important achievements of track design directorate during ...1).pdf · rdso developed design and...

Important Achievements of Track Design Directorate during last five years

Sl

No.

Financia

l Year

Broad Area of

Achievement

Title of Achievement Description of Achievement Likely Benefit Current Status of

Implementation

1 2007-08 Safety Development of Design

and Drawings for

Movable Switch Diamond

RDSO developed design and drawings for 1:8.5 and 1:10

movable switch diamond crossing (without slip, with single

slip and with double slip) on PSC sleepers. Drawings were issued to Northern Railway and North Central Railway for

trial.

The concept will

eliminate the derailments

on diamonds due to unguided length at elbow

of obtuse crossing.

Prototype sets of 1

in 10 - one each for

single slip and double slip have

been developed.

2 2007-08 Safety Development of

specification for

outsourcing of

ultrasonic testing of

rail.

RDSO developed technical specifications for ultrasonic testing

of rails to be used by zonal Railways for outsourcing the USFD

testing to mitigate workload increase on account of operation

of heavier axle loads.

Introduction of state-of-

the Art USFD testing

m/c on Indian Railways.

Implemented

3 2007-08 Safety Development of AT

welding technology

with Compressed air

petrol preheating and

three piece moulds

RDSO successfully developed AT welding techniques with

three piece mould and compressed air petrol preheating for 52

kg/90UTS and higher rail sections in association with approved

portion manufacturing firms.

To improve quality and

in service performance

of AT welds.

Implemented

4 2008-09 Safety &

Reliability

Development of Design

and Specification of

Improved Switch expansion Joint (SEJ)

Drawings and specification for Improved SEJ for 80mm gap

(max.) and 65 mm gap (max.) for BG (1673mm) for 52kg &

60kg (UIC) on PSC sleepers were issued to all Zonal Railways for use.

The existing design of

SEJ has been improved

upon for more service life, better riding quality

and lesser maintenance

efforts.

Implemented

5 2008-09 Safety &

Reliability

Development of

specification of

Improved Rail Pad.

Specification of “Improved Rail Pad” for service life of 300

GMT or 8 years has been framed by M&C Dte in consultation

with Track Design Dte.

To improve the service

life of rail pad.

These pad are being

procured by the

railways for field

trial.

6 2009-10 Economy Field Trial of 22.5T

optimized Sleeper

RDSO had optimized existing design of PSC sleeper for 22.5T

axle load (Drg. No. RT- 7013) with M 60 grade of concrete

and 16 no. prestress strands.

Saving in cost of sleeper Under Trial

7 2009-10 Safety &

Reliability

Development of Nylon

cord reinforced GRSP

The specification of Nylon cord reinforced GRSP have been

developed and sent to zonal railways for trial for using under

CMS crossing to judge the performance.

To increase the life of

pad under CMC

crossing.

Under Trial

8 2009-10 Safety Development of digital ultrasonic rail testers.

RDSO successfully developed digital single and double rail testers and dedicated AT weld testers with digital technology

in association with industry. This will facilitate recording of A-

scan and monitoring of growth pattern of flaw.

Reliability of USFD testing of Rails/Welds

Implemented


specification for

ultrasonic rail testing

using vehicular system .

On account of increase in traffic and introducing of heavier

axle load, the work load of USFD testing has increased

considerably. The USFD testing is required to be undertaken

more frequently, as frequency of USFD testing is dependent on GMT of the section. RDSO developed technical specifications

for ultrasonic testing of rails/welds using vehicular system in

order to mitigate the increased work load of USFD testing and

to bring in state–of-the-Art vehicular systems of USFD testing

on Indian Railways

Introduction of state-of-

the Art Vehicular USFD

testing system on Indian

Railways. These will also help in effective

monitoring of flaw

growth pattern.

Tenders invited by

NR.

10 2010-11 Safety Development of Forged

Junction Rail

At locations of change of Rail Section in track, the junction

fish plate were used. It was not fisible to continue LWR at such

locations. RDSO developed the drawing and provisional

specification of 52kg and 60kg forged junction rail. This will

reduce instances of failure of junction fish plate and facilitate

continuance of LWR.

Reduction in junction

weld failure

Implemented

11 2010-11 Safety &

reliability

Revision of

Specification of Retro-

Reflective Engineering Indicators as per

ASTM-D-4956-09.

Specification for retro –reflective Engineering Indicators has

been revised after conducting literature survey & studying IRC

and International Specification. The provisional specification for retro –reflective May -2011 was approved by Railway

Board and issued to zonal railways for implementation.

Revised specification includes both Type III (encapsulated lens

type) and type IV (micro-prismatic type) of retro-reflective

boards.

Improved visibility of

engineering indicators

specially during night.

Implemented.

12 2010-11 Safety &

Reliability

Design of 1:16 thick

web switch with ZU-1-

60 asymmetric tongue

rail

The design of 1:16 thick web switch on PSC sleepers was

developed by modifying the existing 1:16 turnout to suit the

ZU-1-60 asymmetrical thick-web tongue rail.

Improvement of service

life, better riding quality,

lesser maintenance effort

Prototype set is

being developed.


Drawings for modified

Special Bearing plates

for 1 in 12 PSC fan shaped layout

Drawings for modified special bearing plate to be used on

sleeper No.24,25, 26 & 27 in 1:12 BG 52 kg turnout were

issued to all Zonal Railways for trial. The performance of

above modified plates was found to be satisfactory as indicated by CTE/SWR in TSC meeting in Dec 2010.

Improved safety Implemented

14 2010-11 Throughput Development of

Drawings for 1 :8.5

Symmetrical split

derailing switch

Drawings for 1:8.5 derailing switch (symmetrical split layout)

for both 52 kg and 60 kg rail sections were issued to Zonal

Railways.

This layout shall help in

increasing speed up to

30 Kmph in loop lines

Implemented

15 2010-11 Throughput Development of

Drawings for 1 :12

derailing switch

Drawing for 1:12 derailing switch BG 60 kg (UIC) and BG 52

kg on PSC sleepers were issued to Zonal Railways.

This design will help in

increasing speed of loop

lines.

Implemented

16 2010-11 Economy Development of

technology for in-situ

reconditioning of CMS

Crossing

In-situ reconditioning of CMS Crossing by Translamatic

Robotic Welder was adopted for regular use in October, 2010.

Another technology of Inweld Canada has been approved for

extended field trial. Expression of Interest (EOI) was called for development of more technoloies. The offers received are

under technical evaluation.

Improved service life of

CMS crossing and

elimination of

requirement of traffic block for removal and

insertion of CMS

crossing

Implemented. More

technologies are

under development.

17 2010-11 Safety &

Reliability

Field Trial of Under

Sleeper Pads

Field trial is to be carried out on sleepers fitted with Under

Sleeper Pad(USP) to study its effectiveness in ballast

protection, reduction in ballast pressure, reduction in overall

track maintenance & vibration control etc. RDSO has

formulated trial scheme for field trial of the same in NR &

SCR.

Ballast protection,

reduction in ballast

pressure, reduction in

overall track

maintenance & vibration

control

The trial of this

item is in progress

in NR & SCR.

18 2010-11 Safety &

Reliability

Development of ERC

Mk-V

ERC MK-V with toe load of 1200-1500 has been designed &

developed by RDSO and same has been approved for adoption

in Indian Railways for regular use.

Increase in toe-load. This item has been

adopted on Indian

Railways.

19 2010-11 Safety & Reliability

Development of Composite GRSP

To improve the life and performance of existing 6mm GRSP, RDSO has developed Composite GRSP. After successful lab

tests and satisfactory field performance, composite GRSP has

been approved by Railway Board for regular adoption.

This pad is expected to have minimum service

life of 8 years / 300

GMT.

This item has been adopted on Indian

Railways.

20 2010-11 Throughput Technical scrutiny and

inputs for Operation of

AC Double Decker

Coach on Howrah –

Dhanbad section

The operation of first rake of AC double decker coaches was

planned on Howrah-Dhanbad section. Necessary technical

scrutiny was done on aspects related to track and SOD for

Operation of AC Double Decker Coach on Howrah – Dhanbad

section and further inputs were provided for regular operation.

Increased throughput Implemented.

Running

successfully

21 2010-11 Consultancy Scrutiny and

finalization of Standard

Gauge SOD of Air port express Metro Line of

DMRC and operation

of trains.

The Standard Gauge Schedule of Dimension for AEML was

scrutinized in consultation with all concerned directorates. This

facilitated Operation of trains on Standard Gauge first time in India.

Fast and economical

public transport in Metro

city.

Implemented.

22 2011-12 Safety &

reliability

Revision of Manual for

Flash Butt Welding of

Rails Revised-2012)

Taking into consideration latest developments in the field of

flash butt welding world over, the flash butt welding manual

1972 has been updated and revised.

The Manual for Flash Butt Welding of Rails Revised-2012 has

been approved by Railway Board and issued for

implementation by FBWP.

Production of flash butt

welds of greater quality

& reliability by both

fixed and mobile plants

Revised manual

circulated to all

zonal railways for

implementation.

23 2011-12 Safety &

reliability

Development of track

based gauge face

lubricating system.

The gauge face lubrication is required to enhance service life

of rails particularly on sharp curves.

In order to assess suitability of mechanized lubricators, 12

imported & 8 indigenous lubricators were installed in CR, WCR and ECoR in 2008 with trial of two years. Based upon

the experience gained, Final specification No. IRST-48 of 2013

has been approved by Railway Board on 7/6/13.

Reduction in wear of rail

gauge face specially at

curved locations.

Implemented

24 2011-12 Safety &

reliability

Revision to

specification of fish

plates (IRST-1-2012)

The IRS specifications for fish plates needed revision due to

deletion of approved sources of raw material by QA/Mech Dte,

inclusion of dimensional tolerances etc. The existing

Specifications IRS-T-1:2012 & T-6 were reviewed and

comprehensive specification has been issued.

Comprehensive

specification issued.

Implemented

25 2011-12 Safety &

Reliability

Design of 1:12 Scissor

Cross over with 60 Kg

UIC rail with PSC

sleepers

Design and drawings for 1:12 Scissor Cross over with 60 Kg

(UIC) rail with PSC sleeper layout with 4.725 m c/c spacing of

track have been developed with new concepts having curved

CMS crossings up to tangent point and hollow CI block. Drawings have been issued for trial.

Improved service life,

better riding quality and


Under trial


Weldable CMS

Crossing

Drawings and Specification for 1:12 & 1:8.5 Weldable CMS

Xing BG 60 kg were developed by RDSO to bridge the

technological gap between IR and world railways• Field trial of

1 in 12 and 1 in 8.5 60 Kg weldable CMS crossings of RDSO

design has been ordered in N.Rly and C.Rly respectively

manufactured by firm M/s VAE VKN Sonepat.


track components at

crossing , better riding

quality , lesser

maintenance effort and

feasibility of

continuation of LWR

through turnouts

Under trial


technology for

repair/reconditioning of rail top defects

Technical evaluation of technology has been done by RDSO

for repair of rail top defect by Translamatic Robotic Welder

has been done by RDSO. Field trial of technology has been ordered in two zonal railways under supervision of RDSO


rail/weld, lesser

maintenance effort

Under trial

28 2011-12 Economy Improved SEJ for

curves up to 4 degree

Technical evaluation of Design and drawings for Improved

SEJ to be laid at curve up to 4 degree was done by RDSO.

Field trial has been ordered in three zonal railways for

validation of design and drawing.

Elimination of fish

plated joints resulting in

better ride quality and


Under trial


Composite Sleepers

Extended field trial of composite sleepers of M/s Tietek, USA

design and limited field trial of Composite FFU (Fibre

reinforced foamed urathane) sleepers of M/s Sekisui, Japan's

design were started for development of composite sleepers for

bridges. Composite Sleepers of two more technologies have

been approved for limited field trial.

Composite Sleeper,

made of recycled

materials is eco friendly

and ideal solution to

bridge timbers. It will

also reduce maintenance

effort.

Under Trial



Gauge SOD of BMRC.

The Standard Gauge Schedule of Dimension for Bangalore,

Chennai, Jaipur & Gurgaon Metros was scrutinized in

consultation with all concerned directorates and forwarded to

Railway Board for approval. This facilitated Operation of metro trains on Standard Gauge.

Fast and economical

Public transport system

in metro city.

Implemented.

31 2011-12 Throughput

enhancement

Schedule of Dimension

for Eastern and Western

Corridor

The Schedule of Dimension for Eastern and Western Corridor

for DFC was finalized. The same has been approved & issued

by Railway Board in Jan.-2013.

Enhanced freight

operation capacity.

Implemented.


Explosive Depth

Hardened (EDH) CMS

Crossing

EDH CMS crossings developed by a firm were put in limited

field trial in NR and SCR after inspection by RDSO. The

performance of above crossings were found to be satisfactory

and extended field trial has been ordered in six zonal railways

Improvement in service

life and reduction in the

requirement for

reconditioning

Under Trial

33 2012-13 Safety Revision of

‘Specification for

fusion welding of rails

by Alumino-thermic

process, IRST-19’.

Specification for fusion welding of rails by Alumino-thermic

process, IRST-19 has been revised incorporating all 16 nos. of

A&C slips issued. Theses A&C slips were issued for various

improvements made in quality of AT welding and

advancements made in this area.

Improvement in quality

& reliability of AT

welds.

Implemented.

34 2012-13 Safety Revision of ‘Manual

for fusion welding of

rails by Alumino-

thermic process, 1998’

‘Manual for fusion welding of rails by Alumino-thermic

process, 1998’ has been revised and issued as ‘Manual for

fusion welding of rails by Alumino-thermic process, 2012. All

13 nos. of A&C slips have been incorporated which deal with

various improvements made in quality of AT welding and advancements made in this area.

Improvement in quality

& reliability of AT

welds.

Implemented.

35 2012-13 Safety Revision & printing of

‘USFD Manual’

‘Manual for Ultrasonic testing of rails & welds, 2006’ has

been revised and issued as ‘‘Manual for Ultrasonic testing of

rails & welds, 2012’. All 09 nos. of A&C slips have been

incorporated which deal with various improvements made in

area of USFD testing.

Improvement in

reliability of USFD

testing

Implemented.

36 2012-13 Safety Development of AT

welding technology

with Compressed air

petrol preheating, three

piece moulds and

Automatic tapping

thimble.

In order to reduce human element in AT weld to improve

reliability. As welding techniques with Auto tapping thimble

was developed by RDSO in association with approved vendors

for AT portions. RDSO has successfully developed vendors for

the AT welding technique with Compressed air petrol

preheating, three piece moulds and Automatic tapping thimble.

To improve quality and

in service performance

of AT welds.

Implemented w.e.f.

01.02.2013

37 2012-13 Safety Revision of specification for

ultrasonic rail testing on

outsourcing basis

‘Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds (Provisional) Revised, 2007’ has been revised

so as to incorporate the provisions for outsourcing of welds and

issued as ‘Indian Railway Standard Specification for

Ultrasonic testing of rails/welds (Provisional) - Revised, 2012.

Introduction of state-of-the Art USFD rail and

weld testing m/c on

Indian Railways.



Gauge SOD of Chennai

Metro(CMRL)

The Standard Gauge Schedule of Dimension for CMRL was

scrutinized in consultation with all concerned directorates and

forwarded to Railway Boar for approval. This facilitated

Operation of metro trains on Standard Gauge.

Fast and economical


in metro city.

Under

consideration of

Railway Board.

39 2008-13 Safety Amendments in

IRSOD, BG- 2004

07 No. Amendment and corrigendum slips proposed to address

issues related to safety and enhanced capacity and mobility.

Increased mobility with

enhanced safety.

05 out of the 07

amendment/implem

ented. Remaining

02 are under

consideration of

Railway Board.

40 2008-13 Mobility &

Throughput

enhancement

Scrutiny and vetting of

speed certificates.

More than 500 No. speed certificates were vetted from track

point of view including some very important operations as

mentioned below:

1. Operation of 22.32t (CC+6t+2t) axle load wagons.

2. Operation of BG RS-2 and RS-3 DMRC Coaches.

3. Operation of 22.82t (CC+8+2t) axle load wagons. 4. WAP7 class of locomotive up to a maximum speed of

140kmph.

5. Multi-operation of 3WDG3A/3WCG2 locomotives and 59

BOXN wagons (loaded to CC+8+2t) over Lonavala-

Palasdhari Ghat Section.

6. Operation of MEMU Coaches fitted with pneumatic

suspension up to a maximum speed of 110kmph.

7. Operation of Shatabdi express and other similar trains with

18 numbers of LHB AC EOG coaches at 140kmph.

8. Operation of BG AC EOG Double Decker Chair Car

coaches (width 3050mm) at maximum speed of 160kmph. 9. Operation trials of long haul train-two freight trains

amalgamated into one train (python).

10. Operation of WDP4D twin cab class of locomotive up to

135kmph.

11. Operation of second class Non AC EOG LHB variant

coaches (LS2) up to a speed of 135kmph with pay loads

upto 16T maximum.

Increased Mobility and

Throughput.

Implemented.

41 2013-14 Economy Grooved Rubber sole

plates (GRSP) with

horn for turnouts

RDSO has developed new designs of GRSP with horn for lead

portion, under check rail at crossing, beyond crossing and for

approach and exit sleeper for 1 in 12 & 1 in 8.5 turnouts and

the same issued to all Zonal Railways for trial.

Solution for working out

of rubber pads leading to

increased service life of

sleepers and other track components.

Under Trial


finalization of SOD of

Gurgaon Metro

(RMGL)

The Standard Gauge Schedule of Dimension for RMGL was

scrutinized in consultation with all concerned directorates and

forwarded to Railway Boar for approval. This facilitated

Operation of metro trains on Standard Gauge.

Fast and economical


in metro city.

Under

consideration of

Railway Board

43 2013-14 Reliability,

Economy

Review of Design of

Spring Setting

Device(SSD)

The design of SSD was reviewed to address problems

experienced in field. As a consequence, Drawings for SSD

and their parts –RDSO/T-6216, RDSO/T-6945 and RDSO/T-

6217/1-32 have been altered and issued to Zonal Railways.

The revised ‘Laying and Maintenance Instructions’

incorporate frequency of inspection and oiling & greasing of

SSD has also been issued to ensure smooth operation of SSD.

Improved Reliability and

acceptibility of SSD in

field which in turn shall

enhance the service life

of switch.

Implemented

44 2013-14 Safety,

Economy

Finalization of Drawing

for Combination SEJ Drawings for Comination SEJ with 60 Kg tongue rail and 52

Kg stock rail have been finalized and issued to Zonal

Railways. Such SEJ can be used at the location of change in

rail section from 52 Kg to 60 Kg (or vice versa)

Improved safety due to

elimination of

Compound fish plate.

Cost reduction as only

one SEJ is required in place of two SEJs for

different rail sections.

Implemented

45 2013-14 Throughput &

Economy

Development of

Ballastless Track with

Indigenous Fastening

System (BLT-IFS)

including tunnels and

viaducts

BLT-IFS design has been completed including proto-type

development in a record time of 3 months and its drawings and

construction guidelines has been prepared which has been

approved by the Railway Board vide letter dt. 13.12.2013. The

drawing & construction guidelines have been sent to zonal

railways on 16.12.2013 for undertaking the trial. The BLT-IFS

design can also be used in tunnels & viaducts with suitable

modification in the pad stiffness.

The BLT design has

been developed using

indigenous fastening

system resulting in cost

saving and easy

availability of fastening

components. The

proposed BLT-IFS can

be used in washable

aprons for both platform & non-platform lines, in

tunnels, bridges and

track at formation

requiring very low

maintenance.

Trial in main line in

BINA-BPL by

RVNL and in

various zonal

railways .

46 2013-14 Safety &

Reliability

Revision in

Specification (IRS-T-

44) of GFN-66

Insulating Liners

Corrigendum No. 4 to the ‘IRS specification no. T-44-1995 for

GFN-66 Insulating Liners’ incorporating change of colour &

location for taking sample for specific gravity test has been

issued to all concerned on 27.11.2013.

With the above change,

uncertainty of quality of

existing insulating liners

with black colour can be

Corrigendum

circulated to zonal

railways for

improved with the use of

insulating liners of the

same material but with

natural colour and use of

spurious material can be

avoided by using virgin

raw material of natural

colour and at the same

time hardness & cross

breaking load values are

not compromised

Implementation

47 2013-14 Safety &

Reliability

Revision in

Specification of Metal

Liners

This specification has been issued bearing the title ‘IRS

specification for metal liners for use with Elastic Rail Clips

(Provisional -2013)’ on 29.11.2013 to all concerned.

It will improve the

quality & serviceability

of metal liner bars as

well as metal liners

henceforth on sustained

basis

Specifications

circulated to zonal

railways for

Implementation


Design of Wider

Sleeper using more

concrete & less steel

for 25T axle load

Various preliminary designs have been sent to Railway Board

for in-principle approval of finalized option for developing

detailed drawings. However design with top rail seat width of

230 mm and bottom of 300 mm against existing 150 mm and

250 mm respectively found most suitable with use of 12 wires

as against 20 wires of 3x3 mm in existing 25 t design.

Following are the

advantages of wider &

heavier sleeper

Increase in

frame resistance

of track & avoiding of

buckling of

track

Increase in rail

seat area

resulting in

increase in

rubber pad life,

Reduction in

ballast pressure

leading to

reduction in ballast

pulverization,

deep screening

Awaiting Rly.

Board’s approval,

RDSO is going

ahead with

developing detailed

drawings.

cycle &

enhanced

drainage

49 2013-14 Safety &

Reliability

Development of 10mm

thick Composite

GRSP for 25t sleeper

assembly

Development of 10mm Composite GRSP for 25t axle load has

been taken up by RDSO. Prototype samples of this pad were

asked from the approved vendors of 6.2mm CGRSP, for

testing in RDSO. The samples of four firms have been tested in

M&C Dte. Of RDSO.

Pad is more sturdier &

increased serviceability

for use in heavy axle

load.

The one firm has

already been

shortlisted. Further

development is in

progress.

50 2013-14 Consultancy

UIC Asia project on

‘Optimisation of

Sleeper Design in

collaboration with CHARMEC Sweden.

The modelling & simulation study has been done for

optimization of various design parameters of design of PSC

sleepers for 22.9 axle load and upto speed 75 kmph & LHB

coaches upto 10 kmph. Good practices of manufacturing are

also been recommended

Rationalization of

various design factors

and appropriate

combination of these factors resulting in

optimised design of PSC

sleeper for 25T axle

load.

After completion of

Phase –I , Phase-II

of the project is in

progress for further

study.

51 2013-14 Safety &

Reliability

Development of

Improved Toe Load J-

Clip

RDSO has developed Modified ERC J-clip for increase in the

toe-load of existing J-clip. Increase in toe-load to

solve the problem of

working out of clips at

fish plated joints.

Drawing of

Prototype samples

have also been got

manufactured. &

samples are under

testing at RDSO for

validation. Gauge

drawing and

application-deflection block

drawing for new

design of J-clip will

be issued after

testing.


Design & development

of 25t sleeper along

with fastening system

Prototype design of the sleeper has been manufactured and

same is found successful during lab testing at RDSO. Design

of sleeper and fastening system has been sent to ECoR, SE, SC

& SW Railways for field trial.

Heavy sleeper &

fastening system for

heavy axle load

Trial is in progress

53 2013-14 Throughput Design & development

of 32.5t sleeper along

with fastening system

RDSO has designed and developed proto-type of a new PSC

sleeper for 32.5t axle load. All laboratory investigations of this

sleeper including Fatigue test have been completed and the

sleeper has passed all the tests successfully.

Load carrying capacity

of PSC sleeper will

increase.

Detail estimate &

indent vetted.

Tender is being

called.

54 2013-14 Safety &

Reliability

Development of

Thermoplastic

Elastomer Pads

Status report on trial after one year service has been sent to

railway board on 15.05.2012.

Further, a letter to all the five nominated railways has also been

sent on 27.08.2013 to send certain specific observations of the

performance of the pads.

One of the main reasons

of deterioration of

existing rubber pads is

attributed to the effect of

extreme environmental

conditions in field which

in turn affects the overall

functioning of elastic

fastening system. The

Thermoplastic Elastomer

Rail Pad is made of

polymer and therefore, it

is resistant to the effect

of extreme

environmental

conditions in field and

imparts longevity.

Under trial

55 2013-14 Throughput Revision of

Specification of PSC

Sleeper

These revised specifications have been discussed with the

manufacturers and finally approved by Railway Board. Now

revised specifications have been implemented.

Further, vide letter no. 2011/TK-II/22/11/1/Specification dated

11.03.2013, Railway Board has amended the Guarantee Clause

no. 8.1 of the IRS T-39 (Fourth Revision – August 2011)

which has been issued to zonal railways as Corrigendum no. 1

to IRS T-39-85 (Fourth Revision – August 2011) vide RDSO

letter no. CT/SRC/Specification dated 22.04.2013 after taking

all necessary action as per ISO guidelines of RDSO

Revision of specification

of PSC sleeper (T-39)

has been taken up to fine

tune it in line with latest

practice / production

techniques and

experienced gained by

IR.

Implemented

Long Rail Bed at Bhilai Steel Plant

Long Rails are to be cooled down before online

Ultrasonic Testing Ultrasonic test. Its length is 65

metre

Long Welded Rails:

Indian Railways have laid vast stretches of long

welded rails. These rails are able to provide a more

comfortable journey as the fish plated joints have been

replaced with welded joints. Indian Railways is a large

network comprising majority of track on Broad Gauge.

Broad Gauge (1676 mm) track mostly comprises of

UIC 60Kg long/IRS 52 Kg long/Continuously welded

rails laid on pre-stresses mono-block concrete

sleepers on stone crushed ballast bed. On broad

gauge approximately 47,000 Km of track out of total

approx. 63000 Km are already having long welded

rails.

Ballastless Track with Indigenous Fastening System (BLT-IFS)

BLT-IFS design has been completed including proto-type development in a record time of 3 months and its drawings and construction guidelines has been prepared which has been approved by the Railway Board vide letter dt. 13.12.2013. The drawing & construction guidelines have been sent to zonal railways on 16.12.2013 for undertaking the trial

Achievements: Design Development of Track related components

Automatic tapping thimble:

RDSO has successfully developed the technique and vendors for the AT welding technique with Compressed air petrol preheating , three piece moulds and Automatic tapping thimble to improve quality of welds and in service performance

Digital AT weld tester:

RDSO successfully developed dedicated AT weld testers with digital technology in association with industry. These digital tester have facility of recording A-scan pattern and monitoring of growth pattern of flaw.

Digital Double rail tester:

RDSO successfully developed digital single and double rail testers with digital technology in association with industry. These digital tester have facility of recording A-scan pattern and monitoring of growth pattern of flaw.

Manual for Ultrasonic testing of rails & welds- 2006: Manual for Ultrasonic testing of rails & welds, 2006’ has been revised and issued as ‘‘Manual for Ultrasonic testing of rails & welds, 2012’. The copies of revised USFD Manual, 2012 have been printed and being circulated to Zonal Railways & all concerned.

Standard Schedule of Dimensions for DFC:

Standard Schedule of Dimensions for Eastern and Western Dedicated Freight Corridors on Indian Railways Published in January-2013

Thick Web Switch:

Design, Drawings and Specification for 60 Kg BG 1 in 12, 1in 8.5 and 1in 16 thick web switches have been developed by RDSO. 60 Kg 1 in 12 thick web switches of RDSO design have already been laid in track.

Weldable CMS Crossing:

Design, Drawings and Specification for 60 Kg BG 1 in 12 and 60 Kg BG 1in 8.5 Weldable CMS crossing have been developed by RDSO. Trial for such crossings has been ordered.

Improved Switch Expansion Joint (SEJ):

Drawings and Specification for Improved SEJ of two designs – one with maximum 80 mm gap and other with 65 mm gap have been issued to Zonal Railways for regular use. Such SEJs do not have bends augmenting safety and service life.

Composite Sleeper: Composite Sleepers of Tietek design have performed satisfactorily over a period of 10 years on two girder bridges on Indian Railways. Such sleepers are under extended trial at present.

ERC Mk-V:

Higher toe load clip is required for increased speed and axle load and to control the creep in LWR. ERC MK-V has been developed for toe load of 1250 kg. This clip has been adopted on Indian Railways.

6.2mm Composite GRSP: To improve performance/service life of rubber pad, composite GRSP has been developed and adopted on Indian Railway having service life of 300 GMT as compared to 150 GMT of existing GRSP.

32.5t Axle load PSC Sleeper: RDSO has designed and developed a new PSC sleeper for 32.5t axle load. All laboratory investigations of this sleeper including Fatigue test have been completed and the sleeper has passed all the tests successfully.

important achievements of track design directorate during ...1).pdf · rdso developed design and...

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