chapter 3 rail pway manual

7/24/2019 Chapter 3 Rail Pway Manual

1/27

CHAPTER III

PERMANENT WAY RENEWALS

301. Classification of Renewals -(1) All track renewals can be classified generally into

one of the following categories :

(1) Complete Track Renewal (Primary) abbreviated as CTR(P)

(!) Complete Track Renewal ("econdary) abbreviated as CTR(")

(#) Thro$gh Rail Renewal (Primary) abbreviated as TRR(P)

(%) Thro$gh Rail Renewal ("econdary) abbreviated as TRR (")

(&) Thro$gh "leeper Renewal (Primary) abbreviated as T"R (P)

(') Thro$gh "leeper Renewal ("econdary) abbreviated as T"R (")

() Cas$al Renewals

() Thro$gh T$rn*o$t renewal (TTR)

(+) Thro$gh ,itting renewal (T,R)

(1-) Thro$gh .eld renewal (T.R)

(11) Thro$gh /ridge timber renewal (T/TR)

(1!) "cattered renewal

(!) Primary renewals are those where only new materials are $sed and secondary renewalsare those where released serviceable materials are $sed

(#) "cattered Renewal* 0n this case $nserviceable rails sleepers and fastenings are

replaced by identical sections of serviceable and nearly the same vintage track componentsThese are carried o$t in isolated locations and not more than 1- rails and2or !&- sleepers in

a gang beat in a year "$ch renewals are a part of normal maintenance operations

(%) Cas$al Renewal* 0n this case $nserviceable rails sleepers and fastenings are replacedby identical sections of serviceable and nearly the same vintage or new track components

These are carried o$t in isolated locations of contin$o$s b$t small stretches "$ch renewalsare not a part of normal maintenance operations and cannot be covered $nder scattered

renewals

30. !acto"s #o$e"nin% Pe"&anent Wa' Renewal

(1) Criteria for Rail Renewal * The following are to be considered in connection with the

criteria of rail renewals :*

3 0ncidence of rail fract$res2fail$res

3 .ear on rails


2/27

3 4aintainability of track to prescribed standards

3 56pected service life in terms of 7ross million terms carried

3 Plan based renewals

(a) 0ncidence of Rail ,ract$res2,ail$res * A spate of rail fract$res on a partic$lar sectionshaving & withdrawals of rails per 1- km in a year d$e to fract$re and2or rail flaws detected$ltrasonically falling in the category of 04R 8 R54 will have priority while deciding rail

renewals 0n case the rail fail$res at fish*plated2welded 9oints are pre*dominant end

cropping with or witho$t welding co$ld be considered

(b) .ear on Rails * (i) imiting oss of "ection*The limiting loss in rail section as a criterionfor recommending rail renewals shall be as $nder:

7aige Rail "ectionoss in "ection in

percentage

/ 7 &! ;g 2 metre '

+- R &47 & R %!

'- R #!&

Rail wear may be determined by act$al weighment taking rail profiles at ends after $nfitting

9oints and taking rail profiles with special profile meas$ring gadgets

(ii) .ear d$e to corrosion * Corrosion beyond 1& mm in the web and foot may be taken asthe criterion for wear d$e to corrosion 56istence of the localised corrosion s$ch as corrosion

pits specially on the $nderside of the foot acting as stress raisers from the origin of fatig$ecracks and wo$ld necessitate renewals

(iii)


3/27

A typical profile showing the meas$re of vertical wear of the rail is given below :

A> 8 >/>

Ro$tes mm

7ro$p >C> 8 >?>

Ro$tes1- mm

7ro$p >@> 8 >R>

Ro$tes+ mm

4 7 7ro$p >A> 8 >/> ' mm


4/27

Ro$tes

7ro$p >C> 8 >?>Ro$tes

mm

"traight

/ 7 >@> Ro$tes ' mm

4 7 >R> Ro$tes mm

A typical profile of the worn rail showing the meas$rement of lateral wear is shown asbelow

ateral wear is to be meas$red at 1# to 1& mm below the rail top table .orn rail profilesho$ld be recorded and s$perimposed over new rail profile to find o$t the lateral wear

(c) 4aintainability of track to prescribed standards *

(i) There may be cases where renewals may be necessary on the following considerations

vi=

(1) Poor r$nning $ality of track in spite of e6tra maintenance labo$r engaged for

maintaining the same

(!) ?isproportionate cost of maintaining the portion of track in safe condition

(ii) The condition of rails with regard to hogging2battering scabbing and wheel b$rns and

other conditions s$ch as e6cessive corr$gation of rail as can be ascertained by vis$alinspections which affects the r$nning $ality of track and make the track maintenance

diffic$lt and $neconomical sho$ld be taken into acco$nt while proposing renewals

(iii) Renewals of rail d$e to hogged and battered rails ends sho$ld be considered only ifother remedies have not been fo$nd to be effective

(d) Renewals on consideration of service life in terms of total 74T of traffic carried *The

rail shall be planned for thro$gh renewal after it has carried the minim$m total traffic asshown below *

#a)%e Rail Section Total #.M.T.ca""ie+ fo" T.1

Me+. Man%anese"ails

Total #MT ca""ie+fo" ,0 TS "ails

/ 7 60 kg/m 550 800


5/27

&!kg2m #&- &!&

+- R !&- #&

4 7& R 1&-

'-R 1!&

(e) * The service life in terms of total 74T of traffic carried for considering thro$gh railrenewal on the bridge proper and in approaches ($pto 1-- m on either side) for all theimportant brides and s$ch of the ma9or bridges where height of bank is in e6cess of %- m

all t$nnels and their approaches ($pto 1-- m on either side) shall be half of the 74Tspecified in Pa"a 30 1/+/ above

The released P way material shall be dealt with in accordance with Pa"a 30 of IRPWM.

(f) Plan based Renewals* Renewals to predetermined plan with the ob9ective of modernising

the track str$ct$re on selected ro$tes in the $ickest possible time may be planned even ifit involves premat$re renewals

(!) "econdary Rail Renewals * (a) 0n the case of "econdary Renewals if the condition of rail

is satisfactory it is a good practice to crop the rail ends and weld them into ".R and $sethem in lesser important lines The rails sho$ld be $ltrasonically tested before $se

(b) /$ilding $p of chipped rail ends by welding will also improve the service life

(c) The rails released from primary relaying and not fit for $se in secondary relaying sho$ld

be $sed in sidings

(#) Criteria for Renewal of "leepers *7enerally a sleeper is serviceable if it can hold ga$ge

provide satisfactory rail seat and permit rail fastenings being maintained in tight conditionand retain the packing $nderneath the sleepers "$ch sleepers that are not likely to f$lfill

the above f$nctions even after reconditioning sho$ld be renewed .here re*sleepering only

is 9$stified this sho$ld be carried o$t in contin$o$s stretches the released serviceablesleepers being $tilised for cas$al renewals elsewhere The conditions indicative for the need

for renewal of sleepers are given in Para !%&(!) in case of wooden sleepers and inparas!%'(1) and !%(1) in the case of cast iron and steel tro$gh sleepers respectively

Bn girder bridges when several sleepers are defective renewals sho$ld be carried o$t for

the f$ll span the released serviceable sleepers being $sed for cas$al renewals on the otherspans /efore re$sing the sleepers they sho$ld be reconditioned

303. Plannin% of Renewals * Renewals may be planned in as long and contin$o$s lengths

as practicable within the available reso$rces with priorities to meet the pro9ected traffic"hort isolated stretches of 1- kms and less not d$e for renewal on condition basis may be

programmed along with the ad9oining lengths if these stretches do not confirm to the

re$ired standards Priority in planning renewals sho$ld be given to b$sy and importantlines

Track renewal programmes shall be framed by the Chief 5ngineer of each Railway takinginto consideration the proposals s$bmitted by the ?ivisional 5ngineers

30. T"ac* Renewal P"o%"a&&e*(1) 0nitiation of Proposals * Track renewal proposals

are s$bmitted to the ?ivisional 5ngineer by the Assistant 5ngineer on condition basis andalso on the basis of vario$s inspections carried o$t d$ring the year The ?ivisional 5ngineer


6/27

shall personally check the details s$bmitted by the Assistant 5ngineers at site and compileand initiate the track renewal programme indicating the priorities The 9$stification for track

works shall be prepared on the basis of fact$ally correct data and s$bmitted in proformagiven at Anne)"e 321.0t shall incl$de an abstract estimate of the cost of work and

detailed narrative 9$stification covering technical and financial aspects The ?ivisional5ngineer sho$ld personally satisfy himself abo$t the reasonableness of the proposal and

certify that the 9$stification f$rnished is fact$ally correct The Assistant 5ngineer sho$ldkeep a close watch on the condition of all track on their s$b*divisions so that every lengthwhich after caref$l and 9$dicio$s e6amination re$ires renewal is incl$ded in the proposals

bearing in mind that the programme is prepared a year in advance and as m$ch as two

years may elapse before renewals are carried o$t The proposals sho$ld reach the Chief5ngineer>s Bffice by end of 4arch

(!) s Bffice * 0mportant

items relating to complete track renewal thro$gh sleeper renewal or thro$gh rail renewalshall be test checked by the nominated administrative officer of the ead$arters who will *

(a) Co*ordinate the proposals received from the divisionsD

(b) ,rame programmes for renewal taking into acco$nt the sections planned for renewalD

(c) ?ecide priority for the worksD

(d) "atisfy himself that the renewal is $navoidable in the case of track renewal proposals

which are 9$stified primarily on condition basis b$t are premat$re as far as $ant$m oftraffic carried (74T) is concerned andD

(e) ,inalise the track renewal programme and s$bmit the same to the Chief Track

5ngineer2Chief 5ngineer for his approval Bn receipt of Railway /oard>s sanction to the trackrenewal programme arrangements will be made by the ead$arters for s$pply of track

materials to the ?ivisions and for coordinated e6ec$tion and control over the works

30. T"ac* Stan+a"+s fo" Renewals -

(1) Rails *The recommended section of rail to be adopted for track renewals shall be inaccordance with Pa"a 4/

(!) "leepers and ,astenings * The recommended types of sleepers and fastenings to be

adopted for track renewals sho$ld be as given below

(1) All primary renewals in f$t$re shall be carried o$t with '-*kg PRC sleepers

(ii) PRC or "T sleepers may be $sed on loop lines and private sidings

(iii) "T sleepers $sed on loop lines and private sidings may be with elastic or rigidfastenings

(iv) All renewals on 4etre 7a$ge shall be with concrete steel and C"T*+ sleepers (new orsecond hand)

(#) "leeper ?ensity and "leeper "pacing *"leeper density for vario$s gro$ps on /road7a$ge and 4etre 7a$ge will be in accordance with5a"a /.

The spacing of sleepers for /road 7a$ge and 4etre 7a$ge shall be in accordance with the


7/27

provisions in para !%%(!)

As far as possible in metal sleepered road wooden sleepers sho$ld be provided at 9oints

(%) /allast "ection * The ballast section to be adopted sho$ld confirm to the standards laiddown in 5a"a 63.

306. Plannin% fo" 5ostin% of staff an+ ot7e" facilities -(1) "pecial Permanent .ay0nspectors with clerical staff at the e6ec$tive and office levels as provided in the estimates

shall be posted in good time Provision of ga=etted staff may be made in the estimate in the

case of large scale permanent way renewals according to the yard sticks laid down

(!) The Permanent .ay 0nspector in*charge of track renewal will take over the maintenanceof s$itable lengths of the section to be relaid a few days in advance of the act$al

commencement of the work e will be responsible for its maintenance till the section ishanded over to the maintenance Permanent .ay 0nspector after completion of the work

(#) 56perienced labo$r shall be recr$ited for relaying works which sho$ld be so programmed

that gangs move from one work to the ne6t .atchman for materials at site and at depots

sho$ld be appointed .atchman sho$ld be drawn from the permanent gangs and res$ltantvacancies filled by cas$al labo$r

(%) The "pecial Permanent .ay 0nspector shall make all arrangements for the training o$tof materials selection of camp sites ho$sing of labo$r with re$isite amenities s$ch as

water s$pply drainage etc A f$lly e$ipped ,irst Aid /o6 sho$ld be kept at the site of workabo$r camp sho$ld be so located that men are not re$ired to walk a long distance to

reach the site of work

308. T"affic facilities fo" Renewals * (1) 0n the case of big relaying works additionalsidings as necessary sho$ld be provided at the depots for receipt and dispatch of materials

(!) Arrangements for special rakes for movement of rails and sleepers sho$ld be made bythe ?ivisional 5ngineer in cons$ltation with the Bperating ?epartment .here necessary

separate power and crew sho$ld be arranged Provision of 5ngineering time allowance in theworking time table sho$ld be arranged with the Traffic ?epartment

(#) Traffic blocks may be necessary depending on the method of relaying adopted 0n s$ch

cases the ?ivisional 5ngineer m$st give ade$ate notice to the Bperating ?epartment

before framing of the time table for the period d$ring which the track renewal work will becarried o$t "$ch information is $sef$l to the Bperating ?epartment in framing the time

table and making the re$ired time available by reg$lating certain trains as necessary 0ncase of any diffic$lty the ?ivisional 5ngineer sho$ld refer the matter to the Chief 5ngineer

who will arrange for the re$ired blocks in cons$ltation with the Chief Bperating"$perintendent A minim$m block of ! to # ho$rs d$ration is necessary where renewal

works are carried o$t man$ally 0n the case of mechanical relaying a minim$m block of% ho$rs is desirable

(%) .hen work is being carried o$t between trains in a location from where the 0nspectors*

in*charge cannot readily comm$nicate with the "tation 4aster at either side of the blocksection a field telephone on controlled sections may be installed in order to permit of

every s$itable interval between trains being $tilised

(&) The ?ivisional 5ngineers in cons$ltation with the Bperating ?epartment Bfficers sho$ld


8/27

manage to carry o$t permanent way renewals with the minim$m obstr$ction and detentionto traffic

.henever possible the following arrangements sho$ld be made in cons$ltation with the

Bperating ?epartment:

(a) Bn do$ble line the traffic of both lines may be worked over the $naffected line $nderthe E"ingle line*workingE reg$lations

(b) 0f there are triple or more lines two lines may be worked as the $p line and the down

line respectively s$b9ect to compliance with single line working reg$lations in respect of theline over which trains r$n in a direction contrary to the normal $sage of that line

(') Arrangements sho$ld be made for *

(a) Fotification by the Bperating ?epartment a$thorising 5ngineering ?epartment to

$ndertake the work

(b) 0mposition of blocks and protection by temporary 5ngineering fi6ed signals

(c) 0ss$e of ca$tion orders to ?rivers by "tation 4asters on daily advice of act$alkilometrages received from the 0nspector*in*charge of the work

304. S5ee+ Rest"ictions* The speed restrictions to be imposed d$ring vario$s se$ences

of work are given in Table 0 and 00 which are as shown below:

Ta9le 1

:"oa+ an+ Met"e #a)%e - Man)al Pac*in%

Ta9le II

:"oa+ #a)%e - Mac7ine Pac*in%


9/27

Note: The work of Track renewals on do$ble line sho$ld normally proceed in the direction

opposite to Traffic30, A. P"o;ect "e5o"t fo" t"ac* "enewal wo"*s: "ystematic and metic$lo$s planning forvario$s items of e6ec$tion of track works is essential for achieving $ality economy and

timely completion of works ,or every sanctioned track work eg CTR T"R TRR deepscreening bridge timber renewal etc a detailed pro9ect report sho$ld be prepared The

report sho$ld inter alia cover the following aspects:

(i) ?etails of .ork* Pink book detail scope of work locational details cost and estimatepartic$lars etc

(ii) 56isting track str$ct$re * 0nventory of e6isting track str$ct$re incl$ding the rails

sleepers fittings ballast $antity2deficiency in track type width of formation and otherdetails sho$ld be taken as prescribed in P .ay diagram details of level crossings bridges

electrical fittings c$rves height of bank2c$ttings yards sidings etc

(iii) Classification of track materials * ?$ring inventory of the e6isting track str$ct$re by foot

by foot s$rvey identification classification and colo$r making of e6isting track materials as

second hand and scrap wo$ld be done as provided in Pa"a 30 of0RP.4 The classificationsho$ld be approved by the competent a$thority Action plan for stacking2 storage and

disposal of the released materials sho$ld be clearly indicated 0nventory of e6istingtrack materials wo$ld normally be prepared 9ointly by the P.0 of the section and the P.0

("pl) for the renewal

(iv) Proposed track str$ct$re * The proposed P .ay diagram of the affected length sho$ldbe prepared in the same format as done for the e6isting track str$ct$re and incorporated in

the pro9ect report

(v) 56isting2proposed gradient profile * The levels of e6isting track sho$ld be taken at every!- meters and a gradient diagram prepared 0ntrod$ction of vertical c$rves sho$ld be

critically e6amined and the proposed profile of track shown in red line indicating theproposed grades owering of track sho$ld be avoided Precise lift of track at girder bridges

sho$ld be worked o$t and a separate scheme developed for lifting of girders on each ofthe affected bridges "imilarly the magnit$de of lifting at level crossing sho$ld be worked

o$t and indicated in the report Care sho$ld be e6ercised to keep the road s$rface in one


10/27

level on level crossings spanning to across m$ltiple tracks This may re$ire regarding ofad9acent lines too

(vi) Realignment of c$rves * All c$rves sho$ld be meas$red afresh and slews worked o$t for

realignment wherever necessary keeping the obligatory points in view

(vii) 4ethod of e6ec$tion * The work sho$ld be e6ec$ted Ebottom $pwardsE ie se$ence ofe6ec$tion of works will be in the following order *

,ormation G /allast G "leepers G Rails

viii) ,ormation:

(a) Repair and widening of cess: The pro9ect report sho$ld indicate the re$irement of and

plan for widening of formation in both banks and c$ttings wherever necessary Provision ofproper drains in c$ttings sho$ld also be planned

(b) ,ormation treatment: Areas needing formation rehabilitation sho$ld be identified and a

st$dy for possible sol$tions and method of e6ec$tion of the rehabilitation scheme sho$ldform part of the pro9ect report

(i6) /allast * The re$irement indicating bif$rcation of cess s$pply and depot s$pply and the

so$rce and means of each sho$ld be spelt o$t clearly 4ode of providing ballast c$shion iedeep screening or raising sho$ld be identified along with sketches of cross sections present

and proposed "leeper renewal wo$ld normally not be started $nless ade$atearrangements for s$pply of ballast have been made

(6) Transportation of P .ay materials * The mode of transportation for vario$s track

components and $nloading of rails and sleepers in partic$lar at the work sites sho$ld beindicated in the pro9ect report

(6i) .elding *The complete details of welding re$irements the arrangements need to be

made for its e6ec$tion whether departmentally or thro$gh contract sho$ld be clearly

indicated in the report

(6ii) Renewal of t$rno$ts bridge timbers etc *The pro9ect report sho$ld cover the complete

details of t$rno$ts bridge timbers level crossings etc where renewal is to be carried o$t.hether t$rno$ts are to be laid man$ally or by mechani=ed means sho$ld be clearly

bro$ght o$t indicating the arrangements made The report sho$ld also incl$de the modeand agency for overha$ling and relaying and making $p of road s$rface at the level

crossings

(6iii) Hse of machines * The re$irement of machines for renewal (if machanised renewal isplanned) deep screening ( if mechani=ed deep screening is planned) and tamping2stabili=ing

and the d$ration for which the machines are re$ired sho$ld be indicated The machines

that wo$ld be deployed sho$ld be identified and staff nominated The planning for repair ofmachines at the works site s$pply of f$el and other cons$mables sho$ld be plannedThe re$irement of additional lines in the e6isting yards for making base depot and

arrangements made for the same sho$ld be indicated in the report

(6iv) Contracts * The contracts that are re$ired to be entered into for vario$s activities ofworks and the activities which are to be done departmentally sho$ld be spelt o$t The

planning for deployment of staff2s$pervisors for e6ec$tion at vario$s activities sho$ld beindicated


11/27

(6v) 4aterial Planning * The material re$irement sho$ld indicate the materials to be

arranged by the head$arters and by the ?ivisions Against each material the propernomenclat$re and drawing n$mber sho$ld be indicated Rails nos and si=es (incl$ding lead

rails check rails etc) sleepers (incl$ding specials) rails and sleeper fastenings switchesand crossings level crossing and bridge sleepers and fittings etc sho$ld be f$lly

covered The consignee partic$lars and the destination the mode of transport sho$ld alsobe indicated

(6vi) 4anpower Planning *The re$irement of manpower incl$ding the officers s$pervisors

artisan and other staff sho$ld be worked o$t with min$te details The arrangements madefor camping of these officials and mobili=ation sho$ld be reflected in the report

(6vii) .R2C.R plans * ,or welding of rails into .R2C.R the .R plan sho$ld be got

approved by the competent a$thority in advance "$ch plan sho$ld form part of the pro9ectreports

(6viii) Re$irement of speed restrictions traffic blocks and other material train * Planning

for e6ec$tion of track renewal works sho$ld be s$ch that the time loss on acco$nt of speed

restriction is minimal and is within the permissible limits The report sho$ld indicatere$irement of speed restrictions and traffic blocks together with d$ration The corridor forblocks is re$ired to be planned in cons$ltation with the Bperating ?epartment

and accordingly reflected in the report after obtaining the approval of ?R4 Arrangementsmade for vario$s types of wagons for transportation of ballast sleepers etc together with

re$irement of locomotives sho$ld be indicated in the report in cons$ltation with "r ?B4and with the approval of ?R4

(6i6) 4onitoring mechanism * The list of all activities involved and the time estimation for

each activity sho$ld be worked o$t These activities sho$ld be se$enced and co*related inlogical manner and network diagram prepared $sing CP4 method The critical activities

sho$ld th$s be identified These sho$ld form part of the pro9ect report

(66) The detailed pro9ect report covering the vario$s points as mentioned above sho$ld be

prepared as soon as the approval of /oard to incl$de the works in ,.P is conveyed to theRailways These reports sho$ld be s$bmitted to head$arters for scr$tiny and approval

30, :. P"eli&ina"' Wo"*s -(1) /allast re$ired for making good possible deficiency in

c$shion d$e to deep screening sho$ld be $nloaded on both sides of the track opposite to the

place where it is act$ally re$ired 0t sho$ld be p$lled back on the cess so as not to permitits admi6t$re with $nscreened ballast .here complete track renewal or thro$gh sleeper

renewal is planned deep screening of ballast sho$ld also be planned and e6ec$ted Theprogress of deep screening sho$ld match with the progress of renewals and sho$ld precede

complete track renewal or thro$gh sleeper renewal by a co$ple of days 0n the case of .Rtrack the additional re$irement of ballast for the e6tra profile sho$ld also be ens$red

(!) Treatment of bad formation sho$ld be carried o$t in advance of the relaying

(#) Center line and level pegs made o$t of scrap tie bars as also the pegs for realignment of

c$rves sho$ld be fi6ed before hand .here necessary c$rves sho$ld be realigned andtransitioned onger transitions sho$ld be provided to cater for f$t$re increase in speed

wherever possible 0n case heavy slewing is necessary for providing longer transitionscentre line pegs indicating revised alignments sho$ld be fi6ed and new track laid

accordingly The formation sho$ld be s$itably widened


12/27

(%) Bn sections where creep is noticeable 9oints sho$ld be s$ared and gaps rectified forshort length at the point of commencement

(&) .here wooden sleepers are $sed ad=ing a$g$ring end binding etc sho$ld be done

s$fficiently in advance of the daily re$irements 0n the case of C"T + sleepers and twoblock concrete sleepers tie bars sho$ld be given a coat of coal tar before laying The

$nderside of bearing plates sho$ld be treated with black oil before re*$se A few e6tra boltsn$ts keys spikes rail screws etc sho$ld be arranged

(') As a preliminary meas$re the Permanent .ay 0nspector sho$ld act$ally mark o$t the

position of the new rail 9oints with a tape The lengths marked o$t sho$ld be the length ofthe new rail together with one e6pansion space Bn a c$rve the rail lengths sho$ld be set

o$t along each rail starting from a point on the straight where the sites of the two 9ointshave been set o$t opposite one another by means of s$are The s$are sho$ld be $sed at

each 9oint on the c$rve to determine the amo$nt by which the inner rails gaining over theo$ter rail As soon as the lead of the inner rail is e$al to half the distance between fish bolt

holes a length shall be sawn off the end of the rail e$al to the f$ll distance and a new fishbolt hole drilled The length of c$t rails varies according to the degree of each c$rve and

sho$ld be determined before handD a c$t rail will be re$ired after every two or three or

fo$r f$ll length rails depending on the c$rvat$re

() "$fficient track ga$ges ga$ge*c$m*levels spanners keying and spiking hammers

a$g$rs crow bars tommy bars claw bars grip ga$ges cotter splitters beaters ballastrakes wire claws forks wire br$shes ballast screens mortar pans screening baskets

shovels powrahs rail thermometers e6pansion liners slotted fish*plates rail clos$rescombination fish*plates wooden blocks and wedges and all tools and e$ipment necessary

for efficient e6ec$tion of work incl$ding that for rail c$tting and rail drilling and mechanicaltampers where $sed sho$ld be arranged by the Permanent .ay 0nspector in advance

/efore starting and d$ring the co$rse of work the track ga$ges and the ga$ge*c$m*levelssho$ld be checked periodically for their acc$racy

() abo$r sho$ld be properly organi=ed and s$itably distrib$ted to ens$re ma6im$mefficiency

(+) /efore carrying o$t track renewal work in electrified areas s$fficient notice sho$ld be

given to the 5lectrical Traction ?istrib$tion ?epartment so that they can arrange forad9$stment of overhead wires to conform to the new alignment and level They will also

arrange for bonding the new track 0n track circ$ited sections and in yards where change in

yard layo$t is contemplated notice sho$ld be given to the "ignaling ?epartment forgetting assistance in e6ec$ting 9oint works Advance Fotice as laid down by the respective

railway sho$ld be given to the Bperating ?epartment of the act$al commencement of workby the Permanent .ay 0nspector for sending advice to all concerned The safety of traffic is

of paramo$nt consideration

310. nloa+in% of Rails< Slee5e"s an+ !astenin%s -(1) 0t sho$ld be ens$red thatmaterials are $nloaded fairly opposite to the position where they are to be laid Care sho$ld

be taken to avoid $nloading of materials in e6cess of the act$al re$irement so as to avoiddo$ble handling

(!) Htmost care sho$ld be e6ercised in $nloading rails Ramps made of $nserviceable rails

sho$ld be $sed for $nloading "hort welded panels as well as rail panels for laying weldedrails may be $nloaded by Eend*off*loadingE method wherever possible


13/27

(#) The $nloaded panels sho$ld be caref$lly stacked on a level base care being taken toprevent formation of kinks ,lat footed rails as a r$le sho$ld rest on the foot Any

carelessness in $nloading and stacking is liable to ca$se irreparable damage res$lting inbad r$nning .hile carrying rails they sho$ld be s$pported at several places by rail tongs or

rail slings Carrying of rails and heavy articles on the head or sho$lder sho$ld be avoided;inked rails m$st be Iim*crowed and straightened P$nch marks on rails or marking by

chisel sho$ld be prohibited as these ca$se incipient fail$res

(%) Few rails sho$ld be $nloaded on one side of the track preferably on the cess leaving the

other side free for stacking released rails Care sho$ld be taken not to $nload rails and C0

sleepers one over the other as this practice ca$ses bending of rails and breakage of C0sleepers

(&) Few rails and sleepers for the ne6t day>s work sho$ld be ha$led from the place of

$nloading to opposite to the place where they are to be laid

(') 4aterial new or old lying along side the track is always a potential so$rce of danger andefforts sho$ld be made to keep the $antity down as low as possible

311. Met7o+s of ca""'in% o)t "enewal -Complete track renewal is carried o$t by any oneof the following methods :*

(1) .ith mechanical e$ipment

(!) Complete dismantling of old track and relaying with new track (man$al)

(#) Piecemeal method in which resleepering and rerailing are carried o$t separately

?etailed instr$ctions shall be iss$ed by the Assistant 5ngineer regarding the method ofrelaying which depends on the site conditions

31. Rela'in% wit7 &ec7anical e=)i5&ent-This method sho$ld be adopted whilecarrying o$t track renewals with concrete sleepers as the man$al handling of concrete

sleepers is diffic$lt and may ca$se damage to the sleepers 0t can be $sed with advantagefor carrying o$t relayings with other types of sleepers also

The preliminary (preparatory) work prior to relaying at site the act$al relaying process at

site and the post relaying operations are described in detail in Pa"as 10 an+ 106.

313. Co&5lete Rela'in% Met7o+ Man)al/ -

(1) Preparatory .ork before /lock Period *

(a) Track sho$ld be deep screened one or two days in advance of the relaying as described

in Para !# The ballast section sho$ld be made $p $pto bottom of sleeper to facilitaterelaying The balance $antity of screened ballast sho$ld be stacked on the section for $se

after relaying

(b) work is carried o$t $nder block protection

(c) A speed restriction of !- ;m p h is imposed at the site of work Temporary fi6ed5ngineering signals are erected at appropriate places


14/27

(d) ,ish bolts are oiled and eased one day in advance of the act$al block day

(e) A co$ple of ho$rs before the act$al operation of the block the o$ter fish bolts of each9oint and fastenings of alternate sleepers are removed

(!) .ork d$ring the /lock Period *

(a) ?ismantling of old track*0mmediately after the commencement of the block theremaining fish and fastenings are removed To prevent loss care sho$ld be taken to screw

the n$ts of released fish bolts on to those bolts immediately after they are removed from

fish*plates The old track is dismantled and released materials are removed on one side ofthe line opposite to where the new materials have been $nloaded d$e care being taken not

to dist$rb the center line and level pegs /allast in the sleeper bed is then leveled

(b) inking Few Track * (i) Few sleepers are spread o$t to correct spacing with the help oftapes2 spacing rods on which the sleeper spacing is marked The new rails are then linked

over the sleepers $sing correct e6pansion liners giving correct e6pansion gaps

(ii) Bnly two bolts per 9oint are p$t and tightened lightly The rails are then straightened $p

and ro$ghly aligned and the sleepers ad9$sted to the correct spacing as per making on thenew rails They keys and spikes are then fi6ed to the rails 0t is essential that the base rail isaligned first and fi6ed in position before the other rail is linked to correct ga$ge

(iii) aving reached the predetermined length of track in the above manner rail clos$res

sho$ld be inserted to connect the new track with the old track Combination fish*platessho$ld be $sed where necessary The track is then lifted and packed The traffic block is

cleared and the traffic passed at a restricted speed of !- ;m p h after ens$ring that allsleepers are s$pported by initial packing

(iv) .hile renewals are being carried o$t advantage may be taken of the block period for

loading new materials as also for picking $p the released materials

(#) .ork d$ring Post /lock Period (a) ?$ring this period new track is attended by different

packing parties*at s$itable intervals

These parties generally attend to the track in all respects paying special attention to *

(i) "$aring of sleepers

(ii) Tightening of fittings

(iii) 7a$ging

(iv) "plitting of cotters

(v) Packing the sleepers

(vi) Correcting cross levels

(vii) Providing correct s$per elevation and providing c$rve boards and pillars for each c$rve

(viii) Aligning and s$rfacing

(i6) /o6ing and providing f$ll ballast section

(6) 4aking $p cess to correct depth and


15/27

(6i) Clearing of side drains

(b) The speed restriction sho$ld be rela6ed progressively after attending to the track as per

the sched$les laid down in Pa"a 304.The track will always re$ire attention for some timeand additional labo$r sho$ld be provided to help the sectional gangs Arrangements sho$ld

be made to train o$t released materials

31. Piece&eal &et7o+ of Rela'in% Man)al/ * (1) 7eneral* 0n this method Thro$gh

"leeper Renewals (T"R) is carried o$t first Thro$gh Rail Renewal (TRR) is carried o$t

after the track gets consolidated by three ro$nds of thro$gh packing and also on acco$nt ofpassage of trains This method can be carried o$t when the section of the new rail is the

same as the e6isting rail or where +-*R rails are renewed by &! kg rails in / 7

(!) Preparatory .ork before Relaying * (a) The e6act position of rail 9oints after allowing forone e6pansion gap each is marked acc$rately with steel tape on the base rail

(b) Position of new sleepers is then marked on the base rail with white paint and transferred

to the opposite rail by means of T*s$are

(c) A speed restriction of !- ;m ph is imposed and temporary 5ngineering restrictionboards are fi6ed at appropriate places

(#) .ork d$ring /lock Period * (a) ?eep screening is carried o$t $nder speed restriction

.hile carrying o$t the deep screening work renewal of sleepers is also carried o$tsim$ltaneo$sly The work is a so programmed that at the end of a day>s work both deep

screening and re*sleepering is completed in a contin$o$s stretch witho$t leaving any gap

(b) At the end of the day>s work the track is lifted and packed to the final level and s$itableramp sho$ld be provided to meet with the levels of the e6isting track

(c) After three ro$nds of thro$gh packing thro$gh rail renewal is carried o$t $nder s$itableshort block

(d) The final ro$nd of thro$gh packing is $ndertaken and the speed rela6ed to normal inaccordance with the time sched$led described in Pa"a 304.

Note* 0f ade$ate blocks are available for carrying o$t the work of deep screening both

the deep screening and sleeper renewal works are carried o$t in a contin$o$s stretch 0fhowever the work is carried o$t $nder speed restriction as described above every fifth

sleeper is renewed leaving at least fo$r sleeper space between intact

(%) Post Relaying .orks * ?$ring this period special attention is given to the following items:*

(a) Attending to the alignment s$rfacing ga$ging packing cross*levels and tightening of

fittings

(b) /o6ing and providing f$ll ballast section

(c) 4aking $p cess to the re$ired depth

(d) Providing c$rve boards over each c$rve providing correct s$per*elevation on c$rves


16/27

(e) Cleaning of side drains

(f) Removal of all released materials and clearing the site

31. Essential Points to 9e o9se"$e+ +)"in% Lin*in% -(1) aying of Rails *

(a) Correct e6pansion gap sho$ld be provided according to the temperat$re at the time of

laying in accordance with the e6isting instr$ctions as contained inPa"a 04in the case of".R 0n the case of free rails (single rails) the recommended initial laying gap for 1!21# 4rail length for vario$s temperat$re ranges is as follows :

Rail temperature rangeRecommended initial laying gap for12/13 M. rail length

0 to 100 C 10mm

10 to 250C 8mm

25 to 00 C 6mm

0 to 550 C mm

55 to !0 0 C 2mm

"#o$e !0 0 C %ero

The liners shall be made of steel and so shaped that the wheels of a train can pass overthem 5ach liner m$st have

stamped on it the corresponding e6pansion space in millimeters ?etails of a s$itablepattern is given below

S>ETCH SH?WIN# A LINER

The e6pansion liners sho$ld be kept in position at the 9oints for at least si6 rail lengths at atime and the rails b$tting against e6pansion pieces


17/27

(b) ,ishing s$rfaces of rail and fish*plates sho$ld be greased before p$tting the fish*plates inposition

(c) /ent rails shall on no acco$nt be p$t into the road These sho$ld be straightened with a

9im crow before laying

(d) The rails $sed at evel Crossings and "tation Jards sho$ld be given a coat of coal tarbefore laying

(e) Rails sho$ld be laid with a cant of 1 in !- towards the centre of the track

(f) The shortest length of rails to be $sed in track shall not be less than && 4 e6cept as a

temporary meas$re when c$t pieces can be $sed with s$itable speed restrictions "hortrails sho$ld be laid in yards e6cept where re$ired for approaches of /ridges and evel

Crossing

(g) Rails of the same length sho$ld be $sed in pairs

(!) Rail Ioints * (a) Rail 9oints shall be laid s$are to track Provisions of Paras %!% and %!&

will apply while laying track on c$rves

(b) Provision of rail 9oints in evel Crossings and approaches will be governed by provision in

Para +!1

(c) Provision of rail 9oints on /ridges and approaches will be governed by provisions in Paras!! and !

(#) "pacing of "leepers * Para !%%(!) lays down the standard spacings to be adopted in the

case of fishplated track ".R and .R

(%) 7a$ge on "traights and C$rves * The standards laid down for ga$ge as in Para %-# may

be followed while relaying is carried o$t

(&) Provisions of Creep Posts * Provision in Para !%!(&) may be followed

316. T"ac* La'in% stan+a"+s* (1) Htmost care sho$ld be taken d$ring linking to ens$regood $ality of work which on no acco$nt sho$ld be allowed to s$ffer

(!) As a good practice the laying standards of track geometry meas$red in floatingcondition (as shown on the ne6t page) d$ring primary renewals for /road 7a$ge and 4etre

7a$ge sho$ld be achieved (Track laid with new materials) The track geometry will berecorded three months after the speed is raised to normal * see on 5a%e 1/

318. Renewal of Points an+ C"ossin% -

(1) 0t may become necessary to replace points and crossings d$e to the following reasons :*

(a) .ear on the switches and crossings: The limits of wear have been specified in Pa"a

38

(b) "leeper renewal when the sleepers are not able to hold the ga$ge and maintain crosslevels


18/27

(c) .hen the rail section on either side is changed to a higher section in thro$gh r$nninglines

(!) Any modification in the layo$t of passenger lines sho$ld be carried o$t with the sanction

of the Commissioner of Railway "afety

(#) The following aspects sho$ld be considered while relaying points and crossings in stationyards:*

(a) .hen points and crossings are renewed partic$lar care sho$ld be taken to effect

improvements in the lay o$t

(b) The renewal sho$ld as a r$le be carried o$t with standard rail sections in accordancewith the standard drawings and not with obsolescent sections Fon*standard crossing in

main line loops and sidings sho$ld be replaced with standard crossings

(c) All t$rn*o$ts negotiated by passenger trains sho$ld be 1 in 1! or a flatter t$rn o$tDwhere ade$ate space is not available 1 in *12! t$rn*o$ts with c$rved switches may be

$sed

PERMANENT WAY RENEWALS

(d) 1 in *12! symmetrical split t$rn*o$ts sho$ld generally be $sed for snag dead* endsD

special crossings 1 in *12! for snag dead ends may be $sed in /road 7a$ge

(e) Track at either end of the t$rn*o$t sho$ld be ade$ately anchored At least one rail


19/27

length on either side of the t$rn*o$t sho$ld have the same section of rail as the t$rn*o$t

(f) The following aspects sho$ld be considered while relaying points and crossings in stationyards:*

"tock rail on t$rno$t side of straight switches or c$rved switches having switch entry angle

of more than -K!->--E (all t$rno$ts e6cl$ding those mentioned at cla$se !#*1 (g*i) sho$ldbe bent at theoretical toe of switch to s$ch an e6tent that after the switch assembly is laidin track the g$age meas$red between two stock rails 9$st ahead of act$al toe of switch is

e$al to nominal ga$ge L 'mm

(g) Centre line pegs m$st be fi6ed for the new assembly partic$lar care being taken to fi6

acc$rately the inter*section point of the t$rn*o$t track and the main line track from whichmeas$rements are taken to fi6 other points

(h) Ioints on the "RI and lead rail sho$ld be welded

(i) 0n case of .R2C.R territory three normal rail lengths shall be provided between stock

rail 9oint ("RI) and "5I as well as between crossing and "5I These normal rail lengths shall

be provided with elastic rail clips2anchors to arrest creep as laid down in &an)al ofinst")ctions o" LWR ,6.

(9) 7a$ge tie Plates * Few ga$ge tie plates in replacement of the $nserviceable ones sho$ldbe fitted 9ointly by the Permanent .ay 0nspector and the "ignal 0nspector The Permanent

.ay 0nspector will be responsible for the correct ga$ging of the switches and the "ignal0nspector for the correct fi6ing of the interlocking apparat$s

(k) "tretcher /ars * "tandard "tretcher bars sho$ld be so fitted that the EthrowE of the

switch is as specified in the "ched$le of ?imensions and the clearance between its top edgeand the bottom of the stock rail shall be atleast 1& mm b$t nor more than #-mm The

Permanent .ay 0nspector shall be responsible for the correct fi6ing of the leading and the

following stretcher bars These sho$ld be fi6ed with the tong$e rails opened to half thethrow on both the sides The signal inspector shall be responsible for the correct fi6ing of

the split stretcher bar blades wherever these are re$ired to be fi6ed

(0) "witches * /efore stretcher bars are connected each tong$e rail sho$ld be e6amined tosee that it lies properly ho$sed against the stock rail for the f$ll length of the planning of the

switch witho$t any press$re being applied to keep it in position 0f a tong$e rail does not fit

properly against the stock rail it sho$ld be caref$lly Iim*crowed

0n case of interlocked points close coordination sho$ld be maintained by the Permanent .ay0nspector with the "ignal 0nspector and in case of electrified sections with the 5lectrical

0nspector and work sho$ld be carried o$t 9ointly

(%) Act$al proced$re of carrying o$t renewals*(a) /efore renewing points and crossings theballast in the layo$t sho$ld be deep screened After deep screening the ballast sho$ld be

laid only $pto the bottom of the sleepers and e6tra $antity of ballast kept ready by the sideof the layo$t for f$lly ballasting the layo$t after renewal 5$ipment for rail c$tting and rail

drilling sho$ld be kept ready at site

(b) Renewals can be carried o$t by any of the following methods :

(i) /$ilding $p at the site * 0n this method all the Permanent .ay materials for the t$rn*o$t


20/27

are bro$ght to the site and the t$rn*o$t assembled at site in its correct position afterdismantling the old t$rno$t This method is followed in the case of laying o$t new yards

(ii) Pre*assembling and slewing in at site* The layo$t is assembled by the side of the

e6isting layo$t The gro$nd on which the t$rn*o$t is to be assembled is leveled first 0fnecessary room is not available additional space is created by doing e6tra earth work or by

constr$cting a working platform with the old rails and sleepers The assembly is $s$ally b$ilton a rail grid the top s$rface of which is greased beforehand to facilitate easyslewing ?$ring the block period the e6isting layo$t is dismantled and removed and the pre*

assembled layo$t is slewed in its correct position aligned and packed

(iii) Pre*assembling in depots* 0n this method the layo$t is assembled in a central depot on

a specially b$ilt platform for this p$rpose After assembling the layo$t the correspondingparts sho$ld be s$itably n$mbered indicating the matching rail ends of the vario$s

components when the layo$t is split into components The layo$t is then dismantled and thecomponent parts kept in proper se$ence according to their relative position The old layo$t

is dismantled and the new layo$t laid in its position 0n this method the workmanshipachieved is of a high standard and therefore it sho$ld be preferred to other methods

314. Slee5e"s in Ya"+s an+ R)nnin% Lines-

(1) "leeper ?ensity *

(a) Passenger loops other r$nning lines and b$sy lines in the yards sho$ld have a sleeper

density of 4 L %

(b) Bther yard lines sho$ld have a sleeper density of 4 L !

(c) ,or symmetrical splits where speeds on the main and loop lines will be the same thesleeper density to be adopted on the loop line shall be the same as that on the main line

(!) Types of "leepers *

(a) At large stations the $se of steel sleepers sho$ld be avoided in r$nning lines as far aspossible as at these locations sleepers are prone to corrosion

(b) Bn lines proposed to be track circ$ited concrete or wooden sleepers sho$ld be $sed

(c) Bn other lines as far as possible RC twin block sleepers sho$ld preferably be $sedC"T + sleepers may be $sed as an alternative At least in important stations C"T + sleepers

may be $sed in preference to wooden sleepers which are liable to be damaged by firedroppings

31,. Rails In Station Ya"+s* (1) Renewals in Passenger oops sho$ld normally be carried

o$t with new or second hand serviceable rails of the same section as laid between stationse6cept in terminal yards where all trains stop and loops where speed is to be restricted to

&- ;m ph in which case second $ality rails of the same section may be $sed

(!) .hile carrying o$t thro$gh rail renewals or complete track renewal in yards shortwelded panels of # rail length may be $sed

(#) .R may be provided in yards in terms of and s$b9ect to conditions laid down in .R

4an$al


21/27

30. Classification an+ )se of "elease+ &ate"ial* (1) (a) After a section of track has

been renewed the released material shall be caref$lly sorted o$t so that greatest possible$se may be made of them They sho$ld then be classified by the "r "ection 5ngineer (P

.ay) Tools and plant left over sho$ld also be classified and action taken on their disposal

(b) The rails sho$ld be graded according to their weight and condition into gro$ps s$itablefor re*$se in r$nning lines non*r$nning lines and for conversion into posts or str$ct$ralmembers for vario$s p$rposes or for sale as scrap .here rail*ends are worn or hogged the

feasibility of ECroppingE the ends sho$ld be considered if the condition of the rail is

otherwise satisfactory

(c) The sleepers sho$ld be sorted into vario$s grades s$itable for re*$se in the track or as$nserviceable material not fit for $se in track works The possibility of converting

$nserviceable /road 7a$ge wooden sleepers to 4etre 7a$ge or Farrow 7a$ge ('! mm)sho$ld be considered before their classification as scrap The $nserviceable wooden sleepers

may be $sed for temporary road*ways and other s$ndry p$rposes

(d) ,ish*plates fish bolts keys and dog*spikes sho$ld be sorted into those s$itable for re*

$se and the rest as scrap

(e) 0f the switches and crossings themselves are too badly worn to be re*$sed the small

fittings s$ch as stretcher bars switch anchors st$d*bolts and blocks can generally be $sedCrossings sho$ld be reconditioned by welding if the wear is not too severe as also the

switches

(f) The timbers sho$ld be caref$lly inspected to decide the best $se that can be made ofthem 0f they are not too severely worn the holes can be filled with a s$itable compo$nd or

pl$gged and the timbers re*$sed in less important positions 0t often happens that longtimber is not decayed thro$gho$t its length and it is fre$ently possible to c$t short lengths

0f c$t lengths so obtained are not long eno$gh for re$se two s$ch pieces may be spliced

and bolted together to form a composite sleeper for $se in important sidings interlaced withthro$gh sleepers

(!) /asis for Classification * ,or the p$rpose of classification Permanent .ay materials

sho$ld be divided into three classes depending $pon the section and condition as detailedbelow *

(a) Class 0 material is that which is new and of standard section Few items of obsolescentsections which are interchangeable with standard materials and are p$rchased from time to

time to prevent wastage of other serviceable material sho$ld be bro$ght on to the stockacco$nt as Class 0 material These items sho$ld be incl$ded in the price lists for the

miscellaneo$s and common items

Fo other material of an obsolescent section is to be treated as Class 0 even tho$gh it maynever have been p$t in the road

(b) Class 00 material incl$des all new material of obsolescent sections other than those

incl$ded $nder Class 0 and all standard and obsolete material released from the road and fitfor f$rther $se on track

Class 00 released rails sho$ld be classified and s$b*divided as $nder*


22/27

Class 00 (a) rails fit for $se in r$nning lines

Class 00 (b) rails fit for $se in non*r$nning lines

(c) Class 000 materials shall incl$de all materials that has become $nserviceable This is

either metal scrap or $nserviceable timber This class will incl$de all rails which are neither

Class 0 nor Class 00

Class 000 sleepers wooden or steel sho$ld be f$rther s$b*divided as follows :*

(i) .ooden sleepers* Class 0ll*A not fit for $se in track b$t fit for walling of enclos$res or for

paving

Class 0ll*/ not fit for $se in track b$t fit for scantling or man$fact$ring keys or pl$gs

Class 0ll*C fit for fire*wood only

(ii) "teel sleepers* Class 0ll*A $nserviceable s$itable for reconditioning or conversion to

smaller ga$ge Class0ll*/ $nserviceable scrap

(d) This can be done by act$al weighment of

few representative samples

(&) The yardsticks will then be approved by the "r ?5F2?5F personally based on the report

d$ly test checked by A5F or ?5F These will specify the ma6im$m percentage loss of weightfor different components $nder different gro$nd conditions as per format given in the


23/27

Anne6$re*#2!

(') The conversion to weight in case of each of the items for p$rpose of acco$ntal will thenbe done by the "ection 5ngineer (P .ay) on the basis of the specified percentage loss of

weight over the new components 0n case however some abnormal variation of weight isobserved after the materials have been released and the percentage loss is more than that

specified for that category specific 9$stification will have to be recorded for the same by the"enior "ection 5ngineer (P .ay) and all s$ch cases wo$ld have to be certified by ?5F2"r?5F after act$al sample checking at site

() 0n case however the act$al loss after release is seen to be lower than the yardstick theacco$ntal will be done on the basis of the act$al

() After act$al releases of materials the "ection 5ngineer (P .ay) will take the releases on

books on the basis of s$mmary sheet as per Anne)"e-323.

(+) The sectional A5F will carry o$t test checks to the e6tent of !-M of each item and makeentries to this effect in the s$mmary sheet The sectional ?5F2"r ?5F will also carry o$t

random checks to ens$re that the category and weight of releases are correct to the

ma6im$m possible e6tent

(1-) The periodical ret$rns for track renewals2 ga$ge conversions are to be s$bmitted at the

laid down periodicity as per r$les and the e6isting proced$re for checking sho$ld bestreamlined to ens$re that the ret$rns are looked into detail in the A5F>s office in nos as

also their conversion in weight The ret$rns will be specifically checked with regard to thecorrectness of inp$t2o$tp$t materials having been prepared on the basis of instr$ctions

given in para*! above

(11) As an internal check by the department one of the works acco$ntants in the divisionwith engineering department or with constr$ction department sho$ld be made responsible

to carry o$t methodical checks of all 4A" acco$nts of track renewals2ga$ge conversion

works

(1!) 0n cases where the track work is to be done by contractor the list of released materialsshall be 9ointly prepared on the basis of a field s$rvey to be cond$cted by the "r "ec

5ngineer (P .ay) and contractors representative after the work has been awarded b$tbefore the dismantling work is allowed to commence The contractor shall be bo$nd to hand

over the materials according to the said agreed list and sho$ld be responsible for any

shortages

31. Ma"*in% of Pe"&anent Wa' Mate"ial -All Permanent .ay material sho$ld bedisting$ished as follows or as otherwise directed :

(1) Class 0 * Fo marks

(!) (a) ,or rails*

(i) Class 00 (a) "econd hand rail fit to be relaid in r$nning lines*5nds to be painted with a

da$b of white

(ii) Class 00 (b) "econd hand rail fit for $se in non*r$nning lines*5nds to be painted with ada$b of yellow


24/27

(iii) Hnserviceable rails not fit for $se * 5nds to be painted with a da$b of red

(b) ,or other track materials like sleepers etc*

(i) Class 00 ie "econd hand fit for $se in track works to be painted with a da$b of white

(ii) Hnserviceable material not fit for $se * 5nds to be painted with a da$b of red

0t sho$ld be ens$red by the Assistant 5ngineer and Permanent .ay 0nspector that the

materials of each class incl$ding fittings are separately stacked for convenience of

acco$nting and dispatch and indication plates erectedthere at

3. I+entification of +iffe"ent =)alities of "ails in t7e !iel+ -

(1) ,irst @$ality Rails (T*1!) * In+ian Railwa's s5ecification IRS - T - 12,6gives the

detailed specification of ,lat /ottom Rails '- kg and &! kg of grade - 4Pa 1--- 4Paand 1-- 4Pa &! kg2m and '- kg2m rails shall be classified as Class >A> and Class >/> rails

based on tolerance in 5nd "traightness The rails shall have rolled on it the rail section the

7rade of steel identification marks of the man$fact$rer month and last two digits ofthe year of the man$fact$re process of steel making and direction of rolling of rail

(!) "econd @$ality Rails *These are rails with rela6ation in sectional tolerance as provided inAmendment to 0R" * T - 12,6b$t other wise conforming to T * 1!2+' in all other

respects The identification of s$ch rails will be one hole of ' mm dia champhered at bothends drilled at the center length of the rail and at the middle of the web These rails shall

be $sed only on loop lines 2 sidings with speed restriction of &- kmph These rails shallbe painted with orange colo$r on both sides of the web for a distance of 1 metre from each

end for easy identification

(#) Third @$ality Rails * 0n addition to above two $alities third $ality rails s$pplied by

"teel Plants are arising partic$larly d$ring the inspection of rails while prod$cing first$ality rails as per 0R" *T*1! specification There is no deviation in chemical composition or

echanical property in >0nd$strial Hse> rails from that of 0R"*T*1!The deviations e6ist only intolerance in s$rface defects dimensions and straightness These can be $sed in ind$strial

sidings where speeds are limited to #- km p h in / 7 and !& km ph in 47

The identification of s$ch rails will be one hole of 1!m dia champhered at both ends drilled

at the center length of the rail and at the middle of the web a marking E0HE in 1 mmsi=e shall be stamped on both end faces of rail The third $ality rail shall be painted with

white paint on end face of the flange and on both sides of flange for a distance of &-- mmfrom each end for identification

33. Wo"*s to 9e atten+e+ afte" co&5letion of "ela'in% * (1) Classification and loading

of released materials * 4aterials as and when removed d$ring the progress of relayingsho$ld be collected and classified and despatched to the destination Fo released material

sho$ld be left lying abo$t at the site of the renewals A relaying work shall not beconsidered complete $ntil all released materials are removed from site and necessary credit

afforded

(!) Temporary strengthening of gangs * After the relaying is completed it wo$ld benecessary to strengthen the reg$lar maintenance gangs temporarily to maintain it to the

re$ired standard for the ma6im$m permissible speed on the section


25/27

(#) ?escription /oards*/oards displaying information in regard to track materials laid for

special or e6perimental p$rposes sho$ld be erected at each end of the length over which thetrial is being cond$cted 8 maintained only for so long as the materials remain $nder trial

(%) ?ating of wooden sleepers * The date of laying sho$ld be c$t o$t or branded on each

wooden sleeper in accordance with Pa"a 4/.

(&) Revision of Permanent .ay ?iagrams *As soon as the re*railing 2or the re*sleepering

work is completed the Permanent .ay diagrams 8 the station yard diagrams and the inde6

section that embody the detailed partic$lars of the track in regard to the year of layingsection of rail type of sleepers fish plates 8 fittings sho$ld be amended $p*to*date in the

?ivisional 5ngineer>s office and the head$arters advised Copies of amended diagramssho$ld be iss$ed by the ?ivisional 5ngineer to the Assistant 5ngineer 8 Permanent .orks

inspector concerned for record in their offices

(') Closing of the Acco$nts * The acco$nt for relaying works sho$ld be closed within #months of completion of the work 8 completion report s$bmitted

ANNE@RE-321 PARA 301/

STI!ICATI?N !?R C?MPLETE TRAC> RENEWAL

?0


26/27

ANNE@RE-32 PARA 303//

L?SS ?! WEI#HT ?! RELEASEB SCRAP P. WAY C?MP?NENTS/

?5"CR0PT0BF B, .BR;:,BBT /J ,BBT "HR


27/27

AFF5NHR5*#2# PARA #!-(#)()

SMMARY ?! P. WAY MATERIAL T? :E RELEASEB.

chapter 3 rail pway manual

Documents