bush inside the rail web rather than welding or heating the rail.
Can cable connections be replaced after installation?
Yes.
Once the bush is permanently installed, the external cable connections can be removed, inspected or replaced without disturbing the electrical interface between the bush and the rail.
Is the Cembre AR60A-41 suitable for 40TAL rail?
Yes.
The AR60A-41 is commonly used for bonding 40TAL heavy-haul rail with an approximately 43.5 mm web thickness.
The AR60A-41 is designed for rail web thicknesses between 40 mm and 44 mm, placing a 43.5 mm 40TAL rail web near the centre of its specified installation range.
It provides a double-sided M12 electrical connection through a single 19 mm rail web hole and is particularly suited to heavy-haul mining and iron-ore railway applications.
Cembre AR60A-41 Supply and Technical Support in Australia
Engineering Supplies supplies and supports the Cembre AR60A-41 double-sided rail web bush connection kit together with the specialist drilling and installation equipment required for correct installation.
We can assist with:
- AR60A-41 bush kits
- AR60.41-INST installation kits
- CY190L 19 mm long broach cutters
- Cembre rail drilling machines
- B1300TEP-T battery hydraulic installation tools
- HTEP manual hydraulic installation tools
- Rail web connection selection
- Technical product information
- Complete Cembre rail electrical connection systems
Required Installation Kit:
Cembre AR60.41-INST
Recommended Broach Cutter:
Cembre CY190L 19 mm Long Broach Cutter
Battery Installation Tool:
B1300TEP-T – Engineering Supplies
Manual Hydraulic Installation Tool:
HTEP – Engineering Supplies
Contact Engineering Supplies for pricing, availability and technical support on the AR60A-41 and complete Cembre rail connection range.
