daØhV Lyhij jsyiFk dk vuqj{k.kMaintenance of Concrete Sleeper Track

All concrete sleeper tracks are required tobe maintained by heavy duty on tracktampers. In accordance with the Rly. Bd.’sL. No. 2007/Track III/TK/7/Pt., dt. 16.01.08,the tamping guidelines for throughattention and spot attention of a sectionshould be followed.

A VsfEiax izfØ;k@ Tamping Operations

The important items of attention formachine tamping are as under;

A.1 iwoZ&VsfEiax izfØ;k @ Pre-tamping Operations

(a) Shallow screening of pumping joints.(b) Recoupment of Ballast.(c) Replacement of unserviceable

sleepers, missing/broken fittings.(d) Squaring of sleepers, Gauging and

Gap adjustment.(e) Clearing of ballast from top of the

sleepers to make them visible to theoperator of machine.

(f) Marking of super elevation and designslew on curves, lift and slews onstraight. Those fixtures/ installationswhich cannot be removed should alsobe marked to be clearly visible tomachine operator.

(g) Removal of obstructions like singlerods, cable, pipes, OHE bonds/jumpers, guard rails at the approachof bridges, joggled fishplates, woodenblocks etc. (Guard rails, Joggledfishplates at ‘D’ joints should beremoved just before tamping).

(h) Overhauling of level crossing shouldbe done along with tamping. Checkrails should be removed just beforetamping.

A.2 VsfEiax ds nkSjku izfØ;k @ During -tamping Operations

a) Recording of pre and post tampingtrack geometry parameters andtaking suitable corrective actionwherever necessary.

b) Providing a ramp of 1 in 1000 beforeclosing the block work and atobligatory point such as girderbridges, turn- out etc.

A.3 VsfEiax i”pkr~ izfØ;k @ Post-tamping Operations

a) Fittings that might have becomeloose or become displaced shouldbe reset and those broken/misplaced should be replenished.

b) Ballast should be recouped intamping zone and should beproperly dressed.

c) In areas where DTS has not beenused, hand ramming of shoulder/crib ballast should be done.

d) All the fixtures removed during pre-tamping/ tamping should berestored.

A.4 During working of machines,provisions contained in LWRmanual shall be strictly followed.

B rRdky fuokj.k@[kkfe;kW@ Spot Attention/ Slack Picking

For spot attention/ slack picking,multipurpose tampers and of tracktampers shall be used. Where these

tampers are not available, as aninterim measure, the tamping maybe done with the help of crow barduly taking care that the concretesleepers are not damaged.

C ih vkj lh jsyiFk dk okf’kZd O;ofLFkrj[kj[kko@ Annual Systematic Attention on PRC Track

C.1 In addition to machine tamping,the gangs will carry out annualsystematic attention to track fromone end of gang beat to the otherduring working season. This willinclude-

(a) jsy] Lyhij] ca/kuksa ,oa bZ vkj lh ds Vks yksMekiu dk ijh{k.k@ Examination ofRails, Sleepers and Fasteningsincluding measurement of toe loadof ERCs.

i) jsy ,oa osYM@Rails and welds shouldbe examined for the followingdefects and action shall be taken asindicated below:

• Corrosion on web, foot and atunderside of rails & welds- To becleaned and painted two coats of 100micron thick (each layer) with anti-corrosive bituminous black paint IS 9862with a interval of 8 hours.

• Cracks on rails and welds- Crackedrails or welds shall be replaced.

• Wear on rail profile- If necessary, railsto be interchanged and burrs, if any shallbe removed.

• Wheel burns and scabs on the railtable top- If required, rails shall bereplaced.

• Kinks and bends in rail and weld-Cutting and re-welding shall bedone.

• Cupped welds- Shall be filled up orcut and re-welded.

• High and low welded joint- Shallbe rectified by filing/ filling up orby cutting and re-welding.

ii) ih ,l lh Lyhij]@ PSC sleepers

Sleepers shall be examined for theircondition and wear in rail seat. Any crackin concrete sleeper and damage toconcrete exposing reinforcement shouldbe looked for. The damaged sleeper shallbe replaced.

The end of HTS wire shall be paintedwith anti-corrosive bituminous emulsionpaint conforming to IRS-P-30-96, if thereis any sign of scaling away of paint orcorrosion.

iii) ca/ku@ Fastenings

Rubber pads, Liners and ERCs shall beexamined to ensure that these are ingood condition and appropriately fixed

to hold the rails. Crushed rubber pads,broken/missing liners and ERCs shall bereplaced.

Correct diving of ERCs should be ensuredsuch that leg of the clip is flushed with endface of the Insert. ERCs and metal linersshould be checked for corrosion andcorroded ones should be changed.

In all operations, where ERCs are requiredto be removed and re-inserted, it may beadvisable to clean and grease Insert andERC and clean liner rail foot contact areabefore insertion. The ERCs should beremoved and put back by using clipapplicator and not be hammering.

iv) bZ vkj lh dk Vks yksM ekiu@ Toe Load Measurement of ERCs

Sample check of toe loads periodicallyduring service shall be made by toe loadmeasuring kit approval by RDSO. Toe loadof elastic rail clip should be measured onone percent of ERCs randomly on every100 sleepers. (All 4 ERCs to be measured onone sleeper.)

Initial testing shall be done once in fouryears or passage of 200 GMT traffic,whichever is earlier. Frequency shall bedoubled in corrosion prone areas.

Subsequent testing will be done every fouryears or 200 GMT in normal areas and twoyears or 100 GMT in corrosion prone areas,whichever is earlier. However, if 20% ormore of sample size record toe load below600 kg both frequency of inspection andsample size are to be doubled. If 20% ormore of sample size record toe load below400 kg which is to be confirmed by 5%sample size, proposal of through fasteningrenewal shall be initiated.

The loss of toe load is reflective ofcondition of other elastic fasteningcomponents like Grooved rubber pads,GFN/Metal liners etc. The condition ofthese components along with measuringof toe loads of ERCs shall be checked toascertain cause of loss of toe load.

v) bZ vkj lh dk Lusgu@ Lubrication ofERCs

It should normally be carried out by Keyman in a systematic manner from one toother at the rate of 20 sleepers per day.This will give a frequency of about 1-1/2years.

In case greasing is required morefrequently, gangs may be deputed forthis work. This work should not be donein extreme summer and heavy rainfall.Greasing of ERCs should be done withgraphite grease to IS 408-1981 Gr. ’O’specification.

At any time, Key man should not removemore than one ERC of a sleeper. The eyeof the insert shall be cleaned by suitablebrush. Two ERC, one from inside of onesleeper and one from outside ofadjacent sleeper on same rail shall beremoved and cleaned by wire brush andemery paper. After cleaning, greasegraphite shall be applied to the insidesurface of Inserts and leg of ERCs. BothERCs shall be interchanged and fixedagain. After fixing these two ERCsremaining two ERCs shall be tackled asabove. The process is repeated forcleaning and lubricating remaining ERCs.

(b) baL;wysVsM tksM] ,l bZ ts vkfn dk fujh{k.k,oa j[kj[kko@ Inspection of andattention to insulated joints,switch expansion joints etc.

vof/k@ Period

dk;Z@ Work

Post-monsoon attention. (For six-seven months after end of monsoon)

Immediately after end ofmonsoon, attend to run downstretches in the entire ganglength. Thereafter, thefollowing schedule of work shallbe followed:

(i) Picking of slacks 1-2 days in aweek.

(ii) Remaining days shall beallotted to-

• Annual systematic attention.• Overhauling of level crossings.• De-stressing of LWRs.• Spot renewals of rails,

sleepers etc.• De-weeding.• Cold weather patrolling etc.

Pre-monsoon attention. (For two months prior to onset of monsoon)

(i) Picking of slacks 1-2 days in aweek.

(ii) Remaining days shall beallotted to :

• Cleaning & repairs to side &catch water drains & cleaningof water ways.

• Attention to yard drainage.• Spot renewals of rails,

sleepers etc.

vof/k@ Period

dk;Z@ Work

• Shallow screening of specifiedlengths.

• Hot weather patrolling.

Attention during monsoon (For three-four months)

(a) Picking of slacks as required.(b) Normal track maintenance of

yard lines.(c) Cleaning, removal of loose

boulders from cuttings &tunnels to ensure free flow ofwater.

(d) Monsoon patrolling.(e) Maintenance of side and

catch water drains.(f) Repair to cess and bank.

Disclaimer

The information contained in this pamphlet doesnot supercede any existing provisions laid down inRDSO & Railway Board instructions. Thisdocument is not statutory & instructions given init are for the purpose of guidance only.

Our ObjectiveTo upgrade Maintenance Technologies andMethodologies & achieve improvement in productivityand performance of all Railway assets and manpowerwhich inter-alia would cover Reliability, Availabilityand Utilisation.

The contents of this pamphlet are for guidance only and arenot statutory. If you have any suggestion & comments oncontents of the pamphlet, please write to: Dy.Director (Civil),CAMTECH, Maharajpur, Gwalior (M.P) – 474 005

(c) iqy] leikj igqWp] ,y MCY;w vkj dh“olu yEckbZ ,oa [kjkc QkesZ”ku dhisfdax@ Packing of approaches ofbridges, level crossings, breathinglengths of LWRs and badformation areas etc.

(d) jsyiFk dh mFkyh NukbZ@ Shallow screening of track.

(e) lsl ,oa rVca/k dh vYi ejEer@ Minor repair to cess and bank.

(f) fxêh dh HkjkbZ ,oa Mªsflax@ Boxing and dressing of ballast.

(g) {kfrxzLr@xk;c jcM+ isM] ykbuj vkSj bZvkj lh dk izfrLFkkiu@ Replacementof damage /missing rubber pads,liners and ERCs.

C.2 e”khu vuqjf{kr daØhV Lyhij jsyiFk dk okf’kZdvuqj{k.k dk;ZØe fuEuor~ gksxk@ Annualprogramme for machine maintainedconcrete sleeper track would be asfollows:

Hkkjr ljdkj & GOVERNMENT OF INDIAGOVERNMENT OF INDIAjsy ea=ky; & MINISTRY OF RAILWAYS MINISTRY OF RAILWAYS

daØhV Lyhij jsyiFk dk vuqj{k.kMaintenance of Concrete

Sleeper Track

dseVsd@fl@2011@,e&lh ,l Vh@1-0CAMTECH/C/2011/M-CST/1.0

uoEcj @November - 2011

dsoy dk;Zky;hu mi;ksx gsrq(For Official use only)(For Official use only)

Maharajpur, Gwalior - 474005

gekjk mís’;vuqj{k.k iz©|©fxdh vkSj dk;Ziz.kkyh dks mUu;u djuk rFkk

mRikndrk vkSj jsYos dh ifjlEifRr ,oa tu’kfDr ds fu"iknu esalq/kkj djuk ftlls vUrfoZ"k;ksa esa fo’oluh;rk] mi;ksfxrk vkSj

n{krk izkIr dh tk ldsA

lEidZ lw= : 0751-2470869, Fax: 0751- 2470841E-Mail : dircivilcamtech@gmail.com