Description
Cembre AR60D Rail Web Bush Connection Kit
The Cembre AR60D bush kit provides a permanent, low-resistance electrical connection to the rail web for railway signalling, traction return, continuity bonding, earthing and track connection applications.
Designed for 14–16.5 mm rail web thickness, the AR60D installs into a precision-drilled 19 mm rail web hole and provides an M12 electrical connection for cable lugs and rail bonding conductors.
Unlike welded or externally clamped rail connections, the Cembre AR60D uses a conductive bush that expands mechanically within the rail web. As a result, the bush creates a durable metal-to-metal electrical interface with the rail without applying heat.
Cembre AR60D Bush Kit for Permanent Rail Connections
The Cembre AR60D forms part of Cembre’s established range of permanent rail electrical connection systems.
During installation, the operator drills a precision 19 mm hole through the rail web. The AR60D bush is then positioned in the hole before dedicated Cembre hydraulic tooling pulls a calibrated mandrel through the bush.
As a result, the conductive bush expands firmly against the internal surface of the rail web hole and creates a permanent electrical interface.
Unlike thermal rail bonding methods, the installation process does not require welding or heating of the rail. Therefore, it introduces no heat-affected zone into the rail.
In addition, the permanent bush remains installed in the rail while maintenance crews can inspect, remove or replace the external cable connection separately. Consequently, future cable maintenance does not require a new rail connection each time.
Cembre AR60D Rail Bonding Applications
The Cembre AR60D rail web bush kit suits a wide range of railway electrical applications, including:
- Traction return bonding
- Rail continuity bonding
- Rail earthing and grounding
- Substation rail connections
- Electrical drainage systems
- Signal track circuit continuity
- Signal track circuit connections
- Rail bonding connections
- Track connections
- Railway electrical connections
Because the permanent rail interface and external cable connection remain separate, the AR60D provides a maintainable solution for long-term railway infrastructure.
Cembre AR60D Technical Specifications
- Manufacturer: Cembre
- Part Number: AR60D
- Product Type: Single-sided rail web electrical bush connection
- Rail Web Thickness: 14–16.5 mm
- Required Rail Hole: 19 mm
- Electrical Connection: M12
- Contact Type: Single
- Bush Material: Copper
- Bush Surface Treatment: Tin plated
- Self-Locking Nut: Yes
- Number of Connectors: 1
- Recommended Copper Connection Torque: 80 Nm
- Recommended Aluminium Connection Torque: 50 Nm
- Installation Type: Cold mechanical expansion
- Typical Applications: Signalling, traction return, bonding, earthing, continuity and track connections
For additional manufacturer specifications, visit the official Cembre AR60D product page.
How the Cembre AR60D Bush Kit Works
The AR60D creates its permanent electrical interface through controlled mechanical expansion of the conductive bush.
First, the operator drills a correctly sized 19 mm hole through the rail web using suitable Cembre rail drilling equipment.
Next, the AR60D bush is positioned in the rail web. The appropriate Cembre hydraulic installation tool then pulls an OG13.2 or OG13.2T mandrel through the bush.
As the mandrel passes through, it expands the conductive material against the internal surface of the rail hole. Consequently, the bush forms a large and consistent metal-to-metal contact area with the rail.
This method provides a permanent electrical connection designed for the vibration, moisture and environmental conditions encountered in railway infrastructure.
AR60D Rail Hole Drilling
Correct hole preparation plays an important role in achieving a reliable Cembre AR connection.
The AR60D requires a 19 mm diameter hole through the rail web. For best drilling performance and hole quality, we recommend the Cembre CY190 19 mm Broach Cutter with a compatible Cembre rail drilling machine.
In addition, Cembre recommends VASCO5000 rail drill coolant for rail drilling and AR system installation.
Importantly, when VASCO5000 is used as the coolant while drilling an AR connection hole, the hole does not need to be dried before installing the Cembre AR bush. As a result, installers can move directly from drilling and checking the hole to bush installation.
Cembre AR60D Installation Mandrels
Correct installation requires the appropriate Cembre installation mandrel.
The AR60D can use:
The mandrel controls expansion of the conductive bush during installation. Therefore, using the specified Cembre mandrel and installation procedure helps provide a controlled and repeatable rail connection.
Cembre AR60D Hydraulic Installation Tools
Battery Hydraulic Installation
For portable battery-powered installation, use the Cembre B1300TEP-T Battery Hydraulic Installation Tool with the appropriate installation mandrel.
The B1300TEP-T provides a convenient battery hydraulic solution for installing Cembre AR rail web electrical contacts in the field.
Manual Hydraulic Installation
Alternatively, the Cembre HTEP Manual Hydraulic Installation Tool provides a manual hydraulic option for Cembre rail web bush installation.
Using the correct Cembre drilling, checking and installation equipment helps provide a controlled and repeatable rail connection in accordance with Cembre’s specified installation procedure.
Benefits of the Cembre AR60D Rail Web Connection
No Welding Required
The AR60D 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, the external cable lug and conductor can be serviced independently from the permanent rail interface.
Low-Resistance Electrical Connection
The controlled expansion process creates a large metal-to-metal contact area between the conductive bush and rail web.
As a result, the AR60D provides a stable, low-resistance electrical connection designed 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.
Maintainable Cable Connection
Maintenance crews can inspect, disconnect or replace the external conductor without drilling another hole or replacing the permanent rail bush.
Consequently, the system simplifies ongoing maintenance and future cable replacement.
Repeatable Installation
Dedicated Cembre drilling equipment, installation mandrels and hydraulic tooling allow operators to follow a controlled and repeatable installation process.
Complete Cembre Rail Connection System
The AR60D forms part of Cembre’s complete rail electrical connection system.
Engineering Supplies supplies:
- Cembre AR rail web electrical contacts
- Cembre battery rail drills
- Cembre rail drilling machines
- CY broach cutters
- VASCO5000 rail drilling coolant
- OG installation mandrels
- Battery hydraulic installation tools
- Manual hydraulic installation tools
- Rail hole checking gauges
- Spare parts and accessories
Furthermore, our experienced team can assist with selecting the correct Cembre rail contact, drilling equipment, mandrel and installation tooling for your rail profile and electrical connection application.
Cembre AR60D Frequently Asked Questions
What size hole does the Cembre AR60D require?
The Cembre AR60D 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 Cembre AR60D?
The AR60D suits 14–16.5 mm rail web thickness.
What size electrical connection does the AR60D use?
The Cembre AR60D uses an M12 electrical connection for attaching the rail bonding cable lug or conductor.
What mandrel installs the Cembre AR60D?
The AR60D requires either the Cembre OG13.2 or OG13.2T installation mandrel together with compatible Cembre hydraulic installation equipment.
What tools can install the Cembre AR60D?
For battery-powered hydraulic installation, use the Cembre B1300TEP-T.
Alternatively, the Cembre HTEP provides a manual hydraulic installation option.
What is the Cembre AR60D used for?
Common applications include:
- Traction return bonding
- Rail continuity bonding
- Railway earthing and grounding
- Signal track circuits
- Substation rail connections
- Electrical drainage
- Track connections
- Rail electrical bonding
Does installation of the AR60D require welding?
No. The Cembre AR60D uses a cold mechanical expansion process, so installation does not require welding or heating of the rail.
Can the cable connection be replaced after installation?
Yes. The permanent electrical bush remains installed within the rail web while maintenance crews can remove or replace the external cable lug and conductor without disturbing the permanent rail interface.
Cembre AR60D Supply and Technical Support in Australia
Engineering Supplies supplies and supports the Cembre AR60D rail web bush connection kit together with the associated Cembre drilling, installation and checking equipment.
In addition, we can assist with:
- Cembre AR60D product supply
- Rail web bush selection
- Cembre rail drilling equipment
- CY190 19 mm rail broach cutters
- AR60D installation mandrels
- Battery and manual hydraulic installation tools
- VASCO5000 rail drill coolant
- Technical product information
- Rail connection product identification
- Complete Cembre rail connection systems
Get a Quote
For pricing, availability or technical assistance with the Cembre AR60D Rail Web Bush Connection Kit, contact Engineering Supplies on (08) 9258 8444 or email sales@engsup.com.au.
Engineering Supplies supplies Cembre railway electrical connection systems, rail drilling equipment, installation tooling and consumables throughout Australia.
