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RAIL STEEL

March 2007INDIAN RAILWAYS INSTITUTE OF CIVIL ENGINEERING

PUNE 411 001

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RAIL STEEL

March 2007INDIAN RAILWAYS INSTITUTE OF CIVIL ENGINEERING

PUNE 411 001

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PREFACE TO THE THIRD EDITION

The book on Rail Steel was first published in 1987.Its second edition was brought out in 1997. The book hasbeen found very useful by the field engineers for developingan insight in rail steel.

Rail is the most important constituent of the trackstructure and plays very vital role in the reliability of railwaysystem as a whole. Quality of rail steel with reference to itschemical composition, especially the hydrogen content hasbeen a matter of serious concern to the manufacturers aswell as Indian Railways. In service failure of rail has been abig challenge to the track engineers. Various methods ofrail testing and improved chemical composition are beingadopted. A lot of new developments have taken place in railmanufacturing industry. Bhilai Steel plant has also donemany improvements in rail manufacturing and in postmanufacturing inspection process. Proper handling of railsfrom the stage of its manufacturing up to insertion in trackis equally important especially in case of the high UTS railswhich are more brittle.

The revised and enlarged edition of the book hasbeen complied by Shri Abhai Kumar Rai, Ex. Professor/ Works and Shri Atul Agarwal, Professor/Track-III. The bookis now comprehensive starting from pig iron manufacturingand ending with testing of rails incorporating newdevelopments. RDSO has recently issued 5 th amendment toIRS-T-12-96 which has also been incorporated in the book.

I hope this book in the present format will be foundmore useful by the field engineers.

Shiv KumarDirectorIRICEN

Pune

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ACKNOWLEDGEMENT

The subject of Rail Steel is being taught duringvarious courses at IRICEN. Even though a lot of informationis available on this subject, yet it was not available at oneplace especially regarding rail manufacturing in India.

This book is an attempt to compile all the relevantinformation regarding rail steel starting from manufacturingof the pig iron to rail rolling including its testing andhandling.

It would not be out of place to acknowledge thesupport and assistance rendered by IRICEN faculty andstaff in the above efforts. We are particularly thankful toShri Rajesh Kumar, Professor/Track-1, who has providedlogistic assistance for printing of this book. The wordprocessing of the manuscript and its editing has been doneby Mrs. Vidya S. Jamma. We also acknowledge the helprendered by Shri Sunil Pophale, in preparing various

drawings.

Above all, the authors are grateful to Sri ShivKumar, Director, IRICEN for his encouragement and advicefor improving the book.

Atul AgarwalProfessor/Track-3

Abhai Kumar RaiEx Professor/Works

IRICEN/Pune

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CONTENTS

Page

CHAPTER-1 1

INTRODUCTION

CHAPTER-2 5

STEEL MAKING

CHAPTER-3 25

RAIL MANUFACTURING

CHAPTER-4 40

EFFECT OF DIFFERENT ELEMENTS IN PLAINCARBON STEELS

CHAPTER-5 47

TESTING OF RAILS

Chapter-6 58

IMPORTANT STIPULATIONS OF IRS-T-12-96

CHAPTER-7 65

HANDLING OF RAILS

CHAPTER-8 73

NEW DEVELOPMENTS IN RAIL MANUFACTURING

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ORECONE

STOCK HOUSE

BLAST FURNACE

DUST CATCHER GAS WASHER STOVE

HOTBLAST LINE TO FURNACE

SKIPBRIDGE

ORE

BRIDGE

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PREFACE TO THE THIRD EDITION

The book on Rail Steel was first published in 1987.Its second edition was brought out in 1997. The book hasbeen found very useful by the field engineers for developingan insight in rail steel.

Rail is the most important constituent of the trackstructure and plays very vital role in the reliability of railwaysystem as a whole. Quality of rail steel with reference to itschemical composition, especially the hydrogen content hasbeen a matter of serious concern to the manufacturers aswell as Indian Railways. In service failure of rail has been abig challenge to the track engineers. Various methods ofrail testing and improved chemical composition are beingadopted. A lot of new developments have taken place in railmanufacturing industry. Bhilai Steel plant has also donemany improvements in rail manufacturing and in postmanufacturing inspection process. Proper handling of railsfrom the stage of its manufacturing up to insertion in trackis equally important especially in case of the high UTS railswhich are more brittle.

The revised and enlarged edition of the book hasbeen complied by Shri Abhai Kumar Rai, Ex. Professor/ Works and Shri Atul Agarwal, Professor/Track-III. The bookis now comprehensive starting from pig iron manufacturingand ending with testing of rails incorporating newdevelopments. RDSO has recently issued 5 th amendment toIRS-T-12-96 which has also been incorporated in the book.

I hope this book in the present format will be foundmore useful by the field engineers.

Shiv KumarDirectorIRICEN

Pune

8/12/2019 Rail Steel 1

23/24

ACKNOWLEDGEMENT

The subject of Rail Steel is being taught duringvarious courses at IRICEN. Even though a lot of informationis available on this subject, yet it was not available at oneplace especially regarding rail manufacturing in India.

This book is an attempt to compile all the relevantinformation regarding rail steel starting from manufacturingof the pig iron to rail rolling including its testing andhandling.

It would not be out of place to acknowledge thesupport and assistance rendered by IRICEN faculty andstaff in the above efforts. We are particularly thankful toShri Rajesh Kumar, Professor/Track-1, who has providedlogistic assistance for printing of this book. The wordprocessing of the manuscript and its editing has been doneby Mrs. Vidya S. Jamma. We also acknowledge the helprendered by Shri Sunil Pophale, in preparing various

drawings.

Above all, the authors are grateful to Sri ShivKumar, Director, IRICEN for his encouragement and advicefor improving the book.

Atul AgarwalProfessor/Track-3

Abhai Kumar RaiEx Professor/Works

IRICEN/Pune

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CONTENTS

Page

CHAPTER-1 1

INTRODUCTION

CHAPTER-2 5

STEEL MAKING

CHAPTER-3 25

RAIL MANUFACTURING

CHAPTER-4 40

EFFECT OF DIFFERENT ELEMENTS IN PLAINCARBON STEELS

CHAPTER-5 47

TESTING OF RAILS

Chapter-6 58

IMPORTANT STIPULATIONS OF IRS-T-12-96

CHAPTER-7 65

HANDLING OF RAILS

CHAPTER-8 73

NEW DEVELOPMENTS IN RAIL MANUFACTURING