MECHANISATION IN SOUTHERN RAILWAY CONSTRUCTION ORGANISATION

BY

A.K.KHANDELWAL*

SYNOPSIS

“There is tremendous demand for development of infrastructure to meet the need of the growing economy. Southern Railway is having sanctioned work of 2250 KMs New Lines, Gauge Conversion or Doubling at an estimated cost of about ` 9000 Crores. The completion of these works may take 9 to 10 years with the present trend of progress. Southern Railway has taken certain initiatives for mechanizing various activities to accelerate the progress and improve the quality of construction at every stage of construction. This paper is an effort to bring out the efforts made by Southern Railway in this direction” and suggestions for further improving the performance to match with growing demand of infrastructural development.

INTRODUCTION

With the boom in Indian Economy, there is tremendous demand for development of infrastructure to meet the needs of growing economy. Reserve capacity available with Railway System appears to have nearly exhausted. Conventional methods of augmentation of capacity in small increments would simply not meet the traffic demands. There is need to taken up Gauge Conversion, New Line, Doubling & Tripling of Railway Lines over long stretches on fast tract to meet the growing traffic needs to match with the pace of economic growth of the country. Southern Railway is having throw forward sanctioned New Line & Doubling/Tripling to the tune of 2250 KMs at an estimated cost of about `9000 Crores works as on 01-04-2010. * CE/CN/S&RB, Southern Railway, Chennai.

Plan Head Estimated throw forward as on 01.04.2010

(Rs. in Crores)

Length

Gauge Conversion 3009 553.4 + 168 = 721.40 Doubling/Tripling 1662 530.91 + 54 = 584.91 New Line 4298

(30% of total sanction new line works in Indian Railway)

874.83 + 71 = 945.83

Total 8969 2252.14 KM The average physical and financial progress of basic infrastructure works executed by Southern Railway in last five years is showing an encouraging trend of development.

Year Gauge Conversion Doubling New Line Total

Exp. in

other Plan

Heads

Total Exp.

Length (KM)

Exp. (Crs)

Length (KM)

Exp. (Crs)

Length (KM)

Exp. (Crs)

Length (KM)

Exp. (Crs)

Exp. (Crs)

2005-06 48 331 33 72 0 20 81 423 122 545 2006-07 139 535 19 93 0 28 158 656 114 770 2007-08 294 507 0 235 17 57 311 798 88 887 2008-09 161 488 34 299 0 117 195 904 205 1109 2009-10 323 552 110 329 0 158 433 1038

245 1284

The actual financial progress against initial outlay for 3 major plan heads is encouraging. Allotted funds are fully utilized by Southern Railway.

New Line Gauge Conversion

Doubling Total in 3 Plan Head

Total Plan Head / Financial Year

Initial Outlay

Actual spend

Initial Outlay

Actual spend

Initial Outlay

Actual spend

Initial Actual Initial Actual

2005-06 5 20 214 331 126 72 345 423 507 545 2006-07 18 28 187 535 117 93 322 655 449 770 2007-08 62 57 417 485 239 235 718 798 884 887 2008-09 75 117 455 463 335 299 865 904 1170 1172 2009-10 162 158 245 552 232 305 639 1038 922 1284

The Indian Railways expansion of fixed infrastructure and contribution of Southern Railway is also improving in the last years.

New Line Gauge Conversion Doubling Year Indian

Railway Southern Railway

Indian Railway

Southern Railway

Indian Railway

Southern Railway

2005-06 180 - 744 48 231 33 2006-07 250 - 1082 139 386 19 2007-08 156 17 1549 294 426 - 2008-09 357 - 563 161 363 34 2009-10 - - - 323 - 110

The progress of New Lines and Doubling in the Railway is very poor due to problems of Land Acquisition and Earth permits in State of Tamil Nadu and Kerala. However, the actual spending has always been above the outlays in all the previous 5 years. 2. NEED OF THE DAY : MECHANIZATION

Goals for Indian Railways in Vision 2020 are to expand its route net work at the rate of 2500 KM per annum and add 25000 KM New Line, entire net work to be converted to Broad Gauge at the rate of 2500 KM and 1200 KM Doubling per annum. This includes completion of the pending shelf of New Line Projects of 11985 KM and Doubling/Tripling of about 30000 KM of root. Southern Railway is having more than 30% of new line projects sanctioned by Indian Railway. Attenment of vision 2020 goals would call for concerted efforts to multiply the progress 4 to 5 times. The critical mission are, would be mechanization with upgraded technology, development of human capital and a culture of innovation. Conventional methods may not be able to cope up the challenge. There is no possibility of expansion of organization for improved productivity. The organization is likely to shrink and we have to deliver more with reduced size of organization. Southern Railway has taken certain steps to expedite the progress along with improved quality of execution. 3. PROJECT PLANNING & EXECUTION

Capacity augmentation required in vision 2020 in the Southern Railway would not only require massive resources but also call for organizational & project execution challenges of an unprecedented magnitude. Execution of projects on fast track to match with the current standards of project management in the contemporary construction field throws up quite a challenge to the Railway Engineers. Southern Railway has developed and using IPMS for planning & monitoring of works. Action taken and suggestions in various field of activities are discussed here. 3.1. SURVEYS

The Technological up gradation in the field of survey has to be utilized. Satellite mapping and GPS based surveys should be conducted to select a most feasible alignment with alternatives and most economical and alignments with minimum disturbance to public properties can be selected. The Land Acquisition is the key problem in progress of projects. This problem can be minimized by using technology in selecting alignment with minimum disturbance . Southern Railway has made a start and carry out the work with

Bharthidasan University (Govt. of Tamil Nadu) in Tiruchirapalli, using 50 cm remote sensing data and GPS Survey. Best final alignment from alternatives is being decided and land plans along with LPS are prepared for Land acquisition. Setting out of structures, alignment of track etc., are carried out with latest instruments such as digital theodalites, total stations etc. The final location survey tender should also include.

i) All Soil investigations every 500m. ii) Preparation of Land Plan Schedules and coordination

with State Government for Land Acquisition process. iii) Preparation of all Yard Plans and minor sanction details

for yard iv) All GADs of Minor, Major & Road Bridges. v) Design of Bridges, including substructure and

superstructure where ever required duly proof checked by IIT/Recognized Institution etc.,

vi) Index Plan, Index Section. vii) Working Plan, Working Section. viii) Preparation of Estimate. ix) Preparation of Schedules for calling tenders, etc.,

This reduces the involvement and requirement of Railway staff in progress of works. Railway Board has also provided 2% of Project cost for the purpose without sanction of detailed estimate. This should be fully utilized for expediating the progress with minimum available staff. 3.2. LAND ACQUSITION PROBLEMS

Land Acquisition for projects is the major problem in the state

of Tamil Nadu and Kerala in Southern Railway. Most of the projects are badly delayed on this account resulting in cost and time overrun. The Progress & expenditure in Gauge Conversion is always more than the outlays & planning. The Railway is not in position to utilize funds in new line & doubling due to delay & associated problems in Land Acquisition.

The estimate cost of Land Acqusition in the project estimate is kept as per the advice of State Revenue Authorities. The award of State Government at the time of Land Acquisition is many times The Public is also approaching the High Court and Supreme Court for getting the enhancement in award. The Cost of Land in some of the projects has gone even more than the sanctioned cost of the project. The courts are enhancing the compensation upto 120 times.

The details for two projects are as below,

Item SA-KRR (1996 – 97) Sabri – Anganwali (1997-98)

Estimated Cost of project

320.49 Cr 550 Cr

Original provision for Land Acquisition

18.25 Cr 45 Cr

Actual land cost (now) 200 Cr 400 Cr Revised Estimate 712 Cr 1159 Cr CORRECTIVE ACTIONS Railways was submitting only land plans to State Government. The State Revenue Authorities were preparing Village Maps, FMB Sketches and Land Plan Schedules required for Land Acquisition. This was resulting in abnormal delay in Land Acquisition. Southern railway has taken some corrective action to expediate the process of Land Acquisition.

1) Land Acquisition proposal is being submitted along with LPS, Village maps, FMB sketches after fixing Center line pillars and land boundary stones at site based on the Joint Survey with the Revenue Authorities by the Railways.

2) Bi-weekly Coordination meetings with District Collectors

and Revenue Authorities.

3) Monthly Review meetings with Principal Secretary/ Transport, Government of Tamil Nadu and Commissioner of Land Acquisition.

4) Railways is going for private negotiations for urgent

requirement of land in small extants.

5) Counseling and Pre discussions with land owners on appointed date in District Collector office.

CORRECTIVE ACTION SUGGESTED

i. As far as possible land should be provided by State with in fixed time frame of say 1 year to 1 ½ years failing which the project should be dropped and funds should be diverted to other projects.

ii. Land should be acquired by Private Negotiations by the District Collector similar to NHAI to avoid court cases and abnormal enhancement by courts.

iii. Land Acquisition Act should be modified for timely acquisition by paying actual compensation. Adequate funds should be provided in estimate for Land Acquisition.

iv. District level coordination committee should be developed for Land Acquisition with members such as District Collector, Deputy FA&CAO, Deputy Chief Engineer/Land Acquisition.

v. State should provide land for new line projects at their own cost.

3.3. MEGA TENDERS

Southern Railway has gone for Mega Tender to take care of shortage of technical supervisors. Provisions have been made for adequate,

Site Engineers based on the contract value. Quality Control Engineer to supervise the quality control

tests and maintain quality control records. Preparation of all plans, Site investigations for preparing

CRS application. At present ` 40 to ` 100 Crores tenders are being finalized. The value of such tenders for projects should be still higher, may be in the range of `150 to ` 200 Crores or even higher. The project management tools are required to be used by agency for monitoring by the key persons in Railways.

There is a problem of forward planning of funds allotment. In

case Railways go for mega contracts, assured funds allotment will be required to ensure smooth operation of contracts and to avoid disputes.

Southern Railway has made funds flow planning for each

project for completion in time. Unfortunately allotment of funds is not as per the planning and resulting in disputes for mega contracts. 3.4. PLANNING FOR MAJOR AND MINOR BRIDGES

Activity of construction of major bridges should be planned and taken up first in the project. The construction of major bridges is long lead item. Most of the bridges are constructed for water ways situated in Government land. This portion of Government land can be taken over first and major bridges can be started well in advance The progress of major bridges depends on proper planning of foundation based on soil investigation. Pile foundations are being adopted with Rotary Rigs in most of the cases.

Tripod Method Rotary Rigs

The traditional tripod method is able to complete one pile in three days, where as the rotary rigs can complete three piles in a day at almost same cost of work i.e., 9 times faster. We need to adopt these machines for improved quality and faster progress. We are making the use of this equipment essential in the contracts.

The pre-cast pre-tensioned slabs, girders or boxes are planned for major & minor bridges. These can be launched quickly with the cranes to expediate progress. PSC girders upto 40m spans in case of doublings and RUBs have been launched by Southern Railway without any problem. All girders can be casted and kept ready and launched immediately after the substructure works are completed.

Laying pre-cast RCC boxes

Launching of Pre-cast PSC Girders

3.5. PLANNING OF ROB/RUB

Southern Railway is having 202 ROBs sanctioned for elimination of Level Crossing in addition to a large number of other works as part of projects. 35 more ROBs are sponsored by Tamil Nadu State Government and planned in the next year works programme. The physical progress in last 5 years is varying from 6 to 14 Nos per year With the present pace of work, we may require 15 to 20 years to complete the sanctioned works alone. The main reason for delay was non availability of speed restrictions of 20 to 30 Kmph for long duration for the temporary arrangements.

Southern Railway has gone in big way for completing these works and planned for 30 ROBs on existing lines for closer of L.C. in addition to about 40 Nos. in projects. Almost all of these works are being done with composite girders and launching arrangements without lowering of OHE. Slightly longer spans are being used to avoid temporary speed restrictions for foundation works.

Launching of Composite Girder without lowering OHE wires

Works on about 65 ROBs are in progress and 35 are in Tender

finalization stage in Southern Railway to plan completion of 30 to 50 ROBs every year. Works on 20 ROBs in Railway portion is already completed in the current year by October 2010. The Box pushing/Rolling techniques are being adopted for almost all RUB’s to reduce element of longer temporary speed restrictions.

Chennai – Gudur Section 3x 4.47 x3.25 RCC Triple Box Pushing

Box launching in MS – TPJ Section in lieu of LC 187 A

All Level Crossing, Gates are eliminated in New line and being reduced to barest minimum on Gauge Conversion & Doubling projects. Limited Use Subway or normal Height Subways are being provided chargeable to project or after getting sanction in GMs power.These works are being executed along with Doubling and Gauge Conversion projects. ROB are being proposed for Level Crossings passing through yards and middle of the Platforms on cost sharing basis in consultation with State Government for all doubling works. 3.6. FORMATION

The formation must have sufficient bearing strength and stability with reasonable permissible settlement behavior and must provide good drainage for Rain water.

Soil Investigation is carried out at every 500m and all bridges locations. Based on the results, the ground improvement works and blanketing works are being taken up.

GROUND IMPROVEMENT WORKS

If the existing ground/sub grade is not meeting the required standards, the ground improvement works are taken up to improve the ground stability. Southern Railway has taken up ground improvement works by providing prefabricated vertical drains (PVD) at 1.25m interval at Attipattu – Ennore 3rd & 4th line on Ennore creek. Some of the photographs of the same wok are displayed below.

Removal of Slush Prefabricated Vertical Drains

Blanketing

The blanketing work has been started using pug mills for mechanized blending of different materials to get the required properties for quality blanketing work on various projects. The works on Manamadurai – Virudhunagar and Dindugal – Palani sections are in progress. The output of each plant is about 400- 500 m3 per day and work is being done successfully.

Preparation of blanketing material

Blanketing

Geotextiles, biaxial geogrid, tri axial geogrid and geo cells are planned for reduction of blanketing layers at identified locations in Gauge Conversion projects to improve the stability, drainage and reduce blanketing thickness.

Geotextiles

Vibratory rollers of higher capacity of 19 t can be used to achieve required compaction. Greave Cotters limited has launched heaviest single drum Vibratory Compactor BW 219 D-4 at Gummidipundi factory outlet in Tamil Nadu. This has compaction capacity ranging from 960 to 1440 m3 per hour and capable of compacting layer thickness up to 1.0 m to achieve required density. This may be ultimate choice for faster progress.

10 T Vibratory Rollers 19T Vibratory Roller

Small Vibratory Compactors are also used for widening of banks and platform etc. in the projects to achieve good compaction.

Formation Compaction Hand Compactor Platform Compaction

Adequate number of dozers and water sprinklers are used for getting uniform layers and optimums moisture content.

Water Sprinkler Dozer Grader is used extensively to provide cross slopes of top of formation.

Grader in work 3.7 PLANNING OF YARD WORKS

This is one of the most important activities in the project planning process and requires very close co-ordination at Divisional and Headquarters level. The yard grades, curves, structures within yard and approaches should be able to accommodate future needs of operations, doubling and RE requirements. This is being decided by calling a meeting of all Divisional and Headquarters officers for each project at a time to avoid delays. 3.8 PLANNING FOR S&T WORKS

It is an important area calling attention right in the beginning of the project. All Yard P.Way plans are decided in the Joint meetings within a month time for the projects. S&T accommodation are constructed on top priority. The Yard earth work and linking is carried out before mid section works, so as to give adequate time to S&T department to complete their work by the time mid section linking is completed. 3.9 PLANNING FOR ELECTRICAL WORKS

Electrical works should also be planned along with the start of the project. Power line crossings should be listed out at the time of Final Location survey work and a separate survey shall be conducted at each of those power line crossings to arrive at the arrangements required for shifting them. The concerned state electricity authorities shall be approached for shifting of HT lines, electrical poles, transformers etc will in advance to avoid delays. These activities are some time becomes most critical if due case is not taken at appropriate time like SA – KRR project started in 1997 – 1998 but power line crossings are not completed so far resulting in delay in completion of related works.

Railway Electrification authorities should also be consulted for required facilities for electrification of line to avoid difficulties at later stage. All requirements shall be incorporated in the planning. 3.10 PLANNING OF OTHER INFRASTRUCTURE FOR OPEN LINE

Requirements of user division and operating department should be incorporated in the project planning and execution. GAD’s of Station Buildings, FOB, OH tower, sheds etc shall be got prepared and submitted to user division for approval, along with yard P.way plans. The Headquarters of various maintenance officials along with staff quarters should be planned & executed in consultation with divisions and Zonal Railways. Adequate water supply arrangements should also be ensured. 3.11 COLLECTION & HANDLING OF BALLAST

Machine crushed ballast duly phasing out hand broken ballast, is collected along side the track as per land availability. About 25% of Ballast is collected in depot to truck out with hoppers or ballast lorries at required locations. In addition, mini depots are created nearby the LCs for loading, leading and dumping using rail lorries with shorter lead. Ballast is spreaded and compacted with rollers before placing sleepers. Track linking is carried out on 200 to 250 mm compacted ballast beds. The Cushion is improved to 300/350mm in 3 tamping’s

Compaction of ballast Ballast Lorries 4 TRACK LINKING There is a need to adopt mechanized improved methods for linking in place of conventional method to improve quality & productivity IRICEN suggested methods, in addition to PQRS, can be adopted.

Southern Railway is carrying out most of the linking including new lines with service rails and subsequesntly TRR is being done with 10/20 Rail Panels. Free rail joints are also welded with Mobile Flash Butt Welding plant. The provision of Mobile Flash Butt Welding is also kept in the linking contracts to avoid problems of interdependency of agencies.

Mobile Flash Butt Welding Units

Yard remodeling works are done using multiple number of T-28 machines for improved quality of work. All joints are provided gapless in points and crossing. Two points are laid in each block to optimize traffic block utilization and reduce N.I. time.

Insertion of Points and Crossings byT-28 Machines.

In situ Glued Joint is being used in place of pre-fabricated to reduce number of SKV welds in the track.

In Situ Glued Joints

Most of the conventional platform aprons executed in the past are cracking in 4-5 years and leading to 30 Kmph speed restriction. Southern Railway Construction wing has decided to carry out RHEDA 2000. RCC aprons to avoid cracking and permanent speed restrictions on main lines.

RHEDA 2000 at Melmaruvattur CONCLUSIONS 1. Attenment of the Goals set out in mission 2020 for infrastructural development would call for concerted action for technology development by innovative methods. Mechanization is key to achieve improved quality and productivity. 2. Capacity bottleneck and network expansion works of New Line, Doubling/Quadrupling, Gauge Conversion works should be prioritized. Adequate funds/outlays as per forward planning should be ensured for the priority projects to complete them as per the planning and achieve required benefits out of it. 3. Outlays in Gauge Conversion are over spent every year. The progress of doubling and new line is badly affected due to Land Acquisition problem. The Land Acquisition is very difficult with the present process. The policy need to be reviewed to go some where near mission 2020 planning. The land must be provided by State within period of 1 year of requisition. 4. The funds flow planning for next 3 years should be indicated to plan the work accordingly in mega contracts system to avoid disputes. Adequate BG should be given in place of allotting funds at Revised Estimate stage for smooth progress.

5. Realistic initial estimates should be prepared and allowed as per the policy of Land Acquisition, elimination of Level Crossing and provision of blanketing. 6. General Arrangement Drawings, Plans & Designs should be completed at the time of Final Location Survey to avoid delays and dispute at the time of execution of contracts. 7. Issue of earth permits is causing abnormal delays in project execution in Tamil Nadu and Kerala. Railways should be exempted from permit system. Most of the cost and time over run are basically due to limited annual outlays provided for the projects initially and also due to delays in issue of Earth permits & Land Acquisition. These issues are to be addressed along with mechanization in track laying to improve the performance and productivity to match requirement of Vision 2020.