Basics about Rails and Sleepers

1. Basics about Rails and Sleepers By (N.R. Kale ) AXEN/IRICEN

2. Different types of rails • Double headed rails • Bull headed rails • Flat footed rails

3. Brand marks Brand mark shall include: • Rail section • The Grade of steel • Identification mark of manufacturer • Month (using Roman numbers) and last two digits of year of manufacture • Process of making (O –Basic oxygen or E- electric) (Brand mark will be rolled at every 3.0m)

4. Grade of steel (As per T-12/09)

5. Standard length and Identification for new Rails (As per T-12/09)

6. Rail Section of rails as per T-12/09

7. Main Dimensions of Rails

8. Quality of Rails (C.S.No-117) • Prime Quality Rails: New Rail as per IRS-T-12/09( Its latest version). These rails are further classified based on tolerance in end straightness as under- • Class ‘A’ Rails • Class ‘B’ Rails • ‘Industrial Use Rails’ : Rails with relaxation in sectional tolerance as provided in Amendment to IRS – T-12/09 but otherwise conforming to T-12/09 in all other respects i.e. Chemical composition, mechanical properties etc. These rails can be used in Industrial siding with speed restriction of 50 Kmph

9. Identification of different qualities of Rails (As per T-12/09)

10. Standard sections of Rails (CS-117 dated 19.05.09)

11. Contd. …..

12. Rail Closure (Para-256) • A rail piece of less than the standard length, used in the track for closing a rail gap, is called rail closure. The shortest length of rail closure to be used in the track as a permanent measure is 5.50 m. • On following locations and 500m approaches on both side, minimum length of closure is 11m. Tunnel, Deep cutting, Major & Important bridges and high embankment

13. Guide lines for using closure • Limited use. • Only hacksaw cut, no gas cut. • Avoid on junction of different types of rails and/or sleepers. • Avoid on bridges, level crossings and points and crossings. • Better not to use opposite to each other.

14. Causes of Rail Deterioration (Para- 249) 1) Corrosion and rusting (Generally noticed on web & foot of rail) Locations Prone to corrosion : i) Platform lines. ii) Sidings where corrosive goods are dealt. iii) Tunnels and damp cuttings. iv) Coastal area. v) Industrial belts.

15. Contd. … 2.Wear on Rail Table : • Normally of very small order. • Amount of wear increases with heavy traffic density as in suburban section. 3. Flattening of rail table: • Mostly occurs on the inner rail of a curve. • Indication of over loading

16. Contd. … 4. Wear on Gauge Face: • Noticed on outer rail of a curve. • Due to heavy pressure from the wheels which results in the running edge becoming worn or ‘side-cut’. • Specially in suburban sections where multiple unit coaches are provided.

17. Contd. … 5. Hogging of Rail Ends: • A hogged rail is one with its end or ends bent in vertical direction. • Due to bad maintenance of joints. • Due to unserviceable sleepers on joints.

18. Contd. … 6. Battering of Rail Ends: • Occurs where the gap on fish plated joints are excessive. • Caused by impact of wheels on end of a rail particularly if the fishplates do not fit snugly.

19. Maintenance of joints (Para 251) The efficient maintenance depends on: a. Efficiency of fastening b. Correct spacing of joint sleeper and efficient packing. c. Correct expansion joint. d. Proper lubrication. e. Correct maintenance of gauge & X/Level f. Efficient drainage.

20. Contd. … 7.Wheel burns: • Wheel slipping occurs usually on adverse gradient or while starting on raising gradient. • Heat is generated and depression is caused on rail table known as wheel burns. • Also occur due to sudden application of brakes.

21. Contd. … 8.Corrugation: • Rail table develops hollows and ridges. • Also known as “Roaring rails”. • Excessive vibrations are caused. • Fastening and packing tends to get loose. • Track needs frequent attention.

22. Permissible Wear on Rails(Para-302) • Vertical Wear

23. Contd. …. • Lateral Wear

24. Service Life of Rails

25. Various Types of Fish plates and Their usage • Ordinary fishplate : Used in normal cases. • 1 m long fishplate : Used for repairs to rail fracture, Laying of LWR etc. • Joggled fish plate : Used to protect defective / fractured weld. • Combination fishplate : Used to join different section of rails

26. Contd. … e) Collarless F/plate : Used under lock bar on stock rail joint. Top collar of inside fish plate is trimmed. However, trimming of top collar is not required in case of 60 Kg rails. f) Skimmed fish plate : Used in insulated block joints. g) Slotted fish plate : Used in case of rail failure.

27. Drilling of holes in rails • The position of hole in rail is at a specified distance from the base of the rail and not in the centre of the web. • the proper drilling of a hole should be ensured by making use of template. • Punch should be used for making the hole centres on the web. • The permissible tolerance is only 0.8mm

28. Drilling of holes in rails

29. Chamfering of bolt holes • For hardening of periphery of holes and thereby delays the formation of star cracks. • Existing bolt holes in fracture prone zone should be chamfered. • Elongated holes should not be chamfered to avoid uneven hardening.

30. Drilling of holes in rails

31. Laying of Sleepers (Para-244) • Sleepers shall be laid square to rails on straight and radially on curve. • The sleeper spacing should be marked on outer rail in case of curved track. • Closer spacing should be provided at joint sleepers of fish plated joints and between joint sleeper and shoulder sleeper.

32. Sleeper density • The sleeper density is the number of sleepers used per rail length. • Described as M+1, M+2, M+3 etc. Where M is the length of standard rail in meters. • In case of LWR/CWR, this is expressed in number of sleeper per Km of track. • Sleeper density depends upon max. permissible speed and traffic density.

33. Spacing of sleeper (Maximum)

34. Correction slip no.102 dated 29.05.07 Where concrete sleepers are required to be laid in unavoidable circumstances, in SWR track the sleeper spacing, including at fish plated joint, shall be kept uniform, in addition, 1M long fish plates, be provided at joint.

35. Minimum Sleeper density (CS No-117 dated 19.05.09)

36. Minimum Sleeper density in sidings (CS-117 dated 19.05.09)

37. Types of Sleepers • Wooden Sleepers • Cast Iron Sleepers • Steel Sleepers • Concrete Sleepers

38. Advantages/Disadvantages of wooden Sleepers Advantages • Easy to manufacture and handling. • Suitable for track circuited area. • Can be used with or without ballast. • Suitable for bridges, Points/Crossings. • Suitable for gaunteletted track. • Alignment can be easily corrected.

39. Contd. … Disadvantages: i) Lesser life. ii) Liable to damage by beater packing. iii) Difficult to maintain the gauge. iv) Susceptible to fire hazards.

40. Contd. … • Inspection of Sleeper • Sleeper register. • Wooden sleeper more than 5 year. • Category I- Requiring renewal during the year. Painted with two white lines • Category II- Requiring reconditioning, painted with one white lines. • Test check by ADEN-50 sleeper/km

41. Number of Screw/Spike per Rail seat (Para 245/6)

42. Use of Bearing Plates(Para 245/5) • ‘T’ Category sleepers • Girder Bridges • Turn outs • Ash pits and examination pits • Joint sleepers • On sharp curve of radius less than 600 m on B.G. and M.G.

43. Cast Iron Sleepers (Para 246) Type of Cast Iron Sleepers: A) C. I. Pot Sleepers B) C S T- 9 Sleepers Advantages of Cast Iron Sleepers: i) Lesser corrosion. ii) Easy handling due to light weight. iii) Higher Scrap value.

44. Contd. … Disadvantages of Cast Iron Sleepers: i) Not suitable for high speed route. ii) Difficult to maintain the Gauge. iii) Lesser lateral stability. iv) Not fit for track circuited area. v) Not suitable for mechanical maintenance. vi) Tie bars weakened by corrosion.

45. Usual defects in CST-9 Sleepers • Cracks at rail seats or fracture • Wear of lug and rail seat • Tie bars weakened by corrosion, broken or damaged by falling of wagon parts. • Corrosion of tie bars inside the cast iron plates.

46. Steel trough Sleepers Types of S.T. Sleepers i) ST sleepers with Pressed up lugs. ii) ST Sleepers with loose jaws. iii) Bolt and clip type ST Sleepers. iv) Special ST Sleepers for Turn out. v) ST Sleepers with pad plates for use with elastic rail clip.

47. Usual defects in ST Sleepers(Para 247) • Rusted and corroded metal • Cracks at rail seat or near the lugs • Elongation of holes Inspection of sleepers- Over 20 years old Reconditioning of sleeper

48. Concrete Sleepers & Fastenings Types of concrete Sleepers: i)Mono-block Prestressed Concrete Sleepers. a) RT 2495 for 52 Kg Rails b) RT 2496 for 60 Kg Rails ii) Two block reinforced concrete Sleepers.

49. Contd. … Advantages of concrete Sleepers: i) Greater stability. ii) Track geometry maintained for much. longer duration hence economical. iii) Best suited for machine maintenance. iv) Suitable for Track circuiting area.

50. Contd. … v) No chances of damage by fire/ corrosion vi) No possibility of theft. vii) No chances of gauge widening. viii) 60 Kg Sleeper can be used for 52 Kg rail. ix) Best suited for LWR track. x) Best performance on P & C, S.E.J. Guard rails , Level Crossings, Check rail in curve.