*MECHANISED LAYING OF TRACKIN CONSTRUCTION PROJECTSPresentation ByManoj AroraSenior Professor Track-1

ISSUES DISCUSSEDMechanised systems of track linking which can be followed on Indian Railways

*EXISTING PRACTICESBallast stacks taken on formation are spread. Sleepers and rails unloaded at nul points along the formation & then dragged to location with the help of tractor or by other means.Linking is done manually.

*ADVANTAGES OF EXISTING PRACTICETrack linking becomes a parallel activity to formation construction including ballast procurement and spreading. No assembly yard is required.No Railway wagon or engine is required. No costly machine is required.Manual linking is economical.Multiple handling of track material is avoided.

*DISADVANTAGES OF EXISTING PRACTICEQuality of linking is normally poor to average.Suitable for laying only single rails. All the welding to be done in situ.Sleepers and rails may get damaged because of mishandling.Formation may get damaged because of plying of vehicles and dragging activities.Progress depends highly on labours.Accountal of material is difficult.Manual system is just continuing because of requirement of less capital for contractor and simplicity of operation in spite of bad quality.

BASIC REQUIREMENTS FROM MECHANISED SYSTEMQuality

Safety in case of doubling

Economy

Feasibility of working on discontinuous formation

Possibility of using longer rail panels

*ADVANTAGES OF MECHANISATION In case of high banks, tunnels and bridges, it is not possible to transport track material from the sides. We can lay track from one end to other. Long rail panel can also be transported and laid with very few in-situ welding.Quality of linking is much better.

*BASIC ISSUES OF MECHANISED SYSTEM

*POSSIBLE MECHANISED SYSTEMS FOR TRACK LINKING ON INDIAN RAILWAY 1. New Track Construction Machine2. PQRS3. Russian TRT4. Improvised portal with road crane

*COMPARISONAll the systems have been compared on following factors-Possibility to cross discontinuities in formationHandling of material at siteWhether it requires multiple handling of rail at siteRequirement of auxiliary trackLength of rail or rail panel laidDoes it require assembly yardEconomyQuality of track linkingSafety, specially in case of doubling/tripling Progress achievable/day

*NEW TRACK CONSTRUCTION MACHINE (NTC)This is a special machine for new track linking, developed by Harsco Track Technologies.This is similar to TRT.10 rail panels can be unloaded by this machine at the beginning of the work.First part of this machine can work either on formation or rail. After laying sleepers and rails, later half runs on rail. This is fully mechanised machine.This does not require auxiliary track.

LIMITATIONS OF NTC MACHINE This machine is very costly.This can not cross discontinuities in formation.

*PQRSEnough PQRS sets are available over IR which can be used for track linking.It requires auxiliary track.

For auxiliary track-

In case of new line, single rail is used

In case of doubling, 10/20 rail panels can be unloaded by running EUR on adjoining track.

In case of gauge conversion, EUR can be run on MG track before PQRS work is undertaken.

*PQRScontdPanels of 13mts length loaded on rake are laid in track with the help of this machine.In this system one additional set of rails are to be transported to site & back to depot. In case of discontinuities in formation, it is not possible to shift PQRS

*RUSSIAN TRACK RELAYING TRAINThis machine was imported from Metex JSC (Russian firm).This machine can be utilised for track relaying as well as for new track linking. A cantilevered projected structure is provided at the rear end from where track panels up to 26m length can be laid in track.Does not require auxiliary track.

*Frame Projection for 13m. panelFrame Projection for 26m. panel

*ANIMATION of RTRT

*ANIMATION of RTRT

*ANIMATION of RTRTVIDEO

*ANIMATION of RTRT

*RTRTcontdTrack panels are fabricated and loaded on rake in yard.Panels are moved longitudinally over special BFRs for feeding to portal

*MFC- FOR MOVING TRACK PANELSVIDEO

*IMPROVISED PORTAL WITH ROAD CRANE (HYDRA)Such portals have been used in the Bhatapara-Urkure Tripling project and Bharuch-Dahej GC project with slight difference. This is local version of PQRS.It works on auxiliary track.In place of rail clamps, a beam capable of lifting 15/20 sleepers is provided. In this beam hooks are provided at every 60cm for holding sleepers.

*IMPROVISED PORTALVIDEO

*IMPROVISED PORTALcontdBallast for cushion can be spread and compacted by light vibratory roller.

*IMPROVISED PORTALcontdSleepers & single rails are transported to depot on formation.Such depots can be made on formation at null points/ level crossings. Single rails for auxiliary track can be hauled on the formationWith the help of trailer and road craneBy portal it self up to end of auxiliary track then dragged to small distance

*IMPROVISED PORTALcontdSleepers are lifted by portal & spread at spacing on ballast bed.Then rails from auxiliary track is shifted to rail seat.Double handling of rail is avoided.It is possible to dismantle and shift such portal in case of breaks in formation.

*COMPARISON OF VARIOUS METHODS

METHODSMANUAL LINKINGPQRSNTCRTRTIMPROVISED PORTALFACTORSDiscontinuity in formationPossibleNot possibleNot possibleNot possiblePossibleHandling of material ManualSemi-mech.MechanisedMechanisedSemi- mech.Auxiliary TrackNot RequiredRequiredNot RequiredNot RequiredRequired

Handling of rail One time 2 times One time One time One time Length of rail13m13m130m26m13m

COMPARISON OF VARIOUS METHODS

METHODSMANUAL LINKINGPQRSNTCRTRTIMPROVISEDPORTALISSUESAssembly yard Not requiredRequired Required Required Not required EconomyCheap Costly Very costly Costly Cheap Quality PoorGoodBestGoodGood Safety of adjoining trackLowGoodVery goodGoodGoodProgress/dayVariable500m1000m1000m.500m.

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